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Vestas V80, Repair of Lohmann & Stolterfoht (Bosch Rexroth) GPV 441-R3 gearbox

Our client – a leading german power and gas company specialising in cleaner energy - contacted Stork Gears & Services to perform an inspection of one of their Vestas V80 windturbine gearboxes. The Condition Monitoring System attached to the Lohmann & Stolterfoht gearbox had noticed an abbreviation. A visual inspection was necessary to access the damage.

Stork Gears & Services send one of its diagnostic engineers to the site to perform a visual inspection of the gearbox. It was decided to change the gearbox by one of the gearboxes from the gearbox exchange programme and the damaged gearbox unit was transferred to the Stork workshop for further inspection and analysis. All parts of the gearbox were thoroughly examined:

the planet carrier, planet gears and planet pins
the ring gear and sun gear
the low speed shaft and gear wheel
the intermediate speed shaft and gear wheel
the high speed shaft
the pitch pipe and other part such as the oil pump

Scope of Work
The inspection revealed several damages, e.g. fretting corrosion of the planet carrier bearing fit, stand still indentions on the planet gear and severe damage of the ring gear teeth.
For each damaged item the best option was discussed with the client, repair or replace the item. This resulted in the following scope of work:

- Metal spraying of the low speed shaft bearing fit
- Hand polishing of several components
- Renewal of the following components:: - Bearings and seals; - Oil pump bearings; - Ring gear; - Outside coating and planet carrier
- Regrinding of the following components:: - 3 planet gearwheels; - Sun gear teeth; - Intermediate pinion teeth; - Intermediate gear wheel teeth; - High speed pinion teeth

Why Stork was choosen
Stork Gears & Services is an independent service company specialising in the maintenance and repair of gearboxes. With over 50 years of experience we offer a complete range of gearbox services making use of innovative technologies, state-of-the-art engineering facilities and extensive gearbox knowhow. Over the years, we have established a reputation for combining quality with unparalleled speed.

Below you will find some images of this challenging Vestas V80 wind turbine gearbox repair project.

Location
Germany

Market segment
Wind industry

Gearbox details
Lohmann & Stolterfoht (Bosch Rexroth)
Type GPV 441-R3
Nominal power: 2.0 MW
Windturbine: Vestas V80

Vestas

Vestas V80
The V80 - with a diameter of 80 metres is a pitch-regulated turbine for medium and high winds in both onshore and offshore environments. The V80 is one of the best-selling turbines in the world, more than 2,700 V80 turbines have already been installed worldwide.

Vestas V80 windturbine

Pictures of Lohmann & Stolterfoht (Bosch Rexroth) gearbox, type GPV 441-R3

The gearbox in our workshop in Rotterdam

The gearbox housing

1 = ring gear, 2 = planet carrier, 3 = planet pins

shafts

1 = low speed shaft, 2 = intermediate speed shaft, 3 = high speed shaft