INDUSTRY
Wind Power
Repair composites and protective coatings for maintenance of wind turbines
Long-lasting, in-situ-applied and erosion resistant solutions for the wind power industry.
Wind Power is currently leading the way in the Renewable Energy Sector and is considered to be one of the largest sources of clean energy in the world. Consequently, it has gained global attention with hundreds of billions of dollars invested into the sector each year, making it one of the world’s fastest growing industries.
Problems Facing the Industry
One of the greatest problems facing the Wind Power industry is the maintenance of the turbines themselves. Ceasing energy production and dismantling the turbines for repairs can be a costly and lengthy procedure.
The average wind turbine is made up of 8000 different pieces which can experience a range of maintenance issues. This can be due to environmental damage, erosion and corrosion, amongst other reasons. Offshore wind farms
pose further issues; as well as the harsher environment, in-situ maintenance is also more difficult to perform.
Where Does Damage Occur?
One way to best understand the different issues wind turbines can experience, is by splitting them up into three main areas:
• Blades
• Nacelle
• Tower, Base and Transformer
Belzona’s Interactive Solutions Map guides you through a model wind farm, highlighting typical equipment and application areas.
The Interactive Solutions Map offers detailed descriptions of each area and piece of equipment within a wind farm. It highlights common issues and presents solutions using Belzona’s polymeric technology.
WIND POWER APPLICATION
Blade Repairs
Blade restoration and leading-edge protection (LEP)
Leading Edge Damage
Leading edge damage is recognised as the single largest maintenance problem within the wind power industry. Evidence suggests that damage to the leading edge can lower the AEP (Annual Energy Production) of a wind turbine, with energy losses estimated at between 4% and 20% if the erosion damage is severe.
COMMON PROBLEMS
- Erosion caused by impact from rain droplets and debris
- Factory applied coating not strong enough
- Loss of efficiency due to increase aerodynamic drag
Blade Restoration with Belzona 5711
Belzona 5711 can be used to rebuild pitted sections of the blade prior to further application of a leading-edge protection coating.
Belzona 5711 - Wind Turbine Blade Repairs
- Cartridge Format
- Good working life: 8 – 18mins dependent on temperature
- Fast Cure
- Easily overcoatable: Chemically compatible with Belzona 5721
- Easily overcoatable: Chemically compatible with Belzona 5721
- No requirement for sanding
- Application window of 5°C – 40°C
- CMR free
Blade Protection with Belzona 5721
Belzona 5721 complements in-situ maintenance thanks to its simple one coat application and full service can be restored in as little as 4 hours. This LEP coating is available in white and grey (RAL 7035).
Belzona 5721 - Wind Tubine Leading Edge Protection
- One-coat system minimises labour time
- Brush applied with no specialist tools required
- Suitable for in-situ application down to 5°C
- Solvent-free, 100% solids coating
- Fast back to service time and touch dry in approx. 1 hour
- Tested in accordance with ASTM G73 standards
- Tested at accelerated speeds, equal to 160 m/s (525 ft/s) at the blade tip
- Coating unaffected at 120m/s (394 ft/s) during both 3- and 6-hour tests
- Outstanding erosion resistance and durability
- UV stable
WIND POWER APPLICATION
Nacelle
Rebuild solutions for mechanical components such as the shaft, gear box, rotor brake, oil pump, and yaw motor as well as leakage from the lubrication reservoir
Shaft Repairs
Belzona provides a comprehensive range of 100% solids epoxy composite materials designed to repair and prevent the common failures associated with components in the nacelle. Belzona’s cold-applied epoxy materials offer a rapid and reliable alternative to dismantling, welding and machining techniques which are required for conventional repairs.
COMMON PROBLEMS
- Mechanical damage by misalignment
- General wear over time
- Damage by electrolysis
Using metal repair materials such as Belzona 1212 or Belzona 1131, worn and damaged shafts can be repaired in situ, limiting the downtime and lost production costs which can be incurred. These easy-to-apply systems extend the lifetime of equipment and return assets to service in a fraction of the time. Moreover, they can be used to resurface distorted gearboxes and bearing houses, as well as providing superior erosion and corrosion resistance.
- Applied in-situ
- No hot work
- Reduce back to service time
- No heavy equipment
- Proven in the field
Bearing Repairs
COMMON PROBLEMS
- Galvanic corrosion, general wear and tear creating clearance between bearing & housing, causing a poor fit
Bearing Repairs – Injection Technique
The Belzona Solution: Inject Belzona 1000 series liquid applied epoxy to fill gaps
- Applied in-situ
- Easy to achieve alignment
- 100% contact
- Stops galvanic effect
- No hot work
- Reduce back to service time
- No heavy equipment
- Proven solution
WIND POWER APPLICATION
Tower, Base and Transformer
General maintenance, repair and leak sealing
Tower Corrosion Protection
The taller the turbine, the higher the wind speed at the top and therefore the greater expected power. However, the larger the surface area, the more damage the tower is subject to. Belzona’s coatings protect the turbine’s tower from corrosion and environmental conditions.
Base Repair and Strenghtening
TYPICAL PROBLEMS:
Corrosion on bolts and concrete cracking
POTENTIAL SOLUTIONS:
Belzona 3000 solutions for bolt external protection and base water proofing, Belzona 4000 magma systems for concrete repairs.
Transformer Leaks
TYPICAL PROBLEMS:
Leaks due to corrosion and/or accidental impact
POTENTIAL SOLUTIONS:
Belzona 1000 series 100% solids paste and fluid-grade materials for corrosion protection
