Switchgear replacement at 60 offshore wind turbines in Baltic 2

The gas tanks of the Flusarc medium-voltage switchgear had to be replaced at 60 offshore wind turbines spread across the site. Each heavy and sensitive component had to be transported from a confined turbine room, across multiple levels and designated lifting points, down to the crew transfer vessel.

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Differences between monopile and jacket locations, temporary emergency power supply, mechanical and electrical interfaces, and weather-dependent access all had to be integrated into a repeatable campaign workflow.

01 · Standardizing the series process

Method statements, risk assessments, and shared checklists defined a reproducible workflow for preparation, dismantling, transport, installation, and testing.

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02 · Safely preparing the turbine

Before each replacement, the initial state and transport route were documented photographically, the switchgear was taken out of service, and a temporary emergency power supply was set up.

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03 · Removing the old gas tank

Mechanical and electrical connections were disconnected. Chain hoists, transport dollies, and the turbine's own cranes enabled controlled transport to the external platform and the crew transfer vessel.

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04 · Installing the replacement gas tank

The new gas tank was brought in along the reverse transport route, aligned, and integrated mechanically and electrically into the medium-voltage switchgear.

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05 · Verifying quality for each turbine

Daily reports, digital photo documentation, before-and-after images, and electrical measurement logs provided comprehensive, turbine-specific final verification.

• Series campaign across 60 turbines at the Baltic 2 offshore wind farm.
• Diverse lifting and transport concepts for monopile and jacket locations.
• Heavy components, confined turbine spaces, and multiple transfer points between chain hoists, dollies, the platform crane, and the crew transfer vessel.
• Integration of mechanical dismantling and assembly, electrical work, logistics, HSE, and documentation.

The project documentation records the gas tank replacement at 60 wind turbines. Individual work and photo documentation files were created for each turbine ID; the campaign ran from June to September 2021.

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The standardized process enabled the repeated dismantling, transport, and installation of gas tanks at both monopile and jacket locations. Electrical measurements and turbine-specific condition assessments formed the documented conclusion.