Sunday, February 5, 2017

Building Wind Farm Windmills

Sometimes you use trains to haul the equipment near the site.

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
Ports of Indiana
[I wonder if these are being imported or exported. I read about a forklift handling the big blades like "toothpicks." Judging from the men standing by the blade, the tires on this forklift are about waist high. Given that the ship has three cranes, it is interesting that a dock side crane is also being used.]

This video taught me why they needed a ground based crane even though the ship had its own cranes. It appears that the ship normally docks with its cranes on the dock side and passes the load between the cranes. But in this case the load was too long to pass between the cranes. So they docked the ship with the ship's cranes out of the way and brought in a land based crane to handle the blades.

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 other 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.
Brian Horsman posted
Gearbox changeout today on a GE 1.5.
Jake Wiseman 1/2 done 3-1/2 to go
[Wow. Big windmills have not been around that long. I'm surprised the gearbox is shot already. That is expensive maintenance to setup the crane and take all of the blades and hub off. It sounds like just four of the windmills in this farm need a replacement.]
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.

We have already seen they need to use a big (expensive) crane to replace the gear box. Here are a couple of postings of a crane removing a burnt nacelle.

Robert Pickel posted, April 13
Robert Pickel posted
Robert Pickel posted May 19 two photos with the comment: "Burnt Turbine finished."
James Dunlap I unloaded all of the nacells for those Chinese turbines with a 2250 series 3 and it was all she wanted.
Robert Pickel This one was supposed to be a lil lighter but it still weighed 365,750 lbs,
Bobby Eddy The fire didn't damage the spike at all?
Robert Pickel It passes metal urgentsee test.



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

Screenshot from a video posted by Jane Herrick
Marshract entering Duluth with wind turbines.
[It says "Amsterdam" on the stern so this would be a "salty." (It is small enough to go through the St. Lawrence Seaway.)]
Robert Pickel posted two photos with the comment: "Burnt Turbine Rebuild."
Robert Pickel I'm talking to the rep now he said it's been up 5 years.
Ryan Chapman Where is this?

We've got a burnt out one in McBain MI at Stoney Corners Windfarm too.

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
Paul R Murray posted three photos, one of which is going under the Bluewater Bridges. His comment: "MUNTGRACHT - Upbound Port Huron, Michigan 5-14-2017."



"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
John W. Coke posted two photos with the comment: "Wind turbine blade transport."


Screenshot (source)

The wind may be free, but the maintenance is not free. When the cranes are that big, they have to bring other cranes in to assemble and disassemble them for the "pick."
Bryon Moorhead posted
This week's project, blade change out, 100 meter tower, American 8460-360' boom, Manitowoc 2250.

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
Geoff Miller posted
Carrying wind turbine parts
[I find it very depressing that American can't even build new things anymore. Instead of trying to save underground coal mining, the Feds should have subsidized windmill (and solar panel) plants in West Virginia to create jobs for coal miners.]
David Kaye posted a couple of photos of windmill blades going through the Soo Lock with the comment: "HHL Amur up bound at the West Pier of the Soo Locks. 6-17-17" Ken Janeczko posted HHL Rhine upbound near Detroit, MI carrying tower segments. I gather from the name "Rhine" that these HHL ships are importing windmill pieces from Germany.

Mike Six posted
Good Morning!
Night shift unloading trains. Fun fun fun!
Virginia mn. Broken rotor repair.
Ben Reich The next one has a cracked blade. They have blade guys in suspension baskets working on them now.
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 7550Ben Stalvey Guess it's a good alternative to setting up a 16000Nick Salvatore Only had 160' of luff in itBen 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.]

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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