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UPTOWER SOLUTIONS

ROTOR LOCK REPAIR

Precision repair of a wind turbine rotor lock hole.

Worn or damaged rotor lock holes need our fast response for precise repairs as the unit must operate not only reliable but also with minimal downtime. At CNC Onsite, we have developed repair solutions for a large variety of rotor lock systems that allows damaged  systems to be repaired up-tower (in-situ), on both offshore and onshore turbines. A worn or damaged rotor lock hole can in many cases cause longer downtime resulting in lost production. Our trained technicians can respond quickly and will carry out the repairs efficiently and to our high quality standards.

Wind turbines are equipped with a rotor lock system, a robust safety lock that keeps the blades at standstill during maintenance and inspection. The rotor lock system allows for controlled and precise positioning of the rotor blades. This is particularly important during maintenance tasks that require specific blade angles or when accessing certain parts of the turbine.

One or more locking pins are pushed into holes within the hub which allows control over the blades position for different repair and maintenance tasks – either on the blades themselves or in the turbine. The integrity of the system is crucial for safe as well as efficient maintenance and repair work.

The rotor lock systems can have different designs, but regardless of the design it is important to have a relatively tight fit between locking pin and locking hole. The holes can get worn over time or suffer damaged during insertion or retraction of the locking pin.

Wear and damages can lead to a gap between hole and pin, which may allow small movements of the rotor. This can cause safety issues as even small movements of the rotor can make certain types of maintenance and repair on the high-speed site of the turbine complicated or even impossible.

 

SAFETY

Locking the rotor reliably is a crucial part of safety during maintenance.

FAST RESPONSE

We are on-site quickly as damaged rotor lock holes need immediate attention.

REDUCED DOWNTIME

Up-tower repairs means reduced  downtime and requires only minimal involvement from the customer

RELIABILITY

In-house developed  machines ensure high precision and reliable result

CONTACT US

Our team of experienced professionals will guide and advice you towards
the best possible solution that takes time, economy and durability into consideration.

Søren Kellenberger

Sales Director

+45 25 53 76 50 | ssk@cnconsite.dk

soren_schmidt_kellenberger

Process

From challenge to solution

Quotation request
Wind turbine component repair in progress.

The wind turbine maintenance team report damage to one or several rotor lock holes to CNC Onsite.

Our technicians respond on the same day to assess the damage.

We will issue a quote once the defect has been analysed.

The customer signs the purchasing order, and the repair can commence almost immediately.

Planning
Precision repair of a wind turbine rotor lock hole.

We plan the rotor lock hole repair in advance to work efficiently once we are on-site.

The rotor lock type determines the exact repair method which we follow to restore the hole.

All repairs are based on “method statements” to ensure a correct and efficient process – every time.

Implementation
CNC Onsite checklist and thumbs-up symbol, representing the efficient rotor lock repair process using in-house developed machines

Our technicians usually start work in the morning, transporting the machine to the nacelle.

The team will use our in-house developed machines to repair the rotor lock.

Upon completion, the rotor lock  is tested.

Handover
Successful repair of a wind turbine component.

After the rotor lock has been repaired, the customer signs off and wind turbine inspections and services can take place.

Follow-up

We offer customers a discussion with the technician who will then carry out the next inspection.

Our follow-up program complies with our high quality standards.

AN ADAPTABLE WORKFORCE

 

„We can be working on a project in our workshop one day, and the next day they could be ready to board a flight to Australia. It’s thanks to our adaptable employees and our project managers that it’s even possible‟.

 

Jonas Nielsson, On-site Machinist

 

READ MORE ABOUT OUR YAW RING REPAIR

Rotor Lock Repair

Learn more about our rotor lock repair solution in Q&A section right here:

Can damaged rotor lock holes be repaired? Damages to the rotor lock holes can be repaired using the right precision machines. The repairs to the rotor lock hole are carried out in-situ in the wind turbine nacelle, even if space is limited. CNC Onsite has developed several solutions to be able to handle a large variety of turbine types.
How are the rotor lock holes repaired? The repair process of the rotor lock hole varies depending on the specific rotor lock system chosen for that turbine. Common to all solutions are that the repair is performed up-tower in the nacelle. Even in tight conditions in the nacelle, the rotor lock repairs can be completed. Our technicians can repair a wide range of rotor locks designs, both electromechanical and hydraulic types.
A damaged rotor lock hole has been detected. What is the process to repair it? The customer, usually the wind wind park technicians, contacts CNC Onsite. Within a few hours, our technical team responds to dicuss the damage with the customer who will typically send photographs of the damage. We will then assess the extent of the rotor lock damage. As soon as the customer signs the purchasing order, the CNC Onsite team and wind turbine owner will agree on a date to repair the affected rotor locks.
How many rotor lock holes can be repaired? It is possible to repair all damaged rotor lock holes. If more holes are affected, this will be taken into consideration in the overall planning of the task.
How quickly can the rotor lock technicians come to the wind farm/park? CNC Onsite’s rotor lock repair technicians can be onsite, usually within days. How long does it take to repair a rotor lock hole? The time it takes to repair a rotor lock holes highly depends on the number of damaged rotor lock holes and the extent of the damage. To optimize the repair process CNC Onsite will as part of the planning for job, go through the preparations needed in the turbine, the actual repair work and the final verification test. On average the actual repair work on a rotor lock position will take around half a day.
What does it cost to repair a rotor lock? Each job is different. The costs will depend on the number of damaged rotor lock holes, severity of damages, turbine type and the location to name a few. As part of the task clarification, CNC Onsites evaluates the work and submits a quotation for the repair work.

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