Wind turbines are designed for long-term operation, however it’s important to keep a look out for signs of wear which can lead to costly downtime. For operators, understanding the most common blade issues and implementing effective prevention strategies is essential to ensure consistent energy output.
Below, we outline some of the most common issues and failure types to look out for, why they happen, and how proactive maintenance can help prevent them.
Leading Edge Erosion
The leading edge of the blade faces constant impact from rain, hail, dust, and airborne particles. Over time, this causes material erosion which alters blade aerodynamics, reducing annual energy production (AEP) and increasing structural load on the turbine.
Regular inspections via rope access or drone technology can help to identify early-stage damage. Immediate repair of small cracks or wear is the best course of action to prevent further escalation. Leading-edge protection systems are also a reliable means of guarding against erosion, offering an additional protective layer to the blade and ensuring longevity.
Lightning Damage
It is not uncommon for wind turbine blades to be struck by lightning, particularly in storm-prone regions. Lightning strikes can cause issues such as delamination, or internal damage if systems are compromised.
Although lightning strikes are unavoidable, the installation of lightning protection systems can significantly reduce the impact and potential damage caused by lightning strikes. New industry technology also offers dedicated early detection of lightning strikes, allowing for precise monitoring and faster response times to potential damage.
Regular inspections via rope access or drone technology can help to identify early-stage damage. Immediate repair of small cracks or wear is the best course of action to prevent further escalation. Leading-edge protection systems are also a reliable means of guarding against erosion, offering an additional protective layer to the blade and ensuring longevity.
Surface Cracking and Delamination
Repeated load cycles and environmental stress can lead to cracks on the blade surface or delamination of materials. If left untreated, these small defects can weaken the blade, propagating into major structural failures, forcing costly downtime.
Frequent visual and drone inspections can ensure wind farm owners & operators spot cracks early, allowing for rapid repair of cracks and delamination.
Structural Failures
In rare but high-impact cases, blades can experience major structural damage, often caused by extreme weather conditions, manufacturing defects, or neglected maintenance. This type of failure can result in full blade replacement.
To prevent a full blade replacement, scheduled inspections should be conducted during turbine service cycles. Upgrades or retrofits should also be considered when recurring structural issues are detected.
Ice Accumulation
Wind Turbines located in colder climates can accumulate ice on the blades, especially through the winter period. The build up of ice can reduce a blade’s efficiency significantly and pose a potential safety risk to those nearby if the ice falls from the blade.
Turbines should be regularly monitored for ice build-up, particularly over the winter period. The installation and routine maintenance of Anti-Icing or De-Icing systems can also help to combat the accumulation of ice on the blade.
Why Blade Maintenance Matters
These common blade issues account for a significant share of turbine downtime and lost production. By addressing problems early, operators can extend blade service life, reduce repair and replacement costs and reduce the risk of downtime overall.
At GEV Wind Power, we specialise in blade inspection, repair, and upgrade services delivered by experienced teams using a range of access solutions. From leading-edge protection to structural repairs, we help operators keep turbines performing at their best.
If you would like to discuss any of your own blade issues or how preventative maintenance programs could help you, please contact our team.
If you would like to join GEV Wind Power, please take a look at our vacancies here.
