Client
Haverigg Wind Farm
Sector
Onshore Wind Farm
Location
Cumbria
Our customer, a prominent player in the renewable energy sector, contracted our services to perform crucial major component works on one of their wind turbines as part of additional services within our O&M contract. Our team of experts was recently faced with a critical challenge when one of the turbines experienced an unexpected, automated shutdown due to a major component failure. The issue was pinpointed to a collapsed bearing, causing significant noise and operational issues when the turbine was restarted.
The Challenge:
The main challenge was to address the main bearing failure, which necessitated a complex and meticulous plan that included a full refurbishment of the tiring gearbox. This task required careful consideration of various factors, including adverse weather conditions that are common in wind farms, the sourcing and supply of critical replacement parts, and the need to manage the generator rebuild in-situ.
Our Approach:
Our team of experienced engineers swung into action swiftly. Drawing upon our extensive expertise in wind turbine maintenance, we devised a comprehensive plan that encompassed the following steps:
Visual and Intrusive Inspections: Our engineers conducted thorough visual and intrusive inspections to identify the root cause of the issue, ensuring no stone was left unturned in diagnosing the problem accurately.
Fault Finding and Process of Elimination: Employing a systematic approach, we meticulously carried out fault finding and a process of elimination to determine that the main bearing was indeed the source of the problem.
Generator Rebuild and Gearbox Refurbishment: We carefully planned and executed a major component exchange, which included rebuilding the generator and replacing the worn-out main bearing. Simultaneously, we refurbished the gearbox to ensure optimal performance.
Rotor Removal and Drivetrain Lifting: The most critical part of the operation involved safely removing the rotor from the turbine and precisely lifting the drivetrain, comprising the gearbox and main shaft, to ground level.
Precision Reassembly: The generator was rebuilt in-situ, and new bearings were expertly installed. Following this, we methodically reversed the disassembly process, resulting in a fully operational and functioning turbine.
The Outcome:
Our meticulous execution of this complex operation yielded outstanding results. The turbine was restored to full functionality, and the previous issues related to imbalance and alignment were completely resolved. As a result, the turbine now enjoys enhanced performance and efficiency, contributing to increased renewable energy production.
Conclusion:
Our successful project at the Wind Farm underscores our commitment to excellence in wind turbine O&M services. We are proud of our team’s ability to tackle complex challenges with precision and expertise. Our clients can trust us to deliver top-notch solutions that optimise turbine performance and extend their operational lifespan.