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

Laser Machining and Fabrication Capabilities | Industrial Welding Services | Machining for Wind Turbine Internals | Hot Dip Galvanizing

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 cab modify designs of clients’ fabrication project optimized for logistic savings.

 

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 GE Power, ENERCON, Acciona, TSP, and UNISON.

Custom Wind Turbine Tower Internals | Turbine Platforms and Ladders

Wind Power presents a sustainable source of energy that has several advantages to 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 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 aluminium 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 continually supplied General Electric Power with a variety of wind turbine internal components, including ladder brackets, platforms, and stairways. We have supplied GE Power for numerous projects, 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.

GE Power Wind Turbine Platform Assembly

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 aluminium 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 Beam Machining, Industrial Welding and Fabrication for Wind Tower Internals, HRSG Plants and Heavy Industry

Our large-sized fabrication shop has a comprehensive range of fabrication and machining capabilities for various components for Heat Recovery Steam Generator (HRSG) Plants, industrial machinery frames, heavy equipment parts, and wind turbine tower internals. We started using laser equipment when laser equipment was just introduced to the market. Our early adaption of laser equipment was from our need to shorten the fabrication process for better cycle times and quality. We identified the welding process as a big cost in production and counter-productive for cycle time. We minimized welding requirements by replacing welding with laser cutting and machining, which requires extensive knowledge and experience of laser machining.

 

Our range of clientele for laser machining services exemplifies our precise quality and experience with different materials. While our clientele encompasses IHI and MHI in Japan, our fabricated parts and frames are used in machines for the semiconductor and the heavy machinery 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.

 

Laser Machining

LPR Global’s large-sized fab shop specializes in laser beam machining capabilities. Our laser machining allows us to provide welding, cladding, cutting and drilling services with higher precision and shorter lead times. For example, laser machining was twice as accurate than single notch cutting and stamping methods when tested for concentricity in armature laminations. In addition, laser beam machining is limited only by machine and labour costs, without the additional tooling costs prevalent in other forms of machining such as single notch cutting or stamping.

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 Heat Recovery Steam Generator (HRSG) plants. As HRSG plants are subject to extreme and varying temperatures and mechanical pressures, the welded components must be highly robust.

 

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.

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