Materials Testing Under Special Conditions
Entering the rotor hub
On behalf of Wagenblast, ZEROS GmbH carried out an extensive ultrasonic inspection of a wind turbine in Baden-Württemberg.
The site placed special demands on the inspectors: the relevant joints were located in the area of the rotor hub and the generator, around 110 metres above the ground. Access to the test areas was provided, among other things, through an entry hatch on the rotor hub. In addition to carrying out the ultrasonic testing properly, appropriate safety measures for working at height were therefore required.
Ultrasonic testing of the rotor blade bolts
The rotor blades of a wind turbine are exposed to considerable dynamic loads during operation. Wind forces, changing rotational speeds and continuous rotation place particular stress on the mechanical connections between the rotor blades and the hub.
To verify the integrity of these connections, ZEROS inspectors examined the bolts using ultrasonic testing (UT). Around 70 bolts per rotor blade were tested from inside and outside. The assignment also included the inspection of the bolts at the generator connection.
Why Ultrasonic Testing Matters for Wind Turbines
View from the nacelle across the Black Forest
Ultrasonic testing is one of the established methods of non-destructive materials testing. By introducing high-frequency sound waves, internal material defects can be detected under suitable test conditions without damaging the component.
This is particularly important for highly stressed bolted joints: possible cracks or other detectable material irregularities can be identified early, before they develop further under continued load. Regular inspection of safety-relevant components therefore supports the operational safety and availability of wind turbines.
Non-destructive testing for renewable energy
Wind turbines have to operate reliably for many years while being subjected to high mechanical loads. Non-destructive testing helps to assess the condition of important components and to plan necessary maintenance measures on a sound basis.
With the assignment in the Black Forest, ZEROS GmbH shows that materials testing can be carried out on site even under demanding conditions. Whether in energy and industrial plants, on steel structures or on wind turbines: ZEROS supports companies with professional methods of non-destructive materials testing.
