When the original manufacturer’s warranty ends, the project owner and/or operator must identify the best approach for repairing those systems and components that fail. Most standard repairs can be handled by the on site O&M team. Those repairs needing more specialized attention require trained crews to come in for onsite repair, or may require that the components be shipped off site for additional repair. EMS maintains a modern remanufacturing facility located in Howard, South Dakota where highly specialized repairs and remanufacturing services are performed. Components being remanufactured in this facility include gearboxes, blades, brake stations and yaw components.
Turbine Rebuild >
Gearbox Rebuild >
Blade Repair >
Generator Repair >
Component Rebuild >
Turbine Rebuild >
Gearbox Rebuild >
Blade Repair >
Generator Repair >
Component Rebuild >
Turbine Rebuild
Today’s consumer has very few options available if they are searching for a reliable, cost-effective commercial turbine in the 30kW to 250kW size class. This is primarily due to the market demanding larger, more efficient turbines that are able to produce more energy at lower rates.
The demand for larger equipment creates a ‘capacity gap’. Remanufactured wind turbines installed as early as 1983 in the US provide a viable option. Several models of turbines from this era have proven track records of reliable performance. Despite their age, these turbines when properly remanufactured have the ability to offer many additional years of safe operations and efficient production at a fraction of the cost of a comparably sized new turbine.
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Today’s consumer has very few options available if they are searching for a reliable, cost-effective commercial turbine in the 30kW to 250kW size class. This is primarily due to the market demanding larger, more efficient turbines that are able to produce more energy at lower rates.
The demand for larger equipment creates a ‘capacity gap’. Remanufactured wind turbines installed as early as 1983 in the US provide a viable option. Several models of turbines from this era have proven track records of reliable performance. Despite their age, these turbines when properly remanufactured have the ability to offer many additional years of safe operations and efficient production at a fraction of the cost of a comparably sized new turbine.
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Turbine Rebuild
EMS operates a modern wind turbine remanufacturing facility located in Howard, SD. This facility is staffed with skilled technicians that have the ability to manage the entire remanufacturing process thus providing the highest levels of quality control and a superior finished product for our customers.
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Gearbox Rebuild >
Blade Repair >
Generator Repair >
Component Rebuild >
EMS operates a modern wind turbine remanufacturing facility located in Howard, SD. This facility is staffed with skilled technicians that have the ability to manage the entire remanufacturing process thus providing the highest levels of quality control and a superior finished product for our customers.
< Back
Gearbox Rebuild >
Blade Repair >
Generator Repair >
Component Rebuild >
Gearbox Rebuild
Typically, used gearboxes will have had tens of thousands of hours of operation and had multiple braking events, so it is common for older gearboxes to be severely compromised. Many older turbines were equipped with severely underrated gearboxes so often replacement is the only option.
Our procedures for gearbox repair includes the following: High Speed and Intermediate bearings are replaced. All tooth surfaces are inspected and gearing is replaced if deterioration is detected. All components are thoroughly cleaned. Seals and oil filters are replaced. All tolerances are measured to return the gearbox to optimal performance. The gearbox is filled with new oil designed to meet the temperature profile of the region where it will be operated.
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Turbine Rebuild >
Blade Repair >
Generator Repair >
Component Rebuild >
Typically, used gearboxes will have had tens of thousands of hours of operation and had multiple braking events, so it is common for older gearboxes to be severely compromised. Many older turbines were equipped with severely underrated gearboxes so often replacement is the only option.
Our procedures for gearbox repair includes the following: High Speed and Intermediate bearings are replaced. All tooth surfaces are inspected and gearing is replaced if deterioration is detected. All components are thoroughly cleaned. Seals and oil filters are replaced. All tolerances are measured to return the gearbox to optimal performance. The gearbox is filled with new oil designed to meet the temperature profile of the region where it will be operated.
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Turbine Rebuild >
Blade Repair >
Generator Repair >
Component Rebuild >
Blade Repair
Turbine blades see many millions of turns over their lifetime. Potential problems are likely and can include small cracks, breakdown of the material at the blade root, poor adjustment, or wear on the tip mechanism. All of these problems are well-known, and there are a number of standard repairs that can help prolong blade life.
All blades undergo deflection testing which measures blade integrity. The roots are closely inspected with particular emphasis on checking for de-lamination of the root bundles. The aerodynamic brake tip mechanisms are inspected and metal parts replaced if wear is present. All surface cracks and blemishes are repaired. The blades are then weighed and fully balanced prior to installation.
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Turbine Rebuild >
Gearbox Rebuild >
Generator Repair >
Component Rebuild >
Turbine blades see many millions of turns over their lifetime. Potential problems are likely and can include small cracks, breakdown of the material at the blade root, poor adjustment, or wear on the tip mechanism. All of these problems are well-known, and there are a number of standard repairs that can help prolong blade life.
All blades undergo deflection testing which measures blade integrity. The roots are closely inspected with particular emphasis on checking for de-lamination of the root bundles. The aerodynamic brake tip mechanisms are inspected and metal parts replaced if wear is present. All surface cracks and blemishes are repaired. The blades are then weighed and fully balanced prior to installation.
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Turbine Rebuild >
Gearbox Rebuild >
Generator Repair >
Component Rebuild >
Generator Repair
In hotter climates, the wear effects of the generator are generally caused by the hot summer wind resources. Turbine generators driven by these winds tend to run at full capacity during the hottest period of the day resulting in rapid deterioration of insulation and bearings.
The complete rewind of a generator with replacement bearings and thermal protection is the minimum requirement for the repair and remanufacture of the turbine; otherwise a new generator must be installed for optimum performance.
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Turbine Rebuild >
Gearbox Rebuild >
Blade Repair >
Component Rebuild >
In hotter climates, the wear effects of the generator are generally caused by the hot summer wind resources. Turbine generators driven by these winds tend to run at full capacity during the hottest period of the day resulting in rapid deterioration of insulation and bearings.
The complete rewind of a generator with replacement bearings and thermal protection is the minimum requirement for the repair and remanufacture of the turbine; otherwise a new generator must be installed for optimum performance.
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Turbine Rebuild >
Gearbox Rebuild >
Blade Repair >
Component Rebuild >
Component Rebuild
EMS has earned a solid reputation for maintaining and remanufacturing older turbines and many of their component parts. This has been accomplished through our selective usage of the technologies we have learned over the years. Components we are able to remanufacture in our facilities include gearboxes, blades, brake stations, and yaw components.
Whenever possible, EMS prefers to dismantle and decommission the turbines to be remanufactured because it allows us to spot problems early on. Full inspections are carried out, the towers are fully degreased, and scratches or chips to the surface coating are repaired. If the tower is tubular it is repainted.
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Turbine Rebuild >
Gearbox Rebuild >
Blade Repair >
Generator Repair >
EMS has earned a solid reputation for maintaining and remanufacturing older turbines and many of their component parts. This has been accomplished through our selective usage of the technologies we have learned over the years. Components we are able to remanufacture in our facilities include gearboxes, blades, brake stations, and yaw components.
Whenever possible, EMS prefers to dismantle and decommission the turbines to be remanufactured because it allows us to spot problems early on. Full inspections are carried out, the towers are fully degreased, and scratches or chips to the surface coating are repaired. If the tower is tubular it is repainted.
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Turbine Rebuild >
Gearbox Rebuild >
Blade Repair >
Generator Repair >
Component Rebuild
Remanufacturing Procedure for Components
• All wiring is replaced. New wiring is properly sized to meet current standards.
• Yaw bearings are inspected and unless in exceptional condition the bearings should be replaced. All teeth on slew plates and yaw bearings are inspected for wear. Slider material is inspected and replaced on slew plates.
• Yaw boxes are opened and cleaned. All internal gearing and external pinion gears are inspected for wear. If these show excessive wear the box is replaced. The yaw box is reassembled with new seals, bearings, and repacked with new grease. Yaw box motors are replaced with new motors.
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Turbine Rebuild >
Gearbox Rebuild >
Blade Repair >
Generator Repair >
Remanufacturing Procedure for Components
• All wiring is replaced. New wiring is properly sized to meet current standards.
• Yaw bearings are inspected and unless in exceptional condition the bearings should be replaced. All teeth on slew plates and yaw bearings are inspected for wear. Slider material is inspected and replaced on slew plates.
• Yaw boxes are opened and cleaned. All internal gearing and external pinion gears are inspected for wear. If these show excessive wear the box is replaced. The yaw box is reassembled with new seals, bearings, and repacked with new grease. Yaw box motors are replaced with new motors.
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Turbine Rebuild >
Gearbox Rebuild >
Blade Repair >
Generator Repair >
Component Rebuild
Remanufacturing Procedure for Components (cont.)
• All turbines are refitted with a modern controller that is operationally more sophisticated than those originally supplied with the turbines. This includes a soft start feature that protects the generator and drive system of the turbine. All electrical terminations, wiring, relays, breakers and other components are optimized for ease of operation. When possible, EMS uses breakers instead of fuses.
• In most cases hydraulic units will be replaced, however, some turbines have specialized hydraulic units that will be rebuilt with new seals, solenoids and stats.
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Turbine Rebuild >
Gearbox Rebuild >
Blade Repair >
Generator Repair >
Remanufacturing Procedure for Components (cont.)
• All turbines are refitted with a modern controller that is operationally more sophisticated than those originally supplied with the turbines. This includes a soft start feature that protects the generator and drive system of the turbine. All electrical terminations, wiring, relays, breakers and other components are optimized for ease of operation. When possible, EMS uses breakers instead of fuses.
• In most cases hydraulic units will be replaced, however, some turbines have specialized hydraulic units that will be rebuilt with new seals, solenoids and stats.
< Back
Turbine Rebuild >
Gearbox Rebuild >
Blade Repair >
Generator Repair >
