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Delegates are invited to meet and discuss with the poster presenters in this topic directly after the session 'On- and off-shore installation technologies' taking place on Wednesday, 12 March 2014 at 11:15-12:45. The meet-the-authors will take place in the poster area.

Jann Rene Hansen Demag Cranes & Components GmbH, Germany
Co-authors:
Jann Rene Hansen (1) F P Thomas Bönker (1)
(1) Demag Cranes & Components GmbH, Wetter, Germany

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Presenter's biography

Biographies are supplied directly by presenters at EWEA 2014 and are published here unedited

Mr Jann René Hansen is Senior Manager at Demag Cranes & Components GmbH (DE), a part of the Terex Corporation (US). He is responsible for the global wind business development within Demag and has been working within the wind industry since 2010. He is a Danish native and holds an MBA from Henley Business School.
His main focus is creating logistic solutions for production facilities with overhead cranes and nacelle service cranes. The solutions are developed in cooperation with the global wind turbine manufacturers and the global Demag organisations.

Abstract

THE NEXT GENERATION OF FLEXIBLE CRANE SYSTEMS IN WIND TURBINE NACELLES {F1}

Introduction

The Next generation of flexible crane systems in wind turbine nacelles,
Service crane systems for economical material handling in wind turbines

As turbines has developed in size and gotten bigger and bigger, the need for a flexible solution for
handling and transport of spare parts and materials inside the nacelle is growing, in order to save cost
during maintenance of for example offshore wind turbines.


Approach

As turbines has developed in size and gotten bigger and bigger, the need for a flexible solution for
handling and transport of spare parts and materials inside the nacelle is growing, in order to save cost
during maintenance of for example offshore wind turbines.

The industry is constantly trying to find ways to lower the cost of energy. Important is of course the
manufacturing and the installation costs, but the third also very important factor is the cost of
operation
and maintenance. Especially on offshore wind turbines where man hours are very expensive, due to
transport cost, weather issues etc. it is crucial for the industry to find ways to lower the cost of
maintenance by for example minimising the time a technician is situated on the turbine for
maintenance. If the time of maintenance could be reduced and made more efficient, the industry will
save cost of maintenance and the cost of energy would be reduced.

There are two major issues when thinking about transport of spare parts and materials inside a wind
turbine nacelle during maintenance. The first is the practical issue of moving a part of for example
500 kilos, which due to the second issue, health and safety reasons, cannot be carried by the
maintenance personnel. So, how can you move a part from the front end of the nacelle to the back
end inside the narrow aisles of the nacelle?

Demag has in an innovative way developed a new solution for the wind industry, which based on
reliable technology, will offer the industry savings in operation and maintenance.


Main body of abstract

Previously a simple chain hoist fixed mounted or on a small jib crane in the back-end of the nacelle
was enough for service purposes. However, when a nacelle now could be over 20 meters long, the
need to flexible being able to transport spare parts from the front to the back-end of the turbine is
becoming important and a crucial factor in order to have an easy maintenance of the turbine.

Another problem with use of chain hoists for this purpose, is the waiting time for lifting and lowering
of the spare parts, which when the turbine towers (up to over 180 meters) get quite long. Waiting time
is crucial for the personnel on site, as every minute is cost.

Demag has together with major wind turbine manufacturers developed a flexible solution to this issue
based on reliable and well known techniques within wire rope hoists. A new rope winch with a lifting
speed of up to 50 meters per minutes reduces the waiting time with more than 50% compared to
typical chain hoists.

As turbines more and more often are installed offshore, the need for a crane system with no hydraulics
is important to keep maintenance cost as low as possible.

In combination with the rope winch for reduction of waiting time, Demag offers the well-known KBK
Modular Crane System now also for the wind industry. KBK suspension monorails give the certainty of
solutions tailored to meet the specific requirements for linear overhead handling inside of nacelles.

With the combination of proven technology from the industrial cranes industry, it is now possible to
radically reduce the maintenance time of for example offshore wind turbines.

Case story:
A leading offshore wind turbine manufacturer designed a new turbine type and had the need to
transfer spare parts inside the nacelle. The client wanted a flexible system for up to 1000 kg which
could handle parts and materials inside the nacelle and also hoist and lower parts to the transition
platform. As the turbine is produced for offshore purposes, therefore the cranes must be able to
handle the harsh environmental conditions at sea.

The client was thinking about fixed installation of chain hoist, jib crane solutions and hydraulic crane
solution to reach all areas inside of the nacelle.

The solution chosen was a combination of two KBK monorail systems, KBK I straight and curved
sections tailored exactly to the areas of importance for the client for handling up to 500 kg, and a
KBK II straight section for handling inside the nacelle and for hoisting and lowering to the transition
platform with up to 1000 kg.

The solution was equipped with the new Demag Rope Winch DS-10 Wind for fast hoisting and
lowering of parts to the transition platform. The new DS-10 Wind provides safe and fast hoisting with
speeds of up to 50m/min. The 500 kg monorail system for internal handling inside the nacelle will be
equipped with hand-driven chain hoists.

The monorail system was surface treated (hot dip galvanized) in order to withstand the harsh
environment at sea.


Conclusion

The many advantages for the wind turbine manufacturer and the maintenance staff are amongst
others:

•Fast lifting and lowering of spare parts and materials:
- Save 50% maintenance time compared with use of traditional chain hoist based crane systems

•Highly flexible installation:
- Can be tailored exactly to the layout of the turbine with straight and curved sections, track switches
and turntables.
- A wide range of components and suspensions available.
- Can be equipped with a range of hoists, electrical or manual for use inside of nacelle and for
hoisting and lowering of parts to the ground or transition platform.

•Easy to use:
- Smooth running trolleys provide less force needed to move loads for the user.
- Easy transfer of parts between sections.

•Reliable system:
- Surface treated also for offshore installation.
- Special suspension brackets provide no transfer of vibration torques from the wind turbine to the
crane system.
- Low maintenance system.

•Safe solution:
- Adjustable automatic low speed lifting close to nacelle and ground platform
- Limit switches for safe stop
- Low voltage control with ergonomic pendant

This new solution will offer the industry time savings during operation and maintenance of for example
offshore wind turbines. The high reliability of the solution will provide the service technicians with a
safe system during operation. As the solution is created for the harsh environment of offshore
purposes, the system is guaranteed to provide safe and reliable use in the lifetime of the wind turbine
with cost saving as result for the owner.



Learning objectives
Demag has in an innovative way developed a new solution for the wind industry, which based on
reliable technology, will offer the industry savings in operation and maintenance.