Wind turbine caps (also known as wind turbine blade caps) are critical protective elements for some parts of these large generators and essential components in order to ensure a long life of sensitive components, and perfect operation of the system in general.
As for renewable sources in Italy, the wind power sector is growing steadily. In fact, in our country, the operating capacity of wind power increased to 12.34 GW in 2023, ranking just after photovoltaics and hydroelectric sources (Source: Terna).
For those working in this field, it therefore becomes necessary to use congruent protective elements – such as wind turbine caps – to keep the renewable energy production unaffected and to prevent system slowdowns and failures.
Let’s take a look at the benefits of those caps, the most commonly used caps in this area, and their indicated uses.
The benefits of using wind turbine caps and protectors
As we anticipated, the use of caps and covers in wind turbines is to safeguard critical components from:
- contamination
- wear and tear
- corrosion
The advantage? Ensuring reliable operation and longer plant life.
End caps and caps for wind turbines: here are the most commonly used types
In the wind industry, one has to deal with works of great height and considerable size that are subjected to sunlight and weather every day. In fact, wind turbine towers can reach up to 120 meters in height and accommodate a motor with a diameter of 80 meters for large models.
Furthermore, if the system is placed in the open sea, salt spray could corrode the materials and delicate components more easily. It becomes essential, therefore, to protect modern wind systems as best as possible by using special caps and protectors to be applied in the most sensitive areas.
But what are the most suitable types to do this? Here they are:
1. End caps for bolts
These caps are used to cover the bolts, nuts, and rivets that secure the blades to the rotor hub. Their main function is to protect the bolts from corrosion and wear and ensure that they are securely fastened during turbine operation. In BMP TAPPI the most suitable series for this purpose are:
- TPDR(Cap for nuts and bolts with washer)
- TPDBL (Caps for nuts and bolts, series 1)
- TPDBRTPDBR (Caps for nuts and bolts, series 2)
- TPDBL (Tappi per dadi e bulloni, serie 1)
- TPDBR (Tappi per dadi e bulloni, serie 2)
2. Caps for electrical connectors
Most modern models of wind turbines have numerous electrical connectors that connect the various electronic components. To safeguard them from moisture, dust, and weather and to ensure reliable operation of the system, caps for electrical connector can be used.
In BMP TAPPI the most suitable series for this purpose are:
- TXT (Cap for pipes and fittings)
- ST (Cylindrical undercap)
- STC (Conical undercap, with great potential!)
- TXPE500 (PE pipe cap)
- CTI (Pull-tab cap)
- CTLTPE (Large head cap)
- TES (Hexagonal cap)
3. Sealing caps
Sealing caps can be used to seal openings or gaps in the wind turbine structure. This can prevent water or dust, for example, from getting inside mechanical or electrical components, preventing them from interfering with or damaging the entire system.
At BMP TAPPI, the most suitable series for this purpose are caps for closing holes on sheet metal, available in different shapes, sizes and materials, both rigid (made from technopolymers) and soft (made from low-density polyethylene or PVC).
4. Sensor protection end caps
Wind turbines are equipped with sensors that continuously monitor various operating parameters (such as, for example, wind speed or temperature). To prevent potential physical or environmental damage, special wind turbine caps and covers can be attached to the sensors, evaluating among different types.
In BMP TAPPI the most suitable series for this purpose are:
- TXT (Cap for pipes and fittings)
- ST (Cylindrical undercap)
- STC (Conical undercap, with great potential!)
- TXPE500 (PE pipe cap)
- CTI (Pull-tab cap)
- CTLTPE (Large head cap)
- TES (Hexagonal cap)
Other wind turbine caps to take into consideration
There are also other types of caps and covers that can be used to prevent damage to system components and to preserve the system. Some models, for example, can be inserted at the ends of the wind tower, during transport and pre-assembly, to prevent water, dirt and debris from settling inside.
Another effective solution are threaded caps, special pieces that can be used in wind power applications to prevent access of impurities, and EPDM solutions (such as caps and washer plugs) that are useful for masking.
Have you already thought about tailor-made solutions for your wind turbine caps?
For some wind systems it may be necessary to use large protective caps and special materials (always carefully considering whether to choose rubber or plastic according to your needs). At BMP TAPPI we make customized solutions to meet any customer request and need, including flange covers, thread caps and undercaps, and many other types.
We assist the customer from the very first design phase-involving in-house engineers, the research and development department and, if necessary, even the marketing team – to create tailor-made products, evaluating together the best solutions to meet every need.
We define the design, choose the most suitable material (including eco-friendly and PCR recycled plastic caps), the eventual color, and the addition of logos or lettering. Once the design is approved, we proceed with building or modifying the mold and molding the desired quantities. Each of our production meets strict compliance standards and is tested before delivery to the customer, always according to the agreed timeline.
Do you operate in the wind power sector?
Discover all cap models to protect wind turbines and their sensitive components: ask us for a consultation!