Power & Energy Solutions

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Words: Peter Hearn, Operations Manager, ActSafe In this, second of four articles, we see how ActSafe Powered Ascenders can be used for material lifting in the wind energy industry. What is an ActSafe Portable Powered Winch? A Portable Powered Winch is a Li-ion battery or petrol powered lifting apparatus that is certified for lifting both loads, personnel and for lowering operations. The winches use readily available, 11mm kernmantle ropes so only rope length limits the lifting distances. The Working Load Limit is 200 and 250kg so these winches are a flexible tool that makes it possible to lift a wide variety of cargo and facilitate positioning operations. Nacelle In wind energy maintenance time is money, particularly when offshore, where weather windows are short. What happens when your crew arrive onsite, with a restricted time opportunity to get the turbine back online and they are unable to get tools and material into the turbine because the installed lifting equipment is not fit for purpose? An Actsafe portable battery powered winch, with a lifting capacity of 200Kg will ensure your maintenance teams can complete the task. This will reduce the risk of prolonged downtime. It also means it’s not necessary to have a permanent chain hoist fitted to

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In October 2016 PES brought you the newly baptised Vol au Vent. It has certainly been a winner for Jan de Nul, with ongoing projects and planned improvements to increase the crane’s capacity and available deck space. The Blyth Offshore Demonstrator Project During the third quarter of 2017, Jan De Nul Group’s vessel Vole au Vent will start the installation of 5 MHI Vestas 8.3 MW turbines at the Blyth Offshore Demonstrator Project. This new project is located 5.7km off the coast of Blyth, Northumberland, UK. The Jan De Nul Group was awarded the contract in March 2016 after FID was achieved by EDF Renewables UK. The Blyth Offshore Demonstrator wind farm will have an initially installed capacity of 41.5MW of electricity, which is enough to provide approximately 34,000 homes of renewable energy. Third in a row This project will be the third project in a row for the Vole au Vent since it was acquired by Jan De Nul Group in 2015. The previous projects were the Bligh Bank Phase II project and the Tahkoluoto project in Finland. By the time the new project starts, the two previous projects will have been completed.

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The demand for safe, clean reliable renewable power is growing at an ever increasing rate. Today PV technology is not only ecologically, but also economically a sensible alternative for power generation. A large scale PV power plant has to be competitive against conventional energy sources as well as other PV projects. With the elimination of government subsidies for this kind of energy generation in many regions and markets, the focus has now shifted to the plant’s overall efficiency. In the face of increasing cost-consciousness within all industrial sectors, the downward pressure on costs as well as on BOS components (balance of system) are becoming more and more crucial. Due to this, profitability has been lagging, so companies try to optimise CAPEX costs mainly and safe money on these components – often even during the design phase. But the real keys to improvement are both better capital and operational efficiency. The determining factor concerning favourable conditions for investment loans and credits is the profitability of a project during the operation period on the basis of reliable partners, components and an adequate operation and maintenance. When it comes to the profitability and the return on investment of a PV project, a low LCOE

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PES takes a look at the latest way one company is offering a way to save time, money and be ecologically responsible, by using a new extrusion method. BREYER’s extrusion system “CellProtect” allows the production of low shrinkage EVA encapsulation film at high production speed – on top - no energy consuming annealing and no interlayer film makes the production economic and energy saving Photovoltaic (PV) systems are used to convert sunlight into electricity. Energy will continue to be a catalyst for global economic growth and prosperity and the power of the sun is at the heart of the revolution in renewable energy. The global PVB market is forecast to grow by a minimum of 10% in the next few years. According to a research report from November 2016 by Fraunhofer ISI Freiburg, Germany, the Compound Annual Growth Rate (CAGR) of PV installations was 42 % between 2000 to 2015. Concerning PV module production in 2015, China and Taiwan hold the lead with a share of 67 %, followed by Rest of Asia-Pacific and Central Asia (ROAP/CA) with 14%. Europe contributed with a share of 5 % (6% in 2014); USA/CAN contributed 3 %. In the same way the demand for encapsulant material is

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WAB is the leading business network for the wind industry in Germany’s northwest region and the nationwide contact partner for politics, media and industry for offshore wind power in the country. Projects such as “Inn2POWER” clearly show that WAB is also active in Europe, on behalf of its 350 members, in the wind energy sector. “We have a very heterogeneous membership structure. It covers every aspect of the wind industry, ranging from very small start-up businesses to research institutes and major energy suppliers,” said Andreas Wellbrock, managing director of WAB. WAB’s members are involved in project development, financing, insurance, manufacturing - foundation structures, towers, nacelles and rotor blades - logistics and installation, grid connection, service and operation as well as dismantling and repowering. WAB therefore is always able make up-to-date and first-hand information available to its members on current issues. A recent example of this is the network’s interest in wind-to-gas technology, the exploration of opportunities for its development and research on its market potential for the wind industry. The 5th WINDFORCE Baltic Sea conference was held in February this year in Tallinn, Estonia and proved a resounding success. “WAB is also present where exciting new markets are emerging. At its

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At PES we know that maximising uptime and reducing costs are essential to the offshore wind power business. Semco Maritime helps offshore wind farm operators do exactly this by offering full service and maintenance concepts for offshore substations and wind turbine foundations - the so-called transition pieces. Semco Maritime helps offshore wind farm operators maximise uptime and drive down operational costs by offering full service and maintenance concepts for offshore substations and wind turbine foundations, the so-called transition pieces. It is simply good business to have a pro-active approach to maintenance because it prevents break-downs which cause costly downtime during repair. ‘After building and commissioning more than 20 offshore substations in the North Sea area we discovered a gap in the market. We found that offshore wind farm operators spend much time and energy on coordinating the work of a large number of service providers. Therefore, we are now offering a full scope service concept whereby we release time and resources for the operator enabling him to concentrate on the operation of the wind farm,’ says Bjarne Christensen, Director of service operations at Semco Maritime.

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During October 2015 Moventas Gears, the wind turbine gearbox specialist headquartered in Finland, made an investment decision, which now supports customers all around the UK and central Europe. The 3.6MW Full Load Test Bench & Final Assembly workshop was commissioned in Huddersfield, in August 2016. Supported by the UK government, the Huddersfield upgrade was part of a Regional Growth Fund initiative. All gearboxes serviced at Moventas go through a proven test run process regardless off the gear type or size. This is a Moventas internal and essential quality standard and usually also a customer requirement. Refurbished gearboxes that have gone through partial load or spin test can also have the option to be full load tested; if there has been major component change or modifications in the design, the full load test is a must. Moventas has a range of test benches dedicated to the serial production and service workshop requirements covering kW and MW drive trains. The difference between full load test and partial load or spin test The main purpose for the traditional full load test run is to guarantee successful component manufacturing, refurbishment and assembly process. The test run itself is not to improve quality – it is a

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In this, first of four articles, we look at how ActSafe Powered Ascenders are making wind turbine maintenance quicker and more efficient. We are all familiar with the adage “time is money”, and in offshore wind energy nothing could be more true. Getting people and material onsite quicker and allowing work tasks to be completed more efficiently can save thousands of euros per annum. ActSafe Powered Ascenders are helping to make wind turbine construction and maintenance cheaper by enabling personnel to get themselves in difficult to reach places and manage tools and components more easily, saving both time and material costs. Personnel access and work positioning In wind energy, it is imperative that maintenance and construction personnel can reach their place of work. The technicians need to be able to perform tasks, as efficiently as possible, to reduce work time and get tasks completed during available weather windows. Although many tasks can be performed from existing access platforms, there are still some areas of a wind turbine that are difficult to reach. These include; The interior of the transition piece The exterior of the nacelle The exterior of the spinner Wind turbine blades The exterior of the tower Some areas of the interior of

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Offshore wind turbines suffer from severe corrosion and with limited access to them, the choice of the right corrosion protection is crucial. The most widely used protection methods are anti-corrosion coatings, often in combination with cathodic protection (in the submerged zone). However, these coatings often suffer from premature failure due to mechanical damage, application errors or the wrong choice of coating system. (Insert image  failure of original coating in atmospheric zone). These failures need to be addressed during service life to ensure the integrity of the structure. The lack of accessibility results in high repair costs up to €2000 per m². Therefore it is important to choose a high performance repair system that will last for the remainder of the service life and can easily be applied in the extreme conditions encountered offshore. The high repair costs should be reduced by selecting a system which saves on surface preparation and application costs. This translates directly in a coating that is surface tolerant and reduces the amount of layers. Another concern is the environmental impact of offshore wind farms. Wind turbines are known to create disturbances (e.g. increased noise levels) that affect marine life. The environmental impact of the corrosion protection should be considered

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PES hears from the Belgian company, ADEDE, about the challenges they face during the search for unexploded ordnance (UXO) in the sea and on land. This work is often hazardous and sometimes uncovers some significant archaeological finds. Offshore UXO survey The offshore environment provides huge technical challenges, one of which is UXO. And more importantly, which objects are dangerous and which are not? For offshore surveying we use side scan sonar, multibeam sonar, magnetometry and electromagnetometry or EM. In order to work as efficiently as possible we use these survey methods simultaneously. It means less sails for data gathering and an accurate positioning of anomalies found on and underneath the sea bed. The data sets we produce allow us to make an initial preselection of objects that require further investigation by our dive team. A discarded tyre or oil drum for example could have a magnetic signature similar to UXO. The side scan or multibeam image enables us to exclude harmless obstacles from inspection by divers and focus on the suspect UXO targets. In circumstances where a diving operation is unadvisable we have our own ROV at our disposal for close up inspection, identification and preparation for safe removal of UXO.

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