PES Wind 2 2021

WunderOcean DNV VertAx Ltd ABGI UK A look into sizing of wind South East Asia’s energy Steven Peace explains Graham Beck discusses turbine generators demand looks set for where the offshore wind advancing wind energy explosive growth sector is set to expand science across all elements of the turbine lifecycle WIND We are pleased to bring you some of the most recent innovation & product developments from the global wind sector. We also look into some of the advances in project installation & industry legislation. We are thrilled to bring you some views and insight from several industry mainstays, as well as from more recent movers and shakers. PLUS, enjoy our latest objective assessment, opinion & industry analysis POWER AND ENERGY SOLUTIONS • ISSUE 2, 2021 SMART JUST GOT SMARTER An already intelligent sector is evolving further still. © Jan Kopřiva on Unsplash

Steady Top Feeder Vessel Future proof solution for offshore wind feedering Steady Top He avy Lift Engineering Consultancy Wind Turbine Feeder Vessels Cranes and Support Installation Jack-Ups In some areas, feeder vessels are a suitable GustoMSC’s heavy lift portfolio includes Our involvement in a mobile offshore unit A safe, solid platform is essential when solution to transport WTG components to tub mounted and around the leg cranes does not end after delivery of our design or handling heavy and delicate components. the installation jack-up. This ‘Floating to specifically designed for the demanding the equipment. In more than 200 projects GustoMSC is the world market leader Fixed’ lift-off of delicate WTG components field of offshore heavy lifting. As part a year, GustoMSC provides services for in designing and engineering mobile has to be carried out precisely and of NOV, we can offer complete turn-key units and equipment in operation and offshore units and equipment. Based securely. This specially designed project support, including engineering performs earthquake assessments and on an extensive track record, we have transport vessel (STFV) is able to load & design, installation, commissioning, site-specific analyses. designed a wide range of dedicated jack- WTG components in port and transport operational support, training and up and vessel solutions for the offshore them to the field. At the site, in DP mode, worldwide after market services. wind industry. a dedicated WTI jack-up will be able to lift-off WTG components safely from a Safely unlock the full potential of your 3D motion compensation platform while offshore unit. OSS provides real-time maximizing workability in the offshore guidance to the operator based on data environment. generated by on-board equipment. For more information: nov.com/gustomsc

EDITOR’S NOTE Editor’s note POWER & ENERGY SOLUTIONS A very warm welcome to this edition of PES Wind. We are set for an exciting second half of what has been a whirlwind year so far. Directors Stuart Gillies We are seeing technological and cost barriers being broken on a more frequent basis Mark Smith than ever before, and as the technology continues to evolve, and the wind energy Stefann Perrigot sector is growing and developing alongside this evolution. Client Liaison Manager Vikki Birch As the world prepares to ‘open back up’, the global wind energy industry seems set Editor to shift up yet another gear, and continue to drive toward further growth both on Elaine Perrigot and offshore. [email protected] Associate Editors As you may expect, in this issue, we endeavour to cover a broad range of topics. From Stephen Pearson installation advances, developments in bolting and fastening solutions to inspection Zachary George and drone services along with general maintenance improvements, we are fortunate Design to be able to bring you the thoughts and insight from a number of industry pioneers, Andrew Jenkins indeed, several of those driving the wind sector and shaping the market itself. We put [email protected] several of the most pressing questions to a number of executives in our Ask the Production Experts features and, as ever, you will also find our regular comment, analysis and Paul Lawson views on issues and topics from around the globe. [email protected] Sales Enquiries Safety continues to be of paramount importance of course, safety of both the [email protected] equipment and technology as well as the personnel and workers onsite and offshore. General Enquiries The operating conditions will become even more challenging and complex as projects [email protected] grow in size and scale, but whilst these challenges can prove difficult, they can also be Media Partnership Enquiries viewed as an opportunity to improve, grow and develop the sector further still. There [email protected] may be differences of opinion and perspective, but that can only be a good thing for Advertising Opportunities the wind sector. [email protected] PES is published by P&G Media Ltd As governments and policy makers worldwide begin to shuffle their packs and finalize their priorities moving forward, wind energy continues to force its way the head of the P&G Media Ltd queue in the international energy mix and there is real optimism for seemingly PO Box 310, Bristol, BS10 5WT, inevitable growth in the months ahead. In an industry renowned for its twist and turns, who knows in which direction we will head next? United Kingdom Sit back, relax and enjoy! This publication is copyright © 2017 P&G Media Ltd and may not be reproduced or transmitted in any form in whole Elaine Perrigot or in part without the prior permission of P&G Media Ltd. Editor While every care has been taken during the preparation of this publication, P&G Media cannot be held responsible for the accuracy of the information published herein or any consequence arising from it. From sustainably managed forests. For more information visit: www.pefc.org www.peswind.com WWW.PESWIND.COM 3

CONTENTS 46 WunderOcean tell us 78 The energy transition is shifting national agendas 64 Steven Peace, Director and why new sizing of wind and is cutting across all industries and markets. As a the Chief Technical Officer, turbine generators (WTGs) global hub for innovation, Singapore has built a vibrant VertAx Wind Ltd gives us requires a new perspective ecosystem to advance today’s efforts on energy and his thoughts on where the of wind towers climate change. With South East Asia’s energy demand offshore wind sector is set to forecasted to grow by 50% by 2050, alternative energy see growth. sources need to be explored quickly to move on the decarbonization pathway WunderOcean DNV VertAx Ltd ABGI UK 108 Graham Beck, Innovation Funding Consultant at ABGI UK, explains that whether it’s prototyping, A look into sizing of wind South East Asia’s energy Steven Peace explains Graham Beck discusses turbine generators demand looks set for where the offshore wind advancing wind energy explosive growth sector is set to expand science across all elements of the turbine lifecycle development or experimentation with materials or WIND We are pleased to bring you some of the most recent innovation & product developments from the global physical production processes, there’s a wide variety of wind sector. We also look into some of the advances in project installation & industry legislation. We are thrilled disciplines involved in advancing wind energy science to bring you some views and insight from several industry mainstays, as well as from more recent movers and shakers. across all elements of the turbine lifecycle PLUS, enjoy our latest objective assessment, opinion & industry analysis POWER AND ENERGY SOLUTIONS • ISSUE 2, 2021 SMART JUST GOT SMARTER An already intelligent sector is evolving further still. © Jan Kopřiva on Unsplash Comments Ask the experts 104 As our winters get colder and turbines 6 The UK’s offshore wind industry is 32 Kaveh Etemadi, Managing Director, get bigger, icing presents a host of potential pitfalls for wind farmers. forecast to account for a quarter of ROBUR Wind GmbH and Director Global Wicetec looks to overcome these the world’s offshore wind capacity by Sales of the whole Business Unit challenges with its Ice Prevention 2022. It will also be the only country in ROBUR WIND, spoke to PES about System, helping to avoid a repeat of the the world to generate more wind power his holistic vison and approach to Texas big freeze power outage earlier off the coast than on land. The views of wind: turbines, assets and services. this year. PES caught up with Alexandre Golisano, Strategy Director This company offers a total package Petteri Antikainen, the company’s Power Systems at Schneider Electric throughout the life of a turbine, with Co-Founder and CEO, to discuss the training and H&S permeating every possibility of wind turbine winterization aspect. Firmly established in Europe, the US and Latin America, their sights are firmly set on Africa and South East Asia 54 P ES Wind love the fact that Amanda Gardiner, Managing Director at Durham Lifting, grew up around engineering. She is rightly proud of the company’s place in keeping Teesside’s heritage alive. Embracing change and innovative technology, loving a challenge and doing things right, this team is here to stay 4 PES WIND

CONTENTS PES essential 60 If everything goes smoothly, then the Think tank 68 We have the privilege of hearing from UK’s offshore wind industry should be well 8 T he ever-growing database of offshore on track to hit the Government’s target of Vaisala, and learn more about Using 40 Gigawatts (GW) of generation capacity wind farm production data provides lidar to solve the challenges of offshore by 2030, but this is not an industry the opportunity to improve the wind farms that’s accustomed to everything going understanding of wind energy potential smoothly. Chris Towner, Partner and at existing and future sites significantly. Talking point renewable energy specialist at law firm In principle, the wind turbines provide Womble Bond Dickinson, looks at what a dense measurement system of the 12 W e learn from Seal For Life how the needs to be done to ensure targets are hit wind conditions. These need to be distinguished from all other factors that offshore wind energy industry has 72 Think of a future where the offshore drive production at the site seen enormous growth in recent years and it doesn’t look to be slowing down wind supply chain connects in real 22 Tiphaine Comby & Mus Rezzoug of anytime soon. Those in the industry time. Picture a wind turbine technician will know the stats: the offshore wind installing, maintaining, and fixing SEREEMA explain how Embedded energy market is forecast to reach components with the support of shore- Intelligence is the next engine growth $42bn by 2025, growing at a CAGR of side staff connected through their eyes factor for the automotive industry. 13.6% from 2020 to 2025 and ears. The experts are supporting Specialists estimate that in less than the technicians through every step of a 10 years, the software element will 16 The offshore wind market has critical job represent 60% of the value of a vehicle, compared to 20% today. When you think expanded into new territories, including 88 In October 2020, the UK government about the pace of change in the wind Japan, Taiwan and the United States. industry today, we can expect a similar US offshore wind faces particular announced a target of 1GW of floating trajectory. challenges due to the Jones Act and a offshore wind by 2030, which combined lack of suitable ports on the East Coast. with a 60% target for local content set 82 Eduardo Sanz, Technical Services Accordingly, the use of traditional self- by the UK Offshore Wind Sector Deal, transiting installation jack-ups is being sets manufacturing sites around the UK Product Manager, Ingeteam Wind challenged by alternative concepts, with a requirement for a significant scale Energy, brings PES up to speed with such as the new Steady Top Feeder up in fabrication. This provides a real the latest Firmware development Vessel from GustoMSC. challenge for the sector, as well as an methodology designed to simplify opportunity to innovate and collaborate wind turbine converter validation and 26 C alum Urquhart of Atlas Copco talks certification 92 As applicants prepare submissions to PES about why now is the time to be 96 The Danish shipping company smart when it comes to bolting for Crown Estate Scotland’s ScotWind programme, the leasing round for MHO-Co is heading a consortium 38 Our exclusive insight from Enerpac offshore wind farms in Scottish waters, focused on developing green solutions our industry must sharply turn its for the future of the entire maritime talks us through the 8 most important attention to the formation and delivery industry. In partnership with Danfoss, considerations when selecting your of successful supply chain partnerships Ballard Power Systems Europe A/S, next hydraulic torque wrench that will enable us to apply our Sterling PlanB, Stuart Friezer Marine knowledge of developing wind power and research engineers from Aalborg 42 Vaarst, the new technology spin-off whilst taking learnings from the long University, they will test fuel cells and established oil and gas operators. We new battery technology on the shipping company from Rovco launched March are delighted to hear from company’s advanced hybrid vessels 2021, with the vision to bring artificial Rick Campbell, Head of Offshore intelligence, machine learning and Markets at Natural Power 100 D I Christian Raml, Head of R&D at autonomy to all offshore robotics. Enabling the integration of their Aero Enterprise GmbH talks us through technology into all robotic vehicles, the challenges in evaluating drone data both new and as a retrofit solution to existing ROVs 50 In November last year, the Prime Minister of the United Kingdom, Mr Boris Johnson, announced an ambitious 10 Point Plan for a ‘green industrial revolution’, which is hoped will create and support up to 250,000 jobs. This plan covers clean energy, transport, nature and the use of innovative technologies. The plan will allow the UK to make a positive contribution to global climate change by eliminating the country’s contribution by an anticipated date of 2050 WWW.PESWIND.COM 5

COMMENT Adopt a ‘renewables-first mindset’ by investing in offshore wind Words: Alexandre Golisano, Strategy Director Power Systems at Schneider Electric The UK’s offshore wind industry is forecast to account for a quarter of the world’s offshore wind capacity by 2022. It will also be the only country in the world to generate more wind power off the coast than on land. Alexandre Golisano deliver a net zero power grid by 2035. that can help us achieve this goal. It is Investing in cleaner and greener energy is a efficient, produces no greenhouse gas There is growing pressure from public and priority to push fossil fuel power off the grid. emissions, and is becoming increasingly private bodies to avert the climate crisis by popular as a renewable energy source. moving away from traditional fossil fuel Renewables and other clean technologies, power sources towards low carbon solutions. wind power, solar power, geothermal power, As part of the Build Back Greener initiative, The growth in clean energy projects, such as hydropower, battery storage, fuel cells, the government has committed to ensuring wind power and solar, is a step in the right biofuels, and more, have grown dramatically that offshore wind will produce more than direction for a sustainable future. The UK’s in adoption in the past ten years. This growth enough electricity to power every home in wind, solar and nuclear industry trade bodies has been driven in large part by falling costs. the country by 2030, based on current have made a call to action demanding the Unlike fossil fuels, which must be extracted, electricity usage. This will boost the government to set ambitious targets to shipped, processed, and combusted to government’s previous 30 GW target to generate energy, cleantech is precisely that: 40 GW by 2030. technology. Like all technology, as demand increases and product efficiency improves, While this transition is good for the costs fall. The time is ripe for increased environment, it will be a challenging one for investment in offshore wind. utilities. The country continues to reduce its reliance on fossil fuels while utilities are This article will explore why the UK energy under more significant pressure to improve industry needs to embrace the growing the efficiency and reliability of the power opportunity in offshore wind. Overcoming supply. Yet, the rise of offshore wind poses the challenges, the industry faces will play a new and unfamiliar challenges. key role in meeting the global climate goals. More support and funding mean offshore Offshore wind is the vanguard of an wind farms are expanding. Latest innovations energy revolution. mean they can be installed further out to sea. Wind turbines themselves are also increasing To sustain our own rising energy demand and in size to generate more energy, with 10MW+ bring clean, reliable energy to those still machines likely in the future. going without it, a simplified, innovative solution must be brought to customers at all The potential drawback to giant wind farms is levels of energy consumption and that bigger turbines and longer cables are conservation. Wind energy is one technology required to connect the generated power to 6 PES WIND

COMMENT ‘To satisfy this growing appetite for climate action, more should be done to empower consumers to become ‘prosumers’ able to generate their own green energy through solar, powering their own homes and reselling access power to the grid at peak times.’ the grid. Without an innovative approach to management solutions that can improve Switching to renewable energy and solutions high-voltage switchgear, utilities run the risk power quality and stabilise the voltage. are central to stopping climate change – as of contending with more expensive up to 80% of the world’s emissions are equipment and more frequent power losses. Wind developer should also look towards caused by the fossil fuels-derived energy combining wind generation with energy used to fuel industries, economies, and our The challenges of connecting wind turbines storage to be more flexible. Batteries and daily life. to the grid. other types of storage play a crucial role in enabling companies to embrace clean, To satisfy this growing appetite for climate While it is true that wind turbines do not emit low-cost, renewable energy at a higher level. action, more should be done to empower greenhouse gases, they can still create By mitigating the intermittency issues that consumers to become ‘prosumers’ able to complications for grid operators, especially renewable power sources like wind and solar generate their own green energy through as they become significant contributors to face, storage helps remove a significant solar, powering their own homes and reselling total electricity supplies. Turbine barrier that has prevented greater adoption access power to the grid at peak times. productivity varies with the wind from of wind and solar resources. Enabling decentralised multidimensional minute to minute, and such intermittency microgrids running on renewable energy will can raise havoc with transmission and It’s not all doom and gloom, however. The UK’s help power the growing energy needs of distribution systems designed for steady, wind energy industry is one of the country’s generations to come. reliable operation. most successful industrial stories and will be central in reaching the climate goals. With the increasing pace of digital Connecting wind to the power grid brings innovation, growing interest from investors with it a unique set of challenges, including Renewables are blowing us closer to and the continued growth of the renewables surges, dips, distortions, and stringent grid net-zero. sector, the UK is leading in adopting a code requirements. Even small shifts of ‘renewables first’ mindset that would have power flows can trip circuit breakers, sending Despite the challenges, wind power and other sounded unachievable even just five years larger loads onto neighbouring lines and green technologies hold enormous potential ago. It’s clear that the UK has made causing chain reaction failures. to build a skilled workforce, world-leading significant strides towards decarbonising know-how, and production capabilities across the energy industry. Now is the time to ramp So, what options do wind developers have for the UK. Meanwhile, supporting our collective up offshore wind to accelerate the global ensuring power-quality issues don’t create progress towards net zero emissions with energy transition. problems for either the connected grid or their high-quality products and technologies own operations? They need to look for energy developed in the UK. www.se.com/ww/en/ WWW.PESWIND.COM 7

THINK TANK Reassessing a wind farm’s potential Words: L ukas Vollmer 8 PES WIND

THINK TANK Abstract: The ever-growing database of offshore wind farm production data provides the opportunity to improve the understanding of wind energy potential at existing and future sites significantly. In principle, the wind turbines provide a dense measurement system of the wind conditions. These need to be distinguished from all other factors that drive production at the site. The ‘post-construction analysis’ of the wind usually relies on a short-term wind farm production data can provide the tools measurement campaign at usually just one for this exercise. The industry-wide goal or few locations across the site’s area. The should be to make full use of the potential of projection to the whole site area and to the the production data in order to gain a better operational period as well as the estimation understanding of offshore wind farm of the wind farm downtimes and wind performance in the past and in the future. turbine component failures all have to rely on models or educated guesses. However, The results of a post-construction analysis with the right reference data, an analysis of of production data can have major the first months of operation can already implications not only for the shareholders of reduce the uncertainty about the farm’s a particular wind farm, but also for the long-term potential. industry as a whole. So, which data needs to be manipulated for For wind farm operators, insights into wind the wind farm to reveal its potential? farm performance can have a decisive influence on detailed follow-up investigations First, the performance assessment of wind or negotiations with manufacturers. farms only makes sense in relation to the prevailing wind conditions. In 2017, Wind farm shareholders, on the other hand, Fraunhofer IWES addressed the lack of can refer to the results in connection with offshore wind indexes with highly resolved refinancing and the selling of shares. For numerical weather simulations aggregated in operators of multiple wind farms, the the Fraunhofer Offshore Wind Index question also presents itself of what can be (FROENIX). Offshore, these optimized learned from the performance of the farms meteorological simulations can provide a and the portfolio to date for future projects. precise estimate of the wind resource. The indexing of the wind farm production already The industry-wide implications became prevents many unnecessary discussions more than evident when a press release from about the state of the wind farm in months or one of the largest offshore shareholders, years with a low wind resource. Ørsted, created quite a stir in 2019, claiming that revenues of around two percent lower Second, corrections for technical downtime should be assumed when planning offshore and enforced power restrictions by the wind farms. Internal data analyses had electric grid operator need to be applied to revealed that the wind farm wakes, and the unmask the production potential at the site. large-scale blockage of the flow had been This can be done by calculating the amount significantly underestimated in the yield of underproduction during these periods. An assessments up to that point. In an industry onshore guideline for this procedure exists in where yield projections are generally the German Technical Guideline 10 (TR10). calculated using similar models, the report However, for application offshore, the created unease about the validity of the different characteristics of offshore sites applied methods. The question of how and wind farms need to be considered. credible the projections were and whether fundamental investigations of all methods Due to the low level of atmospheric are necessary has been a topic of lively turbulence and the large farm sizes discussion ever since. compared with onshore farms in Europe, the main reason for intra-farm differences in the The issue for the wind farm operators is wind resource is the reduction of wind speed that, especially in the early years of a wind due to wakes of other turbines and wind farm’s operation, the pre-construction site farms. Wake losses reduce the efficiency of a assessment is the only reference for the typical offshore wind farm by about 40% in measured production. This assessment WWW.PESWIND.COM 9

THINK TANK ‘The reduction of future yield uncertainties leads de facto directly to the wind farm having a higher financial value.’ The post-construction analysis’ task is to quantify the farm’s yield losses based on the production data to date. The combination with meteorological data makes it possible for the determined potential of the farm in the operating period to be projected over its entire lifespan. Schematic sketch. © Fraunhofer IWES some wind speed ranges and external wakes assumptions that had to be made before Due to the time-resolving nature of the of other wind farms can reduce the wind construction can therefore be omitted. The trained model, feed-in management resource even at distances of up to 100 km. reduction of future yield uncertainties leads compensation can, in principle, not only be Thus, it is crucial that this influence is de facto directly to the wind farm having a calculated for the past operational period but considered when calculating any lost higher financial value. also, when coupled to market-price models production quantity. and electrolyzers or batteries, for example, However, the possibilities with a tailored for future scenario calculations. The Fraunhofer IWES uses a data-driven wind farm model do not end with a more model approach to address this issue. Using precise long-term energy yield estimate. It Conclusion the production data as learning data for a also makes it possible to answer a far larger physics-based model renders a precise number of questions. For example: How Production data of offshore wind farms offer representation of the wind farm’s response much would the park actually have been able enormous potential to reduce the to changing wind conditions possible. As a to generate during grid supply outages as uncertainties of offshore site assessment result, the tailored model allows the potential well as during feed-in management? Or: what and the projection of the wind farms’ future yield of the wind farm to be calculated during effects do existing and future neighboring production. Technical downtimes, grid the historical production period that can be parks have on the expected yield and can restrictions, and the mutual interaction of indexed by the prevailing wind conditions previous data already confirm this? the turbines through their wakes, however, from the meteorological model to derive a require new solutions for evaluating the long-term estimate. As wind turbines extract less energy from the potential of the farm during the recorded flow during curtailed performance due to production period. The main value for this production-based feed-in management, they consequently long-term estimate for wind farm leave more energy available for downstream Wind farm models trained with a production shareholders is that it provides greater turbines. This interdependence needs to be data basis offer the possibility of not only certainty about the future energy yield considered for proper estimation of the addressing this issue, but also providing a compared with previous yield assessments. potential production of the wind farm during solid basis for future scenario calculations The reason for this is that the production feed-in management, a problem which grows that focus, for example, on different offshore data already provide a reference of how in complexity when not only the wind farm wind energy expansion scenarios or on measured wind conditions are converted to under consideration, but also upstream wind time-resolved price-market fluctuations and electrical energy at the site. Any farms are operating under restrictions. the integration of hydrogen production. uncertainties stemming from the www.iwes.fraunhofer.de 10 PES WIND

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TALKING POINT The offshore wind energy industry has seen enormous growth in recent years and it doesn’t look to be slowing down anytime soon. Those in the industry will know the stats: the offshore wind energy market is forecast to reach $42bn by 2025, growing at a CAGR of 13.6% from 2020 to 2025. The focus for clean, renewable energy is that could get into the ‘hard to reach’ places are done. The applicator returns with only growing worldwide, evidenced by President such as of rotor shaft heads or boat landings? the release liner and cardboard as waste. Biden who in January signed an Executive The benefits here would mean less Order that includes doubling offshore wind maintenance time, long term protection, time The operator never has to reach the point of power generation in U.S federal waters by back to the operators, reduced costs allowing blasting, creating a roughness, removal of 2030. In October last year the UK reallocation of budget for further chlorides and painting the towers until the end Government, already home to the largest development, a positive impact to production. of their design life, which depending on time offshore wind market in the world, Consider 2 scenarios: a corrosion spot is in-situ could be up to 25-30 years. Every announced a £160m injection into the identified corrosion spot halted from expansion at start. industry to upgrade ports and infrastructure. Scenario 1 Materials and equipment need to be brought Which scenario sounds best? Vietnam has big plans to increase its to the nacelle to work on a rotor shaft or proportion of power from wind and solar blade. This includes surface preparation The subject of surface preparation is always from 10% in 2019 to 42% of the national grid tools, coating and application tools as well as an interesting one when it comes to by 2045. Although most current locations are rope access equipment. corrosion. Blasting is messy; work areas need onshore, they are already making great Where extensive surface preparation to be protected, waste must be contained strides to achieve that goal ahead of equipment is required, you can add in paints, and disposed of, the by products can be schedule, with their next big push in offshore brushes, PPE including safety masks etc. hazardous and it takes time. wind off their southern coast. Once the job is complete all equipment must still be transported back down. Most of this It is a key step in any corrosion prevention Renewable energy is a global cause, a skim equipment is treated as chemical waste and coating, but if it can be simple – such as a wire through renewable news sites reveals new must be segregated and disposed of as per brush, resistance to chloride contamination, projects being commissioned on an almost local environmental regulations. that is a huge advantage to operational weekly basis and with that progress comes Scenario 2 maintenance time. Even better if it’s a simple the need for preventative maintenance A small team, one person is armed with a wire abrasive pad followed by an isopropanol wipe. and protection. brush and a roll of patches. They simply brush the loose corrosion away, apply the patch and Ease, speed and repeatability are key The push for offshore wind takes advantage of the power of the wind produced at sea, Close up patch replacement Easy-Qote is a polymeric coating born of the moving at a much higher and more consistent idea that a corrosion solution could be speed thanks to the open space and absence applied simply as a sticker rather than of structures. What is a benefit to production painting or spraying. The product Is 100% however, poses a logistical disadvantage to safe for both user and the environment and construction and maintenance along with an simple to apply. aggressive corrosive environment? Whilst currently situated near the shore in predominantly shallow waters where possible, the next few years will see a move to deep water installations further away from the coast, as space becomes an issue. These developments will see stronger winds and bigger waves adding pressure to not just the installation phase but ongoing operation and maintenance. We all know that corrosion costs money, time and disruption. Without action to counteract it, the result will be product, maintenance and safety issues. Corrosion creeping into the monopiles, ladders, walkways, boat landings, guard rails and rotor heads – the many areas of a wind turbine that will likely be affected. So, what if we had the answer? What if there was an easily applied, simple fix for when a corrosion spot arises. Something that did not require extensive equipment, could easily be transported offshore and didn’t require extensive training. Something WWW.PESWIND.COM 13

TALKING POINT ICCP flanges close up Offshore coating repair basecoat and self-cleaning patch Case Study 1: Sealing of a transition piece A post-Covid-19 world in workforce allowed in at any one time to comply with these measures will likely slow Any void or exposed groove on an offshore No one could have imagined how 2020 further production. structure is a vulnerable spot for crevice unfolded, a pandemic sweeping the globe, corrosion that may affect the integrity of many countries in recession, budgets being Constraints on travel across the globe pose the structure. Transition pieces are one of hit harder than ever. Oil prices dropped, problems for the movement of personnel to the examples, close to the sea and with high projects put on hold, struggles with supply get to project destinations whether it be chloride content accumulation, is prone to chains, workforce constraints with social inspection or maintenance activities. accelerated corrosion and integrity. distancing measures, turnaround projects Quarantine times and isolation windows Applying our self-adhesive corrosion pushed back with just a focus on the critical could well extend the time people are preventative Easy-Qote SC Patches over work required and regional lockdowns that travelling, and of course whether countries the groove, sealing it off from the halt almost everything locally. have agreed air bridges to enable the environment we prevent corrosion reciprocal flow of passengers. formation from the start, yet due to the The impact on maintenance and asset Visco-Elastic behaviour of the solution, integrity is profound, Maintenance Managers But whilst industry faces constraints to withstanding expansion and contraction of now face a whole new set of challenges to operational maintenance there is one the steel without cracking or loss of balance, on an already sensitive set of scales. universal truth – it still needs to be done. adhesion. Same goes for any other space or connection point on the structures. Deployment of personnel has, and will likely This is where minimal footprint solutions continue, to be a challenge for 2021. Not become a huge advantage. Not only do they Case Study 2: Flanged structure only with the risk of an outbreak amongst make for ease of application, they require the connections staff, but with the need to provide a safe least amount of personnel to complete the environment with social distancing work. We have already discussed the optimal Flanged spots not only have the voids that measures and PPE equipment while scenario for completing the job to bring the accumulate unfavourable environment for vaccines are rolled out. This has resulted in most benefits to the work environment, but the protection of the asset but also expose a smaller workforces in operation at any one view that in our current world and the lot of sharp angles, like bolts and nuts, prone time and careful deployment to where benefits speak volumes. to damage during installation as well as manpower is needed most, delaying service life of the structure. By encapsulating operational and maintenance activities. Offering coating solutions the flange using Easy-Qote paste, basecoat and an addition of extra mechanical Lockdowns across the globe have led to a halt Seal For Life also offers a thermoplastic protection layer such as composite wraps, in production for many businesses in the coating solution in Oxifree TM198. Oxifree we not only prevent corrosion but increase supply chain. They not only face catching up has experience in the Wind Sector bringing the mechanical properties of what would on work lost but the added constraints of the its encapsulation without adhesion benefits otherwise be considered a weak spot. new workplace safety measures. Reductions to the challenging environment Wind Turbines operate in. There are many 14 PES WIND

TALKING POINT ‘The world is embracing wind technology, it’s clear to see, and it is now the job of coating companies to move with these times and offer the vital protection they need.’ situations that require the ability to remove is enough to clean the area, no blasting What happens next? the protective coating for maintenance, e.g. required. In addition, the environment does structural bolting, or repair or simply for not need to be perfect, humidity or cold do The world is embracing wind technology, it’s moving parts. Take for instance a working not affect application. clear to see, and it is now the job of coating catlink, hydraulic fitting or actuator – they companies to move with these times and would all be able to move within the coating A major benefit is the ability to protect offer the vital protection they need. and maintain normal operational use which is without a shut down, keeping costs down and a huge benefit for operators. the industry moving as well as the ease of Seal For Life is primed and ready to do just that. inspection via NDT or simply remove in part, And the preparation is minimal, a wire brush inspect and refill. www.sealforlife.com WWW.PESWIND.COM 15

TALKING POINT Game-changing feeder solution integrates proven technology to support alternate T&I model 16 PES WIND

TALKING POINT The first wind turbines were often installed using existing jack-ups, originally built for civil construction or oil and gas service markets. Then the industry invested in a fleet of purpose-built wind turbine installation vessels (WTIV) jack-ups. Now, current trends and developments in the offshore wind industry are shaping the installation fleet of the future. An increasing volume of wind turbine installations and turbine weights, as well as the heavier and taller cranes require owners to modify existing jack-ups and invest in new, larger WTIV jack-ups. At the same time, turbine installations are moving to deeper waters farther offshore, requiring jack-ups adapted for these conditions. Additionally, the offshore wind market has expanded into new territories, including Japan, Taiwan and the United States. US offshore wind faces particular challenges due to the Jones Act and a lack of suitable ports on the East Coast. Accordingly, the use of traditional self-transiting installation jack-ups is being challenged by alternative concepts, such as the new Steady Top Feeder Vessel from GustoMSC. WWW.PESWIND.COM 17

TALKING POINT Addressing new challenges with an Initial concept investment horizon when using this initial alternative model approach, based on existing equipment In 2018, GustoMSC developed an initial quickly became apparent however. The use of self-transiting WTIV jack-ups has Steady Top Feeder Barge concept to meet been the predominant transport and requirements for US projects awarded at the Though BM-T700 motion compensation installation (T&I) model for offshore wind time and planned for the following years. platforms and modular thruster systems are turbine installation to date. The WTIV jack-up existing and proven products, they are not loads multiple turbines in port using its own This first iteration was based on existing and widely available for commercial lease. As a onboard crane, which it then sails to the available equipment, namely the BM-T700 result, the cost for the solution on a offshore wind farm. Next, the jack-up motion compensation platform from Barge per-project basis is high and a longer-term positions itself next to a turbine foundation Master B.V., and existing 300 ft US barges investment horizon is required. and elevates on its legs to provide a stable and modular thruster systems. installation platform. It installs the turbine Furthermore, the emergence of larger, components from its own deck on the By using existing equipment, the concept could next-generation offshore wind turbines led turbine foundation, then jacks down, refloats be put together in a relatively short time frame to the realization that the Steady Top Feeder and sails to the next foundation location. with minimal investment allowing the concept Barge concept would not scale to these next When the jack-up is empty, it returns to port to be applied on a per-project basis without the generation turbines. Larger motion for reloading and repeats the cycle. long-term investment required for a new-build compensation platforms would be required vessel. And the motion compensated DP barge to handle the larger components. An alternative to this traditional T&I model allowed for relatively high workability and uses feeder vessels to transit components reduced risk of feedering operation compared Based on the combination of these two from port to site and use a separate to other floating feeder operations. findings, GustoMSC developed a more installation vessel for the lifting operations. integrated and well-tuned solution as an The feeder vessel is loaded with turbine The concept was worked out in detail and efficient, capable and future-proof solution components in port using an onshore crane reported in an operational procedure report for the offshore wind industry: the Steady or SPMTs and then sails to the offshore wind for review by marine warranty surveyor LOC Top Feeder Vessel (STFV). farm. The feeder vessel positions itself next and various industry stakeholders. LOC to an installation WTIV jack-up that is already provided its ‘approval in principle’ for the The fully integrated Steady Top Feeder on site, which lifts turbine components from concept in 2019. Vessel (STFV) the feeder vessel’s deck and installs the components on the turbine foundation. This effort led to an understanding of the The STFV is a fully integrated solution based Finally, the feeder vessel sails back to port for DP and achievable motion compensation on proven technology, specially designed to reloading to repeat the cycle, and the WTIV performance and the resulting level of load WTG components in port and transport jack-up moves to the next location. workability. It also led to an understanding them to the field. of the challenges in handling, hook-on and Typically, two feeder vessels would be used release of turbine components, as well as The STFV features the BM-T1500G to support an installation jack-up, but one the development of ancillary solutions for integrated motion compensation platform feeder vessel may be sufficient when the these aspects. capable of compensating motions for resulting waiting time is not a factor or three components up to 1,250 tons in offshore feeder vessels may be required for projects Issues for the initial concept environments. This makes the platform that are located far from port. suitable for next-generation offshore wind A higher than expected cost and required turbines comprising nacelles, towers (in 18 PES WIND

TALKING POINT sections) and blades (in a rack). differences between the two T&I models, and access ports that would be inaccessible to some considerations must be made. self-transiting WTIV jack-ups. The BM-T1500G motion compensation platform is a joint development in In particular, pivoting to the feeder model 3. Port infrastructure partnership with Barge Master B.V. It’s using the STFV in the US is a way to comply based on the existing and proven BM-T700 with the Jones Act. The Jones Act requires Self-transiting installation jack-ups motion compensation platform, which has that vessels transporting merchandise, typically use their main crane for port two units in operation today, with the main including offshore wind turbine components, loading, but in order to do so, typically differences being the increased capacity, from one point to another within the US need need to jack-up in port. In some ports, stroke and velocity of the platform to reach to be US-built, US-flagged, and manned and jacking may be an issue due to the soil the required performance, as well as the owned by US citizens. In the absence of properties or quayside bulkhead integration of the platform with the vessel. Jones Act –compliant installation jack-ups, properties. Feeder vessels, on the other Where the BM-T700 system is designed for none of which currently exist, foreign WTIV hand, would need to rely on a shore crane modular transport and installation on a jack-ups can be used when feedered by or SPMTs for loading. Each model operates subject vessel deck, the BM-T1500G Jones Act–compliant vessels. under different constraints and therefore platform is designed to be integrated in the may be more or less suited for use in hull of the STFV and in a retracted position Other considerations include: particular ports. flush with the skidding deck. 1. Floating vs jack-up feeders 4. Utilization of WTIV jack-ups At site in dynamic positioning mode, a dedicated WTIV jack-up will lift-off WTG The feeders can either be jack-up feeders Using the feeder model, the WTIV jack-up components safely from the motion or floating feeders. Jack-up feeders have is not required to transit from and back to compensation platform while maximizing the advantage that the required lifts are the port, potentially allowing for a shorter workability in the offshore environment. Via fixed-to-fixed lifts without any significant project schedule and higher utilization of the skidding system, components are influence of wave induced motions. For the jack-up. This is, however, only the case transferred from their storage positions to floating feeders, the motion behavior of when the feeders efficiently feed the motion compensation platform one at a the floating vessel in waves will limit the components avoiding supply gaps and time for lift-off. Optimized main dimensions conditions in which these lifts can safely additional weather downtime. and hull design of the STFV offer a high take place. In order to arrive at acceptable transit speed, improved motion behavior for workability levels, some form of motion 5. Size of jack-up maximum workability, low air-draft and small behavior is required. beam for increased port access, and a low A jack-up’s size and cost are typically depth to allow for port loading using 2. Port access dictated by the variable load capacity multi-wheelers (SPMTs). (payload), as well as by the crane capacity. The ports accessible to feeder or A WTIV jack-up that is not required to Considerations for the T&I models installation jack-ups are limited by the transit with cargo can potentially be large air drafts caused by their long legs. smaller and less expensive, provided that it There are a number of real and perceived Floating feeder vessels with limited air has the crane capacity and lifting height to drafts can sail under bridges and therefore pick up and install the components. WWW.PESWIND.COM 19

TALKING POINT ‘To expand quickly, the US offshore wind energy supply chain will have to team up with European players in order to kick-start and to meet the target timelines.’ 6. Constructability The current focus in the US is on American manufacturing. In these cases, the development of bottom fixed wind along the STFV provides an attractive alternative or Feeder vessels or jack-ups are smaller US East Coast. The Northeast has a very complement to the traditional self-transiting and simpler vessels to build than large good wind resource in relatively shallow installation jack-up concept. WTIV jack-ups. As a result, they may be water conditions and is located close to easier to contract at a yard. Also, population centers in need of renewable Ultimately the choice between the different construction times will be shorter. energy. States in the region also see solutions will be determined by which model offshore wind as a promising new industry is more economically attractive. The cost of 7. Versatility and utilization of feeder assets from which they wish to reap economic the feeders will increase the total cost of the benefits. This is an ideal combination that spread. However, if additional costs can be A feeder vessel or jack-up may be used for will fuel the development of the US offshore offset by cost savings due to reduced project other purposes than feedering, adding to the wind industry. durations and a reduction in hired installation utilization and lifetime of the asset, and assets, port facilities, and more, it may be thereby potentially lowering the charter cost. To expand quickly, the US offshore wind worth the additional cost. And specifically for energy supply chain will have to team up with the US, the additional premium for a Jones STFV supports US offshore ambitions European players in order to kick-start and to Act WTIV jack-up will potentially tip the scale meet the target timelines. Many recent in favor of feeders. The new US administration has growing developments and investments strongly rely ambitions for offshore wind energy, setting on US–EU partnerships that build on www.gustomsc.com targets to expand to 30 GW of offshore wind European offshore wind experience and local energy by 2030 and to have 110 GW in place by 2050. 20 PES WIND

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THINK TANK A giant with a brain Words: T iphaine Comby, CMO, SEREEMA Mus Rezzoug MD, SEREEMA 22 PES WIND

THINK TANK Smart turbines: embedded intelligence is the next engine growth factor for the automotive industry. Specialists estimate that in less than 10 years, the software element will represent 60% of the value of a vehicle, compared to 20% today. When you think about the pace of change in the wind industry today, we can expect a similar trajectory. Making big turbines smarter Would it be so incongruous to imagine a The composition of the value chain will similar evolution in the wind industry? evolve with an increasing share of the digital Both the wind and automotive industries are The energy market is in deep mutation. The part in the global value. This evolution is based on the design and manufacture of prices of renewable energies are constantly inevitable, the only fuzzy line being its speed. mechanical devices, even though neither size falling and cutting into the ROI. Very recently, nor age can be compared. Over the last few a court of law in Netherlands imposed binding The driver’s seat behind the wheel of this years, the automotive industry has been emission reduction targets on an Oil Major. evolution will not necessarily be restricted confronted with an unparalleled digital All across the continents, the USA, EU and to the manufacturers. Just like the disruption. From electronic engines driving China are setting ambitious targets to automotive sector, it is bound to be to breakdown diagnosis software, it reached accelerate the energy transition in a rarely distributed among an ecosystem of even deeper levels with the intelligent shared impulse. equipment manufacturers and innovative connected autonomous vehicle. Subjects as However, for the time being, the wind digital players such as Sereema. For all that, complex as data protection held by a vehicle industry’s main ambition, both in the it does not mean that manufacturers will be soon emerged. technology and marketing fields, has been excluded from this transformation. They will to race for size. Bigger and bigger turbines still play a central role, but the speed of This evolution has been achieved through are conceived, built and bought in an effort innovation requires an agility and a capacity the integration of innovative software to lower the purchase price per KW. Not so for change that is often incompatible with technologies, powerful data processing and long ago, the automotive sector walked the the DNA of these large behemoths. AI, which are taking an increasingly important exact same path, throwing all energy and space in the vehicle value chain, and marketing into SUVs to try and preserve Such a cluster of innovative companies is represent a potential business in terms of their margins. already thriving and building up as we speak. monetizable services. Without these At Sereema, we took a bet that sooner rather Tomorrow we might become direct suppliers developments, historical car manufacturers than later, we, in the Wind Industry, would to turbine manufacturers, whereas today we could have been on the verge of disappearing realize as well that this was not the way to go. have mainly been involved in the operations altogether, swept away by the new mobility Our belief is that the future path will dwell on and maintenance steps. This abundant and solutions that are developing at high speed. manufacturing both smarter and bigger rich offer of innovation meets a market need. machines. Hence the digital race towards Such innovations do not necessarily come smart turbines, most likely induced by Turbine design will evolve with the from the manufacturers themselves, but companies with Intelligence in the DNA. integration of more and more software generally speaking, more so from their Digital-induced innovation components making the machines suppliers, or else even from innovative Software, Intelligence and automated data intelligent, capable of better diagnostics, but digital companies that have no historical processing will become more and more above all of better optimization and link with the automotive sector. Digital important in the operation of wind farms. adaptation to their operating environments. giants like Google or Apple are now In short: higher performance with lower investing in this sector and considering Swarm operating mode for higher performance overall operating costs. launching their own vehicles. In the end, it doesn’t really matter where the innovation comes from, be it the turbine WWW.PESWIND.COM 23

THINK TANK manufacturer, one of its suppliers or a optimising their operation costs when it and know how to behave. This opens a door partner or bought-out innovative company. maintenance is insourced. towards real optimisation where the turbine What is important is that the innovation will be able to operate better on its own, irrigates the sector in a favorable context, Digital solutions need to adapt to these knowing all there is to regarding wind that makes digital transition painless where various contexts: packaging raw material in conditions and changes. This translates into the low cost of money boosts its the right format, depending on the targeted more performance and less wear, more development. As a bonus it also tames the audience… human beings or even machines! energy and more lifetime. risks on the profitability of the wind projects Of course, in order to fully embrace the through a combination of the drop in digitization path, we need to lift any A swarm operation mode where each unit will electricity tariffs and rising interest rates, remaining barriers. Ascertaining that we’re react in tandem with its own data merged which is likely to make digitalisation even way past algorithms identifying trends and with its neighbors. The maximum wind farm more necessary but also painful. anomalies that indicate operational issues. performance is not necessarily equal to the Today the wind industry has reached its sum of the maximum of each individual unit Autonomous wind turbine ‘coming of age’ realization that only a thanks to the synchronization of the swarm. combination of engineering, data analysis Streamlined data processing is already and machine learning expertise will provide The potential double-digit gains in global feeding investment, assets or maintenance the accurate interpretation of the data, draw performance gives a new perspective to the managers with comprehensible info to help out the trends of tomorrow’s turbine’s best development of wind energy. Tackling wake them make the right decisions. And this is behaviors in their local context. effect impact on performance is one of the just the beginning. Most of the existing most obvious application cases, but there systems use a single source of data. The That’s why the next step will be making not are many more to be developed. industry hasn’t yet acquired enough only big wind turbines, but even smarter ‘digital maturity’ to be able to define ones! The existing technological bricks make We’ve chosen the automotive industry as a common standards for data sharing, and it possible today to design enhanced turbines use case to be compared to the Wind data cross processing. with in-built ‘intelligence’. Real time industry, but AI has infused across a wide auto-regulation based on information range of other industries: healthcare, The key value isn’t in the data itself, but in all provided by data processing will enable AI to finance, HR, transportation, energy… It will the info that could be automatically apply optimization decisions. deeply impact the wind industry’s value extracted from one or several data sources. chain. Wind power must embrace its Customizable information that is relevant to The turbines will be able to permanently data-driven nature faster to improve its each target should be available in several adapt to local conditions or to pre-program value proposition and to keep playing a key formats. The needs differ according to the maintenance actions by eliminating low role in the energy transition. profile of the data reader, analyst, expert. For value-added human decision steps. example, financial investors long for an Many digital solutions have been developed overall view of profitability of their assets, Once more time, we can reflect on the and marketed in the last couple of years, considering that most of their field parallel with autonomous vehicles, merging which proves that a dynamic and rich operations are outsourced. They need data from different sources and processing ecosystem is emerging, meeting real market additional information to better value their a safe and optimized behavior, in sync needs. These solutions should not be assets at resale, but also to better secure with its environment and other moving, considered systematically as competitors, their investments in new projects. or still vehicles. even if sometimes they target the same budgets, but more as complementary pieces Whereas utilities, or big IPPs are in dire need Current technologies hint at the future, of a larger digital puzzle. of information that SCADA can’t deliver to fit where each smart wind turbine will not only to a more integrated strategy, and their optimize itself as an isolated entity, but as Being one of the pioneers of this adventure is desire to keep close control of the assets in part of a group of machines within one or very exciting, the development perspectives the field. Their technical teams are skilled several wind farms. are even more so. If you’re reading and you’re and able to exploit technical data and not in the driver’s seat, there’s still room for information in a very efficient way to fine More precisely, imagine a turbine that can passengers, join us and hop on, engine’s tune their wind farms operations, challenging adapt to its conditions and environment. revving up! O&Ms, maximizing the performance and Once a turbine recognizes where it stands, and what it’s surrounded by, it can learn from www.sereema.com Windfit Evolution 24 PES WIND

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TALKING POINT Hydraulic torque wrenches are the most widely products used in the market for high torque bolting Time to be smart when it comes to bolting Words: C alum Urquhart Bolted joint assemblies are a critical part of a wind turbine as they have a direct impact on the structural integrity and the performance of the turbines. Applications can be found in all parts of the turbine such as foundations, tower flanges, nacelle, blades and internal components where the bolted joint must be secured according to specific design specifications and must remain secure throughout the turbines life cycle, despite exposure to temperature fluctuations, routine maintenance and repairs, and constant forces being exerted through the movement of the turbine and effects of wind itself. 26 PES WIND

TALKING POINT There are many bolts to be tightened, and The result is that the bolting process today is result, if maintained correctly and used in the for the most part they are all critical more demanding than ever with new turbine right way, by an operator following the design involving new materials, more correct process. However, when it comes to tools and optimised joints and continuous demand for equipment used in the bolting process, the increased cost efficiency, however the This means that result of the work task done wind sector in general has been somewhat tooling used on these joints is largely the is completely reliant on the operators and as conservative in the types of tooling used, same as it has been for many years. we all know, the human factor can and often with much tooling being used today having does, result in errors. not evolved in any significant way for many Interestingly, inside the manufacturing years, even decades. In-fact, there has been facilities of the Wind OEM’s where for The types of errors that can occur may not be a tendency to standardise on the same type example nacelles takes place, then in many deliberate but can simply be the result of the of solutions for many years, despite the fact cases the latest technology such advanced circumstances at the time. For example, a that both the industry demands, and electric nutrunner solutions, data collection contractor under extreme time pressure, or available technology is evolving at pace. systems and even automation are fairly technicians working in extreme commonplace for all bolted assembly work temperatures, or new processes being The reason for this is quite simple. Bolting on the assembly lines as this offers the introduced with limited training, all of which tools are usually specified by the OEM when a highest productivity output combined with a could result in mistakes and this in turn turbine design is made, and then this is consistent high-quality result. This is well creates a risk that a bolted assembly may not standardised in the standard operating established, and in recent years with the be done correctly. The impact this could be procedures which are then pushed out to all arrival of Industry 4.0, we see an acceleration minor with the need from some rework, but it stakeholders, such as contractors or service of these types of solutions where most could also be more significant with a need for companies working on the turbines during assembly tools in the factories are not only costly service or maintenance later. Worse their life. Then when new designs are ‘smart’ in that they have intelligence built in, still it could result in a safety incident, or even introduced, it is based on the previous but they are also now ‘connected’, where a catastrophic failure. generation, resulting in tool fleets which are they integrated for example to a to an MES built up over a number of years meaning large systems in the plant. All mistakes have a cost. Either in lost time, tool inventories are in place, and so there is a additional repair or maintenance costs, or resistance to introduce new solutions which This means that inside the factory, although worst of all in reputation, so ideally, we want may require additional investment, and could operators are using the tools, it is the to ensure that all bolted assembly work is render existing tool fleets redundant. process design, and equipment used that done according to specification, right first controls both the productivity of the line and time, and with a record to prove that this is the quality of the output. the case at the time the work is done. However, out in the field, during construction, Smart bolting, what is it? commissioning, maintenance and service work it’s a different story. The tools used here When we talk about smart tooling, we talk typically consists of hydraulic torque about tools that have sensors or intelligence wrenches, bolt tensioners, perhaps some built in, that can measure or monitor an manual torque wrenches, and most likely operation or a process and can give the some battery-operated impact wrenches for operator feedback that a job has been done pre-tightening. These kinds of tools can be correctly, and can provide a digital record of found in their hundreds, if not thousands in that result. However, smart bolting is not the fleets of OEM’s and contractors. They are only about using smart tools, but is about of course widely available, and easy to working in smarter way, by introducing maintain, but they all have some inherent solutions that can either reduce process challenges, which we will come back to later, time, or make the process easier and safer but one thing they all have in common is that for the operators to do their work. This they are not classified as ‘smart tools’. They results in less mistakes, higher output and are all mechanical solutions that will deliver a happier technicians. Feedback on tightening status allows operators to address problems at source so that processes can be completed right first time. WWW.PESWIND.COM 27

TALKING POINT Tensor Revo nutrunners can reduce bolting process time by more than 50% to improve overall process time but cannot necessarily secure that the right process When talking to Wind OEMs or contractors reached which is then correlated against a has been done because of the way that they about their challenges when it comes to torque level for that pressure. Not only is this measure torque. In many cases these tools bolting work in the field, we hear repeatedly time consuming as the wrench speed is very do not actually measure torque, but they the same messages: slow at tightening the bolt, but the process is measure the current draw in the tool and also time consuming with multiple pulses convert it into torque. This methodology • ‘We want to reduce the time taken to do needed to build up the torque, and there is a can be extremely accurate when used in a the work’ very high degree of operator dependence repeatable environment, however if there involved in this process. are temperature fluctuations or different • ‘We want to eliminate risk of injury ‘ joint characteristics, these will influence the To reduce time in the bolting work, there are result, and as so provide inconsistency in • ‘ We want to be able to secure that the 2 questions that need to be answered: the output. This can be compensated by right work was done’ doing regular ‘torque verification’ • Firstly, regarding the performance of the procedures on site, but this consumes Perhaps this should come as no surprise, but tools themselves: how long does it take to additional time and resource. it is surprising, that despite these desires to rundown and fasten a specific bolt? improve, that in many cases, the tools being To ensure the consistency of the torque used in the field continue to be those • S econdly: can the process be optimised measurement, then the use of electric tools specified since many years ago, with little or to reduce the time needed to use the with integrated torque transducers will be no process intelligence, are solely dependent tools doing the work? the most effective. By having a transducer on the technicians, and can even pose a risk ‘built in’ it means the tool can be of injury. These are all areas which could be In recent years we have seen the introduction programmed to do a task, but it also improved significantly by the introduction of of more and more electrically powered tools, measures itself it has done that task, so ‘smart tools’ to replace the conventional and even battery tools for this kind of thereby providing in integrated verification tools that are commonplace today. application because they can rundown the of the output. Temperature and joint bolts much faster than a hydraulic wrench variations will not affect the result as the ‘We want to reduce the time taken to do with only one pull of the trigger. With tool transducer is providing that feedback to the the work’ speeds 20 times, or more, greater than tool which can then confirm if the correct hydraulic wrenches this saves a considerable result has been achieved or not. Since these Bolting work is time consuming and so has a amount of time in each tower section. tools have transducers, they can also be big impact for example on crane time in independently calibrated, which can reduce construction or turnaround time during This is certainly an improvement but must the need for regular onsite verification that is service work, and so anything that can be also be noted that doing something fast is currently done. done to reduce it has a direct impact on the no good if it is not done right! Many of these cost of construction and maintenance. electric or battery type tools have been able The end result of using an electric tool, with an integrated transducer is that each bolt can The most common tooling used historically be tightening extremely fast, and the has been hydraulic torque wrenches for measured result can also be recorded in the example on tower sections where there are tool memory to secure the specifications are many bolts to be fastened. This can be met, while the set up and usage time of the extremely slow as they operate by using tools is significantly reduced. hydraulic oil in pulses via a pump to ratchet the wrench to build up the torque. This requires an ‘We want to eliminate the risk of injury’ operator to repeatedly activate a pump and to judge when the correct result has been When using bolting tools to apply install high achieved by looking at the gauge and seeing loads or torques into joints inside to turbine, when a predetermined pressure level is there are several areas that can expose the technicians to either injury or excessive strain. The use of all power tools has exposure to risk, and it is critical that users are well trained and aware of the risks in advance, however despite training, and even experience, it is not uncommon for injuries to happen, so a more effective solution can be to introduce different types of tooling that can eliminate or significantly reduce the risk of exposure to injury or strain. For example, when considering the use of common tools such as hydraulic torque 28 PES WIND

TALKING POINT wrenches, there are 3 primary areas we can Tools connect to ‘any smart device’ so no need for complex and costly control panels. look at This will immediately create a safer work occur. The tool trigger is controlled • F inger pinch injuries are the most environment, but also will expose operators electronically so that operators cannot try to common injury when working with these to less strain, which in turn can make them overcome the system for example by ‘fixing’ types of tools. This can result in finger more productive. the secondary trigger in place. damage or even loss when fingers are caught between the reaction device and The challenge of finger pinch points remains Furthermore, the since the safety trigger is the fastener when a wrench is activated. however in many cases where battery tools fully integrated in the design of the tool as are used, as this is a consequence of using standard, it located in a natural ergonomic • T ripping Hazards due to cables and hoses torque tools which require a reaction device position so that the operators can do their are an inherent problem when using to absorb the opposite force when work in an easy and natural way that is free hydraulic tool systems. Power cables to tightening. However, some products are from injury. the pump unit which can run across the available, such as the Atlas Copco SRB HA floor or even up tower. There are also which have fully integrated safety triggers ‘We want to secure that the right work hydraulic hoses which are connecting the into the tool which address this problem was done’ pump to the wrench and there is even a directly. The integrated safety trigger must pendant to control the pump which also be held by the technician’s free hand before All bolting work on site requires technicians has a cable from the pump to the the tool will operate. This ensures his hands to follow a well-defined process and to operator. If the pump is located at some are in a safe position and no pinch injury can document the results of that process distance from the bolts being tightening (typically manually). this can mean an excessively high degree of tripping hazards are present. • H eavy Lifting over a period can result in excessive strain for operators. In order to achieve faster performance, larger pumps are often used, which are heavy and must be moved around the work area. This combined with movement of the tools being used means a lot of repetitive lifting during the work time. One solution to address all these points is to use intelligent battery nutrunners, (not to be confused with battery impact wrenches). Battery nutrunners effectively remove the need for hydraulic pumps, and so eliminate the need for heavy lifting completely, and also remove any tripping hazards because there are no cables or hoses in the system. Safety trigger designed into the tool is both intuitive and ergonomic. WWW.PESWIND.COM 29

TALKING POINT Visual feedback on tools and devices ensures that the operator gets feedback without need for external devices or gauges. For the most part this is strictly adhered to, unknowingly being overlooked. (bolt, or flange) a report is generated but there are occasions that specific factors digitally, which can be tracked, for example a can have an impact. Time pressure, changes Surely if an application is so critical that it technician ID, could be logged against the in contractors, material defects, equipment needs the use of bolt tensioners, you can tool ID and the bolt or component ID so there failure, for example all could potentially result assume that it is also critical that the correct is a traceable chain that can logged and in process steps being done incorrectly or process is followed, however it has been uploaded to a contractors or OEMs own data even missed completely. commonplace to simply use conventional record system. Since that digital record is tensioning tools in the field, and rely on the created by the sensors in the tool, and by Bolt Tensioning is one of the common skill of the operators for the final result. using scanners in the system there is a solutions used for tightening really critical security in knowing it is correct, and joints, due to the fact that tensioning (as To address these challenges, the removing the reliance on human factors. opposed to torque) eliminates the effect of introduction of ‘Smart Tensioning systems’, friction in the joint and therefore can apply a such as Atlas Copco STS can reduce the risk The bottom line more consistent load in the joint. It is significantly and increase the joint quality by especially suited for application which are monitoring each step of the process and The bottom line is that the desire by wind exposed to high forces such as blade to hub, providing feedback to the operators on what OEMs to make their bolting processes quicker, and on foundations. has happened. safer and smarter, can be achieved with technology available on the market today. Traditional bolt tensioners are a mechanical By having sensors integrated into the smart solution where hydraulic oil is used to stretch tensioning tool such as angle encoders, Ageing tool fleets and outdated processes the bolt and by using the pressure applied to torque transducers, and pressure sensors we should be reviewed to evaluate the long- correlate to a load installed in the joint. This can secure different parts of the process term gain versus the short-term disruption involves different steps such as mounting of have been followed within a predetermined of change. the tool, running down the puller bar, specification so that each step is followed applying the hydraulic pressure, securing the correctly and the user cannot continue Some of the smart bolting solutions available nut is wound down, and removing the without doing so. may appear new in the context of wind tensioner. The challenge with using bolt construction, commissioning and tensioning is that it is critical that each step During the operation, feedback can be maintenance, however it based on years of of the tensioning process is done in the right provided to the technician informing him of experience in manufacturing industry where way and in the right order, otherwise there is the result of each step, which then allows the use of these types of products is a risk that insufficient load is installed in the them to understand if it is OK or NOK. This standardised, even in the wind industry. joint. Since there are several steps in the lessens the responsibility on the technician, tensioning process for each bolt, and then as he can simply follow the instruction Smart bolting solutions use intelligence built there are many bolts to be tightened, often onscreen on his handheld device and it will in to improve process control, worker safety more than one time each, this creates a guide them through the process and advise if and productivity and this translates directly high-risk of errors happening, or even any action is needed. to reduced costs and risk. Then finally when the work has been done www.atlascopco.com 30 PES WIND

Smart Connected Bolting We are experts in all controlled bolting techniques. We deliver innovative solutions that improve critical bolting processes by using smart tooling with intelligence and connectivity built in. Quicker.Safer.Smarter. atlascopco.com

ASK THE EXPERTS A holistic approach to wind energy 32 PES WIND

ASK THE EXPERTS Kaveh Etemadi, Managing Director, ROBUR Wind GmbH and Director Global Sales of the whole Business Unit ROBUR WND, spoke to PES about his holistic vison and approach to wind: turbines, assets and services. This company offers a total package throughout the life of a turbine, with training and H&S permeating every aspect. Firmly established in Europe, the US and Latin America, their sights are firmly set on Africa and South East Asia. PES: Hi Kaveh, it’s great to welcome you to Wind is an industry that has matured. There hours and assignments themselves. The big PES Wind and to get know a little bit more are less and bigger players in this sector now. advantage is that we in the office, can see in about ROBUR WIND. I believe you are part H&S and Quality, which have been always our ‘real time’ what is happening in the field. of ROBUR? top priorities, are in the centre of the picture Especially in times of pandemics, this is a now. The amount of information obtained huge advantage. Kaveh Etemadi: Thanks it’s great to be here. from wind farms has skyrocketed, and this Yes, that’s right, ROBUR WIND is part of the allows us to propose tailored solutions that Not to mention that we also rely on new ROBUR Industry Service Group. We are a increase the life of the assets and the technology such as AR and VR in parts of our strong group with 3,000 employees globally benefits to the customers. training. We already conduct many of our and work in the wind, water, energy, industrial basic training courses online. New and process industries. Fortunately, even under the current conditions technologies such as virtual reality are highly we keep on discovering new opportunities and interesting, especially as they offer the PES: It would be lovely to learn a bit more challenges which we are going to develop side possibility of providing training that is about the background to ROBUR WIND and by side with our partners. difficult to carry out in practice, and the services you offer. therefore often cost-intensive, virtually at PES: 2020 was quite a year for us all wasn’t low cost. KE: ROBUR WIND currently unites six it? But what effect has the pandemic had on companies: ROBUR Wind GmbH, ROBUR the industry from your viewpoint, in all the New opportunities are arising every day. For Wind Sp z.o.o., ROSCH Industrieservice territories that you cover, and are you example, EV. Until now, due to high prices, GmbH, Ynfiniti from Spain and our renewable seeing signs of change now? low capabilities and difficulties to find energy specialist RME and EREDA. We deploy recharge stations, EV did not take into teams to onshore and offshore wind farms as KE: 2020 was a crazy year. Our lives have account the mobility needs of our well as PV plants throughout Europe, Africa, changed completely and we have had to technicians. But at the moment the 500km Latin America and the United States. adapt to many new circumstances. 2019 was autonomy capacity has already been already rather weak in terms of the economy, crossed, and we see that our towns are In addition to erecting, troubleshooting, and this is worsened in 2020. Stagnant supply beginning to install charging stations. It is both minor and large correctives, servicing chains due to production downtime in China becoming more and more common to see EV and installing, inspecting and maintaining and Italy lead to production bottlenecks, we in our everyday life, and so in a matter of wind turbines, from gearboxes to rotor also felt this, especially in our production for months they will become a part of our blades, and we also manage the obstacle markings. mobility solutions for wind. replacement of major components of PV plants. For your renewable energy project, In some cases we were unable to meet Drones and AI are also part of our portfolio. we deliver a holistic approach to delivery deadlines. Production of wind Blade inspection has been a very traditional development, implementation and asset turbines came to a standstill for our task, carried out by experienced management and we add value all along the customers, projects were postponed. technicians with either telescopes or ropes lifetime of the projects. The pandemic was felt in many areas. for a closer and more detailed check. Now our drones team have automated this So as you can see, we offer our services along However, now things are slowly starting up activity, relying on drones for taking the the entire value chain of a wind turbine and again, with many ups and downs and photos and in powerful AI programs to see ourselves as a holistic and globally active discontinuous processes. detect and classify damages, determine specialist for your renewable assets. the status of our customer assets and PES: How is technology being embraced to propose ad-hoc solutions that optimize PES: What changes have you noticed in the make the various processes of the job and results and cost. wind industry over the last few years? services you offer easier on and offshore? PES: Health and safety must be high on the KE: On the one hand, wind industry has KE: Some of our technicians are completely list of challenges you face, not to mention reached to be a major player in energy on duty via a specially developed app from adverse weather conditions, are there any industry. At the moment nobody considers one of our partner companies. This means others you would like to mention? the energy mix, without taking into account that they receive projects, carry out the the contribution of renewable energies. documentation there and can track their KE: Creating safe environments must be our WWW.PESWIND.COM 33

ASK THE EXPERTS first commitment with our colleagues and concerned with training our technicians to Kaveh Etemadi the society, H & S must be always at the keep them up to date. We also have our own forefront of our minds. Additionally, we need GWO training centers in Madrid, Mexico, PES: How many technicians do you have on to reinforce the qualification of our Uruguay and Italy. board and how are they managed from a technicians. The requirements of the market logistics point of view? are intensifying, better services carried out We are focused on achieving the highest level by more prepared technicians, with more of training and courses. For this we have KE: We have around 350 technicians in capabilities and able to face the new trainers who, apart from being trained under Germany and around 1000 in the entire unit. technical challenges. the high GWO standard, are superior risk prevention technicians, which means we We have our own service vehicles and travel Offshore wind is already here, and we are provide solutions that not only comply with management, which fortunately takes care going to have to expand our activities there the technique but also with the highest of all the logistics for the technicians. and replicate our success cases also overseas. national legislation found in Health & Safety. New markets, such as Africa and South West PES: ROBUR WIND recently announced a of Asia are going to create opportunities for PES: Talk us through some of your most partnership with OWS Off-Shore Wind those who want to grab them. recent contracts, we would love to learn Solutions which is exciting. Can you tell us a about one or two that you are particularly little bit about that and what it means for Also, lifetime time extension together with proud of. your customers? recycling, for example, blade recycling, are also going to be important topics. KE: We have been awarded with more positions doing commissioning for both PES: How do you ensure that all safety Siemens Gamesa and Nordex Acciona. This regulations are adhered to and keep abreast has always been one of our strongest points. of the changes as and when they take place. Commissioning involves a group of tasks that Training must play a vital role? require a holistic view of the turbine, and so requires highly skilled technicians. KE: Training is part of the core of our business. Our commitment to our colleagues We are proud to see that two of the biggest and we as a part of our company have to companies in industry keep on relying on create safe environments where we all can go ROBUR for the starting point of the life of back home in the afternoon, as we left in the their turbines. After a very challenging 2020, morning, or even better. To do that we teach blade activities have restarted strongly in and train our people so they can be always 2021, continuing with the traditional sites alert and in the event of a problem, they have and customers, and expanding our portfolio a pool of resources that will enable them to with contracts with Käufer and with new minimize the consequences. activities in LATAM. We have signed a partnership agreement with OWS that is We have our own five-people training going to strengthen our presence offshore. department in Germany that is solely 34 PES WIND

ASK THE EXPERTS KE: Yes, sure. We are very proud to announce operational management services, including So we try to make it simple. As our children in our global partnership with OWS and Wind engineering support for the on- and offshore schools, we keep in mind permanently three Multiplikator (WM). The partnership will wind industry. It is intended to limit asset and easy words: reduce, reuse and recycle. combine OWS’s significant operational and operational risks for our clients. executional experience, ROBUR WIND’s We optimize the consumption of resources, on- and offshore services experience and PES: What ecological challenges are driving from fuel to electricity and water, from WM’s extensive experience in operational your range of services and solutions? chemical products to paper in the office or management. The value proposition for our cardboard for packaging. Sorting and clients will be the delivery of targeted asset & KE: Taking care of the environment as we storing the waste properly is a part of our help providing clean safe energy is our goal. everyday tasks. Our contribution to the EV transition is continuous, and this active approach ensures that our footprint is much smaller, helping us to achieve major energy savings. PES: What makes ROBUR WIND stand out from the competition? What are the end user benefits in terms of efficiency and cost? KE: I think what sets us apart is our geographical spread and the associated services. We can cover services along the entire value chain of a plant worldwide - and all from a single source. One supplier, one contact, one customer relationship. Not to forget the cost effects that result from this. It is clear that there are often positive cost effects here, while quality remains the same. We can also look back on a variety of experience, having worked on many different WWW.PESWIND.COM 35

ASK THE EXPERTS turbines ‘from the very beginning’. If the America as well as in Europe; how do these For these customers we carry out nearly customer wants, we can even cover their areas differ in terms of what you offer and everything from commissioning to servicing, obstacle markings as an add-on, as well as how you can operate? troubleshooting, QA/QC, blade repair, light-on-demand night marking, which will be technical supervision and large correctives. mandatory in Germany from 2022. KE: Our presence in America has grown over This portfolio is very similar to the one we the last five years. We have evolved from 40 offer in Europe, taking into account local You need to train your technicians for your technicians four years ago, to more than regulations and specificities. operation? No problem, we have our own 200 at the moment. In parallel with the GWO centers. You need support in the field increase in the number of technicians, our Our teams are deployed in an area of nearly of PV and solar? All right, RME and EREDA portfolio has also widened. Initially we 10,000 km from the north of the USA to the are at your side. What I mean to say is that I worked only for Siemens Gamesa. Now we south of Chile. The agility and flexibility of think we are unique in our construct and have more than ten different customers, our technicians and the superb work of our services covered. both OEM, SGRE, Nordex-Acciona, Vestas, logistics team means we can reach any and final customers ENEL, IBERDROLA, area in the right moment and with the PES: You operate in North and South CMI, Grupo Dragón, Next Era, … proper resources. PES: Geographically, are there any other markets you would like to break into? KE: Africa is a market we have been cooperating with in the previous years. 300 million people in need of safe and cheap energy, and renewables are a solid option. Until now we have been cooperating in commissioning wind farms in Egypt and Mauritania. Taking advantage of our current presence in Egypt with TEC GmbH, our objective is to make that permanent and then to develop all the activities of our wind portfolio throughout the rest of the continent. On the other hand, Asia is also increasing their share of renewables, and we would love to be there to provide our expertise. PES: What do you think is in store for the industry over the next five years or so? Where do you see ROBUR WIND fitting into this? KE: For us, the most important sector over the coming years is going to be offshore, moving from being just a small part of the business to having a central presence. How to deal with aging wind farms is also a beautiful challenge, where lifetime extension, repowering and recycling will have to be combined to offer the best solution in each case. Both offshore and onshore wind farms will have to provide energy to the net in higher quantities than in the past, and this net will have to be strengthened to make sure that this energy gets to our homes in optimum conditions. Last but not least, data. Technology enables the collection of millions of data from each one of our assets, so deciding how to use all this information to improve service will be a major challenge. www.robur-industry-service.com www.robur-wind.com 36 PES WIND



TALKING POINT The 8 most important considerations when selecting your next hydraulic torque wrench Operating and maintaining a single generating station or wind farm and distributing that power in an ever changing and highly regulated market is an enormous challenge. Utility leaders are under constant pressure to meet rising demands, maintain regulatory compliance, shift to a diverse energy mix, and implement sustained cost reductions, without impact to quality and reliability. As their assets and workforce age, power generators recognize the need to innovate and partner with suppliers with the same priorities. 38 PES WIND

TALKING POINT Wind is an important and growing source of combination or hex cassette and a drive close to each other. Many also include tether energy around the globe. Consumer demand unit which is actuated by a hydraulic features for safer working at height – a for cleaner, renewable energy, along with cylinder. A complete hydraulic torque must-have requirement when working on favorable prices has fueled increased wrench system includes a hydraulic pump wind towers. investments in wind capacity installations. with a coupler and hose. Actuating the As onshore and offshore wind farms become pump advances the torque wrench. Consideration 2: versatility and commonplace, demand for specialized tools general-purpose for the installation, maintenance or If you are a seasoned bolting specialist, then decommissioning of wind turbines. you will know the must-have features needed If you want fewer tools that serve a wide to complete your specific bolting projects range of applications, then consider a 2-in-1 A wind turbine can contain approximately like a pro. However, if you are new to general-purpose tool. When working on a 25,000 bolts, each of them under precise bolt controlled bolting, selecting the right wind tower, portability is important and load and up against a variety of forces in hydraulic torque wrench for your job requires battery-powered models fulfill this need by nature. Maintaining bolt integrity with understanding the choices available. The being easy to transport and suited to tight Enerpac wind tower tensioners and torque design and features of each series of torque spaces. Pumps for hydraulic torque wrenches wrenches uniquely supports both wind wrenches are tailored to suit different and tensioners are available in cordless, turbine manufacturers and wind farm applications. Below are key considerations electric, and air-powered models. operators alike with a broad set of proven when selecting a torque wrench for your tool technology and services. unique job. Consideration 3: size and torque output Torque wrench basics Consideration 1: square drive or low profile Will it be powerful enough and the right size to do the job? Each hydraulic torque Hydraulic torque wrenches have come a A square drive hydraulic torque wrench wrench works with many different long way since they were first introduced in shares the same principle as the torque cassettes or sockets. But there are many the early 1960s. Advancements in wrench you might have in your garage. It different drive heads to choose from. Each technology have created countless options, works with different sized sockets to fit the has a different maximum torque output features, and benefits to decipher – making nut to be tightened or loosened. and is designed to cover a certain range of it much harder to have confidence in your hex sizes. You should understand the final tool selection. A low-profile torque wrench uses minimum and maximum sizes you want to interchangeable cassettes (sometimes cover. Then check specifications on the Hydraulic torque wrenches create the referred to as ‘links’). This type of tool is manufacturer’s website. exact torque output or torque load commonly used in the oil and gas industry necessary to loosen or tighten the threads where clearance around the nut is often The right tools used for controlled bolting of a nut and bolt for a leak-free joint. A restricted. The low-profile models are also can make the difference between your job hydraulic torque wrench is comprised of ideal for low clearance applications, for running efficiently or encountering costly two primary parts; square drive socket example, when bolts are positioned very delays. There are many application WWW.PESWIND.COM 39

TALKING POINT considerations and choices. Should you a variety of leading brands. Consideration 6: cassette choice need help with your torque wrench selection, browse the Enerpac Torque Interchangeability works the other way If you select a low-profile torque wrench Wrench Buyer’s Guide. around too. Buy an Enerpac HLP cassette and model, you will need to choose cassettes to it will work with drive units from other many suit various A/F hex sizes (Across/Flats). For Consideration 4: how much do I need to other brands. each drive head there are many available to invest in a hydraulic torque wrench? suit both imperial and metric sizes. Note that Consideration 5: convenience, safety, and different ranges of torque wrenches from the Opinions vary. Are you thinking short term or easy operation same manufacturer often have dedicated long term? cassettes. Do not assume all are compatible It is important to understand how to easily with each other. But as mentioned earlier, the If weighing up the total cost of ownership operate your torque wrench for maximum HMT Series is an exception and is compatible over the long term is your preferred safety and productivity. Features such as with cassettes from a variety of approach, then build maintenance into your safety handles, swivel hoses, tether points, manufacturers. calculations. Higher quality products may be no-drop features, and quick-change a slightly higher investment, but they will cassettes provide improved usability and By default, cassettes for low profile torque require much less maintenance and repair safety. Each of these can make a huge wrenches are designed for tight spaces. over time. difference when working in challenging There are other more slimline models conditions offshore, or up high on a wind available. These are perfect for If you do not intend to use the tools turbine tower. applications where flange nuts are frequently, then mid-market products may positioned very close together. be a better solution. This category includes As wind towers get repowered with bigger interchangeable and 2-in-1 modular designs equipment, more exacting and reliable tools Consideration 7: accessories – enabling you to cover a wide range of are required. applications with fewer tools. Examples There are numerous accessories available for adopting this approach includes the Enerpac New features are available on torque hydraulic torque wrenches. These add RSL Series. These models offer cost- wrenches that set a higher standard in safety, additional safety, certainty, convenience, effective compatibility with low profile to versatility, simplicity, and performance. For and extend the number of applications. square drive, or vice versa, using the same example, when it comes to safety, a built-in, drive unit. work-at-height safety tether connection, Examples include sockets, back up spanners, such as that on the Enerpac DSX-Series different sized reaction arms, safety handles Are you looking to upgrade your torque tools, aluminum torque wrenches, helps prevent and reducers. but want to continue using your existing injuries to workers below. Meanwhile, a fully cassettes and drive units? Select a modular enclosed square drive keeps technicians’ Consideration 8: torque wrench pumps torque wrench design, such as the Enerpac hands protected from moving parts, and its HMT Series. These models use drive heads optimized weight-to-output ratio and slim Given the number of bolts on a wind tower, that are interchangeable with cassettes from design help prevent operator fatigue. for example, bolting pumps should have high flow, fast performance, and portability as key 40 PES WIND

TALKING POINT ‘New features are available on torque wrenches that set a higher standard in safety, versatility, simplicity, and performance.’ advantages. Cordless torque wrench pumps Choosing a hydraulic torque wrench requires For those unique applications, rely on a are available and can work well for wind tower careful consideration. If you need any guidance, custom solution from a trusted brand that maintenance. Pairing your hydraulic torque contact an Enerpac Bolting Specialist. builds tools that are designed to perform wrenches with the most compatible pump every time. All Enerpac tools are fully for your application will ensure optimal speed Why choose an Enerpac torque wrench? supported by our application experts, and performance. Choose from ATEX- calibration and maintenance services, no certified air-driven, battery-powered or Putting an Enerpac torque wrench to work for premium service contract required, rental electric pumps all designed to meet the your bolting application is a sound choice. programs and training. needs across a variety of controlled bolting Choose from a full portfolio of solutions to applications. Your pump pairing is just as meet your needs from the most demanding Visit enerpac.com to view Enerpac controlled important as selecting your torque wrench. applications in the harshest environments to bolting solutions. routine or occasional use. WWW.PESWIND.COM 41

TALKING POINT Enabling data to drive the future of offshore robotics 42 PES WIND

TALKING POINT Vaarst, the new technology spin-off company from Rovco launched March 2021, with the vision to bring artificial intelligence, machine learning and autonomy to all offshore robotics. Enabling the integration of their technology into all robotic vehicles, both new and as a retrofit solution to existing ROVs. A technology company borne from a the vessel while the information is being construction data instantaneously, so they services business collected, they can ensure that all the data can make knowledgeable assessments while needed has been obtained during the dive. the job is still underway. While Vaarst Rovco, out of which Vaarst was born, has So, there’s no need for any expensive rework. already provides this to customers today on operated as a service provider to the a custom-built basis, in 3 to 6 months, this offshore sector since 2016, supplying survey Using relative positioning technology, will be part of their harmonised product set. and asset integrity services across the SubSLAM guarantees that the ROV always offshore lifecycle. But it is Vaarst who has knows where it is, eliminating the Live-streamed data will also be automatically provided the technology that has sat behind requirement for additional positioning uploaded to a geo-referenced data platform. Rovco’s innovation-led services. Indeed, apparatus or scale bars. Although, they can This will keep a historical record of all Rovco has operated as the testing ground for also switch on the IMU for those infrequent customer assets. So, teams will be able to Vaarst, enabling the technology to be refined times where the visibility isn’t optimal. work together in a smarter, more secure and and established in the real-world scenario. It a well-organised way. The geo-referenced has also enabled the naturally cautious Alongside gathering 3D data, their system data platform is also planned for release later energy sector to see the huge benefits that also collects 4K video, which can be this year. Vaarst technology can bring. post-processed for high-resolution photogrammetry. So, the customer receives Multiplying human effort with Vaarst technology was created to transform live 3D data on all their assets while on the machine learning offshore data collection in the survey and job and is then able to concentrate their O&M domain, where processes and systems attention when post-processing on creating The Vaarst ML platform takes visual data are ripe for modernisation. At present, high detail photogrammetry models for and enables much faster analysis than offshore data-gathering demands the areas of significant interest. traditional methods. deployment of sizeable vessels, that create remarkably high levels of environmental Live streaming for instant asset insight For example, to undertake a regular pollution. Each vessel can produce, inspection on a subsea pipeline, an ROV must depending on the job, up to 275K tonnes of The 3D data, gathered by SubSLAM, is travel down the pipeline to gather video CO2 over its lifetime. And can require up to suitably small in file size (150-200 kbits/s) footage. An operator, or a team of operators, 60 people working in risky conditions, with that it can be live-streamed back to any then observe images manually, identifying each vessel costing £1-10m a month to run. device in the world via a low bandwidth data issues and potential risks that will need link, through a ship’s VSAT system. This action, such as free span, corrosion, debris, Vaarst is looking at how to do things gives onshore staff access to survey and and large rocks. One example data set that differently. They started their investigations with educational establishments across the US and Europe, into new methods of data collection in aerial drone technologies. This led them to explore the ExoMars Rover and the methods employed to evaluate landscapes. There was a clear parallel between the challenge of transferring data from Mars back to Earth, and the problem of sending data from deep underwater back to shore. Most evidently with sending video back over this distance. This took Vaarst down the route of SLAM and using 3D data reconstruction as a compression tool. SubSLAM X2, an AI-driven intelligent data collection system Vaarst’s SLAM product, SubSLAM X2, is a data-driven computer vision system that delivers live underwater 3D point cloud reconstructions. The model builds in real-time as the vehicle is navigating around the asset. And because the team are still on WWW.PESWIND.COM 43

TALKING POINT Vaarst has worked with previously was on a remote operations centre to operate the solution. SubSLAM sits at the edge and approximately 120 hours long. robots. So, they are building cloud robotics gathers the data, machine learning analyses with true autonomy abilities, where the on the fly, then the analysis is transferred in Using the ML solution it only takes 7hrs to purpose of the operations centre is only to real-time back to the shore, with the data examine the footage, enabling a significant oversee and supervise, with the vehicles being stored on the platform for collaborative reduction in human effort. This system has driving themselves through their own analysis and future comparison. now just completed trials with an oil data-driven intelligence. supermajor, with plans for rollout. Once this is all bonded together, that’s a true They are enabling robotic vehicles to answer cloud robotics solution. While currently the ML solution is primarily key questions: Where am I now? What’s focused on analysis in post-processing, their around me? And where shall I go next? So Getting access to the technology machine learning capabilities are now being that the system can understand its own combined into SubSLAM at the edge, so it environment, predict the next step, and The SubSLAM X2 is available today for can work at the same time as the data operate without assistance. integration with any suitable ROV, and the gathering is taking place. These technologies system has already been interfaced with have not been merged before and create a Vaarst is also enabling live machine learning at several widely used vehicles. Pricing starts at unique and ground-breaking solution for the the edge, to deliver fast, live-feature £36K per annum over a fixed 3-year term or is offshore energy sector. The outcome being, detection and analysis, all while navigating available on day rates for short-term projects. that there will be no requirement to transfer autonomously at close range around complex visual data back to shore, instead only the underwater structures. The next step is then For more information go to: www.vaarst.com answers will need to be sent. to take things yet further, enabling multiple robots to work together collaboratively. A future vision, that differentiates Vaarst Combine all that with an autonomous vessel, from others and it enables a significant scale-up of operations through connected robotics. The overall challenge that Vaarst is tackling, is how to remove large vessels from our A true cloud robotics company waters. But at the same time, they want to ensure that the replacement solution is The individual technology components, when efficient and intelligent, and not dependent combined, deliver a powerful cloud robotics 44 PES WIND

Wind Power IMAGINING THE WIND Ingeteam is the world’s #1 independent supplier of wind power converters. We offer proven and reliable electrical equipment up to 15 MW for onshore and offshore applications. We give active support for each specific project throughout the entire product life cycle. We can supply equipment from any of our production facilities in Europe, Asia, North and South America, applying the same standards and know-how. Our R&D Policy is focused on reliability and cost effectiveness from a global point of view, optimizing the whole solution in terms of Levelized Cost of Energy. We are flexible in designs and R&D solutions, operations, different business models or additional value-added services.

TALKING POINT New sizing of wind turbine generators (WTGs) requires a new perspective of wind towers The wind market is continuously evolving to bigger and more powerful WTGs, both onshore and offshore, each one has its limitations, but they need to include new solutions and continue to reduce the associated LCoE. Until now, the onshore market has represented approximately 70% of the total MW installed (GWEC), but offshore is growing. Onshore WTGs are evolving from 2-3 MW to due to the massive size of components, this is Embedded foundation simulation 5-6MW platforms, but will be close to 8MW the reason for the difference from the and more in the years to come. onshore market. The offshore market is divided into fixed and floating, where the O&M Each wind farm placement will determine the of WTGs will be decisive for the final LCoE. best configuration of the WTGs and the associated tower with the existing The increasing component size of both technology. However, the logistical markets means there is a need to explore new requirements of the whole process will solutions. These need to be more determine the feasibility of the final options. competitive, keeping in mind an affordable production, reducing the associated carbon Low wind sites require higher towers, forest footprint of renewables. The only way to reach and plains, on the other hand, higher towers new limits is to use modular components. bring a homogeneous flow that is better for the WTG component lifecycle and reduces WunderOcean is focused on developing O&M costs. Anyway, extra height supposes renewables software to optimize the location extra yearly MWh production. of the offshore wind farms (LOOP Wind), offshore commercial projects and working High wind sites usually are on top of mountains on Self-erecting Towers (SeT), in with no easy access, where WTGs <2MW were collaboration with The University of installed. Gusty wind reduces the lifetime of Coimbra. A Portuguese grant towards the the WTG components. Now a lot of the first IDT program, which is a patented system that wind farms are waiting to be repowered, but uses standardized modular components to due to logistical restrictions, the new WTGs fulfil the new requirements of WTGs. cannot be placed on these sites. SeT reduces the whole impact of the wind Offshore WTGs are growing from 8MW to farms before manufacturing to dismantling, 12-15MW and the next developments are both onshore and offshore, thanks to the focused on 20MW modularity Offshore wind market providers are usually SeT is composed of unique geometry, close to ports to avoid logistical limitations scalable to any size that uses standard 46 PES WIND

TALKING POINT Adapting shell foundation Schematic standard crane over adapted platform approximation Blue: foundation transition NB: frame does not include shell cover to allow for helical rail market components to generate a structure done for a 3.4MW by 160m high hub rotor. dismantling. These placements of medium- built in a self-lifting system. Shell production SeT could exceed a 200m high hub with a low wind were previously discarded because can be highly industrialized thanks to small geometrical adaptation. until now this type of towers had a huge standard raw materials, no flanges, no huge Ultra-high towers are focused on the financial impact due to costs not being plates, an increasing number of providers and onshore market, so no cranes dependency proportional for +130m towers. H&S conditions. Indirectly it reduces will reduce costs during the O&M and incidences, logistics, infrastructure and Fixed platform to start self-hoisting process energy consumption during manufacturing Self-positioning crane to rail. White: shell sizing enabling the global scope of providers and WWW.PESWIND.COM 47 emerging countries. Shell geometry does not require special storage or transport, thus avoiding logistical limitations, increasing the placements and reducing the wind farm access requirements, environmental impact and the associated carbon footprint. During assembly, the shells generate an internal helical rail to hold the crane platform and lifting components. The platform rises from the helical rail without any extra load until the safety position is blocked. Then each shell is hoisted without needing to use huge cranes and there is no height restriction for the tower. Mechanical joints are used to raise the instant rigidity of sloped shells on each ring, avoiding flanges or grout. On top of the tower, the standard crane over the platform is used to couple the rest of the components of the nacelle housing. This includes lifting components to hoist into modular nacelle components. The cylindrical tower generates extra space in the nacelle, allowing the optimal placement of components in the modular chassis. Nacelle housing will allow self-maintenance, crucial for the offshore market and dismantling operations. SeT has several adaptations for each WTG manufacturer, from wind turbine carrier to modular chassis, enabling internal or external hoisting of WTG components. A preliminary design has been

TALKING POINT ‘Possibly this is the way to attain true ‘net zero emissions’ and offer to emerging countries the opportunity to obtain renewables.’ Now a single tower wind farm project is to be the key element to the reduction of the Fixed offshore can use specific large jack-up viable, no minimum number of WTGs, associated carbon footprint in the wind vessels, but floating will need massive keeping proportional costs and offering the market and reaching emerging countries, platforms to make huge corrections on opportunity of creating wind energy where logistics and infrastructures are not WTGs. SeT also plans gravity, like a modified communities to expand renewables, the best and improving the local manpower ultra-high onshore tower and floating not only PV. and supply chain. foundation version for the offshore market. Once again, modular components are going WTGs are divided into horizontal (HAWTG) and vertical (VAWTG) axis geometry, so SeT The offshore market is managed by big No height limitation geometry can contain both technologies, because of players due to massive structures involved the high capability of adapting the diameter and associated logistical requirements, and top tower geometry. It can be adapted to once again modularity will generate a hold disruptive configurations such as diversification of providers and a reduction generators, even coupled tested geometries of the logistics’ needs. instead of up-scaling generators, which would increase materials and manufacturing Currently, WunderOcean is collaborating to technologies: bigger components, so bigger develop a ‘Blind Bolting System’ (BBS) for manufacturing facilities are required. high strength connections, with only one The offshore market side access. A patent to get modular The offshore market does not need the same structures that help to avoid critical welds, extra height as onshore due to the higher using mechanical joints that are easy to density of air, but WTG requirements will be industrialize and check, which decrease risks bigger than onshore, which means a bigger and logistical requirements. diameter for towers. At this point, a nacelle housing that provides The ‘BBS’ applications could be the floating O&M independence will be decisive, offshore platforms or jackets: outside especially for floating wind farms, to avoid surface, or bolted towers: inside surface. risky and expensive procedures after However, it also can be used for industrial and commissioning, using only standard vessels. civil construction. It will help to accelerate the offshore floating wind, avoiding huge Top tower leveling shipyards requirements to manufacture them a slow and expensive welding process and allowing new, or restructured industrial ports to offshore wind terminals, for the assembly of these massive platform structures. Renewables is still an emerging sector representing huge opportunities for the R&D companies to cover the gaps left by the big players, especially analyzing disruptive concepts, hybrid and wasted materials. So the wind market must continue evolving to be more competitive, but also diversify the use of providers, such as smaller companies through modular components to decentralize the industrial production and contributing to reaching the UN 17 Sustainable Development Goals, because most of them are linked. In parallel, renewables must follow a green philosophy and should focus on the whole carbon footprint reduction, not only to install new renewables resources. This way the impact before installations has also a huge value and the industry must adapt to it. Possibly this is the way to attain true ‘net zero emissions’ and offer to emerging countries the opportunity to obtain renewables. www.wunderocean.com 48 PES WIND

MHO-Co hybrid CTVs Safe, reliable and green crew transfer MHO-Co introduces two innovative hybrid vessels for MHO-Co reliable, safe, and environmentally friendly crew transfer. We offer a fleet of CTVs with high safety, reliability in strong weather, and large cargo capacity. Specifically designed to service the offshore wind industry. Our two 35-meter hybrid catamarans have electric motors which saves weight, space, and fuel. And makes it possible to eliminate emission when idling. All vessels are operated Office in Esbjerg Follow us on: Morsøgade 4, · DK-6700 Esbjerg according to our ISM Call us today! Facebook.com/MHOvessels [email protected] · www.mho-co.dk ISO 9001 Tel: +45 53 70 46 45 LinkedIn.com/company/mho-co-a-s ISO 14001

TALKING POINT Wild weather and wind turbines 50 PES WIND