Customer Success

Real Challenges.
Proven Solutions.

Explore how Kavaken helps renewable energy companies optimize performance, prevent failures, and maximize production across their portfolios.

Portfolio Size

Issue Type

Component

Cross-Turbine Comparison Exposes Faulty Gearbox Cooling Valve

0–50 MW

Failure RiskGearbox Oil System

Cross-Turbine Comparison Exposes Faulty Gearbox Cooling Valve

When the OEM attributed abnormal temperatures to model differences, cross-turbine comparison revealed the real culprit—a faulty thermal bypass valve that standard checks had missed.

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Electrical Relay Fault Revealed by Subtle Pitch Box Temperature Anomaly

0–50 MW

Failure RiskBlade Pitch Box

Electrical Relay Fault Revealed by Subtle Pitch Box Temperature Anomaly

A minor electrical defect inside the pitch box went unnoticed until heat patterns exposed a welded relay contact disrupting the box’s temperature control.

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Airflow Restriction Behind Generator Bearing Overheating

50–250 MW

Failure RiskGenerator Bearing (NDE)

Airflow Restriction Behind Generator Bearing Overheating

A subtle temperature rise in the generator bearing traced back not to a lubrication fault but restricted airflow. A simple duct cleaning restored normal operation and avoided a potential bearing failure.

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Hidden Cooling Inefficiency Behind Generator Winding Temperature Rise

50–250 MW

Failure RiskGenerator Windings

Hidden Cooling Inefficiency Behind Generator Winding Temperature Rise

A gradual rise in generator winding temperatures revealed a hidden cooling inefficiency that required multiple interventions before full recovery.

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Yaw Sensor Misalignment Behind Long-Term Power Loss

500–1000 MW

Power Curve DeclineYaw System

Yaw Sensor Misalignment Behind Long-Term Power Loss

Kavaken uncovered a static yaw misalignment that had been quietly reducing power output for months. The calibration issue in the wind direction sensors was identified and corrected, restoring expected performance levels.

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Cooling Inefficiency Behind Transformer Overheating

50–250 MW

Failure RiskTransformer

Cooling Inefficiency Behind Transformer Overheating

A steady temperature rise in the transformer went unnoticed by standard systems until Kavaken’s analysis revealed a cooling inefficiency caused by clogged ventilation grills.

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0–50 MW

Failure RiskMain Shaft Bearing

When an Oil Top-Up Wasn’t Enough

A rise in bearing temperature first seemed fixable with an oil top-up, but continued monitoring proved a full flushing was needed to restore normal operation.

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Bearing Misalignment Found Weeks Before CMS Alarm

0–50 MW

Failure RiskGenerator Bearing (NDE)

Bearing Misalignment Found Weeks Before CMS Alarm

Weeks before the CMS alarm, Kavaken had already flagged rising temperatures pointing to a bearing misalignment later confirmed by the site team.

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Power Curve Restored After Blade Load Sensor Replacement

0–50 MW

Power Curve DeclineBlade Load Sensor

Power Curve Restored After Blade Load Sensor Replacement

A sudden drop in turbine performance was detected as it switched to a different power curve mode. Further analysis traced the cause to a faulty blade load sensor, which was replaced to restore full power output.

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50–250 MW

Unusual OutageCable Management System

Frequent Cable Untwist Stops Identified

Kavaken identified unusually frequent cable untwist stops in one turbine compared to others on the same site.

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False Hydraulic Fault Resolved After Module Connection Fix

0–50 MW

Failure RiskHydraulic System

False Hydraulic Fault Resolved After Module Connection Fix

A rising hydraulic oil temperature trend triggered a flag on Kavaken. After cross-checking similar turbines, the team discovered that the issue wasn’t mechanical but caused by loose module connections creating a false fault signal.

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Slip Ring Temperature Stabilized After Cooling Pressure Adjustment

250–500 MW

Failure RiskGenerator Slip Ring

Slip Ring Temperature Stabilized After Cooling Pressure Adjustment

Kavaken detected abnormal slip ring temperature behavior and traced it to the cooling system pressure settings. A simple pressure adjustment restored stability and prevented unnecessary maintenance.

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Frequent Generator Overheating Outages Linked to Cooling System Faults

250–500 MW

Unusual OutageGenerator Cooling System

Frequent Generator Overheating Outages Linked to Cooling System Faults

Kavaken detected recurring overheating-related outages in a generator and traced the issue to cooling system faults. Routine actions like coolant refilling, radiator cleaning, and fan replacement restored stable operation.

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Pitch System Optimization Restores Power Curve Performance Across 25 Turbines

50–250 MW

Power Curve DeclinePitch System

Pitch System Optimization Restores Power Curve Performance Across 25 Turbines

Kavaken detected a consistent performance drop near the rated power region across 25 turbines. The issue was traced to the pitch system and resolved after corrective adjustments, restoring full production efficiency fleetwide.

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False Ice Alarms at 20°C Led to Avoidable Turbine Stops

50–250 MW

Unusual OutageControl System

False Ice Alarms at 20°C Led to Avoidable Turbine Stops

Kavaken identified repeated turbine stoppages caused by false ice detection signals, even at temperatures above 20°C. The insight directed attention to control system calibration rather than environmental factors.

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Repeated Angle Errors Traced to Pitch Encoder Failure

+1 GW

Unusual OutagePitch System

Repeated Angle Errors Traced to Pitch Encoder Failure

Kavaken identified a pitch control malfunction that was causing notable production loss. The root cause was traced to a faulty pitch encoder, which was replaced by the OEM, restoring normal operation.

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Grid-Induced Power Limitation Identified Behind Performance Drop

+1 GW

Power Curve DeclineGrid Connection

Grid-Induced Power Limitation Identified Behind Performance Drop

Kavaken detected a sharp performance drop in one turbine’s power curve and helped confirm that the issue stemmed from grid-related power limitation, not turbine performance.

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Cooling Fan Replacement Prevents Converter Overheating

+1 GW

Failure RiskConverter Control Cabinet

Cooling Fan Replacement Prevents Converter Overheating

Kavaken detected consistent temperature deviations in the converter control cabinet, indicating reduced cooling efficiency. The issue was resolved after the OEM replaced malfunctioning cooling fans.

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False High Wind Alarms Caused Production Loss Under OEM Agreement

+1 GW

Unusual OutageControl System

False High Wind Alarms Caused Production Loss Under OEM Agreement

Kavaken identified a pattern of false high wind alarms that were shutting down turbines at moderate wind speeds. These false triggers, excluded from the OEM’s availability guarantee, caused unnoticed production loss until Kavaken’s analysis revealed the malfunction.

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Real Challenges.Proven Solutions.

Cross-Turbine Comparison Exposes Faulty Gearbox Cooling Valve

Electrical Relay Fault Revealed by Subtle Pitch Box Temperature Anomaly

Airflow Restriction Behind Generator Bearing Overheating

Hidden Cooling Inefficiency Behind Generator Winding Temperature Rise

Yaw Sensor Misalignment Behind Long-Term Power Loss

Cooling Inefficiency Behind Transformer Overheating

When an Oil Top-Up Wasn’t Enough

Bearing Misalignment Found Weeks Before CMS Alarm

Power Curve Restored After Blade Load Sensor Replacement

Frequent Cable Untwist Stops Identified

False Hydraulic Fault Resolved After Module Connection Fix

Slip Ring Temperature Stabilized After Cooling Pressure Adjustment

Frequent Generator Overheating Outages Linked to Cooling System Faults

Pitch System Optimization Restores Power Curve Performance Across 25 Turbines

False Ice Alarms at 20°C Led to Avoidable Turbine Stops

Repeated Angle Errors Traced to Pitch Encoder Failure

Grid-Induced Power Limitation Identified Behind Performance Drop

Cooling Fan Replacement Prevents Converter Overheating

False High Wind Alarms Caused Production Loss Under OEM Agreement

Real Challenges.
Proven Solutions.