Maintenance and repair of wind turbines (in wind blade jargon) should not be a complex task, as is often the case. In this article, we will explore the most common challenges and the most reliable solutions to optimize key MRO processes for wind turbines.
Wind turbine maintenance: what you need to know
Wind turbine maintenance can be a complicated process without the knowledge of an expert. Recent studies have determined that the average lifespan of a wind turbine is 20-25 years. This is due to the extreme wind and weather forces to which they are exposed during their life cycle. Consequently, to optimize the operation of wind turbines during their relatively short life, manufacturers must invest in effective maintenance techniques. In addition, the global wind turbine maintenance market is estimated to reach a value of $27 billion by 2025, with a compound annual growth rate of 8 percent. This growth is due to increasingly innovative products that aim to make wind blade maintenance easier to perform, cheaper, safer, and more sustainable.
The repair of wind turbines
Wind turbine repairs can cause significant disruption, unplanned downtime, and unplanned costs for operators. In 2019, wind blade repairs cost the wind industry more than 6 billion pounds. Unexpected failures can cause preventive shutdowns, delays in power delivery, and a loss of reliability. Reducing the probability of unexpected failures is possible through planned maintenance and the use of intelligent scheduling systems. However, even with maintenance programs in place, wind turbines can become damaged in various ways that require repairs.
The most common ways in which wind turbines are damaged
Wind blades can be damaged and fail in a variety of ways. Here we explore some common problems that lead to the need for wind turbine maintenance.
Gearbox failure
Gearbox failure is a major cause of maintenance in wind turbines. The gearbox accounts for about 13% of the total cost of the turbine, making it an expensive component to replace. Gearboxes generally fail due to non-torsional loads and the high speeds that the bearings must withstand. The main causes of failure include:
- Contaminated lubrication
- Improper lubrication of bearings
- Uneven load distribution
- Low service factors
- Extreme wind levels
Blade failure
Blade failure is the most common cause of maintenance in wind turbines. As blades increase in size to produce more energy, they become more susceptible to failure due to the immense pressures. Damage from bird strikes, lightning strikes, and improper design amplify this risk. Blade breakage is the most common type of failure in wind turbines, with an estimated 3,800 cases of blade breakage each year. Specifically, blade failures are due to:
- Junction failure
- Erosion
- Cracks along the blade
- Broken fibers
Generator failure
Generators, which are responsible for converting the kinetic energy of the blades into electricity, can frequently fail due to electrical problems. Generator failure can lead to overheating and fire, causing dangerous and costly situations. The main causes of failure include:
- Contaminated lubrication
- Temperature extremes
- Excessive vibratory loads
- Irregular voltage management
Best products for wind blade maintenance
Costly and time-consuming maintenance and repair activities can be largely avoided by using high-quality sealing adhesives and lubricants in wind turbine manufacturing. It is critical that operators and maintenance teams have access to repair solutions that allow quick and easy application, enabling efficient and uninterrupted maintenance and repair. For example, industrial adhesives offer numerous advantages over mechanical bonding techniques because of their versatility in bonding and repairing in extremely challenging environments. Quality products offer benefits such as:
- Extension of component life and durability
- Improved efficiency of components
- Weight reduction
- Resistance to extreme temperatures
- Performance over wide load ranges
- Protection of intricate components from vibratory damage
- Strengthening the structure of the wind turbine
- Precise mixing and dispensing – saving time
- Ease of repeatability.
Here are the best products for each wind turbine component:
Pale
Here we explore the leading products that can be used to repair and maintain different parts of wind turbine blades. Bonding of added shovel elements
Lubrication of blade orientation
Threaded connections
Generator group
Braking system
Tower
Here we explore the leading products that can be used for repair and maintenance of different parts of wind turbine towers. Sealing of joints:
Shaft assembly:
Why rely on Mascherpa
Relying on Mascherpa means choosing a trusted partner in the field of wind turbine maintenance. We offer innovative, top-quality products that meet the essential requirements for operating in extreme conditions, ensuring durability, reliability and high performance. Our solutions have been tested in numerous applications, demonstrating their effectiveness in mechanical stress management, heat dissipation, and protection against contaminants. With our 100 years of experience and quality products, we guarantee constant support to optimize the performance of your wind turbines.
