High-Speed Technical Audit and NDT Inspection of Flender TSD45SX Turbo Gearbox

Precision on-site condition assessment of a 1.3 MW high-speed power generation drive, verifying tooth contact patterns and bearing tolerances through non-destructive testing and forensic metrology.

We conducted a high-precision on-site technical inspection of a Flender TSD45SX turbo gearbox, an exceptionally high-speed parallel shaft unit serving the power generation industry in Russia. Operating at an extreme input speed of 27,522 rpm, this 1,300 kW gearbox requires rigorous maintenance standards, as even minor deviations in geometry or clearance can lead to significant operational risks at such high velocities.

The technical audit performed by Wikov specialists focused on a comprehensive evaluation of the internal health of the drive. The scope of work included a precise check of the contact patterns for each gear stage to ensure optimal load distribution. Furthermore, our engineers measured both axial and radial bearing clearances and performed non-destructive testing (NDT) on critical individual components to detect any subsurface fatigue or structural irregularities. The inspection concluded that the gearbox has been maintained in excellent technical condition, with all measured parameters falling strictly within the manufacturer’s specified tolerances. This proactive assessment confirms the unit’s reliability for continued long-term service in a high-demand power generation environment.

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