Wind turbines in offshore settings face the dual challenge of salt spray and extreme wind exposure. A leading renewable energy provider struggled with gearbox seal failures on their turbines, leading to contamination ingress and costly helicopter-based maintenance operations.

Case Background

Each turbine was stationed 30 miles offshore. Previous seal systems degraded quickly under salt corrosion, resulting in gear oil contamination and rising maintenance interventions — often requiring airborne crews.

COMBI Custom Seal Design

COMBI proposed a corrosion-resistant sealing configuration using marine-grade elastomers, triple-lip defenses, and self-lubricating coatings to handle the pressure and salinity. The design minimized friction while preventing micro-particle intrusion from ocean spray.

Results & Impact

After 18 months of operation, the turbines fitted with COMBI seals showed zero incidents of gearbox oil contamination. Service visits dropped from four times a year to just one annual inspection, cutting maintenance costs by 75%.

Customer Feedback

The maintenance director stated: “With COMBI seals, we’ve significantly reduced both risk and cost. These seals have stood strong in one of the world’s most demanding environments.”

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SEO Description: See how COMBI sealing technology protected offshore wind turbine gearboxes from salt spray and wear, delivering 18 months of performance and cutting service visits by 75%.