As part of our mission to extend the lifespan of the E44 ENERCON wind turbine, one of our aims was to refurbish the rotor hub and main shaft.
The hub of a wind turbine is the central part that connects the blades to the main shaft, allowing the rotation of the blades to generate clean, renewable energy. In the Faroe Islands, harsh weather conditions and high salt content could have caused wear and tear to the hub and its components.
We wanted to comprehensively understand the hub’s condition so using our reverse engineering capabilities, we stripped it down for inspection and went on to do a comprehensive examination of the stator hub and the main shaft.
The two main bearings were thoroughly examined. The large bearing showed no issues, while the small bearing had an extra bolt left over from its original construction. For safety and optimal functionality, we strongly advised replacing the second bearing. But we didn’t stop there.
We subjected the remaining bearing to rigorous testing to assess any wear and tear. We also inspected the pitch motors and decided replacing them would be the best course of action. These motors play a pivotal role in adjusting the angle of the blades to control the rotor speed and regulate the power output.
Instead of discarding the old pitch motors, we overhauled them, ensuring they could be used wherever needed within the wind farm. This approach allowed us to minimise waste and make the most of existing resources, aligning with our commitment to sustainability.
By conducting this thorough examination and testing, we ensured that the hub and the main shaft was in top- condition and high specifications were met. The hub was ready to support the wind turbine’s reliable and efficient operation for years to come.
Our commitment to precision and quality is what sets us apart, and we’re proud to be part of the success of the onshore wind turbine life extension project.
As the main contractor, we’re proud to be part of this journey towards a greener future. Our collaborative efforts have not only extended the life of the wind turbine but also exemplified our commitment to sustainable practices.
Read the full Enercon E44 Wind Turbine Repair case study
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