The system has been tried and tested in real world applications for both onshore and offshore windfarms. In one case, an operator required yaw brake replacement across hundreds of offshore turbines but wanted to minimise the effects of downtime across the site. The LBS yaw brake lifting tool was sourced for the job, which greatly expedited work over the year-and-a-half project. As a result, downtime was slashed by 50% and maintenance work was carried out with increased efficiency.

Beyond brake pad replacement, damage to the actual brake disc is another issue which can lead to significant expense and long periods of downtime. Typically, the average turbine brake disc could measure 2.5 m wide and 40 mm thick. Consequently, the nacelle and blades must be removed completely to replace the disc. The entire process could cost up to €800 000 depending on the location.

One operator required brake resurfacing, but also turbine operations at night to reduce downtime, which required the reinstallation of all brake components on turbines at the end of each day. This was unprecedented, so the service engineers reviewed the options available to them. It was decided that an LBS yaw brake lifting tool could be used for the project.

First the two brakes were removed, next, a computer numerically controlled disc resurfacing tool designed and built in-house by Svendborg Brakes was winched into place and attached to the bedframe. With the brakes removed, the resurfacing tool machined the disc back to the optimum condition without nacelle removal. Brake resurfacing was finished in a day at less than 50% of the usual costs. Further, the process was efficient enough to have all brake components reinstalled for the evening, allowing power generation at night.

Renewable energy is set to provide 30% of the world’s electricity supplies by 2040. As of 2018, wind energy is already covering close to 6% of global electricity demand. For an industry built on the principles of efficiency, it is essential that maintenance procedures are perfected to keep the costs of energy down for consumers. This is a sector where innovation is standard, therefore it is only correct that the aftermarket and maintenance, repair and operations side of the industry mirrors this process.

The nature of wind farms is that they are installed in remote areas, which are very hard to access. Innovations such as the LBS lifting system and disc resurfacing tool helps maintenance crew to complete work faster, with reduced manpower, while keeping turbines turning longer.