Power & Energy Solutions

The premier renewable energy publication

China is well on the way to being a market leader in wind energy and ZF is already there, in the established Tianjin facility and the satellite plant in Beijing. The European trained Chinese staff includes designers and technicians all eager able to provide a top class service worldwide. PES brings you the latest developments from this dynamic, pioneering company, who is set to remain top player in our industry for some time to come. ZF Group is a world-leading technology group in driveline and chassis technology as well as active and passive safety technology. ZF Wind Power (ZF) is one of its major industrial business units, as part of a long-term corporate strategy of involvement in the wind market; ZF has enhanced its product range and advanced gearbox solutions through the acquisitions of wind gearbox suppliers Hansen Transmissions in 2011 and the Bosch Rexroth AG wind business in 2015. ZF has been pioneering wind gearboxes since 1979 and has always had a strong focus on advancing the wind power market, with innovative designs, to drive down the cost of electricity. With over 60,000 gearboxes shipped, ZF has installed more than 110 GW covering 25 percent of the globally installed base of

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In this day and age when downtime prevention, maintenance and cost reductions are key, remote surveillance must be one of the top ways to improve all three. PES went to find out the latest developments from Moventas who have remote surveillance centres in Finland, Italy, UK and the US to monitor over 2,500 wind turbines globally. The Moventas Condition Management System (CMaS) gathers critical data on turbines in operation, which is analysed by a team of experts to help ward off unexpected failures. CMaS operates on all gearbox types. Thus Moventas provides surveillance for turbines deploying a range of different gearbox brands. A broader view of the whole drivetrain with CMaS and its intelligent sensors CMaS was developed to monitor how the gearbox and other drivetrain components in a wind turbine perform. It anticipates possible upcoming failures and it guarantees the continuity of their energy yield. Traditional condition monitoring products focused mainly on measuring vibrations from rotating components. CMaS, on the other hand, is based on a profound understanding of the various failure modes of the drivetrain as whole. For example, it is possible for early changes in oil lubrication properties to be visible, long before they can be measured in vibration. CMaS technologies

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Buss Offshore Solutions GmbH & Co. KG is a member of the Buss Group in Hamburg. It was founded in 1920 as a stevedoring company. Today, it is made up of several units, which are active in different areas of maritime logistics. One of them is the Buss Offshore Solutions GmbH. Right from the start the company, which is also located in Hamburg, has been an active player in the offshore wind logistics industry, and has established itself successfully in this specific business sector. Focusing on heavy, challenging loads, a team with international experience develops tailor-made logistic solutions for its customers. Buss Offshore Solutions handles the project planning and management at all stages between the manufacturing plants and the offshore installation sites: from handling, trans-shipment and interim storage to pre-assembly, maintenance and the required engineering services. This logistics consultant has its own terminals such as the Orange Blue Terminal, Eemshaven in the North Sea and the Mukran Port Terminals, Sassnitz in the Baltic Sea. Additionally Buss Offshore Solutions offers its know-how by consulting international clients during all stages of port development, project preparation or project execution. Meanwhile we have successfully completed our fourteenth major project, including various offshore wind projects such as Veja Mate, Gemini,

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In 2002 the first ever offshore high voltage substation was delivered by HSM Offshore. This was under an EPCI contract from Eltra/Energinet, for the Horns Rev A project, off the Danish West coast. Things have gone from strength to strength since then, as this report to PES shows. Earlier this year the company signed the EPCI contracts for the TenneT TSO B.V. Borssele Alpha and Beta Substations. It really is remarkable to see the growth in transformer capacity lead to larger topsides and substructures. Lately we have also seen further increases in inter array and export voltages, as well as significant growth in the supply scope for EPCI contracts. The Horns Rev A Substation featured a transformer capacity of 160 MW and topside weight of 1,100 mt and was placed on a multiple pile foundation. The Asian Hercules II floating sheerlegs and the IB 909 jack-up were used for the installation. In 2007 there was another EPCI contract for the same customer, for a 250 MW Substation, featuring 1,300 mt topside and this time, with a jacket weighing 1,000 mt, the installation of both were undertaken by the Matador 3 floating sheerlegs. The 325 MW Thornton Bank Substation was HSM’s first Substation project in

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Words: Ignacio Serrada and Alfonso Hernández, members of Offshore and Modular Department By the end of October, the first shipment of transition pieces (TP) for the MERKUR offshore wind project had been completed. The brief was to take full responsibility for organising the transportation and associated engineering, to ship these components from the manufacturer’s premises to the hub port for the transfer of TPs to the installation vessel. COORDINADORA, in charge of the engineered transportation, is thrilled to share this stunning case study exclusively with PES. The challenge came from an established customer IDESA-WINDAR, the joint company in the DANIEL ALONSO Group, they were awarded the order to manufacturer 66 transition pieces for the Merkur Project. They were manufactured in their Aviles facilities and had to be delivered to GeoSea, part of the DEME Group, in Eemshaven Port who was the main contractor. The first task was to select the most suitable vessel to match the obvious competitive requirements and the technical reliability needed to carry this crucial cargo, especially with regards to the lifting capacity of ship’s cranes. Thus, COORDINADORA, an expert in the shipping sector for over 35 years, prepared a particular RFQ for the ship owners to bid for the necessary

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Even though the foundation may seem like a minor detail in a wind power development project with a EUR 50–200 million price tag, slow progress in foundation design, production and assembly will postpone the day when the investment starts to generate profits. With that in mind, Peikko has created a holistic solution consisting of the design, manufacturing and installation of both gravity and rock foundations. Since 2014, Peikko has been the technology distributor for more than 1,200 foundations for Nordic wind power projects. Success has come with a simple insight that is easy to relate to, whether you are an investor or a contractor. ‘Any delay in the building process will postpone the day when the investment starts to generate profit,’ Kari Tuominen, Business Director of Peikko’s wind turbine foundation business, noted. ‘It’s not a small detail we are talking about, as the overall price tag of these projects may well reach 1 billion euros.’ In 2012, Peikko started the quest for faster wind power projects by fine-tuning its design, manufacturing and installation process with gravity foundations. The result was quickly noticed and the market share rose quickly. Currently, around 600 wind turbines are built annually in the Nordic countries. One third of

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Construction of offshore wind farms has advanced rapidly over the last few years and is maturing into a market where subsidy funding is diminishing. Numerous companies joined in to develop the offshore wind market and are further developing their assets to provide services to this market. PES shares this insight in to one company’s continued search to improve tools and equipment. At Huisman we see this development of assets through the contracts we have received for the construction of several cranes, intended for the construction of wind farms. Part of the development of this maturing market has been the growth of the wind turbine’s output, through increasing the size of turbines and blades, resulting in higher turbine towers. This upscaling of size of the different components of an offshore wind turbine, results in the need for larger installation tools: i.e. larger cranes. Due to the larger components, installation procedures and the tools to perform these procedures are becoming more important in ensuring handling ease and safety during installation processes of offshore wind turbines. Part of our contribution to the wind installation market is our range of cranes, which are adaptable with a variety of components of various sizes. Some tools are foldable

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Height Specialists was established in 1995. It is a specialist company that provides rope access inspection, maintenance and modifications for on and offshore inspection, maintenance services to clients, operating in various industrial sectors, as well as at promotions and public events. The business started as a one-man venture but today operates as fully a qualified IRATA, ISO 9001 and VCA-P company with over 75 employees working worldwide. ‘Height Specialists is an innovative and dynamic organisation that offers a quick and professional response to its clients’ questions,’ comments general manager, Henri Hoogenes. ‘Safety is always our first priority and as such, each project will endure a risk analysis and methodical planning before execution. Height Specialists only works with fully certified technicians, tools and materials.’ Indeed throughout its history the company has managed to adapt itself quickly, notably by providing abseiling and zip wire services at Rotterdam’s Euromast and later by supporting various Dutch television productions. During the early years it also turned its hand to work at height, using rope access and industrial climbing. Rope access is a method for working at heights utilising ropes, climbing harnesses and other materials to enable access to working locations in difficult and inaccessible situations. It is a method of

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In this, the third of four articles, we will examine the rope access, work positioning and enclosed space entry capabilities of ActSafe Powered winches. In wind energy, it is imperative that maintenance and construction personnel can reach their place of work and perform tasks as efficiently as possible to reduce work time and get tasks completed during available weather windows. Powered ascenders allow easy, quick and efficient access to all areas of a wind turbine that have previously proven difficult to access. Although many tasks can be performed by alternate access methods such as access platforms, most areas of a wind turbine are more easily reached using a powered winch. Rope access ActSafe Powered Ascenders have become the go to product for rope access technicians contracting to the wind energy industry. Powered Ascenders augment traditional rope access techniques to allow workers to reach areas of the wind turbine for blade inspection, repair and tower cleaning tasks. Once ropes are established, it is equally viable to work from ‘bottom up’ as ‘top down’ which doubles the efficiency and speed of work. The reduction of physical effort means more actual work can be performed and the risk of accidents reduced with a subsequent reduction in fatigue. Technicians

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Trojan brings power to the northern state of Choco, located in western Colombia, in the Municipality of Acandi, an area that is mainly jungle, along the Caribbean Sea bordering Panama. This region is in a remote area of the country that is not tied to an electrical grid. The Colombian government issued a mandate to expand the availability of electricity to the remote area of Acandi by building five solar hybrid installations, or microgrids. Acandi is mostly jungle, located on the Caribbean Sea bordering Panama, and its remoteness made it impossible to effectively connect to the country’s main electrical grid. These communities were forced to rely on diesel generators which only provided power for a few hours each day. The government decided to improve electricity service to the communities using state-of-the-art solar photovoltaic technology with energy storage powered by advanced deep-cycle batteries. One of the greatest incentives to installing these microgrids was to reduce the use of diesel fuel. Not only were the generators loud and emitted pollutants, but because the area can only be accessed by boat, the cost to transport fuel is prohibitively high. Also, when a generator broke down, the community would have to go without electricity until someone could

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