Craneless Wind Turbine Rotor Blade Exchange System

All about the advantages of use Craneless Wind Turbine Rotor Blade Exchange SystemHow to replace the rotor blade efficiently?

Normally this type of blades measure between 40 and 60 meters, weigh more than 16 tons, are located on high platforms that can reach up to 200 meters, and are usually found in areas with strong gusts of wind, which makes it a highly complex task. This makes blade replacement a very costly and dangerous job, requiring large cranes and a significant investment in equipment and staff.

Due to these factors, Crosby Airpes looked for a more straightforward, efficient way to change rotor blades.

What is our way of replacing Rotor Blade Exchange System?

The evolution of our wind turbine blade replacement systems has been remarkable. Seeking efficiency and avoiding the assembly of giant cranes, with all the significant operating costs involved, we changed the concept starting from a basic design for an operational tower with a height of up to 80 meters and a weight capacity of 8 tons.

We placed a customized rigging according to hub root blade characteristics. A few meters away from the tower, we find the System Control Orientation of the blade during operation. This control can be made by an auxiliary crane or by extra winches.

How much does it cost to replace a wind turbine blade?

Our solution is not a closed system:

  1. We develop customized strategies to improve the connection to the bucket and shovel based on bucket geometry and shovel requirements.
  2. We then developed a second significantly improved system with a height capacity of 100 meters and the ability to support a weight of up to 15 tons.
  3. We perform a next-generation system that takes wind power maintenance to a new level. This new solution allows tower heights of up to 170 meters and a weight capacity of 30 tons, making it a game changer in the industry. This solution is a 100% crane-free system, eliminating the need for extensive and costly cranes to perform maintenance.

At Crosby Airpes, we understand that every wind energy system is unique and has specific requirements. Therefore, we do not offer a one-size-fits-all solution but develop customized strategies to meet the individual needs of each project. This makes it impossible to know the exact cost as it depends on the specific project.

Our goal is to improve the connection between bushing and blade. After that, we take into account the geometry of the bushing and the requirements of the blade. In this way, we ensure that each replacement is carried out efficiently and safely, with minimal disruption to the wind power system.

Advantages of having a system to change the blade

Reduces work times by making them more efficient

Replacing a blade in this way it is possible in about half a day. A quick and efficient replacement process is a significant advantage in the wind energy industry. Replacing a single blade in just half a day can significantly reduce downtime and increase the overall efficiency of the wind energy system. This allows the system to return to total capacity and quickly generate electricity. The reduced time required for replacement also saves on labor costs and eliminates the need for extended equipment rentals.

The quick timing of blade replacement offers several benefits and is a critical factor in maintaining the optimal performance of wind energy systems.

Fast and efficient shipping process

The tool is transported in a 40-foot open-top container. The use of an open-top container for shipping the tool offers several advantages. The 40-foot size of the container provides a high space to securely transport the device, minimizing the risk of damage during transportation. The open-top design allows easy access to the tool during loading and unloading, making the process more efficient and faster.

In addition, this type of open-top container is more cost-effective than other methods of changing shovels, making it a convenient and economical solution.

Cost savings for the company

Operational cost is reduced by approximately 50% compared to crane-based operations. Reducing operational costs is a significant advantage in the wind energy industry. By lowering the cost of maintenance operations by 50%, wind energy systems increase overall efficiency and profitability. The savings come from several factors, including reduced labor costs, extra equipment rental fees, and transportation costs.

In addition, the decreased operational cost can also lead to increased safety, as the elimination of cranes minimizes the risk of accidents and incidents.

Optimal transportation availability

Optimal transportation availability for reaching remote and isolated sites. The ability to transport tools and equipment to remote and isolated sites is a crucial factor in the wind energy industry. By having optimal transportation availability:

  • Maintenance operations can be performed quickly and efficiently, regardless of the location of the wind turbines, ensuring that repairs take as little time as possible.
  • Wind power systems can be brought back into the entire operation and generate electricity as quickly and consistently as possible.
  • The ability to reach remote and isolated sites also eliminates the need to rent extra heavy equipment, which reduces operating costs and increases profitability.

The quick timing of blade replacement offers several benefits and is a critical factor in maintaining the optimal performance of wind energy systems.

Crosby Airpes is the partner you need for your wind energy solutions

Our blade replacement service offers a cost-effective, efficient, and safe solution for the wind energy industry. Whether you purchase or rent our service, we are committed to providing the highest quality and expertise. With our advanced technology and experienced team, we are confident that we can meet your blade replacement needs. Take advantage of the opportunity to reduce operational costs and increase the performance of your wind energy system.

Contact us to learn more about our blade replacement service and how it can benefit your business.