The need for increasing windfarm output, whilst reducing operational costs, particularly as the UK faces spiralling gas prices, has placed significant added pressure on the renewable energy sector, which already faces major financial and logistical challenges. In the context of tower construction and turbine maintenance, Atlas Copco Tools and Industrial Assembly Solutions is focused on helping its business partners to manage these challenges, as well as delivering competitive advantages in efficiency, reducing risk, time on task and ultimately, costs
INTEGRATED BOLTING SOLUTIONS
From a supply chain perspective, Atlas Copco is experiencing rising demand for its smart integrated bolting solutions, as newer, bigger turbines come on stream. The requirement, therefore, is the capability to tighten larger bolts in more extreme environments, as well ensuring improved operational efficiency and faster installation. On a mission to apply its evolved Smart Integrated Assembly approach in the field, the company has pioneered a number of transducerised tools and data driven systems which, thanks to in-built cloud connectivity, has made it possible for a fully traceable process to be effective at remote installations.
PRODUCTS AND FEATURES
The SRB HA Smart and Connected battery-powered nutrunners feature an internal WIFI server, allowing the tools to be linked to any mobile device. This enables torque, angle and batch data collection without the need for additional software. For the ultimate in functionality and process control, the SRB HA features an accessory bus for a barcode scanner and can also be integrated into overlying systems for live data feed and analysis. Powered by Lithium-Ion 36V battery technology, the SRB HA will see an increase in torque capability from a maximum of 4,000Nm up to 7,000Nm in the near future.
The Tensor Revo HA was designed specifically for use in the construction and maintenance of turbines, requiring high access. Delivering tightening performance of up to 8000Nm with future plans for an increase up to 16000Nm, its DC electric motor is the fastest on the market by up to 6 times and also features an integrated torque transducer, which measures real torque applied to the joint. To ensure error-proofing, the Tensor Revo HA has a signal light incorporated in the motor housing, indicating green for ‘tightening OK’ and red for ‘fail’. Its high torque, slim gearbox with 360° gear swivel enables access to the trickiest located bolts.
SAFER, QUICKER, SMARTER
Working on increasingly larger turbines is extremely hazardous, so Atlas Copco’s ergonomically designed safety triggers mean there’s no risk of finger pinch points, whilst low noise and vibration levels means operators can work more safely and comfortably both outside and inside the turbine Quicker – Atlas Copco’s tools provide superior speeds to shorten cycle times, resulting in faster tower builds and reduced project time. Years of research and development have resulted in proven motor performance, which overcomes the issue of overheating whilst operating in challenging environments. In addition, Atlas Copco tools can be used for final torquing of bolts, whereas other tools are just used as run up tools, meaning that final torque has to be completed with other tool types, which makes the process longer and more complex. Smarter – not only does the torque transducer measure the real torque but angle measurement ensures each bolt is tightened correctly by detecting damaged threads or variation in lubrication. All bolt tightening data can be downloaded and linked to bar codes or identifiers. Even graphical traces of the actual tightening can be stored for later analysis Recognising the difficulties and limitations of working in remote and often climatically hostile environments, Atlas Copco continues to develop its product portfolio in line with customer requirements. Its latest addition is the PFXC (Power Focus Cross-Country) power pack, which delivers an industry-leading power capacity in the field. Featuring rugged waterproof construction and robust metal framing that’s built to withstand the harshest conditions, the unit can be easily transported to site.
COMMON USER INTERFACE
In order to have a truly connected and efficient system it is critical that all bolting technologies (hydraulic torque, bolt tensioning, continuous rotation) have one common user interface, both for operational process control and data analysis. Users can instantly connect tools to the power pack with any WiFi device via the QR Code and programme in presets, such as target torque, method and speed. Combined with smart technologies, the PFXC provides the functionality for instant tightening data, so that field operatives know that the process is being completed correctly first time out, saving time, money and vastly increasing safety.
RIGHT FIRST TIME
Our latest tooling and controllers enable Atlas Copco to take its Smart Integrated Assembly principles directly into the field. This delivers a clear return on investment and full traceability, by blending advanced tooling with data-driven services, backed up by total customer support.”
Within the energy segment, Atlas Copco continues to raise the bar higher. When it comes to brand reputation, operators need to get it right first time and the demand for error-proofing is high from both a safety and cost perspective.
