Premature failures in the GE 1.5 gearboxes are driving unexpected downtime and increased costs. The industry is seeking solutions to reduce future failures.
To solve these failure modes, Moventas developed upgrades for the GE 1.5 gearboxes. The Extra Life gearbox was designed for any type of gearbox being replaced to reduce future failures. Sentient Science validated the technology advances and life extension claims for the owner operator community and quantified the improvements in performance, durability and reliability.
The computational testing showed an overall gearbox life improvement by a factor of 4x. The life extension achieved was due to improvements made to the case carburized ring gear, integrated planet gear bearings, high speed stage bearings, tooth surface roughness, and material specification upgrades in both bearings and gears. The key factors in the analysis accounted for in DigitalClone computational modeling are the material quality, surface roughness, and stresses based on full gearbox model subjected to real turbine operating conditions, which aren’t accounted explicitly in industry standards.
The upgrades showed a factor of 4x life improvement for the GE 1.5. The life extension reduces the probability of future gearbox replacement. Compared to the legacy platform, the Extra Life gearbox has a lower cost of ownership. Due to the results and confidence in performance, Moventas is offering a 5-year warranty on the Extra Life gearbox.
Moventas designs all gearboxes in-house allowing for end to end manufacturing to ensure quality control to implement quality standards. These improvements can be reused in Moventas’ future gearbox designs, rebuilds, and uptower repair services, to help reduce additional costs.
Moventas has over 35 years of experience in wind turbine gearbox manufacturing. Moventas’ predecessors Metso Drives and Valmet have manufactured industrial gearboxes since the 1940’s, and Moventas was among the first companies to extend the gearbox expertise into wind turbine gearboxes. The very first kWOur Mission is to provide innovative drive train solutions to improve wind power competitiveness. class wind gearbox was delivered in 1980.