Availon, the independent provider for WTGS services, has established itself as a reliable partner in the wind energy sector. Competence and trust are the most important factors for a good partnership as demonstrated by the cooperation between the wind turbine manufacturer Kenersys and Availon GmbH.

The OEM has commissioned Availon, Rheine with the construction of its pilot series K82 and K100 turbines. The K82, a 2.0 MW turbine with an 82 m rotor diameter and the K100, a 2.5 MW turbine with a 100 m rotor diameter integrate a completely new type of electrical system, designed, in particular, for locations with a weak grid, where an irregular voltage is the norm.

During power failures and major fluctuations in grid voltage, the WTGS are not switched off but remain in operation until they can be connected to the grid again. With their sophisticated cooling water system, the turbines are also designed for constant high and low temperatures.

For the construction of the first prototype, the K82, Availon first of all developed a concept of installation steps based on Kenersys´ design drawings. The logistics and thus the schedule for the Just-in-Time delivery of spare parts and components were based on the calculated assembly times.

A well planned assembly of a prototype is a key prerequisite for ensuring a smooth production. This applies in particular to the determination and implementation of optimisation potentials deviating from the planning.

When during assembly it became, for instance, clear that the planned cable routing did not represent the best possible solution, Availon changed and adapted the cabling in close cooperation with Kenersys. This modification was also included in the Bill of Material for subsequent series production. This is, however, only one of many examples of the important preliminary work, carried out by Availon for subsequent assembly steps of the series production of the turbines.

The K82 prototype with a total weight of 68 tons was built on a trailer and loaded, once assembled, onto a truck for its trial operation in another hall, where the K82 was tested and then transported to its installation site in Sweden. Whilst the K82 was still being tested, Availon already built the K100 with a total weight of 92 tons. Tests were carried out at the Rheine assembly site in cooperation with Kenersys engineers prior to this turbine also being shipped to Sweden.