Common Causes of Wind Turbine Failures (and How to Prevent Them)

Wind turbines operate in some of the harshest environments, where failure often leads to costly downtime and major repair work. That’s why proactive maintenance and reliable components are critical to long-term performance.

Potential failures can stem from mechanical wear, electrical faults, or environmental stress. While they can’t always be avoided entirely, their impact can be significantly reduced with quality components, regular servicing, and early intervention.

Below we break down the key causes of wind turbine failure and explain some of the steps you can take to minimise their impact. 

Common causes of wind turbine failures

Blade damage

One of the most frequent failure types, wind turbine blade damage can result from extreme weather (hail, lightning, high winds), debris impact, or material fatigue over time. Even minor surface cracks can develop into larger structural issues if not detected early.

Steps you can take to prevent issues: 

Regular inspections using drones or ground-based sensors help identify issues before they escalate. Protective coatings and lightning protection systems further improve resilience against environmental factors. 

Gearbox failures

Gearboxes convert the low-speed rotation of the blades into high-speed rotation required by the generator. Failures are often caused by lubrication breakdown, wear and tear, or manufacturing defects, making the gearbox one of the most maintenance-intensive components.

Steps you can take to prevent issues: 

Condition monitoring (oil analysis, vibration sensors), along with proper alignment and high-quality materials, reduces failure rates and extends gearbox life.

Electrical failures

Electrical components, including the generator, transformers, and control systems can fail due to overheating, surges, insulation degradation, or simple aging.

Steps you can take to prevent issues: 

Using durable components and ensuring clean, consistent signal and power transmission is critical. High-performance slip rings, like those developed by BGB, are designed to withstand vibration, temperature variation, and moisture, reducing the chance of electrical failure within rotating systems.

Yaw system failures

The yaw system adjusts the turbine’s position to face the wind. If this system fails, the turbine may operate inefficiently or be exposed to damaging off-axis forces.

Steps you can take to prevent issues: 

Regular calibration and inspection of motors, gears, and control logic are essential. Sensor data should be monitored continuously to catch positioning anomalies early.

Structural failures

Structural issues can affect the tower, nacelle, or foundation, typically due to poor design, fatigue, corrosion, or environmental stress.

Steps you can take to prevent issues: 

Schedule regular inspections using non-destructive testing methods (like ultrasonic or thermal imaging) to detect early signs of cracking or deformation.

Overloading

Operating beyond the turbine’s rated wind speed capacity can overstress key components, including the drivetrain and generator.

Steps you can take to prevent issues: 

Turbine control systems must respond accurately to wind conditions by feathering blades or initiating shutdowns. Well-maintained sensors and responsive software are key to preventing overload events.

Bearing failures

Bearings in the rotor hub and gearbox endure high loads and rotational stress. Contamination, misalignment, and lubrication failures are common causes of premature bearing failure.

Steps you can take to prevent issues: 

Use of sealed bearings, along with temperature and vibration monitoring, helps extend service life and avoid unplanned downtime.

Poor maintenance

Inadequate or inconsistent maintenance practices are a contributing factor to many turbine failures. Missed inspections or improper repairs can allow small issues to escalate.

Steps you can take to prevent issues: 

Implementing a structured, data-driven maintenance schedule is essential. Components like slip rings should be inspected for wear and cleaned, repaired or replaced at set intervals.

Corrosion

Turbines located in offshore or coastal environments face high exposure to salt, humidity, and condensation. Without proper protection, corrosion can weaken structural elements and degrade electrical performance.

Steps you can take to prevent issues: 

Components should be made from corrosion-resistant materials and housed in sealed, IP-rated enclosures. BGB slip rings, for example, are designed to perform reliably in high-humidity and salt-air environments.

Control system malfunctions

The control system manages pitch, yaw, braking, and other critical functions. Failures can result from sensor drift, software glitches, or signal transmission issues.

Steps you can take to prevent issues: 

Regular firmware updates help maintain safe and efficient operation. Using high-quality signal transmission components also improves overall system integrity.

Improving wind turbine performance with BGB 

From custom-engineered slip rings to expert knowledge in rotary systems, BGB supports OEMs and wind farm operators in keeping turbines running longer, safer, and more efficiently.

Our wind-specific components are engineered to withstand high vibration, extreme temperatures, and moisture ingress — reducing downtime and extending service life.

Browse our catalogue of products or get in touch with us today to discuss our bespoke solutions for wind turbines.