KHIA headerKnow-How in Action

VOL XXXII, NO 92

Belzona® Repairs Wind Turbine Shaft In Place

 
 

Industry:

Power (POWR)

 
 

Application:

Fans, Blowers and Compressors (FBC)

 
 

Customer Location:

West Texas, USA

 
 

Application Date:

December 2011

 
 

Application Situation:

Wind Turbine Shaft on Wind Farm

 
 

Problem:

The shaft in this wind turbine at a wind farm was not grounded properly causing electrolysis damage. The damage was considerable and was destabilizing the turbine.

 
 

Products:

Belzona 1111 (SuperMetal)

Belzona 9111 (degreaser) 

Belzona 9411 (Release Agent)

 

Substrate:

Carbon Steel

 
 

Application Method:

The application was carried out in accordance with the Belzona System Leaflet FBC-13. A brass cast former was made to the exact dimensions of the shaft repair.

 
 

Belzona Facts:

The Customer was very pleased that the Belzona solution offered prevented them from taking the turbine apart and bringing it to the ground. Two other options were considered originally: 1.Call a crane company and replace the generator shaft. Cost - $300,000.00 2.Call a crane company, lower the generator, ship it to a shop and repair by welding. (Includes stress relieving, and straightening) Cost - $275,000.00. Additionally, both options would have caused a downtime of 2-3 weeks.Cost of application, including labor,($5000 brass, resuable former), 1111 2kg, 9411 and 9111 < $10,000.The method is now standardized over the energy company's wind farms and the contractor has 10 different size formers(all reuseable) for the different size shafts that they have repaired with Belzona. There were $250K savings in comparision to a traditional repair. 

 
 

Photographs Description

1. Shaft damage by electrolysis.

2. Shaft with Belzona 1111 being applied

3. Shaft with copper former whle Belzona 1111 is curing. The release agent was applied on the former.

4. Former removed and the application is now completed.

 
Case study pic one

 

 
 Case study pic two

 

 
 Case study pic three

 

 
 Case study pic four

 

 
 
For more information about Belzona visit: www.belzona.com