Our Approach

Scientia does not just inspect and implement repairs necessary to get the turbines operational again.  Our goal is to remanufactures the turbine to its original specifications.  With proper maintenance, these turbines should have an operational life of over 20 years before requiring another major overhaul.

Scientia’s principals’ intimate knowledge of the Windmatic turbines makes them uniquely qualified to refurbish these turbines.  With 23 years of operational and ownership experience, we know the turbine’s strengths and design attributes.    In the refurbishment process, the turbine is stripped down to its component parts. Gearboxes are completely rebuilt with new seals and bearing. Gears are inspected for wear and replaced if deemed necessary. Hydraulic pumps, brake calipers, and yaw systems are rebuilt. Main shaft bearings are dismantled and inspected for wear, replaced or cleaned and repacked with grease as necessary. Generators are rewound to the highest of specifications, undergoing a vacuum pressure resin impregnation. Rotors are dynamically balanced. After assembly, the drive train is tested for any gearbox or hydraulic leaks, the brake system and all sensors are tested.

Re-manufactured Wind Turbines – Scientia currently has an inventory of 65 kW and 95 kW Windmatic wind turbines, These turbines were originally manufactured by the Danish wind turbine company Wind Matic A/S. They were installed on a California wind farm in 1985 and 1986.  They were taken out of service in 2007 due to re-powering of the wind farm with larger megawatt size turbines.  Scientia also has access to an inventory of larger European designed/manufactured turbines,

New Wind Turbines – Scientia is developing a new wind turbine based on the proven designs of the 1980′s vintage Danish turbines.  Availability is expected by the 1st quarter of 2012.  MW size turbines can be sourced if this size is more appropriate for the application.

Replacement Components – Through our rebuilding process, we have sourced numerous replacement component parts for these Danish turbines.  If there is a part you are looking for, give us a call and we’ll see if we have it in stock or have sourced it.

Wind Resources Assessment and Site Evaluation – Scientia can provide wind resource assessment equipment and coordinate the gathering of and analysis of the wind data.  We can help you evaluate the viability and economics of developing wind energy at your site.

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The Process

Chassis

The chassis is cleaned with high pressure hot water and a biodegradable solvent. After a thorough cleaning, the chassis is inspected for any cracks or other anomalies. The chassis is made of welded, galvanized steel. In over 20 years of operation, we have never observed any stress related cracks or other failures attributable to normal operations.

Drive Train

The gearboxes are cleaned and dismantled. Gears are inspected for wear and turned or replaced as deemed necessary. All seals and bearings are replaced. The main shaft is checked for wear and repaired as necessary. Disc brake calipers are dismantled, cleaned and rebuilt. New brake pads are installed. The main shaft brake disc is turned if necessary. Main shaft bearings are disassembled and inspected for wear. As necessary, bearings are repaired or replaced. Old grease is removed and replaced with new grease. Sensors for high and low speed drive shafts are replaced.

Generators

Both the small and large generators are rewound, bearings replaced, new thermistors installed, and the rotor dynamically balanced.

Brake System, Hydraulics Lines and Wiring

All internal nacelle hydraulic lines are replaced, as are wiring harnesses. The braking system is rebuilt and calipers rebuilt or replaced if necessary. New brake pads and wear sensors are installed

Yaw System

The yaw motor and pinion gear are inspected and rebuilt or replaced as necessary. The bull gear is inspected for wear and repaired if necessary to insure a good mesh with the yaw pinion gear, or replaced.

Controller

In most cases, the original controller will be replaced with a new controller. The new controller is based upon a commercially available industrial controller, which provides all functionality of the original controller, plus remote monitoring and control with two-way communication capability. The software is open source, easily programmed for adjustment to varying wind regimes characteristics.

Blades

All blades are visually inspected for nicks, pitting, cracks, and de-lamination. They are then attached to a static jig and a deflection test is performed. This deflection test measures any movement between the steel root hub where it terminates and marries the blade spar. An endoscope is used to inspect the interior. The air brakes, which have previously been removed, are inspected to ensure that all hold tabs are within specifications, the shock absorbers for the spoilers are rebuilt or replaced, and deployment tested. Once the blades pass the structural integrity test, nicks and gouges are repaired, the blade is then buffed with rubbing compound to remove surface oxidation, re-gelcoated and polished.

Tower

The turbine is normally sold with its original 80 foot lattice tower. The towers are inspected for any cracks or bends which might affect its integrity. No problems have been observed in the over 20 years of operation for towers that have experienced normal operation conditions.

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