Poland

Dabrowice Wind Farm
Client: GE/Engie

Situation: Rotor falls, wind vane hits the edge of the foundation, severely damaging it.

• Emergency repair in winter conditions: November to February.

Scope of project work: 

• Scanning the surface of the foundation.
• Drilling with an endoscope.
• Concrete sampling.
• Pile continuity check.
• Geodetic control.
• Measurement of earth resistance.
• Design verifications: CAT III checks, fatigue analyses, analyses of the impact on foundation failure, ground reinforcement analyses
  and piles, computational analyses of damage in concrete.

Scope of foundation repair:

• Cutting out and rebuilding a section of the foundation. 
• Removal of waste from wind blades and rotor.
• Cutting out a section of foundation: diamond lines, crown drilling of various sizes.
• Concrete demolition and removal: pneumatic and hydrodynamic methods.
• Reinforcement reconstruction: joining reinforcement using HALFEN MUFFS MBT technology.
• Concrete pouring.
• Construction of a tent over the entire foundation area: temperature-controlled work.
• Pressure injections.
• Bitumen insulation and system waterproofing of plinth.
• Reconstruction of the assembly area and embankment.

Poland

Situation: Reconstruction of 3 foundations to ensure safety, due to seasonal occurrence of high groundwater levels, which were not taken into account in the detailed design.

Scope of work: 

• Analysis of the actual condition with a comprehensive foundation reconstruction project.
• Detailed CAT III check and selection of a solution to increase the foundation dimensions “fit for purpose” to ensure the stability and safety of the structure.
• Ensuring safety, effective repairs, and cost-efficiency despite major challenges caused by the use of two different ground stiffness values in the original design — a solution commonly known in the industry as a “SOFT SPOT.”
• Choosing the most appropriate method of repair and the flow of the whole process, including the required documentation, to ensure that the work is completed in the shortest possible time.
• Comprehensive preparation of documentation for the start of remedial work: development of procedures and scope of individual remedial tasks, preparation of budget, work schedule, quality control and acceptance policies, and safety (health and safety) policies.

Foundation problems – why is proper maintenance crucial?

• We monitor the condition of thousands of foundations throughout Europe.
• Based on the experience of our experts and the statistics we have gathered in recent years, it appears that 10% of turbines older than 5 years have some degree of foundation issues, of which operators are often unaware.
• The nature of foundation work means that even minor issues can gradually escalate and eventually lead to serious failures, resulting in costly repairs and turbine downtime.
• This is why it is important to carry out a technical condition assessment at least once a year.

France

Loudéac Wind Farm
Client: EDF
Turbine type: Gamesa G90 78m 2MW

Scope of works

• Inspection of the turbines and detection of the problem.
• Analysis of the detailed design, visual inspection, determination of the cause of the problem.
• Development of a cost-effective and safe repair design.
• Carrying out pressure injection and laying an effective heavy type insulation system.

Added value for the client:

• Comprehensive problem solving and taking full responsibility for the entire process: problem identification, analysis, implementation and providing the appropriate guarantee.
• Certainty of correct diagnosis of the cause, accurate execution and effective problem solving, thanks to the involvement of experts in foundation design.
• Fast response times and very competitive pricing conditions resulting from cooperation with leading material manufacturers.

FOUNDATION PROBLEMS – WHY IS PROPER MAINTENANCE CRUCIAL?

• We monitor the condition of thousands of foundations throughout Europe.
• Based on the experience of our experts and the statistics we have gathered in recent years, it appears that 10% of turbines older than 5 years have some degree of foundation issues, of which operators are often unaware.
• The nature of foundation work means that even minor issues can gradually escalate and eventually lead to serious failures, resulting in costly repairs and turbine downtime.
• This is why it is important to carry out a technical condition assessment at least once a year.

Based on years of experience and thousands of inspections carried out, our designers have developed the WFF Standard, a new foundation inspection standard certified by Bureau Veritas.

A proper assessment involves two key aspects:

• a visual inspection in accordance with the WFF Standard,focusing on a dozen critical points of the foundation,
• an analysis of the detailed design by the foundation designer.

The list of these points is adapted to the type of anchoring element.

Why this solution is right for you:

• A report from an inspection conducted according to our WFF Standard allows for identifying issues, accurately diagnosing causes, and proposing solutions that even regular inspections may fail to detect
• We offer foundation assessments at reasonable prices by using modern IT solutions.
• We help avoid costly repairs and manage the risks associated with foundation problems.
• If necessary, we carry out advanced diagnostics and foundation repairs.
• We are offering a pilot trial period of our WFF Standard. Conditions are agreed individually.

Poland

Suwałki Wind Farm
Client: RWE
Turbine type: Siemens SWT-2.3-93

Scope of work:

• Turbine inspection and issue identification
• Execution design analysis
• Visual inspection
• Determination of damage cause
• Development of a safe and cost-effective repair design
• Grout repair execution
• Application of a durable protective coating system

Added value for the client:

• Comprehensive problem resolution with full responsibility for the entire process – from fault detection through analysis and implementation to warranty provision.
• Confidence in accurate diagnostics, effective and safe repair, and long-term problem resolution – enabled by foundation design experts.
• Fast response time and highly competitive pricing – made possible through cooperation with leading material manufacturers.