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Advancements in Bolt Tensioning Technology for Wind Turbines ​

Published in: Wind, Digital Blog

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As wind turbines continue to grow in size, the challenges associated with bolt tensioning become increasingly complex. Ensuring precise, reliable, and safe bolt tensioning is crucial for the effective operation and longevity of these massive structures. Richard Outram, Sales & Business Development Manager at TensionPro, shares insights on how his company is tackling these challenges with innovative solutions designed to meet the evolving demands of the wind energy industry.

The Challenges of Bolt Tensioning in Larger Wind Turbines

Larger wind turbines require bolts with larger diameters and higher load capacities, adding complexity to both initial installation and ongoing maintenance. Traditional tools and methods may need additional technology or processes to meet the demands of these supersized structures. Improper bolt tensioning can lead to serious problems, including structural damage, operational disruptions, and catastrophic failures. Ensuring the correct bolt load is essential to maintaining the structural integrity and safety of wind turbines.

Evolution of Bolt Tensioning Methods

Bolt tensioning has been used extensively for over 40 years across the energy sector. However, the approach has evolved significantly, with a shift from torque tightening tools to more advanced bolt tensioners. This evolution is driven by real-world experiences and an awareness of the importance of ensuring more accurate and repeatable bolt loads. Advanced bolt tensioners offer several advantages over torque tools, including a linear relationship between applied pressure and bolt load, negating the need to account for frictional forces.

Overcoming Limitations with New Technologies

Conventional hydraulic tensioners rely on pressure measurement to determine bolt load, which can be limiting due to potential inaccuracies. New technologies incorporate additional measurement methods, such as bolt elongation, to provide more accurate and repeatable tension values. TensionPro's latest innovation, Quantum, is a semi-automated tensioning system designed to improve asset and operator safety. It features a digitally controlled pump unit connected to an electro-hydraulic tensioning tool, providing visual confirmation of target pressure and recording crucial bolt tightening data.

Enhancing Operational Efficiency and Safety

Advancements in bolt tensioning technology include digital or hands-free controls, real-time data recording, and fully automated functions. These innovations streamline the tensioning process, reduce manual adjustments, and minimize human error. The Quantum system focuses on traceability, allowing operators to track and review tensioning data specific to projects or individual bolted joints. Preprogrammable system settings, automatic shutoff, and real-time user feedback enhance safety and reliability.

Versatility and Applications

The Quantum system is highly versatile and can be adapted for a wide range of applications, accommodating different bolt sizes and flange geometries. It is suitable for both large and small-scale applications, including monopile to transition piece connections and tower bolts. The advanced features provide greater process control and long-term assurances that challenging technical requirements can be met for both onshore and offshore wind energy projects.

Customer Feedback and Demonstrations

TensionPro anticipates positive feedback from customers seeking more precise, efficient, and reliable bolt tensioning solutions. The new technologies offer several advantages over traditional methods, including improved automation, real-time data collection, and enhanced safety features. Potential customers can learn more about these advanced bolt tensioning systems by contacting TensionPro at sales@tensionpro.co.uk or visiting their website at www.tensionpro.co.uk. Onsite demonstrations and facility visits are also available to showcase the technology.

Conclusion

The advancements in bolt tensioning technology are crucial for the growing wind energy industry. By addressing the challenges posed by larger turbines and improving accuracy, efficiency, and safety, these innovations contribute to the effective operation and longevity of wind turbines. TensionPro's commitment to innovation and customer feedback ensures that their solutions meet the evolving needs of the wind energy sector.

Read the full article here: https://pes.eu.com/exclusive-article/advancing-bolt-tensioning-for-larger-turbines/

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