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Cortec® Publishes Guide to Corrosion Remediation at Wind Farms

As the wind industry continues to grow, the need for corrosion solutions will only become more obvious. To address these ongoing concerns, Jim Holden (Cortec’s Technical Director, Energy & Engineered Solutions) developed a guide in conjunction with Cortec® Technical Services to address corrosion mitigation on wind farms. The guide was specifically designed with a Newfoundland Cortec® distributor in mind (Newfoundland is a prime spot for wind turbines and corrosion). However, it promises to benefit those who service wind turbines in all regions of the globe.

Wind Farms

The Stakes of Corrosion on Wind Turbines

The stakes of wind industry corrosion are high because of the millions of dollars invested into most wind turbines. Unfortunately, these costly assets are naturally exposed to corrosive conditions simply by being outdoors or—even worse—in harsh marine environments that accelerate the corrosion process. Therefore, any small outlays to slow down corrosion and delay equipment repair and replacement until the turbine reaches its desired service life (or beyond) could have a significant ROI.

Steps to Mitigate Corrosion

The good news is that many simple corrosion mitigation steps are outlined in our guide to corrosion remediation at wind farms. These include the following:

  • Rust removal on various surfaces
  • Protection of electric/electronic controls
  • Coatings and MCI® for metal and concrete structural components, respectively
  • Corrosion inhibitors for generators and motors
  • Removable protection for nacelles and blades (e.g., while awaiting commissioning)

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Time to Hit the Brakes

Although rust does not rest, Cortec® Technologies can help wind farms figuratively step on the brakes to slow the process down and buy time for wind turbine owners to recoup their investments. Read the guide to wind turbine protection below and reach out to us with specific questions.

NOTE: The following recommendations are applicable for installed systems. Contact a Cortec® representative to discuss Cortec® applications during the manufacture of individual components.

Wind power plants are susceptible to corrosion due to their locations, materials, and maintenance feasibility.

Wind Turbine:

A wind turbine consists of the following major components that are susceptible to rusting:

  • Gearbox (various carbon steels)
  • High speed and low speed shaft (various carbon steels)
  • Brake (various carbon steels and non-metallic pads)
  • Generator and motors (carbon steel, copper, stainless steel, insulation)
  • Drive mechanisms (various carbon steels)
  • Electric/electronic controls (carbon steel, copper, stainless steel, insulation)
  • Tower (pre-stressed concrete or steel)
  • Base/foundation (steel-reinforced concrete)
  • Nacelle
  • Blades

The following treatments are recommended.

Gearbox:

  • M-535 as an additive to run in oil or as a fogging application (1 oz/ft3 [1 L/m3]).
    • NOTE: Not to be used in operating oil unless detailed compatibility testing is completed.
  • VpCI®-391 or EcoShield® VpCI®-386 clear for all exposed machined surfaces.
  • Coating of exterior surfaces (options):
  • VpCI®-422 and VpCI®-414 for removing any internal rust.
  • VpCI®-423 or VpCI®-422 with VpCI®-414 to remove any external rust.

High Speed and Low Speed Shaft:

  • VpCI®-391 or EcoShield® VpCI®-386 clear for all exposed machined surfaces.
  • VpCI®-423 or VpCI®-422 with VpCI®-414 to remove any external rust.

Brake:

NOTE: For metallic surfaces only. Do not apply VpCI® product to non-metallic surfaces.

  • VpCI®-391 or EcoShield® VpCI®-386 clear for all exposed machined surfaces.
  • VpCI®-423 or VpCI®-422 with VpCI®-414 to remove any external rust.

Generators and Motors:

  • VpCI®-239 for fogging into the generator and motor core (ensure the generator and motor are not energized).
  • VpCI®-391 or EcoShield® VpCI®-386 clear for all exposed machined surfaces.
  • VpCI®-423 or VpCI®-422 with VpCI®-414 to remove any external rust.
  • VpCI®-101 Device placed in junction boxes.
  • Coating of exterior surfaces (options):
    • Prime with VpCI®-395 and topcoat with EcoShield® VpCI®-386 (color match).
    • Prime with VpCI®-396 and topcoat with VpCI®-384 (color match).

Drive Mechanism:

  • VpCI®-391 or VpCI®-386 clear for all exposed machined surfaces.
  • VpCI®-423 or VpCI®-422 with VpCI®-414 to remove any external rust.

Do not apply any Cortec® product to the non-metallic brake pads.

Electric/Electronic Controls:

Tower (Steel):

  • Option to (a) remove existing rust with VpCI®-423 and VpCI®-414 or (b) power wash to remove surface contaminants and loose debris, and coat with CorrVerter® Rust Converter Primer.
  • Coat interior or exterior surfaces (options):
    • Prime with VpCI®-395 and topcoat with EcoShield® VpCI®-386 (color match).
    • Prime with VpCI®-396 and topcoat with VpCI®-384 (color match).

Tower (Pre-Stressed Concrete):

  • Power wash to remove surface contaminants and loose debris.
  • Apply Migrating Corrosion Inhibitors such as MCI®-2020/2020 V/O to cleaned surface.
  • Apply Cortec® MCI®-2018 to treated surface.
  • Contact Cortec® Migrating Corrosion Inhibitor™ specialists for proper selection and application technique.
  • NOTE: Migrating Corrosion Inhibitors such as MCI®-2005/2005 NS can be added to the concrete during the construction phase to protect the steel rebar reinforcement to extend tower life.

Base/Foundation:

  • Power wash to remove surface contaminants and loose debris.
  • Apply MCI®-2020 to cleaned surface.
  • Apply MCI®-2018 to treated surface.
  • Contact Cortec® Migrating Corrosion Inhibitor™ specialists for proper selection and application technique.

NOTE: Migrating Corrosion Inhibitors such as MCI®-2005/2005 NS can be added to the concrete during the construction phase to protect the steel rebar reinforcement and extend tower life.

Nacelle:

  • Option to (a) remove existing rust with VpCI®-423 and VpCI®-414 or (b) power wash to remove surface contaminants and loose debris, and coat with CorrVerter® Rust Converter Primer.
  • Paint interior or exterior surfaces (options):
    • Prime with VpCI®-395 and topcoat with EcoShield® VpCI®-386 (color match).
    • Prime with VpCI®-396 and topcoat with VpCI®-384 (color match).

Blades (Metallic):

Blades (Non-Metallic):

Hub:

  • Clean with VpCI®-414.
  • Coat with VpCI®-391.
  • Shrink wrap with either MilCorr® VpCI® Shrink Film or VpCI®-126 HP UV Shrink Film.

Keywords: guide to corrosion remediation at wind farms, Cortec, corrosion remediation, wind industry, corrosion solutions, wind turbine corrosion, rust prevention on wind turbines, generator corrosion, investing in wind turbines, protection on wind turbine blades

For a PDF version please click here.

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