Converter, skiip pak, delta module repair and refurbishment for wind turbines
To ensure high quality power conversion refurbishment we perform in-house testing and diagnostics of components and replace all wearing components such as capacitors as part of our remanufacturing process. We understand that some of our customers have had negative experiences of refurbished parts so all of our repairs are subjected to rigorous end of line testing to ensure that they will perform reliably before being installed back into the wind turbine.
Testing
We also ensure software version updates and compatibility checks to ensure that your parts remain compatible with your wind turbine version.
- Functional Testing of the IGBT Modules
- Testing of the Bus Capacitance
- Testing of the Bus Capacitor ESR
- Power Supply Test
- Control Signals Testing
- Cooling System Testing (Fans)
Circuit analysis is performed to isolate and identify any marginal components. Components are inspected for integrity, insulator breakdown, and connections. When the inverter is determined to be free from any physical or electrical issues, the next step is to benchmark it. This is achieved by conducting a test under full load in parallel with a ‘golden sample’ (previously re-pasted) at a continuous current of 750A, equivalent to approximately 80% of its full load capacity. During this process, we closely examine the ‘Delta T,’ which represents the temperature difference between phases and between the inverters. The Delta T serves as the parameter that activates the Temperature Differential warning (+15°C – by default) and the Temperature Differential Alarm (+20°C – by default). The results obtained from this benchmarking test are meticulously documented and logged for further analysis following the repair.
Responsive and Responsible Service
- Customs support into and out of UK
- Reasonable warranties – if your part hasn’t been installed on the WTG during the warranty period we will be reasonable about it.
- Here for a long time not a good time. We treat our customers how we wish to be treated.
Legacy support
For every year that passes, obsolescence for aging wind turbine converters becomes an increasing problem for owners and operators as they try to source parts and solutions for turbines approaching their end of life. We develop engineering solutions to enable continuity of operation even when supply of cores diminish.
- Semikron
- Inifineon
- ABB
- GE
- Ingeteam
- Prowind
- Skiip
- Moog Pitch Control
- Care and diligence at every step
The unit is then carefully disassembled using our standard practices (torque schema is recorded/followed and documented and parts isolated to individual jobs). A thorough inspection of all internal components, such as the IGBT modules, capacitors, resistors, fans and control boards is completed to identify any damaged, worn or malfunctioning components that need replacement. Individual components are tested to confirm if no visible damage is apparent.
Once technically assessed then the unit is quoted to the customer. If the unit is irreparable then it is not invoiced and there are no assessment fees.
Additionally, we replace ribbon cables, snubber capacitors, and any faulty bus capacitors. All power connections are meticulously inspected for proper torque and marked using a calibrated torque wrench, and new thermal paste is applied on all the IGBT modules and installed in strict adherence to OEM specifications.
We perform a megger test to assess the inverter’s insulation resistance before it is mounted into our custom ABB ACS800 test cabinet. Subsequently, the inverter’s cooling system is rigorously examined before being subjected to a parallel load test alongside our golden sample unit. During the 30-minute load test and burn in, detailed results are recorded and logged. We compare current waveforms and analyze temperature variations, ensuring that the Delta T remains below 5 degrees Celsius when compared to the golden sample. In the event of any issues identified during testing, necessary rectifications are carried out, followed by retesting of the module.
The entire process from initial inspection to final functional testing is documented including any changes that have been made
- Customer fault description, if provided
- Testing/visual inspection notes
- Test results
- Notes on completed work
- Benchmark test results
Delta modules, Skiip, (grid and rotor) converter repairs for wind turbines
Converter Overhauls
Peace of Mind
We operate a RMA system to ensure traceability of our components and carry insurance in the event of loss or damage. Our systems are also ISO9001 accredited to ensure that quality processes are audited, sound and fit for purpose and provide the best possible customer experience.
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