Case Study: HYTORC Provides Custom Solutions For Breakthrough U.S. Wind Farm
A breakthrough wind farm in the northeastern United States needed a reliable company to supply bolting tools for the construction of over 50 offshore 13-megawatt turbines, each towering an impressive 814 feet (248 meters). The project’s European turbine manufacturer, familiar with HYTORC's Washer System and its role in ensuring secure bolted connections, recommended our precision solutions for optimal assembly, establishing it as the trusted choice for efficiency and security.
Customer Challenges
Ensuring all bolts on wind turbine components were torqued accurately was crucial. Even minor discrepancies in torque values could have compromised structural integrity, leading to unexpected downtime, revenue loss, and increased maintenance costs. In the worst-case scenario, improperly torqued bolts posed safety risks to personnel and created environmental hazards, especially in offshore locations where conditions were more challenging. Accurate bolting was essential for operational efficiency, safeguarding the investment, and protecting the surrounding environment.
How HYTORC Helped
Custom Solutions
HYTORC’s customized approach demonstrated its commitment to finding tailored solutions for unique project requirements. HYTORC PEG engineers designed a custom washer system specifically for a temporary bolt-down procedure. This innovative solution facilitated the secure storage of wind blades onshore and the safe transportation of components via barge for offshore construction.
The Right Equipment
HYTORC New England ensured the customer had all the tools needed, providing a complete setup to meet all operational requirements. Numerous LST electric torque tools and single speed pneumatic jGuns were used, including for the wind tower installation process, showcasing the versatility and adaptability of HYTORC equipment.
On-Site Support
Recognizing the dynamic nature of offshore wind farm construction, HYTORC provided comprehensive on-site support from the beginning. A dedicated HYTORC service van was stationed there to ensure prompt tool calibration and address any service needs that arose. This proactive on-site support minimized downtime and contributed to the overall efficiency of the project.
Customized Training
HYTORC developed and taught custom training programs for onsite crews and for an associated local ironworkers union. Courses included Bolted Joint Integrity Train the Trainer, as well as tool-specific training.
Conclusion
HYTORC was pivotal in ensuring the structural integrity and reliability of the project’s turbines. The collaboration between HYTORC and the European turbine manufacturer, coupled with customized solutions and on-site support in the US, underscored the importance of precision bolting in the renewable energy sector. HYTORC not only met but exceeded client expectations, contributing significantly to the success of the largest offshore wind farm in the United States and setting a benchmark for future projects in the renewable energy landscape.
