Improving The Life Of Gearboxes &Lowering Repair Costs

State of the Art Manufacturing Facilities & Heat Treatment Pioneer

• 35 years experience• Certified supplier network• Moventas material specifications• Cleanliness levels• ME/AGMA grade 3 quality level

inspections• State of the art superfinishing

processes• 100 % Grinding burn inspection• Full component traceability

In-house Manufacturing

To ensure the highest quality and durability of gearbox components, Moventas keeps key design & manufacturing processes in-house.

ISO 9001, ISO 14001, OHSAS 18001 certified

• Metallurgy • Case carburizing• Inspections & Testing • Castings• Ring gears• Planet gears• Hollow shafts• High-speed shafts• Intermediate speed assemblies

Let’s Going Deep Right Into It;

• Part I: Improving The Life Cycle Of Your Gearboxes – The ones you must do!

• Monitoring; From day one!• Inspections;• Maintenance;• Upgrades/Repairs;• End of Warranty;

– The ones you don’t want to do! • Gearbox design:• Site Specific flaws:

Monitoring: From day one!

From commissioning:• Oil sampling:• Noises:• Vibrations:• Temperatures:• Service Reports:• Trends:

CMaS Condition Management System• Sophisticated remote monitoring system for drivetrains.• Developed specifically for wind gear use, to prevent unexpected disturbances in energy

generation.• Predictive maintenance tool, proved to reduce OEM maintenance costs.• Identifies potential causes of damage with seven parametres. • Can be installed on both new and old equipment.• Easy interface for the customer to use • Can also be complemented with remote management service by Moventas experts.

Let’s Going Deep Right Into It;

• Part I: Improving The Life Cycle Of Your Gearboxes – The ones you must do!

• Monitoring; From day one!• Inspections; As soon as a doubt appear!• Maintenance;• Upgrades/Repairs;• End of Warranty;

– The ones you don’t want to do! • Gearbox design:• Site Specific flaws:

Inspections: As soon as a doubt appear!

Inspections:• Use all your senses:

• Use Expert Services:

The Gearbox Case Study of the Year;

Direct Drive WTG

Let’s Going Deep Right Into It;

• Part I: Improving The Life Cycle Of Your Gearboxes – The ones you must do!

• Monitoring; From day one!• Inspections; As soon as a doubt appear!• Maintenance; Ever seen a GBX maintenance manual?• Upgrades/Repairs;• End of Warranty;

– The ones you don’t want to do! • Gearbox design:• Site Specific flaws:

Maintenance: Ever seen a GBX O&M Manual?

Maintenance:• Preventive:Good practices…• Corrective: Don’t wait till it fail…• Predictive: Extending the life… Importance of good housekeeping:

Detecting leaks.

Let’s Going Deep Right Into It;

• Part I: Improving The Life Cycle Of Your Gearboxes – The ones you must do!

• Monitoring; From day one!• Inspections; As soon as a doubt appear!• Maintenance; Ever seen a GBX maintenance manual?• Upgrades/Repairs; BHT! • End of Warranty;

– The ones you don’t want to do! • Gearbox design:• Site Specific flaws:

Repairs & Upgrades: BHT!

What’s are your expectations?• Repair cheap or last?• Upgraded Components• Extra-Life Series™

Key to success life-cycle extension

Let’s Going Deep Right Into It;

• Part I: Improving The Life Cycle Of Your Gearboxes – The ones you must do!

• Monitoring; From day one!• Inspections; As soon as a doubt appear!• Maintenance; Ever seen a GBX maintenance manual?• Upgrades/Repairs; BHT! • End of Warranty; The must of the must, why wait!

– The ones you don’t want to do! • Gearbox design:• Site Specific flaws:

End Of Warranty:

The must of the must, why wait?• Where lies the knowledge?• Transparency – Open Book

Remember: Undiscovered problems affect your budget and wallet…

Let’s Going Deep Right Into It;

• Part I: Improving The Life Cycle Of Your Gearboxes – The ones you must do!

• Monitoring; From day one!• Inspections; As soon as a doubt appear!• Maintenance; Ever seen a GBX maintenance manual?• Upgrades/Repairs; BHT! • End of Warranty; The must of the must, why wait!

– The ones you don’t want to do! • Gearbox design: If the original one wasn’t good enough…• Site Specific flaws:

Gearbox design:

If the original one wasn’t good enough…!• Design loads & Testing's:• Materials & Finishes:• Manufacturing processes:

Let’s Going Deep Right Into It;

• Part I: Improving The Life Cycle Of Your Gearboxes – The ones you must do!

• Monitoring; From day one!• Inspections; As soon as a doubt appear!• Maintenance; Ever seen a GBX maintenance manual?• Upgrades/Repairs; BHT! • End of Warranty; The must of the must, why wait!

– The ones you don’t want to do! • Gearbox design: If the original one wasn’t good enough…• Site Specific flaws: Remember what the sales guy said…

Site Specific Flaws:

Remember what the sales guy said…• Site Suitability:

– Capacity Factor, Wind Speed & Turbulence, Etc:– Wake, Slope Effects:– Wind Turbines Operating Specifications:

Certainly not returning to original WTG spec’s…..Manage the risks!

Let’s Going Deep Right Into It;

• Part I: Improving The Life Cycle Of Your Gearboxes – The ones you must do!

• Monitoring; From day one!• Inspections; As soon as a doubt appear!• Maintenance; Ever seen a GBX maintenance manual?• Upgrades/Repairs; BHT! • End of Warranty; The must of the must, why wait!

– The ones you don’t want to do! • Gearbox design: If the original one wasn’t good enough…• Site Specific flaws: Remember what the sales guy said…• Litigation: TSA, MSA, WMSA…been at the forefront!

Litigation:

Up-front contract management…• Always involve OP’s in contract!• Contractual clarity. • Managing Operating Risks.

Let’s Going Deep Right Into It;

• Part II: Lowering Repair Costs – Repairs – Retrofits – Upgrades

• Description: What? Does I’m paying for that?

– Up-Tower, Down-Tower, Workshop, Replacement • Possibilities: Is up-tower possible? Down-tower? Workshop?• Replacement: No chances, need to replace! Wise decision?

– New Methods, Costs & Cases• 1+1+1 method: Replace a gearbox in less than 3 days, yes we’ve done it! • Repair kits: Just replace the broken parts type…• Modules Swap: The in between solution!

Repairs – Retrofits – Upgrades

• Repairs: Something is broken• Retrofits: They discover a problems - Recall• Upgrades: They discover a problems

& They want me to pay for the fix!

Make sure you read the contract…before!

Moventas Multi-Brand Service

Moventas Multi-Brand Service

Replacements

Factory Service

ConditionManagement

Field Service

DiagnosticsSpare Parts andSpecial Tools

Analysis Services

Extended Warranties

Inspections andAssessments

Service Contracts

Modernisations

Let’s Going Deep Right Into It;

• Part II: Lowering Repair Costs – Repairs – Retrofits – Upgrades

• Description: What? Does I’m paying for that?

– Up-Tower, Down-Tower, Workshop, Replacement • Possibilities: Is up-tower possible? Down-tower? Workshop?• Replacement: No chances, need to replace! Wise decision?

– New Methods, Costs & Cases• 1+1+1 method: Replace a gearbox in less than 3 days, yes we’ve done it! • Repair kits: Just replace the broken parts type…• Modules Swap: The in between solution!

Full Service Scope for the Entire GE 1.5 Fleet

• Complete Up-tower repair capability• Reduced crane costs

• Modernized upgraded solutions

• Moventas has reverse engineered• Winergy PEAB 4410 & PEAS 4390

• Bosch Rexroth GPV451 & GPV453

• Eickhoff CPNHZ-195

• Moventas has the complete ability to repair and manufacture or source any component

• Improve predictive maintenance with CMaS

• Main shaft repairs and modernizations

• + 2,000 Up-tower endoscope analysis & end of warranty inspections• + 10 Up-tower planetary repairs• + 150 Up-tower helical repairs• + 400 Up-tower HSS & IMS bearings & shafts replacement

Why Extra Life?

• Remove known premature failure modes to extend gearbox lifetime

• Extended warranty for your fleet• Spot problems early on and solve them on-site• Save money, reduce downtime and decrease OPEX• Available for multi-brand replacements,

refurbishments, up-tower services and spares• Reliable partnership and proven quality

with a gearbox OEM

Moventas’ 35-year wind industry

experience and core technologies harnessed for service fleets

Extra Life for GE 1.5 turbine drivetrains

Extra Life for GE 1.5 Replacement Gearbox

• Strongest planetary stage with case carburized gears and integrated planet bearings

• Improved gear design with even better pitting and scuffing resistance

• White Etch Cracking resistance extends bearing life • Eliminates inclusion derived tooth breakage with

upgraded material for the intermediate speed gearing • Enhanced lubrication filtration and moisture prevention to

increase gear and bearing life• Condition Monitoring 24/7 • Excellent up-tower serviceability• The industry’s most comprehensive Five-year Warranty

covers crane costs and lost revenues during downtime

Professional Field Service

Our Texan team working on an up-tower job in Oregon. On-site service by Moventas often saves the customer dozens of thousands of euros.

The wise and safety tip!

• Always test a new repair/exchange procedure on the ground and in the shop before going up-tower.

• Practices and simulations with the tools and lifting gears is a must to discover where the risk are!

Remember…the Devil is in details and its costly in both; risks and $!

Let’s Going Deep Right Into It;

• Part II: Lowering Repair Costs – Repairs – Retrofits – Upgrades

• Description: What? Does I’m paying for that?

– Up-Tower, Down-Tower, Workshop, Replacement • Possibilities: Is up-tower possible? Down-tower? Workshop?• Replacement: No chances, need to replace! Wise decision?

– New Methods, Costs & Cases• 1+1+1 method: Replace a gearbox in less than 3 days, yes we’ve done it! • Repair kits: Just replace the broken parts type…• Modules Swap: The in between solution!

Replacement Schedule GE Sle 1.5• Day 1 - Prep

– Shut down turbine– Remove all external gearbox connections + drain GBX

• Day 2 - Crane Day– Remove cover– Lift tool box, manage all up-down operations, lift & Install mainshaft clamp– Push back and remove old gearbox– Lift new gearbox and reinstall– Remove mainshaft clamp, take down tool box– Put cover back

• Day 3 - Wrap Up– Torque shrink element / Install brakes and coupling– Reinstall all wiring and sensors– Refill with oil– Perform final checks and place back in service

Replacing 1 + 1 + 1

Let’s Going Deep Right Into It;

• Part II: Lowering Repair Costs – Repairs – Retrofits – Upgrades

• Description: What? Does I’m paying for that?

– Up-Tower, Down-Tower, Workshop, Replacement • Possibilities: Is up-tower possible? Down-tower? Workshop?• Replacement: No chances, need to replace! Wise decision?

– New Methods, Costs & Cases• 1+1+1 method: Replace a gearbox in less than 3 days, yes we’ve done it! • Repair kits: Just replace the broken parts type…• Modules Swap: The in between solution!

New Parts & Replacement Kits

Let’s Going Deep Right Into It;

• Part II: Lowering Repair Costs – Repairs – Retrofits – Upgrades

• Description: What? Does I’m paying for that?

– Up-Tower, Down-Tower, Workshop, Replacement • Possibilities: Is up-tower possible? Down-tower? Workshop?• Replacement: No chances, need to replace! Wise decision?

– New Methods, Costs & Cases• 1+1+1 method: Replace a gearbox in less than 3 days, yes we’ve done it! • Repair kits: Just replace the broken parts type…• Modules Swap: The in between solution!

Siemens 2.3 Planetary Section Replacement

• Our proposed replacement procedure for Siemens 2.3MW planetary sections will roughly mirror our successful methods from the GE 1.5MW

– Use of LiftraTM mainshaft clamp– Splitting gearbox in two– Removing each section seperately to

reduce max lift • Basic order of operations:

– 1: Old helical down– 2: Old planetary down– 3: New planetary up– 4: Old helical up

First GE 1.5MW Up-tower Planetary RepairPanther Creek - September 2015

Replacement Schedule Siemens 2.3• Day 1 - Prep

– Shut down turbine– Remove all external gearbox connections + drain GBX

• Day 2 - Crane Day– Remove cover– Lift tool box, manage all up-down operations, lift & Install mainshaft clamp– Helical section remove and lowered to the ground, in the MSU– Planetary section remove and lowered to the ground– New planetary lift and re-installed– Helical section re-installed– Remove mainshaft clamp, take down tool box– Put cover back

• Day 3 - Wrap Up– Torque shrink element / Install brakes and coupling– Reinstall all wiring and sensors– Refill with oil– Perform final checks and place back in service

Planetary Module Exchange on Siemens 2.3

Thank you

Questions & Information's:Daniel CharetteTerritory Sales Manager;Eastern Canada, US Northeast & US Mid-Atlantic