Only NGC has OEM knowledge of the gearbox design, a deep understanding of how it’s intended to operate within the context of the turbine system, and most importantly, the design intent.
Our remanufactured units undergo a rigorous disassembly, inspection, upgrade, and testing process that eliminates known failure modes and ensures that they meet the same specifications and performance characteristics as new units.
How it works
Our Repair and Remanufacturing Process
Step One
The process begins with an incoming inspection to identify the condition of the gearbox and to inventory peripheral components.
Step Two
Complete drive trains are separated at the main rotor shaft and gearbox connection, as these main components have very different process paths.
Step Three
Disassembly is completed only when engineering and quality have reviewed and accepted the inspection report, including critical measurements, images, and disposition of damages.
Step Four
Our engineering team assesses individual gears through a thorough, formal visual inspection. They then look for cracks via a magnetic particle inspection.
Step Five
A comprehensive cleaning in the wash bay is conducted. These tasks are completed through a combination of manual cleaning, machine washing, and hand polishing.
Step Six
Gears are dispositioned as required for gear grinding. Both precision grinding and coordinate measuring are conducted in-house to maximize quality and minimize cost.
a. Gears are sent to the Klingelnberg P150 gear checker for pre-regrind measuring/evaluation
b. Gears are reground as needed on the HOFLER Rapid 1600
c. Gears are then sent back to the gear checker for reevaluation/recertification
Step Seven
Any additional critical components which require repair through a machining process are also completed at our in-house machine shop.
Step Eight
Many components of the gearbox are upgraded to the latest revision possible and replaced with new products that improve overall performance.
Some examples include:
a. The high-speed, rotor side bearing is upgraded to a notched-and-pinned design, preventing the possibility of bore spin
b. All structural components
c. All bearings
d. If needed, the housing is machined and bearing bores are sleeved
e. The cooling system is refurbished or replaced
Step Nine
The assembly team delivers the gearbox to the testing department who utilizes a back-to-back style dynamometer rated up to 4MW. Load testing is completed in a predetermined sequence of load spectra while critical measurements are captured and documented. Learn more about our load testing capabilities and process here.
Step Ten
Upon successful completion of load testing, the gearbox is delivered to the final assembly team who puts the finishing touches on the gearbox. This may include mounting and wiring of peripherals, installation of exterior lubrication components, and other requirements called for by our specifications.
Step Eleven
The remanufactured gearbox is returned to our inventory of completed remanufactured units to be sold as needed.
Zero Defect Policy
Our philosophy of Zero Defects informs every aspect of what we do and is especially relevant to the repair and remanufacturing aspects of our service offering. NGC assembly and repair teams work in direct collaboration with engineering and quality control teams, creating reports that include the documentation of critical measurements, component serial numbers, and process validation.
Related Products & Services
Core Exchange Program
A subset of our remanufacturing process, our core exchange service, helps to limit downtown and drive efficiency for our customers.
