Sunday, February 5, 2017

Building Wind Farm Windmills

A video describing the design of a windmill.
Derek Leverknight Flamable high maintenance components.
If El Seif Gears

One option is to lift each blade separately:

Shawn Douglas posted
2250 doing single blade install

Another is to install the blades on the ground and then...

Shaun Douglas posted
16000 and the little guy is a 2250.
Shaun Douglas This job was in 09 in southern utah
...lift the whole assembly up to the top.

Shawn Douglas posted
18000 in Maui.
Parker Mims How much sticks that got in it? Around 300' or so?
Shaun Douglas I think 340
Kyle Avinger 0 wind speed @ time of pick?
Shaun Douglas There was always wind. The towers were built with the wind blowing into the face of the tower. The wind always blew the same direction.
Shaun Douglas commented on his posting
All 8 were built facing into the wind.
Shaun Douglas posted
Ronald Ritter 1 tower covered by the other.Shaun Douglas Well I was at the top of a tower 2 towers away and that's the best I could get lol
[I could not figure out what was happening until I saw Ronald's comment. It is interesting that the tops of the three towers are in a straight line.]
Sean Jett posted two photos:


Al Easton posted
Yan Duguay posted
Ben Stalvey Big bad 16000
Jason Morgan posted
Another day at the office

Jens Hadel shared
Liebherr LR 11000 with Sennebogen 5500
Video shows the construction of a tower. There is a time lapse at the end of the video that compensates for the "tight editing" in the rest of the video. It is amazing how many contemporary construction videos include, what I assume is the safety meeting, where the manager stands in the front of the workers and tells everyone to work safely.

This contractor adds one 177-foot blade at a time rather than build the hub assembly on the ground and lift all three blades at the same time as we have seen at other sites.

Josh Neudorf A couple 16000's and a MLC 300 on a job we did a couple years ago.
Winifred Stephenson Cool! How do they handle the threat of tornadoes? Won't even think about fracking earthquakes....but, it just seems so much more worthwhile to use technology and industry for these things with a future!! Great building job, too!

Noah Aronson Did I see that right? No deep foundations, just a big a** spread footing?

Screenshot -0:10
A video showing a mobile crane instead of a crawler crane being used to erect the windmill. But it is so big that it needs the help of another another crane and truckloads of stuff to build it up for the job. The video uses a "choppy" style, so it was hard for me to understand how it was built.
Lanna N Eric posted, cropped
Two years ago in Iowa [2015]
Brian Schenck Hurry up base mid. Top-off coming in
[This implies the little crane is used to start the tower and probably add the blades to the hub and then the big crane finishes the tower and then adds the nacelle and blade assembly. Moving that big crane from one tower to another would require a very firm, level road. A slight tilt of that long boom would move the high center of gravity too far to the side.]
Rob Freestone posted two photos. In the second one they must be laying out the boom for disassembly because they have the dolly on the end of the luffer.


Kran & Schwerlast Bremerhaven posted
[Scroll down on the linked page because they have other postings for installing the nacelle and the other two blades.]

Bobby Casados posted, cropped
Vestas blade repair. Texas Panhandle
[The ratio of luffer to main caught my eye. Comments indicate that blades are normally 7-9 tons but this one has 14 ton blades.]
Bobby Casados Had 73,000#@110' radius
Riley Anderson Nice configuration, minimum Main & Max Luff.
I don't like the choppy editing, but I do like the time-lapse scene showing two cranes raising the hub and blades assembly.
Screenshot from Crane Operators of the World 2 posting

"Assembly of a wind turbine on open sea" I don't like the editing because it is too "choppy." And you can mute it without loosing any information. But it is still interesting. From what I can tell, they take the tower pieces and nacelle in one trip and the pre-assembled hub+blades in another trip.
Screenshot at -0:11

ENERCON E-126 IS THE WORLD’S MOST POWERFUL WIND TURBINE! Enercon E-126 was manufactured by a German company named Enercon and is the most powerful wind turbine in the world. This model has a rotor diameter of 126 m, a a hub height of 135 m, and a height of 198 m. With this, the Enercon E-126 is capable of generating up to 7.58 megawatts of power per turbine. Since its technical revision in 2009, the power output is 7 MW instead of 6 MW.

There are no interior shots, so, after a while, skip to scale comparisons.

Screenshot, unlike American farms, the blades don't turn in phase.
Bay Crane posted
Bay Crane posted
Bay Crane posted

Nick Salvatore posted
Our 550ton in mega wing & luffer setting a new 78meter wind turbine in Sandusky, Ohio!
Mick Salvator posted
Finishing up the wind turbine!
Ben Stalvey Mega wing big bad GMK 7550
Ben Stalvey Guess it's a good alternative to setting up a 16000
Nick Salvatore Only had 160' of luff in it
Ben Stalvey Odd why Grove has not gone bigger yet. I have seen several 7550 very popular for erection of towercranes too.
Nick Salvatore posted
Here's another shot.
Bob Costine posted
[Evidently the yellow boom crane has just finished helping the lattice boom crane tip the blades and hub. The yellow boom crane will be unhooked and the taller crane will complete the lift.]
Tom Nugent posted
18000 compared to a 10000. A few years back in Edgewood, Iowa,
Jake Steinfeldt Half the size of the backmast! 😂 we have a 10,000 i always thought it was tiny next to a 1600 with just main boom. Gotta love them big cranes!
Michael Best 360' of main plus the tip. Looks like 100 meter Gamesa towers.
Robert Pickel posted some pictures showing a tower being built. Ben Stalvey indicated the big crane was a Manitowoc 16000. It looks like they were racing an incoming storm.






Mike Nelson posted
Gotta love wind farms
Ed Johns Good ole 18
Boom collapse at Swedish windfarm
["The crane operator was able to jump clear of the crane and suffered only minor injuries to his leg." I just noticed how high the cab is on that crane. Jumping out to the ground below, which is covered with "stuff," would be tricky.]
Screenshot (source)
Jamie Bryant Largest crawler rig in the world.
[Note the man near the left. The crawler track is taller! The nacelle this thing is lifting looks pretty big also.]
Stuart Andrews posted
William Platou How long does it take once pad is prepared, to complete the lifting phase, tower to the blades??
Kenneth Ohl 2 or 3 on a good day.
[Unfortunately there was no answer to the question of how much boom. That is a big pile of counterweights on the rear end of the crane for lifts that can be kept at a short radius.]
Phillippe Dumas posted six photos with the comment: "GMK 6300L & GMK 6400 Altead tandem lift on 🇫🇷 windmill job site."





Mike Nelson commented on a posting

Sean Jett posted two photos with the comment: "MLC 650."
David Waller That thing just looks funny! Judging by the pictures it just looks like the turntable is the weak link. But I'm sure it's not!! Give me house rollers and hook rollers all day long.
[Comments indicate they are putting up wind towers. It looks like they pre-assemble the hub and blades on the ground.]



Stuart Andrews posted
Paul B. Anderson Wow! Would love to watch it come to life from here. I mean, I've never seen one boom up from the ground before.Ben Stalvey Mlc 650 715 tonTj Belcher 772 with vpc maxGlenn Mansfield How much stick is that?Oliver DeJong Would love to know as well. Looks about 400 - 410 comparing to some drawings.Shonny Prichard So they went with the stubby boom
John Scarcella Thats a lot of stick over the side [I assume "over the side" means the 90-degree angle with the crawler tracks.]
Josh Neudorf posted, cropped
And we sit!! Like father like son best cranes out there.
Brian McBride Getting ready to head to Iowa and do a repower job.  I believe they are 1.5 ge towers, don't have specs of what mw replacement is going to be.
[Unfortunately, none of the comments indicated the model numbers for the cranes. Usually someone chimes in with that info. Also Brian reminds us that the wind may be free, but the maintenance is expensive. ]
Mike Nelson posted
Big red getting it done
Frank Keeney How much boom you got Mike?Mike Nelson That's norm. He has 350'
[A problem with expert groups is that they don't include basic info like the crane model.]
Part of the challenge of building and maintaining the windmills is moving the crane from one windmill to the next. Andrew Erickson posted two photos with the comment: "Found on another page no details." An MLC300.
Jon Dyer This is a normal thing for the company. They are so big, they have lobbyist in DC. They won't get run off. It took them flipping a brand new 999, crushing a brand new company truck, destroying an ESS(the brain of a wind turbine)and pancaking a base section for them to fire someone.

Michael Best That don't look to bad to dig out. Granted I wouldn't have allowed to get that far along. Since it's a Blattner crane it's on a wind site. 
Laying mats for a mile walk is slow going. Been there done that. 
I have always said I like winter for wind farms. Cranes don't sink when ground is froze in the upper Midwest.

I can't find the comment that said the crane worked on mats while at a windmill while, but when it moved to another windmill, they did not bother to use mats for the trip. And some observed that he was at least able to sink evenly and not fall over.


Philippe Dumas posted two photos with the comment: "GMK 6400 in Denmark,"


Larry Poush posted
What's better than one 16000 ? Having 4 on a project.
[The comments indicate Arcadia, Iowa.]
AJ Treu posted
Scott Erickson commented on the above posting
I've done some time on that rig.

An example of building the rotor on the ground and lifting the entire assembly.  (new window)

An example of building the rotor in the air balde-by-blade. (You probably want to move the video slider forward to skip some of the lift.
(new window)

I had to set through more talking heads than I like, but the part about edge erosion because of rain was interesting. And I learned that the design life of a windmill is 20 years. The blade is 88.4 or 390 feet.
(new window)

A video of a windmaill failure because it spun too fast.
Christopher Thomas Over speed braking failed. Wind turbines must be locked in high winds. The blades have a speed limit.
Eric Kurowski That video is 14 years old. 
The new power plants have multiple layers of safety to prevent such catastrophic structure failure. Come to Wisconsin where they are made and we can show you. 
New technology in the Rotor Blades eliminated the over run senerio.

A time lapse video of raising a hub+blades assembly from Rob Freestone.

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