Main Bearing Replacement Programme – Onshore Wind Farm (Australia)

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Objective

Aurora supported a major wind turbine maintenance programme at a wind farm in Victoria, Australia, with works commencing in July 2024 and ongoing. The project involves the replacement of main bearings across 33 Senvion 3.4 EBC turbines. The works include full turbine disassembly, bearing replacement, and reinstatement activities to restore operational performance. To safely and efficiently replace damaged main bearings across 33 turbines, restoring reliability and performance while maintaining the highest standards of safety, quality, and operational execution.

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Challenges

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Solution

  • Prepared turbines for disassembly, including full rotor lifts and removal of drivetrain units.
  • Removed and replaced damaged bearing assemblies by decoupling from the gearbox on the ground, installing new components, and reinstating drivetrain and rotor systems.
  • Completed final mechanical works including high-speed coupling installation, generator alignment, full walkdowns, demobilisation, and submission of quality documentation.
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Value to Client

Aurora delivered the project safely and efficiently while adapting to both technical and environmental challenges. The team demonstrated flexibility by adjusting working hours, reallocating resources, and maintaining productivity despite wind delays. Innovative problem-solving, including the development of new tooling solutions now adopted into service, added long-term value beyond the project itself. This proactive and collaborative approach strengthened the working relationship with the client and reinforced confidence in Aurora’s ability to deliver complex, first-of-its-kind scopes.

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