Solutions for wind turbines
Experience and ever-expanding expertise since 1994
Ever since the business was founded 20 years ago, we have developed in-house service concepts and technologies that have led us, almost inevitably, to be able to provide a level of service that now defines the standard for the wind turbine sector. Our range of services are oriented on technological developments, innovative material research and application techniques for repair and processing that are state of the art – our services have a range and depth that's hard to beat.
This applies to the service and repair work required on site as part of servicing rotors, just as much as the fibre composite technologies applied in the rotor blade reconstruction at our works. When it comes to rotor optimisation, new technologies now enable us to correct rotor imbalances and pitches, be they due to mass or statics.
Certified quality service provider for all makes and categories
All rotor services have been certified according to the guidelines and specifications of German Lloyd (GL Wind) when it comes to requirements pertaining to materials and manufacturing processes, acceptance and inspection of fibre composite materials, as well as the repair of rotor blades and components.
In addition, all services including bulk transport logistics, have been certified to DIN ISO 9001:2008.
All necessary steps together with the certificates required are recorded in full by our service teams, and passed onto our customers in their entirety, by our technical documentation service.
The future in our sights
Wide ranging developments in the wind power market call for service concepts that are focused on the practical application of technological developments and the highest demands for efficiency.
We are a leading service provider for the wind power sector. In delivering our range of services, we draw on more than 18 years' experience and technical expertise. This has helped us to positively affect the service standard in the past and will continue to do so in the future.
- Repairs on Site
- Repairs at the Factory
- Rotor Optimisation
- Extended Warranty
Competence for a trouble-free future
Blade damage is best detected by routine inspections, accompanied by detailed technical records. Even before the warranty period expires, this enables specific repairs to be discussed and carried out under optimum conditions in mutual cooperation with manufacturers, insurers and operators. One of the most frequent causes for downtime are lightning strikes. A regular inspection of lightning protection systems is therefore essential and required by insurers.
For wind turbines, our trained teams of staff provide quick and straightforward, as well as economical, analyses of the rotor blade in situ. Such inspections are performed from suspended climbing gear or special access platforms.
The following services form part of either an individual or regular rotor inspection:
- Checking the blade shells
- Checking the internal blade body
- Checking the lightning protection system
- Checking the aerodynamic elements
- Checking the blade flanges/joints to the hub
- Checking the tip mechanism (where installed)
- Damage documentation with extensive pictorial backup
- Damage analysis
- Expert opinion
- Checking for blade imbalance
- Checking the blade pitch
Maintenance for long term value retention
As part of the routine maintenance of rotor blades, our staff will advise you in detail as to what specific steps your system requires to safeguard its economically optimum operation and to retain the value of the turbine in the long term.
You can then determine whether some of the recommended services, or a comprehensive service with a maintenance contract, would suit you best. All of our services would include the maintenance work requested in the operating manual by the turbine manufacturer, as well as the steps required by our own specific inspections.
As an option, any faults may be remedied on site, avoiding the additional costs entailed in another repair job and trip to site.
Experts and insurers recommend bi-annual inspection intervals. For sites with extreme exposure we may recommend even shorter maintenance intervals. We offer these essential inspections either by means of affordable suspended climbing gear or, if necessary, using the BayWa r.e. Rotor Service access platform. Once it has been established that there are no faults to be found or, if a defect is detected, after the repair has been completed, we will produce our report which details the overall state of the rotor blades. This can be submitted to insurers and approval bodies alike as verification of blade condition.
- Routine maintenance as a stand-alone service
- Complete maintenance and care contracts
- Maintenance and care services tailored to individual customer requirements
Preservation for economical long term protection
Many different environmental influences, long hours run and high tip speeds demand a lot from rotor blades of all classes.
Dirt and damage resulting from the high stresses and harsh conditions to which rotor blades are subjected result in reduced output, for example. Output reductions of up to 1.5 % are, according to DEWI (German Wind Energy Institute) investigations, the regular result of blade contamination alone.
After the rotor blades have been cleaned, a special wax treatment can be applied on customer request. This protects the blade surface and seals small shrinkage cavities. This type of preservation also notably prevents frost damage on the surface.
The service costs entailed in cleaning, preservation and rotor blade inspection are subsequently rapidly made up by higher yields.
Rotor blade care services:
- Surface cleaning
- Surface sealing
Minimised downtime – irrespective of make and turbine size
In spite of being designed for a service life of two decades, even robustly made rotor blades will, after a time, frequently indicate damage that results in reduced yields.
Specially designed platforms enable safe and quick access to the damaged sections of the rotor blades to be repaired. Independent of the output categories of various manufacturers, we guarantee a rapid and perfect repair to remove cracks and faults, applying special methods and materials. Repairs to the tip mechanism and reinstatement of the lightning protection system are part of our on-site repair portfolio.
Erosion on the leading edge of rotor blades is a typical form of damage discovered by expert inspection. A high performance protective film is applied to the leading edges of rotor blades to provide effective long term protection. This anti-erosion film withstands extreme loads and protects the leading edge of the rotor blade, thereby preventing further damage over an extended period.
Our repair services are certified and implemented in compliance with the stringent specifications of German Lloyd Wind.
On-site rotor blade repair services:
- Removal of cracks and surface faults
- Reinstatement of lightning protection
- Repair to tip mechanism and joints
- Application of erosion protection and aerodynamic elements
- Application of high visibility paint
Special solutions for complex cases
Repairs to laminated structures and general overhaul are frequently unavoidable in order to prevent greater loss of performance or the complete replacement of rotor blades.
For more complex blade repairs and complete overhauls, our repair workshops at Basdahl are available and have been specially sized to cope with blade dimensions. These new facilities offer the best conditions for professional repair and overhaul services in line with industry standards.
All repairs are performed according to manufacturer's specifications by trained and experienced fibre composite specialists who work to the most exacting standards, and who are also experienced in working with vacuum technology.
The use of innovative process technologies and materials guarantees that specifications can be met, such as the level of elasticity which is demanded for more complex reconstructions. Our spectrum of repair work stretches from tip repairs to retrofitting a complete set of blades.
Repair services at the factory:
- Rotor blade repairs
- Complete updating of rotor blades according to industry standard
- GRP component reconstruction (e.g. where partially destroyed by a lightning strike)
- Application services according to manufacturer's specification
- Various GRP repair processes with vacuum technology
- Partial and complete paint application
- Weighing and balancing
- Own shipping and loading facilities
- 7300 m² facility for blade lengths up to 70 m
Small corrections with gigantic effects
In many wind turbines, increasing vibration levels accelerate the wear of mechanical components. Static and dynamic imbalances and incorrectly set pitches result in substantial and early material fatigue on vital parts.
Higher noise levels, cracks in rotor blades, damage to the pitch mechanism, blade bearing damage with loss of lubricant, gearbox damage, cracks in the mainframe and wear in the yaw brakes can follow.
In order to deal with these signs of wear in good time, we can call on measures and methods following an effective vibration analysis that allow us to balance rotor blades and effect pitch corrections. This reliably corrects blade imbalances and incorrect pitches due to dynamic and mass-related influences, resulting in a reduction of vibrations in the rotor and nacelle. These corrective measures minimise high yield losses and repair costs sustainably and over long periods.
Rotor optimisation services:
- Vibration analysis (rotor and nacelle)
- Pitch check and adjustment
- Checking blade imbalances (static and dynamic)
- Removing imbalances (trimming)
Capacities for large dimensions
Our Basdahl facility enjoys ideal infrastructure links between Hamburg and Bremen and offers optimum storage capacities for rotor blades, used wind turbines and components. On a plot of some 50,000 m² with 7300 m² of covered warehousing, we can store renovated replacement blade sets on behalf of customers, so these can be drawn on immediately as a need arises. Within an extremely short response time, these sets can be transported with our own heavy haulage vehicles to the relevant wind farm.
This rapid replacement service reduces downtime and safeguards turbine operation with almost unrestricted positive operation and yield results.
Used wind turbines and components, too, such as nacelles, tower sections and rotor blades, find specialised storage facilities on this site within its constantly expanding warehouse space.
The clearly structured storage areas offer optimum loading and shipping conditions that facilitate rapid and reliable handling into and from the storage facility.
- Storage of replacement blade sets
- Storage of used wind turbines
Success based on a first class team
Our staff are highly qualified in all technical areas – the result of our policy to encourage certificated training and career development. In addition to our own service engineers, we also train apprentices to become qualified service specialists for the wind power sector.
Internal courses on individual manufacturers round off our training program. Safety courses held regularly by specialists make our teams of fitters well versed in all matters concerning safety on site.
Services with a quality seal
We are a leading supplier of services and are certified to DIN ISO 9001:2008 as well as by German Lloyd Wind.
All work is executed in compliance with the demanding specification of German Lloyd Wind, detailed by material certificates and documentation. This translates into seamlessly certified safety without compromise. Our independent expert opinions are accepted by manufacturers, insurers and planning authorities alike.
Our independent reports are accepted by manufacturers, insurers and planning authorities alike.
Certified by German Lloyd Wind
Quality management certified to ISO 9001:2008
Total peace of mind: Repair guarantee extended to three years!
Repairs guaranteed for three years
Our high quality and extensive certification makes us the only service provider in our industry to offer an extension to the statutory guarantee period on repairs carried out by us. This three year warranty is backed by a large German insurer for industry.
In addition, this service pack includes an annual inspection of the repairs carried out. This offers the best possible risk reduction and assurance to all operators.
An assured future with effective protection
Tower and nacelle require care that safeguards value and function, as do all turbine components. Cleaning is essential on account of the contamination and possible fungal growth that result from normal operation; the same applies to oil contamination of the nacelle and tower.
Extensive cleaning is required following restoration after a fire. In such cases, we take care of cleaning the nacelle and tower, together with other components both inside and out. In addition, we check the corrosion protection and the paint thickness.
Tower flanges that are particularly subjected to environmental influences, as well as the external tower joints must be checked at their abutting edges and repaired, if required. Tower flanges that are particularly prone to corrosion are effectively protected against ingress of moisture by a special permanently flexible coating.
In spite of highly stable coatings, tower paint finishes sometimes indicate massive damage. This could have been caused by inadequate substrate preparation or other possible environmental factors. After corrosion has been removed, the surfaces to be renovated are coated with a proven and high grade paint system.
All cleaning materials and consumables are caught at the foundation level and disposed of correctly, naturally with an appropriate certificate. Such processes again prove that we take care of environmental concerns to the last detail.
Tower and nacelle cleaning and surface treatment services:
- Internal and external tower cleaning
- Nacelle cleaning
- Surface coating
- Corrosion protection, painting
- Checking the thickness of coatings
- Sealing flanges
Mobility for mobile phone traffic
We are one of the leading wind turbine service providers. This has created the opportunity for us to act as a partner to major mobile phone providers in the installation of phone masts on wind turbines.
Many mobile phone masts are now up and running, thanks to our installation teams. Nowadays, the practice of mounting masts on the towers of wind turbines and industrial chimneys is much more widespread.
Here too, our highly developed platform technology and our skilled operation of lifting and climbing aids on the turbine itself ensure affordable access and appropriate installation work with up to four platforms simultaneously. Our skilled installation teams are available to support you with their experience and acquired expertise for all phone mast installation services.
Phone mast installation services:
- Installation and repairs on straining rings, cable routing and aerials
- Provision of platforms and installation teams
- Cleaning and corrosion protection