Comprehensive Generator Expertise for Direct Drive Wind Turbines
At REI Wind, we deliver a full range of services to support asset owners and operators in Direct Drive Generator assessment, maintenance, and repair. These generators are particularly sensitive to stator coil degradation, often caused by moisture ingress or heat-related resin breakdown.
Generator evaluations are vital to accurately determine the condition of your generator. Our detailed reports highlight areas of wear, identify degraded components, and recommend corrective actions to maintain turbine performance and reliability. Routine assessments significantly reduce the risk of costly coil failures.
Inspection & Diagnostics
After a coil fault occurs, identifying the exact defective coil is critical before any repair or replacement. Studies show that over 85% of coil issues are not visible through standard visual inspections, making thorough testing essential.
Our engineers perform precise Insulation Resistance (IR) testing to locate faulty coils, enabling targeted repairs such as coil bypass, single-core repair, or full replacement. With experience on par with manufacturer-level specialists, our team ensures efficient troubleshooting and minimal downtime.
Maintenance & Lifespan Extension
Direct Drive Generators can experience phase-to-phase or phase-to-earth faults as they age, highlighting the need for regular maintenance every 3–5 years, adjusted for environmental moisture levels.
Our generator maintenance process includes:
Removing loose resin and paint
Cleaning and addressing corrosion
Reapplying heat-resistant resin
Repainting and protective treatments
We also utilize advanced methods such as dry ice cleaning, reflecting the latest industry practices to deliver high-quality, long-lasting maintenance.
Coil Repair & Replacement
Depending on the severity of damage, we provide:
Coil replacement: Manual removal of faulty coils, cleaning, re-insulation, and installation using specialized presses. Typically completed in 15–20 working days.
Temporary coil bridging: Quick restoration of generator operation, generally completed in 2–3 days, suitable only for short-term use.
Single-core repairs: Efficient solutions for minor damage affecting up to five cores, completed within 3–4 days.
These strategies ensure your turbines remain operational while minimizing production losses.
Pole Shoe Services
Generator pole shoes are prone to failure due to resin deterioration, moisture, and core degradation. REI Wind offers a full spectrum of services, including:
Troubleshooting: Comprehensive testing of pole shoes and temperature sensors
Replacement: Partnering with manufacturers to source and install new pole shoes
Temporary bridging: Maintaining limited output while awaiting repairs
Refurbishment: Coordinating manufacturer refurbishment for long-term reliability
Moisture management Soutions
Moisture ingress is a leading cause of generator failures, particularly in humid environments. Proper airflow is essential to prevent overheating, and moisture buildup is a common byproduct of air-cooling systems.
REI Wind provides generator moisture mitigation solutions, including:
Yaw section and cooling fan filter retrofits
Generator-specific filtration systems
Sealing and rain collar installation
De-humidifier integration
These measures significantly reduce moisture-related damage, prolonging generator lifespan and ensuring continuous turbine operation.