Wind

Blade Bolts Study

Background

Previously, hydraulic wrenches were this company’s sole tool for blade bolting. Return on investment was accelerated due to decreased man hours and the tool paid for itself in accelerated labor savings in the first week. While effective, there was room for improvement.

Problem Being Addressed

The company needed to loosen and torque 54 blade bolts on approximately 200 turbines for a total of 10,800 blade bolts. Quickness and accuracy were imperative.

Approach Taken

The Alltite representative recommended using an electric torque gun.

End Result

Compared to the previous method of tightening blade bolts, the electric torque method proved to be extremely fast, while ROI was accelerated in the first week because of man hour savings. The project experienced a high degree of success due to a 3% accuracy rate of repeatability.

Wind Turbine Tower Rod Removal Study

Background

The customer was using an 1-1/2″ impact wrench to remove installed rods that were deemed incorrect.

Problem Being Addressed

The customer needed an efficient way to remove installed wind turbine tower base rods. They were experiencing massive impact tool failure, exposing employees to potential harm. There was also the possibility of an unacceptable amount of lost production time that could lead to project delay as well as unnecessary expenses.

Approach Taken

Alltite assessed the torque requirements and found that the application needed steady torque to remove the rods, which was opposite of the pulsed energy method of impacting. We specified the proper hydraulic method and suggested a way to provide a reaction point for the recommended tool in order to quickly remove the rods.

We provided the required hydraulic pumps, wrenches and custom reaction tooling within 24 hours. We helped keep the rod replacement ahead of the tower erecting crews, eliminating any production delays.

End Result

The customer was able to maintain all production schedules and successfully remove the suspect rods.

Tensioning on Blade Bolts Study

Background

Certain wind turbine manufacturers require that torque on blade bolts be checked using a tensioning device. This has typically been done using a standard tensioning setup which includes the tensioning tool and a 20,000 psi pump.

Problem Being Addressed

The pump is designed specifically for use with a tensioner and typically can not be used for other applications. Additional, limited-use equipment on operations and maintenance (O&M) trucks needed to be eliminated.

Approach Taken

Alltite developed a tensioner that could operate from a 10,000 psi pump and suit certain space constrictions. This is the same pump used to operate hydraulic wrenches, the external shape of  which needed to be modified to fit the available space.

End Result

This solution saved the O&M company approximately $6,000 and a gave them a piece of equipment offering multiple functions, which saved the company the expense of an extra pump per O&M truck.