How Deutsche WindGuard saves up to 59% inspection time with TOPseven

Speed and utilization 

• Reference V112. Using TOPseven technology reduces the inspection time from approximately 7 hours to around 3 hours, which means that with suitable layouts and the same  crew, two turbines can be inspected per day instead of one. 

• Reference E-126. Rope access work took around 9 hours due to repeated movements and positioning of the rotor blades. Visual inspection with drones and LPS reduced this time to around 4 hours. 

Compliance and risk 

• Enercon to E-82. Inductive measurements finally enable operators to meet insurer and guideline requirements for measuring LPS continuity where resistance measurements fail due to microcracks in the aluminum profile.  

• Verifiability. A complete set of images per turbine supports legally admissible documentation. DWG cited a rotor blade fracture years after inspection, with images showing that there were no visible signs of this at the time of inspection.

People and skills

• Safety. Fewer hours on the rope reduce the risk. In cold or tall towers, physical strain and cumulative risk are significantly reduced. 

• Retention of expertise. Inspectors who cannot or do not want to climb continue to make a valuable contribution as drone pilots and testers. 

• Better training. Repeatable image data and asset histories help specialists teach younger employees what to look for using models and known vulnerabilities.  

Scope and limitations 

• Offshore. Mixed regulations continue to apply. The standards require a proportion of climbing or paired visual inspections and climbing tests.  

• The rope remains in the toolbox. Older models with defects that are not visible with drones, or split rotor blades that require access to the interior, still require rope-based procedures. 

• Product requirements. DWG wants to see further progress in offshore readiness and portal optimization.