After more than 25 years in the industry TCS and Boltstress Ultrasonics created a new force in bolting technology in January 2014.
The combined expertise, technology and service provide an un-paralleled offering to many industries but in particular to the wind energy sector.
The Benefits we will provide
- Total Bolted Joint Reliability
- Faster Assembly – typically 75% time saving
- Lower Cost Maintenance
- Non-intrusive maintenance
- Extended Slew Bearing Life
The Wind Turbine Industry has many bolted joint applications and most are critical to safe and reliable operation, these include: -
- Blade bolts
- Generator to nose (??) coupling bolts
- Slew Ring Bearing Bolts
- Tower Section Flange Bolts
- Foundation Bolts
Technology
- Ultrasonic Verified Bolt Integrity
- Australian Manufactured Bolts - Australian Steel
- Fast Assembly Torque Tooling
- Faster Assembly Process
- On-going Bolt Relaxation Testing
- On-going Bolt Crack Detection
- Upgradeable to on line
Benefits we provide
Total Bolted Joint Reliability
Ultrasonic Bolt Tension Measurement provides real information; it is not subject to the variations that occur when using either torque wrenches
or bolt tensioners.
The process we employ ensures that the start up occurs with ALL bolts
have precisely the tension required; furthermore the future testing is
both quick and non-intrusive.
Faster Assembly – typically 75% time saving
We provide special tooling that is custom designed to suit wind turbine
applications. Special reaction arms, reduced headroom, power and torque
requirements are all considered before selecting the optimum tooling for
the job.
Lower Cost Maintenance
During operation most existing procedures call for cumbersome, heavy
tooling to be carried to each turbine and then manipulated inside the
tower. The instruments we use are only 1kg in weight and can be easily
carried around the turbine structure. Measurements take only 15 seconds
per bolt.
Non-intrusive maintenance
The current methods are not only cumbersome but also require some application of torque or tension. This can disturb the joint
Extended Slew Bearing Life
High accuracy bolt tensions have proven to extend the life of slew
bearings. The best example of this is Offshore Cranes in the North Sea
Oil Rigs. Following extensive testing Lloyds of London have allowed
operators to extend the statutory strip down inspections from every 6
years to every 11.
Technology
Ultrasonic Verified Bolt Integrity
The use of ultrasonic bolt stress measurement began with NASA during Apollo space Missions. Scientists discovered that the change in time of flight due to stress is a very accurate method of ensuring correct bolt
tension.
We have been developing and using this technology since 1991, we have un-equaled experience and expertise in this field.
The 5 main advantages are:
- All bolts have known exact bolt pre-load at commissioning
- Re-measurements are quick and very accurate
- The equipment is lightweight and easy to carry inside a tower
- All results are stored in Excel and can be view to identify trends
- Any cracks are found prior to any fracture occurring
Australian Manufactured Bolts - Australian Steel
We have relationships with Australian Bolt Manufacturers that allow us
to ensure that the highest quality is maintained In some cases we store
base line ultrasonic readings at the factory. The stored ultrasonic
waveform can be compared to future readings, giving an alert to changes
prior to failure.
Fast Assembly Torque Tooling
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Faster Assembly Process
We combine the optimum engineered tooling that is both the fastest and
lightest that can generate adequate torque, with process improvements.
These improvements utilize “real readings” to determine what is the most
practical and time-saving tightening patterns and passes. In most cases
we can remove several stages whilst still maintaining a much higher
integrity.
On-going Bolt Relaxation Testing & Reporting
Existing procedures require that heavy cumbersome torque wrenches and
pumps are painfully manipulated up and down towers and then are applied
to each bolt and tested to see if they “move” at the original torque.
This is extremely labour intensive and very inaccurate.
Our technology stores every single reading ever taken. These can be
compared to the original status and recorded into memory. Our reporting
then uses electronic data and graphing software to depict any changes to
the bolt tension.
On-going Bolt Crack Detection
Our ability to drill down to each individual reading not only allows us
to see relaxation but also by comparing original waveform patterns with
current ones we get an early warning of defects. This allows us to make
timely, low impact changes that avoid catastrophic failures.
Upgradeable to on line
All of the ultrasonic technology can be up-graded to an on-line system that would allow remote condition monitoring.
