Nacelle Remanufacturing

Our Technical Director Mark Wilson can answer any specific questions you have about the following nacelle remanufacturing process….

Disassembly

Once the nacelle is in our workshop, we organized the components in separate areas, nacelle, control cabinet and hub.

We then identify and label all components. Especially those ones that have been removed from the turbine at the dismantling stage like power cables, bolts, covers, sensors, etc.

Surface treatment

To ensure a long life for the wind turbine we apply a new and complete surface treatment to all the main and small components. Our objective is to not remove the original galvanising but to lightly shot blast it to remove any residue and corrosion; this guarantees our protective coatings bond.

Bushings & Mounts

All wearing parts are replaced and great care is taken to ensure the turbines we refurbish are in as new condition as possible.

Wind Turbine nacelle stripped ready to degrease
Nacelle stripped and ready to degrease
Wind Turbine Chassis After Degreasing
Chassis after degreasing
Wind Turbine Chassis and All Parts Are Shot Blasted
Chassis and all parts are shot blasted
Nacelle parts primed with specialist paints
All parts are primed with specialist paints
Top Coat and Anti-Slip Tape is Applied
Top coat and Anti-Slip Tape is applied
Yaw Gear Is Refurbished
Yaw Gear is refurbished

Gearbox

We are currently working hand in hand with a UK gearbox specialist that is also used by ZF wind division, who is one of most important gearbox manufacturers in the wind industry.

The refurbishment consists of the following:

  • Complete disassembly of the unit
  • Gears checked for damage
  • Cleaning and surface treatment
  • NDT testing on all gears and shafts
  • Replacement of bearings and seals
  • Reassembly of the unit
  • Final Test

After this service the gearbox bearings will have a 2 year warranty.

Main Shaft

The refurbishment consists of the following:

  • Complete disassembly of the main shaft and the main bearing housing.
  • The components are degreased and cleaned.
  • Main bearing seats are reworked.
  • Replacement of bearings
  • Reassembly of the unit
  • Auto-lubes are installed.

After this service the main shaft bearings will have a 2 years warranty.

Generator

The service for this component consist of the following:

  • Disassembly of the generator
  • Cleaning and surface treatment
  • Ferodo, elastic coupling and conical springs inspection
  • New linings fitted to torque limiter
  • Inspection of bearing housing caps
  • Inspection and measure of bearing fixing on both sides
  • Inspection and measure of shaft alignment
  • Stator cleaning and new varnishing
  • Replacement of bearings
  • Reassembly of the unit
  • Auto-lubes are installed.
  • Electrical testing to the double winding (6-8 poles 1000-750rpm)
  • Inspection and testing of welding inner connection terminal block
  • Testing of insolation
  • Generator AV mounts are replaced with new ones.

After this service the generator bearings will have a 2 year warranty.

Hydraulic system

  • We clean, inspect and test the hydraulic unit. All shock absorbers on the basement plate of the hydraulic unit have been replaced.
  • The hydraulic accumulators have been recharged with nitrogen.
  • Brake calliper have been disassembled and painted, their internal components has been cleaned and inspected.
  • Hydraulic seals have been replaced by new ones.

Yaw motors

The service for this component consists of the following:

  • Disassembly of the motors
  • Cleaning and surface treatment
  • Inspection of bearing housing caps
  • Stator cleaning and new varnishing
  • Replacement of bearings
  • Reassembly of the unit
  • Isolation Testing

After this service the gearbox bearings will have a 2 year warranty.

Yaw Gearbox

The service for this component consists of the following:

  • Flush the gearbox and refill with grease/oil
  • Cleaning and surface treatment

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Copyright © Boythorpe Wind Energy Limited, 2013. All rights reserved. UK Registered Company No. 08433182. VAT Registration # 160 092831.
Boythorpe Farm, Butterwick, Malton. North Yorkshire. YO17 8HF. Telephone (01377) 267615 E-Mail: info@boythorpewindenergy.co.uk
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