Yaw Ring Repair Project of a Wind Turbine in Spain

In the Spanish wind energy sector, the age of certain wind farms is beginning to pose corrective maintenance challenges that go beyond usual wear and tear. An unexpected fracture in the yaw ring’s teeth can indefinitely halt a wind turbine, becoming a bottleneck for energy production.

Recently, iZanda deployed its rapid response unit to a wind farm in Spain to address a critical breakdown. Unlike progressive wear, this case involved the complete breakage of a main tooth, which prevented the transmission of movement and jeopardized the yaw motors’ gears.

Our philosophy is clear: in-situ repair is the smart alternative to replacement. Instead of managing the complex logistics of bringing a new yaw ring and large cranes to the site, our team ascended to the nacelle with portable machining technology to restore operability in a matter of days.

Corona Orientación de aerogenerador dañadaCorona Orientación de aerogenerador despues de reparación

FAQ:

Q: How do you ensure that the new tooth fits perfectly with the motor pinion?

A: Precision is absolute. As shown in the final images, we use specifically manufactured “go/no-go gauges” for that wind turbine’s module. During the machining of the insert, we constantly check the geometry until the gauge fits with zero tolerance, ensuring that the contact with the pinion is smooth and uniform.

Q: In in-situ machining operations inside the wind turbine’s nacelle, are chips generated that could damage other components?

A: It’s a common concern, but our protocol is strict. We isolate the work area by creating an “operating room” inside the nacelle. We use industrial suction systems and magnetic guards to instantly capture any metal debris, ensuring that the lubrication system and bearings remain uncontaminated.

Q: How much time is saved compared to replacing the yaw ring?

A: The difference is huge. While manufacturing, transporting, and installing a new yaw ring can take months (lead time) and require a week of complex crane maneuvers, our in-situ repair is typically completed in less than 5 working days, returning the turbine to the grid almost immediately.

Yaw Ring, before repair

The image documents the extent of the damage to tooth number 121. A complete fracture of the tooth body is observed, with massive material detachment from the root. Unlike wear from friction, this structural break left an irregular surface that rendered the yaw system in that sector unusable, necessitating the immediate shutdown of the machine.

Yaw Ring after repair

The image shows the definitive solution applied by iZanda. The affected area has been hollowed out to accommodate a new high-strength steel block. Most notable is the use of a verification template (gauge) on the newly machined profile, ensuring that the pitch, height, and involute curve of the new tooth 121 are identical to the originals, ensuring perfect integration.

  • IMMEDIATE REACTIVITY
    Operating locally in Spain, our mobilization times are minimal, drastically reducing lost revenue. In Europe, our response times are similar.
  • STRUCTURAL INTEGRITY
    The fastening method of our inserts is calculated to withstand loads greater than those of the original tooth, eliminating the “weak point” of the yaw ring.
  • REAL SUSTAINABILITY
    We avoid the disposal of tons of steel and the carbon footprint associated with manufacturing large new components.
  • COST SAVINGS
    Since it is an in-situ repair and not a replacement of the yaw ring, the savings are very significant.

Is your wind farm experiencing downtime due to broken teeth?

Don’t let a fracture in the yaw ring compromise your annual production. At iZanda, we turn a major breakdown into a swift and guaranteed repair.

Request an urgent diagnosis today and get your turbine back up and running as soon as possible.

Speak with our engineering department today for a technical evaluation