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Comparing Replacement Components to
Extend the Life of Gearboxes
Summary
• What are the Pros and Cons of Uptower replacements and what challenges
do they help solve in the wind industry?
• How does prognostic data help operators set-up proactive uptower and
downtower major component replacement strategies to maximize ROI?
• Case Study: Broadwind DriveMAX Ring Gear Upgrade Comparison
• Q/A
Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
• 15+ years of drivetrain,
blade and field service
experience across
numerous platforms
• kW to MW inspection,
test, repair & swap
capabilities
• In-house precision
gearing shop
Harness our expertise across WTG platforms to expand your business
Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
Most Comprehensive Uptower Repair Offerings on the Market
Two Shop Locations
Increase asset life
Increase major component budget
accuracy
Minimize long term maintenance
costs
Eliminate gearbox CapEx
Limit turbine down time
Reduce crane costs
Reduce shipping costs
Less management resources
consumed
Importance of a Healthy Gearbox
Proactive approach = reduces risk
5Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
Uptower Shop Rebuild
Assessment
Safety
Cost
Time frame
Cleanliness
Testing
Validation/Quality
Control
Uptower vs. Shop Gearbox Rebuild
Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
Cleanliness Environmental
concerns related to
cleanliness
Proper flush and
break in
Gear and bearing
asperities from
manufacturing
Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
Testing Test stand
2-stage test uptower
Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
Validation/Qualit
y Control CM
Wear Pattern
Oil Analysis
Quality Reporting
Procedures
Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
DigitalClone Live – Site Level
Asset Ranking Default Most-at-Risk, Sortable, Filterable …
Asset Map View Risk Level,
Interactive, Navigable
Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
Component Risk Failure risk ranking down to the component
level for O&M planning (e.g. uptower vs crane)
DigitalClone Live – Component Level
Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
DigitalClone Live – Individual Component Tracking
Individual Component Replacement Tracking Component failure risk
predicted individually as part of the system per installation date
Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
DigitalClone Live – ROI Optimization
ROI Optimization All trade-offs based on ROI at the
individual asset level/group, maximizing ROI for the fleet.Grouping Asset type,
sub-site, region, etc.
Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
Maximize the lifecycle of your drivetrains Inspections & failure mode analysis
Data analysis
Upgrade rebuilt gearboxes
Uptower gearbox remanufacturing
Oil changes, major component exchanges, and
“turn-key” service
14
Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
15
Gearbox Upgrades
15
• Gearing
• Bearings
• Lubrication
Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
Gearbox Upgrades: Gearing
• Geometry
• Heat Treat
• Material
Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
Gear Box Upgrades: Bearings
• Work closely with bearing OEMs on RCAs
• Validate upgraded bearing solution through test and inspections.
Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
Gearbox Upgrades: Lubrication
• Work with OEMs to add lines, flush and clean
• Heat exchangers and plumbing
• Seal upgrades
Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
Broadwind and Sentient Science
Partnership
• In-depth metallurgic
analysis
• Prognostics to validate
the life extension
benefit
• In-depth
understanding of
failure modes based
on inspections and
RCA
Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
Build DigitalClone Prognostic Model
Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
Ring Gear
Ring Gear #1Process: machine and cut teeth, contour induction harden teeth, finish machine and finish grind teeth.
Ring Gear #2Process: machine and cut teeth, carburize and harden, finish machine and finish grind teeth.
DriveMAX Ring Gear #3Process: machine and cut teeth, heat treat, grind teeth, contour induction harden, finish machine and finish grind teeth.
Ring Gear Fatigue Comparison Results
Sentient PredictionsL50 (Years of Operation)
OEMRing Gear
Alt.Ring Gear
DriveMax4340 Ring
Gear
4.72 14.93 37.84
- 3.2x 8x
Fatigue Life Predictions – Load Case 1 – Max. Contact Stress: 1371.2MPa
LEGEND
Ring Gear
#1
Ring Gear
#2
DriveMaxRing Gear
Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
New advanced steels for gearing applications:
Commercially available Ferrium® C61™ and C64®
Typical Alloy
PropertiesYS (ksi)
UTS
(ksi)
Core
Hardness
(HRC)
El (%) RA %
Fracture
Toughness
(ksiin)
Achievable
Surface
Hardness
(HRC)
Tempering
Temperature
(°F)
AISI 8620 121 168 41-48 14 53 53 450
18 Cr-Ni-
Mo-7-6150 200 30-40 13 71 60-63 300-350
Ferrium®
C61225 240 48-50 16 70 130 60-62 900
Ferrium®
C64199 229 48-50 18 75 85 62-64 925
Strength, toughness, and fatigue (axial and single tooth bending) performance upgrades versus existing
gear steels 18 Cr-Ni-Mo-7-6 (standard wind turbine gear material) and AISI 8620
• Being qualified for helicopter transmission gears and rotor shafts; Increased power density
• Used in NASCAR and F-1; Increased component life and durability
C61 steel forward rotor
shaft
New materials should be considered to improve reliability of wind turbine gear boxes
Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015
Summary• Sentient allows customers to simulate the Gearbox RUL before and after
component replacement
• There are scenarios where Gearboxes will not have expected extended
life – you want to know before replacement
• Todays its possible to create a prioritized list of all GBXs where up-
component replacement may be a clear lower cost alternative to gearbox
replacement
• The same method can be used to create a watch list for optimized
borescoping schedules
• You can validate the life of existing designs or new designs computationally
• Check with Broadwind direct for uptower component options and services
Repairing Replacement Components to Extend the Life of Gearboxes February 24, 2015