Power & Energy Solutions

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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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Getting almost every spare part and accessory for wind turbines from a single source to the customer - this is the business model WINDSOURCING.COM launched in 2013. Within three years the Hamburg-based company has developed to become the largest online distribution platform for the wind sector. PES Wind Magazine reports how the company was created and what concept stands behind it. “When it comes to failures in the operation of wind turbines, the time factor is decisive for operators and owners,” Stefan Weber, Managing Director and Founder of WINDSOURCING.COM, tells us. “One substantial factor to help reducing the downtimes of wind turbines is a good availability of spare parts and repair material as well as a well organised and expedited transport from the warehouse to the destination.” This is the point WINDSOURCING.COM comes into play. The distribution company is often the final lifeline for a service engineer or a wind farm operator. WIND-SOURCING.COM provides almost every part required to get a failed wind turbine system going again. Stefan Weber and Seher Kaygusuz set up their distribution company WINDSOURCING.COM in 2013, entered the profit zone in 2015 and are now making a name for themselves in the wind energy sector.

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Words: Philip Rood The marine renewables market is ever growing and SEA, a part of Cohort plc, has expanded its engineering capability to provide a variety of support services to the wave and tidal energy sectors. Cohort plc, business SEA, has showcased its credentials, in the growing wave and tidal energy support sector, by installing a 13.2kV cable connection to support the Oceantec wave energy device located at the Biscay Marine Energy Park (BiMEP) test site in Northern Spain. BiMEP tests prototype devices for generating wave energy, in advance of commercial production, to ensure economic and technological readiness and to ensure they are reliable and safe for commercial deployment. Once the devices have been verified, they can be considered ready for mass production and operational use. A team of engineers and technicians from SEA, subsea engineering division, terminated the device cable connection onshore and travelled offshore to connect the two halves at the wave site. The device is now fully operational and generating wave power back to shore. The BiMEP connections are a new variant of the nine 33kV connections first installed by SEA in 2009 at the Orkney-based European Marine Energy Centre (EMEC) test centre for marine renewable energy. The connections supplied by SEA

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Words: Dipl.-Chem. Joachim Rother, Technical Director, novatic COATINGS Group The novatic® COATINGS Group has an extensive portfolio of high quality coating materials, for industrial corrosion protection, for use in various industries. There is a wide range of corrosion protection systems and applications available ranging from easy to use, for the protection of interior steel constructions, without additional demands, to high corrosion stress in maritime domains (C5M-high), as well as the protection of steel constructions within an industrial atmosphere (C5I-high), also with permanent exposure to moisture and for the chemical industry with its additional demands. Proven coating systems for the protection of the materials e.g. steel, spray- and hot galvanised steel, stainless steel, concrete and the like are available. This is why novatic® has been very successful over the past 20 years, in the wind energy sector and has numerous references. In the middle of the 90s the first wind turbine steel towers (WTGS) were coated with a novatic® corrosion protection system. The importance of this market was already recognised at this time, so product development was purposefully encouraged. A team, composed of chemists and application technologists, successfully worked on applications on towers, drive engineering, gondolas, hubs and rotor blades. They developed a focus

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DONG Energy awarded DEME’s subsidiary Tideway cable installation contract for the Hornsea Project One offshore wind farm. PES investigates to find out why and introduces readers to the ‘Living Stone’. Early June this year, Tideway BV, Breda, the Netherlands, a subsidiary of the Belgian dredging, environmental and marine engineering group DEME, was awarded a cable installation contract (Transport and Installation) by DONG Energy for the world’s largest offshore wind farm, Hornsea Project One. Tideway will deploy DEME’s newest, multipurpose vessel (MPV), ‘Living Stone’ for this project. This Dynamic Positioning 3 (DP3) vessel is the most advanced subsea cable installation vessel in the world. It is currently being built by the Spanish shipyard LaNaval near Bilbao, Spain. The ‘Living Stone’ will have two turntables below deck each with a capacity of 5,000t making a total capacity of 10,000t. There is also the possibility of a third carrousel above deck with an additional load capacity of 2,000t. Delivery of the state-of-the-art ‘Living Stone’, which is equipped with dual fuel engines, is scheduled for April 2017. LNG will be the primary fuel. This means the ‘Living Stone’ will be amongst the cleanest installation vessels in the world, having a Green Passport and the Clean Design Notation, which

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Offshore terminals are the most important interfaces during the construction of wind farms off the coasts of the North and Baltic Seas. Many wind farms have been created in recent years and more are already in the planning stages. The Hamburg-based company Buss Port Logistics (Buss) recognised the opportunities early on, and with their own Orange Blue Terminal (OBT) in the Dutch port of Eemshaven, they developed the “Offshore” sector. Martin Schulz, Head of Offshore Logistics at Buss, offers PES a glimpse behind the scenes: from the initial planning of a terminal to the completed offshore project. From sandy desert to a heavy cargo terminal The Eemshaven offshore terminal was already an important hub for many projects in the North Sea. However, in order to bring ashore the massive components, to put them in intermediate storage, to perform the pre-installation and to ship them back out, extensive construction measures were required at the terminal, situated on the southwestern bank of the Ems estuary. “When Buss came to visit the future terminal in Eemshaven for the first time, it looked more like a sandy desert, without even a quay wall in place,” explains Schulz, adding: “The management team was quite optimistic however. This way, Buss

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Words: Dr. Wolfram Palitzsch, Loser Chemie GmbH Loser Chemie is developing high quality, cutting edge recycling technology especially for the photovoltaic industry. The recycling of this waste is important from a political, economic and environmental perspective. Loser Chemie GmbH (LC) was a chemical company whose main business was in water chemistry. Recently Mr. Loser restructured his company. He founded a holding company and sold the aluminium and barium chemistry sections. In order to build and run a photovoltaic recycling turnkey system he bought a plant engineering company – TESOMA GmbH. Loser believes that you can only expect a first-class solution from a specialist. Thus Tesoma has established a reputation for providing precisely that, especially in the handling of flat glass. The company ranks as an international market leader when it comes to drying and fixing. Tesoma develops and manufactures their dryer systems in exclusive cooperation with JRT Photovoltaics. The highest precision and optimised processes allow mean minimal breakage when producing solar wafers. Partnering with qualified market leaders gives the competitive edge along with the maximum possible potential for photovoltaic modules. This venture has brought the Loser group in to the photovoltaic industry. LC is aware that in the future natural resources such as water or

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