The EU-funded SkyServiceShop’s mobile maintenance system for wind turbines decreases the time a turbine is out of service for repairs, thus increasing the energy potential of wind power plants — not only in Brandenburg, Germany, but around the world.
A new way of repairing wind turbine blades
- 28 August 2017
With Terra, rotor blades can now be used on twice as many days, meaning their high purchase price is met within a very short time.
To be profitable, wind power plants must be inspected and repaired in short intervals, thus minimising downtime and maximising the short windows of opportunity when conditions are favourable to perform maintenance work. To meet this demand, the EU-funded SkyServiceShop S³ developed a mobile workshop. The rotor blade maintenance system, which features a closed maintenance chamber, lets wind turbine blades be tested, serviced and repaired in safe, workshop-like conditions.
The Terra solution
Like any machine, wind turbines require maintenance. With the growing popularity of wind farms — often located in remote areas or even out at sea — the need for safe maintenance practices is increasing. Currently, maintenance work on a wind power plant’s blades is done in the field, usually by an industrial climber hanging by ropes or standing on open platforms.
When the weather brings rain, strong winds, or extreme temperatures, this type of maintenance work cannot be performed, leaving the turbines out of commission for extended periods of time — up to 100 days every year. Needless to say, this results in longer plant stoppages and a failure to fully exploit the energy potential of wind power plants.
Known as Terra, the flexible rotor blade maintenance system developed by the project is built around the blade, similar to a shoebox, with the two ends of the blade emerging from the mobile workshop. It uses a floor and ceiling consisting of two movable plates, allowing it to be easily built and taken down.
Using a patented pusher system, the enclosure can be sealed around the rotor blade using just your hands. Once closed, workers benefit from interior lighting systems. Knowing that not all wind turbine blades are designed the same, the Terra system can be quickly adapted to the unique twists and turns of a specific rotor blade. It is also easily transported from one site to another.
Within this enclosed structure, maintenance crews are able to repair blades independent of climatic conditions and within a safe working environment. The system has already successfully reduced wind turbine downtime, making wind plants and farms more efficient — and profitable.
Looking towards the market
Following the patenting of the Terra rotor blade maintenance system with a closed maintenance chamber, the project is now looking towards bringing the system to market. The funding supports this effort, and the prototype is expected to be finished by the end of May 2017. Once complete, the project will take the prototype on a demonstration tour across Germany, meeting with potential customers and exhibiting at relevant trade fairs. eFooter – keep exactly to this subhead and format.
Total investment and EU funding
Total investment for the project “SkyServiceShop S³” is EUR 1 744 721, with the EU’s European Regional Development Fund contributing EUR 1 146 552 through the “Brandenburg ERDF” Operational Programme for the 2014-2020 programming period.