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ALE’s bespoke onshore wind tower heightening pushes engineering boundaries

Sector:

Renewables – onshore wind

 

Key benefits:

  • Innovation
  • Bespoke solution
  • Time savings
  • Reduced costs

 

 

 

Project:

ALE has achieved another world first and provided a bespoke engineering solution to heighten the prototype of one the world’s highest wind towers, the Nabralift self-erecting tower, with limited use of cranes for significant time and cost savings in Navarra, Spain.

ALE was tasked with transporting and heightening the self-erecting wind tower, weighing 450t, so Nabrawind Technologies could develop future onshore wind farms without the need to perform solely crane operations and the associated costs and time involved in additional equipment, civil and logistical works. They also wanted a solution that was as time-effective as possible, so operations could continue even at high wind speeds.

Measuring 160m high, this tower is the third tallest in the world. ALE utilised 12 axle lines of SPMT to transport the tower to the assembly area. The crane installed the first 62m and once enough height clearance was reached steel lattice sections were introduced underneath. This was repeated for each of the seven sections, until reaching 160m.

The bottom shape of this first structure was modified into a three-pointed star from where three low-height gantries, one at each corner, were used to jack-up the whole structure.

This self-erecting tower system breaks all logistical barriers to install towers at any hub height.

This methodology made it feasible to continue raising the tower sections even if weather conditions became hostile (prototype developed with winds up to 16m/s) as the lateral guidelines along the gantry frames constrains the lateral movements and keeps the tower vertical.

“It is fantastic to have been given the opportunity to work on this unique project and showcase our capabilities within the onshore wind market. Recognising our track record in Spain, the client was confident we could supply the complex solution necessary,” explained Project Engineer David Arias Blanco.

“By providing this customised solution, our client can now have the means of developing onshore wind farms in the most cost and time effective method ever thought possible. This is game-changing technology, specifically for those located on difficult-to-reach islands or mountainous sites. From our findings, we are already developing engineering processes to fulfil the requirements of future large-scale installations with an aim to develop two towers a week.”

ALE has worked alongside the client to develop the methodology used for this prototype for the future production of these wind towers from 2019.

 

Las Soluciones a medida de ALE en torre eólica onshore impulsa los limites de la  ingeniería

Sector:

Energías renovables – eólica terrestre

 

Beneficios clave:

  • Innovación
  • Soluciones personalizadas
  • Ahorro de tiempo
  • Costos reducidos

 

 

 

Proyecto:

ALE ha logrado otra primicia mundial y ha brindado una solución de ingeniería a medida para realzar el prototipo de una de las torres eólicas terrestres más altas del mundo, la torre autorizable de Nabralift en Navarra, España.

ALE realizó el transporte y recrecido del prototipo de torre eólica, con un peso de 450 t, para que Nabrawind Technologies pueda desarrollar futuros parques eólicos terrestres, con una solución lo más efectiva posible en el tiempo y costo operativo.

El sistema autoizable de Nabralift rompe todas las barreras logísticas para instalar torres a cualquier altura de buje. Es una tecnología innovadora especialmente para lugares de difícil acceso como islas o lugares montañosos que pueden tornarse en practicables.

Las tres primeras secciones de torre tubular fueron transportadas a la zona de ensamblaje mediante 12 líneas de ejes SPMT, donde esperaba una grúa para instalar estos primeros 62 m de los 160 m del total.

La forma bajo esta estructura tubular fue modificada por una celosía metálica en estrella de tres puntas desde donde se utilizaron 3 pórticos de baja altura (menos de 20 m), uno en cada esquina, para levantar toda la estructura.

Cuando se alcanza la altura requerida para cada fase, se introducen las secciones de celosía repitiéndose para cada una de las 7 secciones hasta alcanzar los 160 m. La estructura completa alcanza las 450t.

Esta metodología hace viable continuar izando secciones incluso si las condiciones climáticas se vuelven hostiles (prototipo desarrollado con vientos de hasta 16 m/s). Esto es posible utilizando guiados laterales a lo largo de los marcos de los pórticos, restringiendo los movimientos laterales manteniendo la torre en su vertical.

ALE ha trabajado junto con Nabrawind Technologies para desarrollar la metodología utilizada en este prototipo para liderar la futura producción en escala de estas torres eólicas desde 2019.

 

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