Endurance E-3120 Turbine Gearbox Overhaul and Repair

E-3120 turbine gearbox arrangement

The Endurance E-3120 wind turbine is fitted with a Siemens WD5008A gearbox, this provides the necessary speed increase from the rotor (43 rpm) to the generator (1,500 rpm).

As the turbines age we are starting to see various issues occurring.

These issues can range from leaking oil seals, bearing wear, keyways bruising, or more seriously gear failure.

The gearbox has to work hard on the E-3120, it has a nominal rating of 50kW compared to turbine outputs of 60-80kW and the braking events are harsh.

We are delighted that we can now offer our customers rapid and cost effective solutions for gearbox overhaul and repair.

Rapid E-3120 turbine gearbox repair

The gearbox has a torque limit of 1,250Nm on the high speed shaft, and the standard Endurance braking system has a specification of 900-1100Nm. DC21 always try to keep turbines at the lower end of this range to minimise wear and tear.

E-3120 turbine gearbox arrangement

DC21 have worked with a local gearbox specialist with over 90 years experience in power transmission, to offer our customers the most cost effective solutions for gearbox overhaul and repair. We hold complete gear sets in stock to enable a rapid repair.

A new gearbox from Siemens has a lead time of 22 weeks. We can overhaul an E-3120 gearbox in just 2 to 3 weeks.

Gear and pinion wear and failures

Within the casing of the gearbox there are three reductions pairs (gear and pinion). Experience to date is suggesting that the 2nd and 3rd reduction pairs are most vulnerable to failure of the teeth. So far we have seen no major issues on the 1st reduction pair.

Gear and pinion wear and failures

Hollow shaft issues

The low speed shaft that delivers the power from the rotor/blades is connected to the gearbox via a hollow shaft and shrink disc arrangement. Again due to the duties the turbine asks of the gearbox it is not uncommon to find the low speed shaft has spun and friction welded to the hollow shaft. The key way in the hollow shaft can also become bruised.

Low speed shaft issues on E-3120

We are pleased to be able to offer an upgraded hollow shaft with an additional key way to improve the longevity of any replacement.

We can overhaul your E-3120 turbine gearbox in just a few weeks

Normal lead time for gear manufacture is 10-12 weeks, in response to the issues we are seeing we have made the decision to hold stock of several complete gear sets. This now means we can overhaul a gearbox in around 2-3 weeks.

E-3120 Products, Upgrades & Repairs

Cost Effective Solution

E-3120 Low speed shaft (LSS)

DC21 can offer a new LSS that has been designed and manufactured in the UK. The design has several key features.

Cost Effective Solution

E-3120 Bedplate

DC21 can provide an alternative to replacing the bedplate by delivering a reinforced bedplate at a fraction of the cost of a new bedplate.

Fast & Easy Installation

E-3120 Hub refurbishment

DC21 can provide complete refurbishment of the E-3120 hub, our hub removal tooling means there is very little risk of having to purchase a new hub.

Minimum of Disruption

Spring tubes

DC21 are pleased to offer the Serenity Wind spring tube upgrade with all E-3120 and E-4660 models. These spring tubes come with a 5 year insurance backed limited warranty.

A Permanent Solution

E-3120 oil filtration

DC21 can offer a complete oil filtration retrofit for those E-3120s that did not benefit from oil filtration from new. Our kits come with the all important oil level switch system to protect the gearbox in the event of loss of oil.

A Permanent Solution

E-3120 Reaction Arm

DC21 have worked with Nordlock to develop the Reaction Arm Expander pin for the E-3120.

A Permanent Solution

E-3120 Gearbox Repair

Fast, efficient and cost effective E-3120 gearbox overhaul and repair from DC21. We hold complete gear sets in stock to enable a rapid repair

A Permanent Solution

E-3120 Brake Upgrade

New wind turbine braking system for the Endurance E-series that will reduce the strains placed on the turbine compared to the original braking system.

Need More Information?

Please feel free to contact us if you would like to know more about our highly competitive endurance wind turbine upgrade and repair services.

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