Innovative Solutions for Onshore Wind Turbine Maintenance
The rapid growth of wind power technology has brought about unique challenges that require timely solutions. Altra Renewables, a leading expert in wind turbine solutions, is offering innovative aftermarket solutions to address problematic maintenance procedures, reduce environmental impact, and maximize reliability for onshore wind turbines. These solutions not only unlock the energy potential of onshore wind power but also contribute to improving sustainability in the industry. With a rich history in wind turbine braking systems, Altra Renewables, consisting of renowned brands such as Svendborg Brakes, Stromag, Ameridrives, Twiflex, and Warner Electric, brings decades of experience and expertise to the table, providing comprehensive solutions throughout the entire wind turbine lifecycle.
Challenges in Onshore Wind Turbine Maintenance
Maintenance of onshore wind turbines presents several challenges, including their tall structures, large size, and remote locations. Scheduling and executing maintenance and repair services for power transmission assemblies in the nacelle can be difficult and costly. It is crucial for turbine operators to have access to specialists who can deliver turnkey solutions quickly, minimizing disruption to energy production. Additionally, operators and service providers must consider the impact on local residents and the surrounding ecosystem.
As the development and adoption of onshore wind power have surged, the tools and techniques required for turbine maintenance have struggled to keep pace. Every operator seeks efficient and safe maintenance procedures, but the work involved in repairing or replacing heavy equipment at great heights poses risks and challenges.
Introducing the Yaw Brake Lifting and Installation Tool
Altra Renewables offers a patented solution, the Yaw Brake Lifting and Installation Tool, to improve the speed and ease of yaw brake replacement. Yaw brakes, which can weigh up to 200 kg, play a crucial role in controlling the position of wind turbines. The innovative tool allows for easy interchange of yaw brakes in situ, eliminating the need for heavy lifting by maintenance personnel. Brakes can be attached to the tool and lowered to the floor for maintenance work, significantly reducing repair steps and enhancing personnel work conditions and speed. The tool's various configurations make it suitable for different turbine models, and its lightweight design ensures easy transportation.
Resurfacing Brake Discs with Efficiency
Maintenance of yaw brake discs, which can be large and heavy, traditionally required the complete disassembly of the turbine nacelle. Altra Renewables offers a portable Disc Resurfacing Tool that enables on-site operation within the nacelle. With its compact and lightweight design, this tool features a milling machine that quickly replanes the disc, restoring its optimal condition. By eliminating the need for nacelle disassembly, the tool reduces downtime, minimizes costs, and maximizes energy output, making maintenance work more efficient and effective.
The Groove Tool for Yaw Brake Noise Reduction
Noise generated by onshore wind turbine brakes can disturb local residents and wildlife. Altra Renewables' Groove Tool offers a permanent solution to reduce yaw brake noise. The device cuts grooves in the yaw brake disc, which act as razors to remove detritus from the brake pad as the turbine moves with the wind. A brush between the brakes removes debris from the grooves, allowing the disc to clean itself and maintain optimal braking performance. The tool is customized to suit the specific needs of each turbine, considering wind direction, turbine diameter, and disc material.
Environmentally Friendly Brake Pads
Brake dust produced by braking systems can contain harmful substances that pose contamination risks to the local environment and maintenance personnel. Altra Renewables has developed the Green Alternative yaw brake friction material, which adheres to the Restriction of Use of Hazardous Substances (REACH) standards followed by the automotive industry. This material is asbestos-free, contains minimal amounts of mercury, chromium 6+, lead, and cadmium, and produces inherently less dust than traditional friction materials. By using environmentally friendly brake pads, the company significantly reduces the environmental impact and health risks associated with brake dust.
Maximizing Reliability
To ensure a return on investment (ROI), onshore wind turbines must operate reliably. Altra Renewables, as a capable and responsive global aftermarket service partner, offers a range of benefits to maximize electrical output and safeguard the profitability of wind turbine installations.
Partnership with OEMs
Altra Renewables collaborates closely with onshore wind turbine original equipment manufacturers (OEMs) during the development phase to create highly reliable products that align with turbine designs. Through rigorous testing in different weather conditions, the company ensures the performance and quality of its replacement components and assemblies, providing OEM-quality reliability in application. With a turnkey approach and involvement in all aspects of the turbine lifecycle, Altra Renewables extends service intervals, allowing onshore turbines to generate energy for longer periods.
Responsive Maintenance Support
As older installations age and the wind turbine fleet expands, responsive maintenance support becomes vital in reducing unforeseen downtime. Altra Renewables offers 24/7 global maintenance support via a dedicated service app, enabling maintenance engineers worldwide to access key technical information and guidance for critical repairs. The company leverages innovative aftermarket service tools and solutions to quickly resolve issues, even for competitor products, ensuring smooth servicing, retrofitting, and replacement processes.
Industrial Internet of Things (IIoT) and Smart Technology
Altra Renewables leverages IIoT to monitor uptime and optimize preventive maintenance. The company offers 24/7 IIoT solutions in cooperation with customers, providing insights for maintenance assessment and early detection of brake system failures. Smart technology service tools, such as the Universal Control Case, enable remote monitoring of product performance, facilitating in-depth diagnosis and contributing to increased turbine uptime.
Altra Renewables, with its extensive experience in wind turbine braking systems, offers innovative aftermarket solutions to overcome challenges in onshore wind turbine maintenance. Through tools like the Yaw Brake Lifting and Installation Tool and the Disc Resurfacing Tool, the company streamlines maintenance procedures, reduces downtime, and maximizes energy output. Additionally, Altra Renewables addresses environmental concerns with solutions like the Groove Tool for reducing yaw brake noise and environmentally friendly brake pads. By partnering with OEMs, providing responsive maintenance support, and leveraging IIoT and smart technology, Altra Renewables ensures the reliability and longevity of onshore wind turbines, unlocking their full energy potential and promoting sustainability in the wind power industry.
HVH Industrial Solutions is an authorized distributor for all Altra Motion companies such as Svendborg Brakes, Stromag, Ameridrives, Twiflex, and Warner Electric. We work closely with their engineering team to provide superior customer service and engineering support.
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