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EMERSON
Automation Systems
Wind Turbine Control Systems

Wind Farm Operator Reaps Results and ROI with Vestas V44 Wind Turbine Control Retrofit

Executive Summary: Rapid Recovery of a Decommissioned Vestas V44 Turbine

A U.S.-based wind farm operator restored a previously decommissioned Vestas V44 wind turbine by implementing an Emerson wind turbine control system retrofit. The turbine had experienced persistent controller-related issues and extended downtime, making traditional repair efforts ineffective.

By replacing the legacy controller with an Ovation™ WP3500 controller and integrating Ovation™ Green SCADA, the operator rapidly returned the turbine to reliable operation. The retrofit significantly reduced commissioning time, enabled remote visibility, and restored availability to near 100%, delivering measurable operational and financial returns

Results: Rapid Commissioning and Near‑Perfect Availability 

  • Maintained availability close to 100% since the control system upgrade 
  • Commissioned in just six hours, significantly reducing downtime 
  • Enabled reliable turbine operation without ongoing controller faults 

Application

Wind turbine retrofit of a decommissioned Vestas V44 turbine. The Vestas V44 remains a legacy workhorse across Northern Europe and the U.S., increasingly sought for refurbishment and resale as a decentralized power solution for emerging markets and smaller industrial sites.

Customer

A US-based renewable energy provider that operates a wind farm with Vestas V44 wind turbines.

The Challenge: Restoring Reliability After Control System Obsolescence

A US-based renewable energy provider purchased a decommissioned Vestas V44 turbine that had been sitting unused for two years following several performance issues, including multiple outages and low availability.

Initially, the wind farm operator attempted to repair the poorly performing wind turbine. The company rebuilt the hydraulics, pitch system and brakes; adjusted the original control system; and also performed smaller tasks such as changing fluids, rewiring and cleaning the turbine. Despite these efforts, there were still issues with the existing wind turbine controller, including:

  • Difficulties acquiring spare parts 
  • Random controller faults 
  • Controller ‘overload’ 
  • No remote connection 
  • No feasible repair options 
  • Issues with a faulty rotor current control unit 

It was clear another course of action was required. The company turned to a control retrofit solution.

The Solution: Ovation WP3500 Controller and Ovation Green SCADA Retrofit Package

The energy provider selected an Ovation™ WP3500 controller solution from Emerson. The solution uses the latest software and technology innovations and included a service app tool designed specifically to speed up the maintenance work tasks for service personnel. The solution enabled the energy provider to override the faulty rotor current control unit and increase power, while making all unit data available through Ovation™ Green SCADA software.

Commissioning took six hours - much shorter than what is typically required - and was conducted by the customer’s engineers with online and phone support from Emerson wind experts. The wind farm operator noted “great documentation and great support all the way through” from Emerson.

After retrofitting the V44, the turbine performed at nearly 100 percent availability. The service app was used for periodic maintenance tasks and received high grades from the service team for its functionality and high user-friendliness.

Why It Matters: Unlocking Value from Legacy Wind Turbines

For operators managing aging wind assets, control system obsolescence is often the primary barrier to continued operation. This Vestas V44 retrofit demonstrates how modern turbine controls and SCADA can restore performance, reduce downtime, and extend asset life without mechanical replacement.

By enabling faster commissioning, remote access, and long-term supportability, Emerson’s wind turbine retrofit solutions help operators maximize return on existing turbines while reducing operational risk and maintenance complexity.

“The solution gives us opportunities. With the retrofit in place, we can accomplish so much more in the future.”

- Wind Farm Manager

Learn More About Emerson Wind Turbine Retrofit Solutions

Strengthen turbine reliability and extend asset life with Emerson’s portfolio of retrofit and monitoring technologies:

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Considering a Retrofit?

Learn how Emerson helps operators improve performance, extend turbine life, and simplify O&M for aging wind assets. Contact our wind retrofit experts to start the conversation.