Innovating hydraulic systems and tools for the wind energy industry

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Ernest Freeman
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1 Innovating hydraulic systems and tools for the wind energy industry Contact: Karen BERGMANS SPX

2 2 New hydraulic systems and tools for the wind industry SPX Hydraulic Technologies, part of SPX Corporation, is a global manufacturer of highperformance systems in the hydraulic energy and railway sectors, such as high pressure cylinders and jacks, pumps, torque wrenches, bolt-tensioners, nut splitters, work holding and railway track systems. Leading product brands are: - POWER TEAM: Brand solutions including tools, equipments and a variety of other components, technologies and services for energy infrastructure construction - STONE: AC and DC hydraulic power units - HYTEC: High performance, hydraulic work holding - GLOBE: Radial piston, pneumatic motors - RAIL SYSTEMS: High speed solutions for the world s railways Headquartered in Rockford, Illinois, global sales and manufacturing locations include The Netherlands, Shanghai, Singapore and the United Kingdom. SPX Bolting Systems helps contractors to improve work productivity with a line of tools that drive efficiency on the site. SPX Bolting Systems in Energy industries Growth in traditional and renewable energy requires increasing infrastructures among local, regional and global communities. Demand for wind power is extending around the world and, with it, the need for wind turbine installations. Companies are under pressure to work harder and smarter. SPX Bolting Systems offers on-site solutions to enable assembly of large wind turbines, as well as various power plants generations, by developing a series of hydraulic torque wrenches and pumps to target the bolting process. Bolting is a key component in the construction of wind turbines. For each of them, hundreds of bolts are required for fastening tower sections, the foundation and blades. Tightening and applying final torque settings to the bolts quickly and precisely is crucial to maintaining schedules and keeping labour costs down. Power team hydraulic wrenches and pumps facilitate the bolting process by providing greater tool portability, flexibility and continuous operation. Employing constant horsepower technology, the Power Team hydraulic torque wrench pump increases the flow rate across the flow curve. The result is faster tool operation and improved process efficiency more bolts tightened per hour. A Fortune 500-listed company, SPX Corporation (NYSE: SPW) is a leading, multi-faceted industrial body providing its clients with highly specialized technical solutions that answer the most complex requirements. SPX, whose global headquarters are in Charlotte, North Carolina, USA, has over 15,000 employees and operates in more than 35 countries all over the world. SPX products and technologies play an important role in the expansion of global infrastructures that have to meet growing energy demands, whatever the source: whether coal, natural gas, nuclear, solar energy or even geothermal. The company offers innovative products, and specializes in equipment that is energy efficient, such as cooling systems for power stations, adjustable, ready-to-use edge tools for agriculture, production equipment for diverse flow control systems in oil and gas drilling, as well as equipment for the distribution, refining and generation of power. The range also includes manual diagnostic instruments for vehicle maintenance and repair, and power transformers for the regulation, transmission and distribution of electrical currents.

3 PE 45: The first continuous pressure hydraulic pump Power Team, one of the leading SPX Bolting Systems product brands, has long been the market leader in high pressure hydraulic pumps due to

3 3 PE 45: The first continuous pressure hydraulic pump Power Team, one of the leading SPX Bolting Systems product brands, has long been the market leader in high pressure hydraulic pumps due to durability, ease of use and life cycle cost benefits. Power Team introduces Infinite Stage Pump Technology the first continuous flow hydraulic pump that results in up to 200 % speed improvement making jobs faster and easier. The SPX PE45 is an Infinite Stage Pump increasing productivity on the job by providing continuous flow for up to twice the speed of typical 2-stage pumps. The features included in the SPX PE45 in order to excel within the market and to answer operator s needs are: - The possibility of continuous duty in an operating environment from -25 C to +50 C - Portability is facilitated due to a weight of 32.2 kg excluding oil. - A 5 meter long pendant control switch which is easily removable. - Improved oil filtration and a 1.8 horsepower Universal Motor which is used to cope with up to a 20 % voltage drop. Safety, one of the major concerns of SPX Bolting Systems is always the priority, a contributing feature to this end is the built-in retract relief valve in the manifold set at around 350 Bar which protects both the tool & operator from any possible pressure intensification that may occur if the couplers should be incorrectly connected. The PE45 pressure regulator valve is also now more easily adjustable to vary the output torque from the tool. The SPX Bolting Systems Infinite Stage Pump technology is bringing the next generation to the market.

4 PE 39: The newly designed compact pump The compact PE39 incorporates a new, durable pump design for reliable operation, specifically designed for the wind tower maintenance teams.

4 4 PE 39: The newly designed compact pump The compact PE39 incorporates a new, durable pump design for reliable operation, specifically designed for the wind tower maintenance teams. It also lends itself to be utilised for checking bolt torque integrity. Whilst there are other products potentially competing with the PE39, its lighter weight (17.7 kg), higher horsepower motor and higher flow definitely bring exceptional and additional values for a great performing pump. The lighter weight and the small form factor consequently make it easily portable and comfortable for the technician to use in confined working spaces. The PE39 can be carried in a vertical, as well as a horizontal orientation due to a bladder-type reservoir and is ready to work inside or outside the tower. It is based on a proven pump design for reliability in rugged torque wrench applications to support operation and maintenance requirements. A cooling fan option allows for continuous duty in high ambient temperature operating environment (-25 C to 50 C). If temperatures are at extremes of the operating range, it is recommended to use hydraulic oils that are rated for those temperatures. The durability of the PE39 is exceptionally long compared to the competition as it has been tested to over cycles. In order to be able to prove this, SPX Bolting Systems has made special tests for typical use and the PE39 passed with exceptional results.

5 5 TWHC, the Torque Wrench High Cycle The TWHC is SPX Bolting Systems additional line of Square Drive Torque Wrenches. It is designed to reduce costs by improving the cycle life of torque wrenches by 2-3 times existing technology. It is primarily intended to be used in the Wind Energy sector where the usage rate is very high. There are hundreds of bolts in each wind turbine and typically contractors are working 24/7 to erect the turbines. Standard hydraulic torque wrenches are generally not built for this continuous duty (a maximum of cycles); the TWHC has been tested in excess of 30,000 cycles - 2 to 3 times standard torque wrenches and designed to operate in the rigors of the outdoor environment where they are typically used. The TWHC is highly-resistant to corrosion in harsh environments, both on and offshore due to top grade materials and a nickel coated finish. Its compact nose radius allows the tool to fit in tighter, hard-to-reach spaces. The ease of use is enhanced thanks to its light weight, optional carry handle and multiposition, high-flow swivel manifold which allows the operator to manoeuvre the hoses into almost any position required. Some wrench manufacturers use a short stroke (generally less than 25 degrees), lightweight aluminium-based body and a locking-pawl mechanism in order to try and make the wrench size lighter. Although the lighter wrench sounds good, this combination has a negative impact when turning the bolt/nut as it only provides a small amount of rotation. SPX Bolting Systems TWHC wrenches have a steel body, long stroke piston and fine-tooth ratchet combination which results in a degree nut rotation reached during tests. Keeping safety in mind, SPX Bolting Systems encloses the drive mechanism in the TWHC by means of a rubber-compound cover which does not present a sharp-edged protrusion commonly seen on metal covers of other wrenches after damage from normal wear and tear. Some other torque wrenches have open and exposed drive mechanisms, which not only allow ingress of debris but also put the operator at risk of trapping their fingers. Where the movement occurs, the TWHC nose is consequently fully enclosed.

6 Wind Tensioners WD/WS: The new standard SPX Bolting Systems launches a series of Wind Tower Tensioners - they have a superior quality designed with optimal operational features reducing fatigue and

6 6 Wind Tensioners WD/WS: The new standard SPX Bolting Systems launches a series of Wind Tower Tensioners - they have a superior quality designed with optimal operational features reducing fatigue and improving productivity whilst at the same time increasing safety. WDD (Wind Double Deck) and WSD (Wind Single Deck) tensioners are used for the assembly of the blades, gearbox, generator, nacelle, etc WDD tools are small in diameter but tall and are made to fit into areas where there is reduced clearance around the bolts. WSD tensioners are larger in diameter but short for applications that require bolts to be tensioned but have limited access space above the bolts. The tensioners are designed to achieve 90 % proof load requirement for ISO 898 Grade 10.9 bolts. WSS (Wind Stroke Short) and WSL (Wind Stroke Long) are only used on the turbine foundation bolts. Note: It is of utmost importance for site technicians and contractors to accurately apply the correct load requirement on each bolt when tightening a joint. If the application has been unequally loaded then this could result in a weakened structure, therefore, correct training is important which SPX can also provide. The SPX Bolting Systems range of wind tensioners are designed to have all its components protected from environmental debris and conditions. Operational maintenance is therefore considerably reduced over the life of the product: - The fully enclosed load cell eliminates debris in the automatic piston retract mechanism. - The body surface has an anti-slip grip. - The piston stroke indicator allows the user to gauge the tensioning progress across the set of tools. Also, should a tool be taken to the end of its stroke, there is an unloading function which prevents the piston from being overextended which would lead to the longlife seals possibly being damaged. The SPX Bolting Systems wind tensioners resist the extreme working conditions of use. All Wind Tensioners will cycle in excess of cycles.

7 PE8 : New lightweight ultra-high pressure electric pump SPX Bolting Systems launches a new 1500 Bar electric pump specifically designed for the high requirements of the wind industry: light weight,

7 7 PE8 : New lightweight ultra-high pressure electric pump SPX Bolting Systems launches a new 1500 Bar electric pump specifically designed for the high requirements of the wind industry: light weight, high level of cycles and continuous duty in high temperatures. There are between 800 and bolts in each wind turbine and checking their bolting integrity can be long, hard work. SPX Bolting Systems electric pump PE8 is especially manufactured for power wind tensioners and incorporates proven design for reliable operation. Its compact form and lighter weight (20.6 kg), unique to the market of electric pumps make it easily portable and therefore well-suited to the small spaces found inside the nacelle. PE8 can be used for remote locations thanks to its low current draw and a removable control pendant (15ft / 5m cord length). Its heavy-duty drive train provides durability for rapid and repetitive cycling applications. While standard electric ultra pressure pumps are generally not built for continuous duty the PE8 does it from -25 C / -13 F up to 50 C / 122 F and has been tested to over cycles. This high quality level means lower lifetime costs. Furthermore, it features a high efficiency Universal Motor for superior performance in remote locations and for reduced voltage applications (up to -20% nominal voltage). Two versions are available: 11amps (115 volt) or 5.5 amps (230volts). Designed with safety in mind, PE8 is equipped by an easily adjusted pressure regulator valve.

High pressure hydraulic systems for Energy Industries

www.spxhydraulictech.com High pressure hydraulic systems for Energy Industries Stand localization: Hall 3 - Dutch Pavilion 3F Press contacts : Brigitte LESCURE TARA bl@tara-communication.com - +33 149