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Better methods are needed to install, service and replace major components on large wind turbines

Published in: Wind, Exclusive Articles, PES Spotlight

Better methods are needed to install, service and replace major components on large wind turbines image

As wind turbines grow larger, SENSEWind’s SENSE system could simplify installation and maintenance, reduce reliance on heavy lifting equipment and lower costs.

Larger turbines and more challenging wind farm locations are making turbine installation and maintenance increasingly difficult and expensive. Using current approaches, taller towers and heavier components require larger cranes and more specialised vessels, which are more expensive and less readily available. In turn, large cranes require modifications to infrastructure, including ports and roads, particularly at remote onshore sites and offshore projects far from shore.

Unplanned major maintenance brings particular difficulties when lifting equipment must be mobilised rapidly and can result in disproportionate costs. Replacing a blade, generator or complete rotor nacelle assembly (RNA) can involve expensive lifting equipment, lengthy mobilisation periods and revenue losses while the turbine is out of service.

For floating wind, major repairs can be even more complicated. One maintenance strategy involves disconnecting a turbine and towing it to port, where suitable cranes and facilities are available. This approach has been used at the Kincardine and Hywind Scotland floating wind farms. All five Kincardine turbines have been towed to Rotterdam for major component replacement (MCR) during 2022 and 2023, while all five Hywind Scotland turbines were towed to Norway for maintenance in 2024.

Kincardine subsequently demonstrated an alternative in 2024, replacing a generator offshore without towing the turbine to port. This early experience is leading the industry to question whether towing turbines to port is a practical and affordable long-term solution.

SENSEWind offers an alternative installation and service system which eliminates the need for ever larger cranes and crane vessels to install and service large turbines. Using SENSE (Self Erecting Nacelle and Service system), large turbines, for example 8 MW onshore and 20 MW offshore, could be installed using existing cranes and crane vessels.

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