04.05.2023 | Wind power plants

Exciting insights into the working life of a service engineer for wind turbines

The subject of safety, as viewed by an expert. At INNOTECH we therefore examine in detail the special challenges created in practice by the various wind turbine models, and how we can optimise our fall protection systems for this specialised application. That is why we interviewed BWTS on this topic.

2 Ratings

Specialist series: Fall protection at and on wind power plants

01
Rescue training interview RelyOn Nutec and Innotech - Onshore

“What happens when something happens?” – Birk Schütte in the interview about rescue training for wind power technicians

In addition to a professional, certified fall protection system, in-depth training is amongst the major elements of a comprehensive safety concept. Rescue training is an extremely important component of this. Birk Schütte explains what matters in terms of rescue training, and how important professional fall protection systems are, even at the level of training.

02
Godewind II relies on fall protection from Innotech

Success Story Gode Wind 2

Protecting an offshore wind farm requires the most modern, certified safety systems which can be optimally adapted to the actual situation. In the case of Gode Wind 2, the ascent on the one hand, and the maintenance routes along the shunts on the other hand had to be protected appropriately.

03
 BWTS & Innotech

Professionals pinpoint potentials for improvement in terms of safety on wind power plants ...

Wind power parks or plants are among the workplaces that carry the highest risk potential of all. When it comes to safety, these installations pose a tremendous challenge in more than one way: as they average a height of 100 to 140 metres and are usually set up in far-off locations. In this article, we look at the danger areas from the perspective of BWTS experts.

04
BWTS interviewed by Innotech

Exciting insights into the working life of a service engineer for wind turbines

The subject of safety, as viewed by an expert. At INNOTECH we therefore examine in detail the special challenges created in practice by the various wind turbine models, and how we can optimise our fall protection systems for this specialised application. That is why we interviewed BWTS on this topic.

05
Danger sources wind turbines - fall protection

Challenges for service engineers on wind turbines

Wind turbines - the giants on land and water - reach dizzying heights in order to generate energy from the power of the wind. In this blog post, we explain the challenges relating to each danger area, how fall protection and wind power interact in general, the solutions which we offer for this and, as a modest digression, how the development of wind energy came about.

06
INNO|talk - expert discussion on the subject of fall protection on wind turbines

The importance of fall protection systems for wind power

To ensure that service technicians are protected in the best possible way during their dangerous work, safety systems must undergo continuous development. For this reason, INNOTECH continuously exchanges information with operators of wind power plants as well as training and education institutions in this segment. Find out in our INNO|talk what experts report on this topic based on their practical expertise.

07
Safety first - Innotech & wind power plants

Best Of INNO|talk Part I: Danger areas on wind turbines - safety is always first

In the INNOtalk on the subject of safety at wind power plants, Marc Wollschläger and Michael Pett share their hands-on experience on the subject. They spell out their practical knowledge of the TAURUS rail system, which they have dubbed the perfect fall protection system for wind turbines. The reason why is very simple: Not only does this solution allow for a seamless connection between the vertical and horizontal passages, but it can also be precisely adapted to the individual needs.

08
Best Of INNO|talk Part II - experiences and feedback

Best Of INNO|talk Part II: Experiences, feedback and cooperation for improved safety on wind turbines

The fledgling discussion format INNOtalk provides experts from all relevant areas of wind power with an opportunity to take the floor and describe their respective problems and challenges. Following the motto of "listen and comprehend", the panel makes it possible to utilize the needs and requirements of the affected employees in a way that allows for the creation of a safe working environment on wind turbines.

09
The big overview - safety at wind power plants

Safety on wind turbines - the big picture

Because wind turbines are one of the most dangerous workplaces in terms of industrial safety, it is natural that fall protection systems and safety solutions are currently gaining in importance in this regard. This article provides you with all relevant information about the legal requirements, technical solutions, and developments in the area of safety.

The greatest danger comes from the enormous height of such a wind turbine!

Marc Wollschläger
BWTS interviewed by Innotech

Renewable energy sources are a basic piece of the jigsaw on the way to a sustainable lifestyle. And wind power plays a central role when it comes to generating the energy required in a clean, climate-friendly way. BWTS is a specialist in services relating to the generation of renewable energies, and since its foundation it has pursued the goal of making green energy successful in the long term. Just recently we looked over the shoulder of a BWTS service engineer during the maintenance tasks on a Senvion 3.4 wind turbine.

And these tasks are really something, because a power generator like this is about 100 metres in height, and is generally in an exposed location. This means that the safety of all engineers who venture into such dangerous areas has top priority. At INNOTECH we therefore examine in detail the special challenges created in practice by the various wind turbine models, and how we can optimise our fall protection systems for this specialised application. We can reveal this much: It was a very exciting day. But read it for yourself.

 

The start into the day

INNOTECH: How does your day start? What activity is planned today?

BWTS: Today the 6th annual maintenance of this wind turbine is on the agenda. The turbine has been generating power for 6 years, with a rated output of 3,400.0 kW. The actual work today includes various repairs, plus the main service, and any other jobs which arise – that’s what the service engineers from BWTS were contracted for.

 

INNOTECH: How do you actually proceed, and what do you have to look out for?

BWTS: The first thing is to register. That’s very important, because the wind turbine operators must know that these tasks are going to be undertaken, as the turbine has to be switched off to allow this. It’s the only way to work safely. In addition, the operators then know that the respective wind turbine will provide no power during the maintenance period. On top of that, they have to be able to react quickly in an emergency and therefore they need to know the exact location of the service engineers at that moment. This procedure is extremely important, above all in terms of safety. Problems of any type can occur at any time. So this principle applies: Register and inform before starting the work.

 

INNOTECH: That makes sense; so what happens after registering?

BWTS: After registering, we log in, and the wind turbine is brought to a stop. Only when the rotor blades are stationary are we allowed to access the turbine and start our vertical ascent. Either, as here, by using the service lift, or else directly by means of a ladder with appropriate fall protection. 

 

Challenges during the ascent 

INNOTECH: Okay, this turbine has a service lift, but what are the challenges when climbing vertically using a ladder? What are the actual dangers, and what are the particularly critical points?

BWTS: It’s obvious: The greatest danger comes from the enormous height of such a wind turbine – in this case it’s 96 metres for the maintenance staff to overcome. The risk of a fall is present at all times. That’s why, depending on the type of wind turbine, there are always a number of platforms used by the maintenance staff for taking a rest. Such an ascent is extremely exhausting. This wind turbine has 4 platforms. As a rule, a medium-sized wind turbine has 4 or 5 of them, installed at intervals of about 25 metres. 

 

INNOTECH: What sort of safety precautions are there for the ascent?

BWTS: To reach the respective platform, the service engineer, wearing his personal protective equipment (PPE), must detach from the safety solution on the ladder, such as a rail system, and attach onto the single anchor points (EAPs). The other option is to attach yourself directly from the service lift onto the EAPs on the platforms. This is the only way to master a transit with the least possible risk. Although there isn’t a big gap between the service lift and platform, even there the service engineers must always be protected by means of PPE and EAPs. Because, here too, unexpected incidents can always arise – for instance when the technology doesn’t work perfectly. Ideally, the EAPs should be easy to reach from the service lift! 

BWTS & Innotech together at wind turbines
BWTS interviewed by Innotech

INNOTECH: Does the service lift go all the way to the top?

BWTS: No. The service engineers still face a vertical ascent in order to access the wind turbine’s nacelle. Of course the wind turbines differ in this regard, depending on type and structure. For example, there are also wind turbines which don’t have a nacelle any more. Regardless of that though, when transferring from the ladder towards the nacelle, the positioning of easily accessible EAPs is of utmost importance, because this represents a moment of increased potential risk for us service engineers. 

 

INNOTECH: And what happens after the ascent?

BWTS: After the vertical ascent, which takes place by means of a rail system and matching sliders, we detach and re-attach onto single anchor points at the top end of the ladder. After climbing in through the hatch which leads into the nacelle, we close it, and so there is no longer a fall risk at this point. 

 

INNOTECH: Okay, and what happens then in the nacelle?

BWTS: The rotor is then braked, brought to a stop, and locked in place using bolts, in order to create as stable a situation as possible while the work is carried out. A fixed rotor is also important for being able to lower the crane which is used for the transport of materials. Also during this work step the service engineer is permanently secured via EAPs. Then all planned and necessary repair tasks and the annual maintenance are performed in the nacelle.

 

Potential for improvement from a practical perspective

INNOTECH: On a wind turbine like this, where would you like to see improvements in fall protection?

BWTS: Particularly on the ladder there are a number of areas which always present a challenge. In addition, the EAPs are not always perfectly positioned, so they are difficult to access or even completely absent. This is where there is an increased fall risk. But the optimum positioning of the EAPs is also of great importance for the guiding of the rope, because it can be damaged by sharp edges or can even tear in the worst case. In other words, the correct placement of the EAPS is enormously important – there’s often room for improvement here.

 

INNOTECH: What is there on the roof of the wind turbine?

BWTS: The weather station with its wind vane is mounted out there. This supplies relevant data about the wind speed and direction. Sometimes a visibility meter is also installed on the roof of the turbine. This switches off the turbine when it casts an excessive shadow. All these devices must be inspected in the course of the annual inspection. The positioning of the EAPs varies according to the type and structure of the wind turbine. 

 

INNOTECH: What do you have to look out for on the outside of the wind turbine, and where are the greatest dangers there?

BWTS: In general EAPs are installed on all wind turbines, and so the work can be carried out in relative safety. But I have to admit that on the outside of a number of wind turbines, I feel uncomfortable. Sometimes struts are present which lead you relatively close to the fall edge. And in addition, this is where quite a few single anchor points are not optimally positioned. Particularly in this area, an improvement in fall protection would be desirable.

 

If you have questions about safety on wind turbines, you should contact us now. Our experts will be happy to advise you. And: Download our checklist for this!

New call-to-action