Daily companions can be “potentially deadly”
At the turn of the year 2024/25, WEG installed and commissioned the prototype of a new 7-megawatt wind turbine. The location: a wind farm in the state of Bahia in northeastern Brazil, 500 kilometers west of Salvador. For the installation of the rotor blades, WEG ordered an SBI rotor blade beam from Axzion.
From September to December 2024, we were on-site several times to train WEG employees in handling the beam. The focus was on assembly, operation, daily maintenance, and test lifts. During the final installation of the “7.X MW” prototype shortly before Christmas, Mr. Lehmann supported the customer with hands-on assistance and advice.
Less than 30 minutes between hook-up and disconnection
The learning process during installation was remarkable. By the time the third blade was installed, the customer was able to complete the full cycle—from attaching the SBI beam to lowering and detaching after the blade installation—in under two and a half hours. That’s incredibly fast, considering that lifting, inserting and bolting the blade, and crane lowering alone took two hours. This meant that only about 30 minutes were left for attaching and detaching the lifting solution and slings for the guide ropes.
Far away from any mobile network
Although our teams are used to working in harsh environments, this project came with some unique challenges. We had to prepare even more meticulously for every contingency because there was no mobile network coverage anywhere nearby. Getting quick updates or documents sent to a smartphone was out of the question. The construction site was 75 kilometers from the nearest town, where our hotel was also located. Half of that distance was on a paved road, the other on a sandy track.
Another unusual challenge: deadly wildlife
Working at height always comes with risk, but we know how to protect ourselves. However, the bigger danger on this job was something else entirely: During the initial safety briefing, we were warned that anything crawling or creeping in the area could be potentially deadly—especially snakes and spiders. Wearing gaiters was mandatory. On top of that, the sun was brutal—sleeveless shirts and uncovered heads were strictly forbidden.
About WEG – 40,000 employees worldwide
Founded in Brazil in 1961, WEG manufactures electric motors, generators, and turbines, among other products. Production sites are located in Brazil, Argentina, and Mexico. The company employs 40,000 people globally and has an annual turnover of six billion euros. The German-sounding name “WEG” derives from the initials of the founders’ first names: Werner Ricardo Voigt, Eggon João da Silva, and Geraldo Werninghaus.
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