WindGuard Insight - The Blog

Synergies within the WindGuard universe occasionally result in quite unexpected, extraordinary and exciting projects. Recently, for example, our Technical Management and Safety Training divisions jointly ensured a smooth film shoot on the nacelle roof of a 170 meters high wind turbine. WindGuard Insight tells you the whole story.

Deutsche WindGuard's Technical Management team looks after the seven state-of-the-art Vestas V136 4.2 MW wind turbine generators (WTGs) of the ground-breaking flagship project “Windwasserstoff Salzgitter” (Wind Hydrogen Salzgitter). With a total output of almost 30 MW, they supply power for the production of green hydrogen, which Salzgitter AG uses to replace previously required carbon in its steel production.

Earlier this year, Avacon Natur GmbH, as the constructor and operator of this exceptional wind farm, gave Max Schlappa, their point of contact at Deutsche WindGuard’s technical management, a call and asked for support with an extraordinary idea: Twelve months after the wind farm had been commissioned, as part of a corporate video, a member of Avacon AG’s Executive Board would be invited to speak about experiences and achievements in front of a camera at airy heights on top of one of the wind turbines.

He immediately picked up the phone and asked Alexander Treichel, Head of Safety Training at Deutsche WindGuard, for assistance. Together, they developed a safety concept that allowed three guests to be safely escorted onto the wind turbine in compliance with all regulations and risk assessments for occupational safety. In addition to Avacon Chief Technology Officer Dr. Stephan Tenge, videographer Max Kruse from Escape Film Production also had to go up. And Sebastian Wöltje, Asset Manager at Avacon Natur, couldn't miss the opportunity to personally accompany this exciting project on one of his turbines, of course.

Explaining the safety concept Max adds: “This event reminded me how exposed my usual work environment appears to other people. Heights and confined spaces in the turbines don’t affect me anymore. Yes, I know about the risks and behave accordingly but they don’t paralyze me. It was even more important for us to demonstrate this calm routine to our visitors, in order to make them feel safe while moving within the WTG’s tower and on its roof top. I can only admire what an outstanding job the visitors did overcoming their fears while totally trusting our instructions on how to move securely in the WTG.”

Already the ride in the tiny elevator inside the WTG’s tower was an adventure, and it took some time until all six had made their way into the nacelle. “I wish I had taken the drone up with me right from the beginning,” is Max Kruse’s lesson learned, “the 25-minute ride up and back down was something I hadn't taken into account at all.” Standing on the approximately 25 square meters large nacelle roof and 170 metres above the ground is nothing for anyone not immune to giddiness. Through the exit hatches at each narrow end of the nacelle, Stephan Tenge on one side and Max Kruse on the other climbed onto the roof with their Deutsche WindGuard escorts who ensured correct securing at all times. Captured by Max Kruse’s camera, Stephan Tenge recited his four-minute text freely and several times in a row. For the film sequences recorded by the drone, the WindGuard team coordinated Stephan Tenge’s appearance on the roof top in cooperation with the ground staff via mobile phone. “We calmly explained him when to go up and secured him to the anchor points,” Max says, “during the breaks in between the recordings we moved inside the nacelle where I tried to get Stephan’s mind off the height by doing some small talk.”

The spectacular pictures speak for themselves - all the effort and the adventure were worth it. “This was a whole new experience,” Max Kruse expresses his enthusiasm, “standing on a wind turbine for the first time while filming an interview!”

Deutsche WindGuard’s onsite team was also highly satisfied with the smooth and successful event – and took home a follow-up assignment straight away: Just a few days later, they stopped by at one of the Vestas wind turbines in Salzgitter again. This time, they trained some Avacon employees directly on site – because the scenario at a real WTG with its original equipment is simply the most authentic. This ensured the instant connection of theory and practical exercises – and even a rescue by ladder from the lift at a height of 20 metres was on the training agenda. “While we are currently installing an elevator at our modern training centre in Norden to offer customers even more realistic conditions,” Alexander concludes, “reality is still the best training environment.”