Game-changing ‘virtual factory’ offers all-weather offshore wind turbine repair

Offshore wind turbine maintenance is about to get a major upgrade thanks to a new concept called ‘Jack-up on Jack-up,’ revealed by Danish naval engineering firm Knud E Hansen.

This innovative design creates what the company describes as a “virtual factory” around the turbine blades, enabling technicians to work continuously, regardless of weather conditions.

If this design lives up to its promise, it could drastically improve the efficiency and reliability of maintaining offshore wind turbines , pushing the industry into a new era of operational stability.

All-weather operation for maximum uptime

The ‘Jack-up on Jack-up’ concept is centered around a unique four-legged platform. The platform features a 49.2-feet-wide (15-meter-wide) working area that can be raised to match the height of the nacelle—the key housing at the top of wind turbines .

The design has a telescopic weather cover that creates a controlled environment. This allows technicians to work on turbine blades in nearly all weather conditions, both during the day and at night.

Knud E Hansen explained the advantages, saying, “With a telescopic weather cover fitted on the platform, work on the blades can be done in practically all weather conditions, day or night.” This feature significantly increases the number of working hours possible throughout the year.

Traditional methods using maintenance vessels and rope access are heavily dependent on favorable weather, but this new platform design could allow for a much more dependable maintenance schedule.

The potential benefits are massive. More working hours lead to less downtime for turbines, helping them produce power continuously. Currently, maintenance is often delayed by unpredictable sea weather, keeping turbines inactive for longer periods.

A fully equipped, on-site workshop

One of the most impressive features of the ‘Jack-up on Jack-up’ design is its onboard workshop. A large, air-conditioned workspace is located at the rear of the platform, providing technicians with the tools and comfort they need to handle complex repairs on-site.

“When the weather cover is deployed, a virtual factory hall is created around the blade,” said the company. This makes it possible to carry out various types of work on the turbine blades, from minor fixes to major repairs.

The virtual factory eliminates the need to remove damaged blades and transport them to shore for repairs. Instead, everything can be handled on-site, reducing transportation time and costs.

The concept also includes a “cherry picker” mounted at the opposite end of the platform. This piece of equipment gives technicians easy access to the nacelle for repairs or replacements. It adds more convenience and efficiency to the design. This makes it easier for workers to do their jobs without the usual logistical challenges.

Capable of handling next-generation turbines

As wind turbines grow larger and more powerful, maintenance becomes increasingly challenging. The ‘Jack-up on Jack-up’ design is built to handle even the largest turbines, up to 20 megawatts (MW).

According to Knud E Hansen, the vessel is 505.25 feet (154 meters) long and 209.97 feet (64 meters) wide, making it capable of managing turbines in water depths of up to 262.47 feet (80 meters).

It’s not just the blades that this platform can service. The design is strong enough to replace nacelles weighing up to 1,000 tons, even at hub heights of 574.8 feet (175 meters).

The platform can also handle blades up to 426.5 feet (130 meters) long. This ensures that even the most advanced and powerful turbines in operation today—and in the future—can be efficiently maintained using this revolutionary platform.