Custom Wind Turbine Tower Internals | Wind Turbine Tower Platforms, Ladders, and Stairways

Precise Laser Machining and Fabrication for Metal Plate Frames and Tower Internals

We supply custom wind turbine tower internals, including tower platforms, hatches, ladders, stairways, and doors made in South Korea. Our ISO 9001 certified plants are equipped with cutting-edge laser machining centers, coupled with state-of-art comprehensive machining equipment. We offer quality fabrication and machining services with short lead times and low production costs. With in-house design and engineering capabilities and experience we can modify designs of clients’ fabrication project optimized for logistic savings.

 

LPR Global supplies both steel and aluminum wind turbine internals at a competitive rate. All wind tower internal parts are hot dip galvanized at our in-house hot dip galvanizing facility to increases the lifetime of tower internals and lower maintenance costs with superior corrosion resistance.

 

Utilizing expert fabrication techniques, including 5 patented processes, we provide all cutting, pressing, welding, grinding and coating-painting services in-house. Over 10 years we have been serving HRSG plants, heavy equipment manufacturers and top wind turbine producers such as ENERCON, Acciona, TSP, and UNISON. We have been a long-term supplier of wind tower internals to GE Power’s Direct Buy Program.

Wind Turbine Internal Platform Assembly

Custom Wind Turbine Tower Internals | Turbine Platforms and Ladders

Wind Power presents a sustainable source of energy that has several advantages over conventional forms of energy. Wind Turbine Tower Internals are components within a wind tower that provide access throughout the structure and facilitate its maintenance. Tower internals can include platforms, hatches, ladders, stairways, and doors, and are a key factor in successful turbine operation.

 

We have been supplying various wind turbine tower internals and internal kits and assemblies for industry leaders such as GE Power, ENERCON, Acciona, TSP, and UNISON. Our expertise and flexible manufacturing capabilities allow us to fulfill custom tower platforms, stairways, and hatches with higher precision, short lead times and a longer lifespan.

 

Wind Turbine Tower Platforms

Wind Turbine Tower Platforms placed throughout the height of the tower are crucial for successful maintenance of the turbines. LPR Global supplies both steel and aluminum platforms for wind turbine towers of various sizes.

 

Our clients benefit from our design capabilities for various top and bottom platform sizes, which we continue to develop through years of specialization in wind turbine towers. In addition, we ensure that the platform internals for the top and bottom of the tower are easy to identify for assembly. Our wind turbine platforms are incorporated in wind turbine towers from GE Power, ENERCON and Acciona.

 

GE Power Wind Turbine Platform Parts

We have been a long-term supplier to GE’s Directed Buy Program for wind turbine internal components, including ladder brackets, platforms, and stairways. We have supplied for numerous projects for GE Power, including 1.6 MW-rated turbines with 80 m blade diameters.

Wind Turbine Internal Platform
Wind turbine platform for GE Power wind turbine project.
Wind Turbine Platform
Wind turbine platform for GE Power wind turbine project.

Wind Turbine Platform Assembly for GE Power

Wind turbine platform assembly
Wind turbine platform assembly for GE Power wind turbine project
Assembled platform for monopole wind turbine.
Assembled platform for General Electric monopole wind turbine.

ENERCON Wind Turbine Platform Components

A German manufacturer and market leader ENERCON is another long-term client of ours; we have been supplying parts for various assemblies in models such as the E-82 and E-92 wind turbines, with both having a rating of up to 2.3 MW. ENERCON turbines have been used in a range of design scenarios, attesting to the high standards of our products.

Wind turbine internal platform supplied to ENERCON for E-82/ E-92 turbine
Wind turbine internal platform supplied to ENERCON for E-82/ E-92 turbine.
Wind Turbine Platform Assembly
Wind Turbine Platform Assembly for ENERCON

Wind Turbine Tower Ladders

Wind Turbine Tower Ladders for access to various tower platforms are also custom manufactured with steel or aluminum alloys. Laser machining expertise allows us to manufacture ladder internals with short lead times.

 

Unison GoldWind Ladder Internals

Custom Steel Wind Turbine Access Stairs
Access Stairs Machined for Unison wind turbine.

Wind Turbine Tower Hatches | Wind Turbine Tower Doorways

LPR Global also manufactures custom Wind Turbine Tower Hatches and Wind Turbine Tower Doorways. Our access doors and wind turbine hatches are robustly manufactured and treated with corrosion-resistant zinc to last the lifespan of the wind turbine with minimal maintenance.

Non-Destructive Testing for Quality Assurance & Quality Control

To guarantee robust and durable wind turbine internals and other machined components, LPR Global utilizes a variety of non-destructive testing (NDT) methods to check for defects. These methods include ultrasonic testing for flaws in the material, penetrate inspection to check for surface-breaking defects, and magnetic particle inspection to detect discontinuities in metals.

Ultrasonic Testing of Metal Machined parts
Ultrasonic Testing to Check for Defects in Metal Wind Turbine Internals and Other Machined Components
Penetrate Inspection, Penetrant Testing, dye penetrant inspection, liquid penetrate inspection for surface breaking defects
Penetrant testing for surfacing-breaking defects in metal machined parts
Ultrasonic Testing of Metal Machined parts
Ultrasonic Testing to Check for Defects in Metal Wind Turbine Internals and Other Machined Components
Penetrate Inspection, Penetrant Testing, dye penetrant inspection, liquid penetrate inspection for surface breaking defects
Penetrant testing for surfacing-breaking defects in metal machined parts
Magnetic Particle Inspection, Magnetic Particle Examination
Magnetic Particle Inspection for Surface and Shallow Discontinuities in Steel and Aluminum
Magnetic Particle Inspection, Magnetic Particle Examination
Magnetic Particle Inspection for Surface and Shallow Discontinuities in Steel and Aluminum

Laser Machining for Metal Frames of Farming Equipment and Excavator Construction Equipment

Our large-sized fabrication shop has a comprehensive range of fabrication and machining capabilities for various components for industrial machinery frames, Heat Recovery Steam Generator (HRSG) Plants, industrial machinery frames, heavy equipment parts, and wind turbine tower internals.

 

We have been using laser equipment since they’ve been introduced to the fabrication market. Our early adoption of laser equipment was prompted by our desire to shorten the fabrication process for better cycle times and quality. We identified that correctional machining work after conventional machining process was a big cost in production, and therefore lengthened cycle time.  With our specialty in laser machining, we have minimized after-machining work and shortened production time, which has enabled us to provide great prices and excellent quality to our clients.

 

Our range of clientele for laser machining services exemplifies our precise quality and experience with different materials used in different industries. Our clientele encompasses IHI and MHI in Japan, who use our laser machined parts for their HRSG plants, and our fabricated parts and frames are used in machines for the farming and the construction industry.

 

We possess five patents in South Korea for manufacturing processes. LPR Global maintains a high degree of quality assurance and quality control; our Quality Management System has been certified to the standard of ISO 9001:2015.

 

Precise Laser Plate Cutting and Drilling Services for Equipment Frames

LPR Global’s large-sized fab shop specializes in laser beam machining capabilities. Our laser machining allows us to provide precise cutting and drilling services for metal plates with thickness of 5mm up to 20mm. This range for common sheet metal thickness is used for frames of farming equipment and heavy construction equipment. Our clientele for laser machining and fabrication services include manufacturers of farming equipment, excavators and construction machines.

Laser Machined Farming Equipment Frames

Laser machined farming equipment frames
Laser machined farming equipment frames

Laser Machined Parts for Passenger Boarding Bridges

Laser Machined Passenger Boarding Bridge Parts
Laser Machined Passenger Boarding Bridge Parts
Laser Machined Passenger Boarding Bridge Parts

Laser Machined Excavator Buckets

Laser machined excavator buckets
Laser machined excavator buckets
Laser machined excavator buckets
Laser machined excavator buckets
Laser machined excavator buckets
Laser machined excavator buckets
Laser machined excavator buckets
Laser machined excavator buckets

Laser Machined and Fabricated Frames for Construction Equipment

Laser machined and fabricated frames for construction equipment
Laser machined and fabricated frames for construction equipment

We operate several in-house machines for industrial laser machining and cutting, described below.

Laser Machining Centers and Specifications

Welding Quality Control

LPR Global’s extensive welding capabilities are used for extremely robust welded components for Farming Equipment, Construction Equipment and Heat Recovery Steam Generator (HRSG) plants.

 

LPR Global maintains a high level of welding quality control with our in-house inspection and testing process. We begin with an initial assessment of the raw materials. Then, a visual inspection of workmanship is conducted for each welded component, including inspection of the outer and back beads.

 

Welding Inspection Procedure

  1. Prior to welding, the drawings, welding process standards, and the Process Quality Report checklist are checked to confirm the work to be performed. Furthermore, the license of the welder, the welding equipment and tooling are inspected as work begins.
  2. During the welding process, the cleanness of the interlayers, adherence to welding procedures, the interlayer temperature and the air flow through the workspace are monitored to ensure a stable welding process. The adequacy of tack welds and the width of weave beads are constantly checked to certify that the weld will be as specified. This ensures that defects such as arc strikes, crater cracks, uneven beads, and the deformation of unwelded areas do not occur.
  3. After welding is complete, we inspect the bead height, width, and depth, as well as check for surface defects, weld slag or weld splatter, arc strikes and post welding heat treatment to ensure that the weld is free of deficiencies.

 

HRSG Project References

We specialize in producing custom components for HRSG Harps, such as baffle plates, lug plates, end plates, and HRSG drums. Our laser machining capabilities are especially suited for the high precision required by these internals.

 

Our HRSG clients include Doosan Construction, Doosan Engineering, IHI, and BHI for Heat Recovery Steam Generator Components for heat recovery boilers.

HRSG Stator Core Laser Machining
HRSG Stator Core Components for Doosan HRSG
Precision Machined HRSG Stator Core Components
HRSG Stator Core Components for Doosan HRSG, Laser Machined
HRSG Baffle Plate Industrial Machining, Laser Machined HRSG Parts
HRSG Baffle Plates
HRSG Drum Template Machining
HRSG Template Components

Hot Dip Galvanizing

Hot Dip Galvanizing, also known as zinc galvanizing or zinc dipping, ensures that our products are highly corrosion resistant. LPR Global performs in-house hot galvanizing to eliminate burning, zinc pimples, dark staining or storage staining, which commonly impact ungalvanized or poorly galvanized surfaces. Industrial Hot Dip Galvanizing ensures that our wind tower internals are robust and have excellent anti-corrosion protection.

 

Our in-house zinc coating also provides a lustrous finish and reduces impurities while providing anti-corrosion properties to our custom components.

 

Hot dip galvanizing finishes are thoroughly inspected to guarantee quality before shipment to our clients. We ensure that our zinc dipped fabricated products meet ISO:1461 standards, a standard for hot dip galvanizing coatings on iron and steel.

Hot Dip Galvanizing Finishing
An example of finishing imperfections reduced by hot dip galvanizing

Conventional Fabrication and Machining Services

In addition to our specialized laser machining capabilities, we also have in-house expertise in conventional machining techniques such as industrial cutting, pressing, milling and grinding. Our capabilities have been used in fabrication for heavy industry, power plant facilities, and other steel structures such as parking facilities.

 

Listed below are some of the equipment that LPR Global possesses for conventional machining processes.

 

Bending Machines

  • NCB1260 (Gook Do, South Korea)
    • 750 Ton, 12T x 6000L
    • 450 Ton, 16T x 4000L
    • 150 Ton, 6T x 3000L
  • HS1303 (Amada, Japan)
    • 130 Ton, 4.5T x 3000L
  • TRUMF 5170 (Trumf, Germany)
    • 170 Ton, 6T x 3050L

 

CNC Milling Machines (with working capacity dimensions)

  • MCT VX950, 600 x 2400 x 700
  • MCT KV60, 600 x 1100 x 600

 

Our conventional machining and fabrication services, combined with our unique capabilities such as laser machining allow us to deliver a variety of products to fit the various component needs of your project. LPR Global also provides metal fabrication painting in addition to our hot dip galvanizing finishes to ensure that our clients have a complete product ready for assembly.

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