The environmental impact of energy production is under scrutiny as never before. Maximising the efficiency of fossil fuel power generation while deploying new forms of energy production such as offshore wind is where Enerpac bolting tools and lifting systems are playing an important role.
Power Plant Turbines
As a world leading supplier of hydraulic tools for controlled bolting and lifting, Enerpac can provide power generation engineers with tools that they need to work safely and productively.
Whether it is turbine installation or maintenance of the turbine itself, the Enerpac range of hydraulic and pneumatic torque wrenches provide the exact torque output or torque load necessary to loosen or tighten the threads of a nut and bolt. For example, in low-profile applications, where clearance around the nut is restricted, the Enerpac RSL Series and the aluminium-bodied HMT Series are a good choice. Where a flange joint is misaligned, the Enerpac flange alignment tools can be used to resolve bolt-hole rotational or lateral misalignment that can occur within flange joints. For other flange issues, Enerpac offers flange spreading and pulling tools along with a series of hand pumps. The wedge-shaped flange spreading tools use mechanical and hydraulic actuation for separating flanges and can spread small, medium or large flange joints with a minimum required access gap of 4 mm.
Enerpac cylinders, too, are an invaluable tool in turbine installation and maintenance. These range from 4.9 tonnes to high tonnage cylinders with capacities up to 1,000 tonnes. For additional operational deployment to handle large objects, the cylinders can be connected to an Enerpac EVO system to allow synchronised lifting using all the cylinders. In this way, loads of over 10,000 tonnes can be easily lifted synchronously.
Offshore Wind Turbines
Monopile TP Levelling and Fixation Systems
Enerpac hydraulic levelling and fixation systems for offshore wind turbines allow accurate levelling and fixation of transition pieces (TPs) on the monopile foundation. Grouted connections are widely used in offshore wind turbine construction to transfer multiple loads from the TP fitted on top of the monopile foundation.
The transition piece is first lowered onto the monopile and levelled. It is then grouted into position to fix the transition piece to the monopile. Levelling is important to ensure that the turbine will generate maximum yield. Both sets of cylinders are optimised in terms of capacity and stroke needed for TP levelling and fixation. In addition, the subsea fixation cylinders feature a reinforced return spring that eliminates the risk of point load and contact corrosion with the monopile.
Precision Lifting – SyncHoist
The Enerpac lifting technologies for wind turbine construction have focused on ease of manipulation and positioning of turbine components using its SyncHoist system. Deployed below-the-hook, the SyncHoist is a self-contained PLC-controlled hydraulic lifting cylinder.
Typically, four SyncHoist systems are used either directly or under an auxiliary frame, enabling accurate hoisting where space is limited.
Geometric positioning of heavy loads in a horizontal and vertical plane is frequently carried out using more than one crane. However, synchronising movements between multiple cranes can be difficult. The SyncHoist system is an easier to use, safer and more cost-effective alternative for below-the-hook lifting and positioning heavy loads.
In offshore wind projects, SyncHoist lifting cylinders have been used for assembly of onshore turbines and offshore transition piece installation. A lifting frame comprising SyncHoists has been used for the installation of gravity base foundations. With four SyncHoist hydraulic cylinders at each corner, and a diesel hydraulic powerpack with battery back-up, it enabled the foundation lift and lowering, without distorting the transition piece flange used to connect the turbine tower.
Fusion Power Research
India is a partner in the global research on developing fusion as an energy source. Here too, Enerpac has a role. In the ITER project, the world’s largest fusion experiment, Enerpac hydraulic cylinders are set to play a key role in the final construction of the ITER fusion tokamak in 2024. On the completion of assembly of the tokamak’s vacuum vessel sectors, nine cylinders, now pre-installed at the bottom of the machine, will lift a 11 metre diameter, 320 tonne, circular poloidal magnet into position at the base of the tokamak. The hydraulic cylinders are connected to an EVO Synchronous Lifting Pump, enabling each of the nine lifting points to be monitored and controlled by a single operator.
Meanwhile, an Enerpac SyncHoist lifting system is being used to assist in the assembly of the ITER Vacuum Vessel. The SyncHoist’s millimetre lifting accuracy is needed to lift 550 tonne vacuum vessel sectors into an Up-Ending tool for vessel assembly by the ITER Sector Sub-Assembly Tool.
As has been shown, there is no limit to the ways in which Enerpac tools and lifting systems can be used in power generation. No matter the application, Enerpac has the tools needed to work safely and productively.
Enerpac India, Marketing & Communications Manager
Tel: +91 803 928 9000