Trunnion System Rebuild – Pin Replacement and Arm Boring
Four turbines at the same site were found with migrated trunnion arm pins and elastomer bushings well past their service life. GEARED was brought in to complete the repair up-tower rather than removing the gearboxes. After the damaged pins and bushings were pulled and the mounting block bores inspected, each pin bore was machined to an r6 interference fit to accept new pins manufactured in the GEARED shop. Boring the arm in place called for tooling built specifically for this gearbox and tower configuration to carry the boring bar and hold it true, work that kept the gearboxes in the nacelle and the cranes off site. With new pins set and new bushings installed on both sides of each gearbox, the drivetrain was brought back into proper alignment, and the turbines were returned to service.
Generator Bedplate Crack Repair and Stiffener Installation
A crack in the generator bedplate brought GEARED up-tower for a two-part repair completed without removing the generator or the bedplate itself. The crack was welded out in the nacelle, and the bedplate was then reinforced with an X-style stiffener plate kit designed, manufactured, and supplied by GEARED, which included the stiffener plates, aluminum diamond plate decking, fasteners, and anti-corrosion coating. Crews laid out and marked the plate positions, drilled the mounting holes, and coated each hole with anti-corrosion paint before setting the stiffeners in place. New walkway plates were installed along with the reinforcement, leaving the bedplate stronger than the original configuration and the nacelle deck in better shape than crews found it.
Planet Gear Replacement
The CMS installed on this gearbox detected an abnormal operating condition, prompting the customer to halt operation of the tower and call GEARED. This project focused on the replacement of a damaged planet gear assembly within the gearbox. The work included removal of the damaged gear, measuring and documenting the existing bore dimensions, installation of the new planet gear assembly, and recommissioning of the gearbox.
Water Treatment Plant Tank Repair
During a planned maintenance outage, a water treatment facility discovered significant damage to its water distribution box requiring section removal and replacement — under a tight outage window, in a hazardous atmosphere, with difficult access to the work area.
Understanding the impact on local water supply, GEARED rapidly mobilized personnel, tooling, and resources. The team documented the damage on site, modeled the distribution box in CAD, fabricated replacement sections, and removed and replaced the damaged sections of the box and walkway — field measurement through final repair, all handled in-house.
Broken Base Bolt Extraction
A customer’s turbine sat offline for five years after its base fasteners broke 3–4 feet below the base flange — a repair they were told was impossible. The only alternative was a $175,000 retrofit involving multiple outside parties, with the broken studs buried under the tower door flange in a working space just 1.70 inches wide.
GEARED modeled the tower base in CAD, then designed, fabricated, and validated custom extraction tooling entirely in-house. The result: broken fasteners removed, turbine back in service, and over $100,000 saved for the customer.
Custom Drone Trailer Retrofit
A customer needed their drone trailer reworked to fit new operational needs. GEARED cut off the existing hitch and fabricated a new gooseneck from raw steel tubing — complete with wiring, 7-way connection, and epoxy paint finish. The team then designed and built custom flight deck extensions, cutting, bending, and welding aluminum diamond plate into a second fold-out deck, and finished the unit with new decals. From structural fabrication to custom made decals, GEARED took care of the details.
