Maintenance and repair of wind turbines – Onshore and Offshore
For over 50 years, wagner GmbH has stood as a reliable partner across all industrial sectors, including more than 25 years of specialized experience in wind power, providing comprehensive services and solutions. We specialize in servicing and maintaining wind turbines both onshore and offshore, using state-of-the-art technologies and our extensive industry expertise to maximize the efficiency, safety, and reliability of your installations.
Comprehensive repair and maintenance services for wind turbines:
- Precision machining: Our experts perform highly precise milling and turning operations on tower and nacelle flanges as well as brake discs, supported by modern laser measurement technology and endoscopy for accurate diagnostics.
- Structural integrity: We offer specialized spindle, re-spindling, and boring operations to optimize the structural integrity and alignment of your wind turbines. Our straightening and spreading work on flange connections helps to increase the service life and performance of your turbines.
- Certified quality: As an SCC-P certified company and partner of leading brands such as ENERPAC and Palfinger Cranes, we integrate advanced lifting and positioning technologies into our projects to ensure the highest safety standards.
- Flexible and efficient solutions: Whether manufacturing spare parts, welding, crack inspections or customized special solutions, our mobile teams carry out all necessary work with a high degree of flexibility and expertise.
With our know-how and many years of experience, we help you improve the performance of your wind turbines through precise maintenance and tailor-made solutions. Contact us today to learn how we can optimize the longevity and cost-effectiveness of your wind turbines.
Root-cause investigation using state-of-the-art laser measurement technology and endoscopy
Laser surveying plays a crucial role in identifying and analyzing defective components in industrial plants. By using state-of-the-art laser measurement technology and endoscopy, we enable precise diagnostics and support effective alignment as well as the proper installation of mobile machine tools.
In addition to conventional measurement technology, we use rotary lasers and laser trackers to capture the geometries of machines with extraordinary accuracy. These highly precise measurement methods form the basis of our damage analyses, which are carried out by specially trained personnel. These detailed analyses are essential for understanding and remedying structural issues such as flange tilting, which ultimately increases the reliability and safety of your plants.
Boring and spindle work for the renewal of bolt threads
A homogeneous load distribution is essential for the safety of flange connections, particularly in blade-bolt and tower flange connections. Even individual, non-load-bearing fastenings play a decisive role and must be properly replaced if damaged. To meet these requirements, wagner GmbH carries out specialized boring and spindle work aimed at the renewal of bolt threads.
We use modern mobile machining technology and have specially manufactured drilling rigs that enable us to machine bolts of any size precisely. Damaged threads are professionally repaired by our experts, thereby restoring the structural integrity and functionality of the flange connections. These technical measures guarantee not only safety but also the durability of the connections in critical applications.
Machining of brake discs in the installed state
The operational safety of wind turbines critically depends on the flawless functioning of their braking systems. In particular, the azimuth brake discs play a central role for the stability and safety of the turbines. wagner GmbH offers specialized services for machining brake discs directly in the installed state, eliminating the costly removal of the components.
With individually tailored tools and precise machining techniques, we ensure that your brake discs are maintained in proper condition. This approach not only minimizes maintenance costs but also the downtime of the wind turbines. Through our efficient on-site repair, we ensure the long-term functionality and reliability of the brake components, which leads to increased overall efficiency and safety of the turbine.
Milling and turning work on tower and nacelle flanges
The structural integrity of wind turbines depends heavily on the precise maintenance of their flange surfaces. wagner GmbH carries out specialized milling and turning work on tower and nacelle flanges to ensure the accuracy of the flat faces, even in hard-to-reach areas.
With mobile face-turning and milling machines that enable machining operations up to a diameter of 10,000 mm, we guarantee high-quality results that facilitate the installation of bearings and rotor blades and optimize tower alignment. These measures improve the overall stability of the plant and reduce operational disruptions, significantly increasing the reliability and service life of your wind turbines.
With wagner GmbH as your partner for precise milling and turning operations, your installations are always in optimal condition and comply with all safety standards.
Alignment and Spreading Work on Flange Connections
Manufacturing tolerances or transport damage can affect the assembly and safety of wind turbines. wagner GmbH specializes in alignment and spreading work to ensure the precise positioning of rotor blade flanges and tower segments. With our advanced spreading technology, we adjust connection flanges up to a diameter of 5,000 mm, which improves the structural integrity and performance of the installations.
Using these techniques on site reduces the need for extensive disassembly and minimizes downtime. Our measures to eliminate irregularities ensure efficient, safe, and high-performance operation of your wind turbines.
Welding and Crack Inspection
We ensure the operational safety of machine supports and other critical plant components through comprehensive crack inspections and certified welding services. By employing advanced techniques, we enable thorough inspection and treatment of cracks in hard-to-reach areas.
Our specially trained technicians perform precise repairs, including drilling out and professional welding, to ensure structural integrity. Our welding specialist company is certified according to DIN EN 1090-2:2018 EXC3, which guarantees the high quality and safety of the welding work.
These measures minimize the risk of unforeseen operational interruptions and increase the longevity and efficiency of your equipment.
Manufacture and Installation of Spare Parts
We offer an efficient solution for the replacement of sliding bearings in industrial applications, especially in the pitch system of wind turbines. By developing custom-made, split sliding bearings, we reduce the need for extensive disassembly, minimize downtime, and significantly lower costs.
These bearings can be quickly and seamlessly integrated into existing systems, thereby significantly reducing maintenance time and costs. Our advanced manufacturing techniques and well-thought-out installation strategies optimize the lifespan and efficiency of your equipment, providing our customers with considerable advantages in maintenance processes.
Customized special solutions
wagner GmbH offers rapid and flexible development of tailor-made special machines, adapted to specific customer requirements. Our design department uses advanced technologies to design innovative solutions such as surface milling machines that can be integrated precisely and efficiently into existing production processes.
With a strong focus on customer satisfaction and technical excellence, we guarantee that every custom-made solution meets the highest quality standards and contributes to increased productivity.
Bolting and Tensioning
When repairing damaged threads on rotor hubs, the proper installation of new fasteners is crucial for the operational safety of the installation. wagner GmbH carries out these tasks with certified personnel who perform and document all work carefully. As a contractual partner of ENERPAC, we also offer high-quality bolting technology specifically developed for the demanding requirements of the wind energy industry.
Our bolting and tensioning services ensure that all bolted connections on the rotor hub meet the technical specifications and function reliably over the long term. This minimizes the risk of operational disruptions and extends the service life of your installations.
I’ll take care of it: Your point of contact
Do you have any questions?We’ll be happy to assist you quickly.
Guillaume Cuvelier
We are available 24 hours a day and ensure downtime is kept to a minimum.
We provide tailored solutions for your specific needs across nearly all industrial sectors – for 60 years.
We carry out on site machining and assembly work internationally.
Special projects | Wind technology