Update and upgrade procedures

Testing and validation before return to service

Every wind turbine gearbox overhauled at ZF Services UK undergoes a rigorous test procedure before release to the customer. A unique, purpose-built validation rig for testing gearboxes of turbines up to two megawatts generating capacity can analyse oil flow, gearbox temperature, tooth contact pattern, and noise and vibration profiles. The test rig applies a load through the gearbox via a slave gearbox and output motor and records the current draw, temperature, vibration and torque figures on the test rig’s human-machine interface (HMI) panel. Thermal imaging is used to ensure that there are no local hot spots in the gearbox, and an oil filtering unit checks for correct oil flow and filters oil down to five microns to ensure the gearbox is free of any particulate contaminants prior to despatch.

For gearboxes from larger turbines of up to four megawatts generating capacity or for customers requiring a comprehensive, full-load test, evaluation can be undertaken on the industry-leading test bench at the ZF Centre of Competence for Wind Energy in Dortmund, Germany. ZF Services is the only multi-brand service provider to offer a test rig of this capacity.

Fault Diagnosis in the field

In addition to the comprehensive workshop capabilities described above, ZF Services UK employs specially-equipped technicians with industry-approved training in working at height and sea survival. These technicians provide 24-hour field support for wind turbine operators and can assess gearbox component condition on-site using oil sampling, vibration analysis techniques and the latest endoscopic equipment in onshore or offshore environments.