Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - AIRCRANE (New Concrete-Towers Assembly system for taller Wind Turbines. )

Teaser

The wind sector is facing the challenge of reducing energy production cost. Bigger turbines at higher heights seem to be one of the most efficient solutions, which can only be achieved by concrete or hybrid towers. However, as the towers grow, the current installation means...

Summary

The wind sector is facing the challenge of reducing energy production cost. Bigger turbines at higher heights seem to be one of the most efficient solutions, which can only be achieved by concrete or hybrid towers. However, as the towers grow, the current installation means are limited in both lifting capacity and availability.
In order to solve this challenge, ‘HWS CONCRETE TOWERS’ has developed an innovative climbing crane for a more cost-efficient installation of wind turbines - Aircrane system, a self-climbing crane that defies the limitations of existing cranes. Uniquely designed for construction and maintenance of precast concrete structures, the Aircrane is a smart, versatile and cost-effective crane for installation of wind turbines at unlimited heights.

The system has two main advantages: (1) it radically reduces current assembly costs in the tallest concrete towers, and additionally (2) it opens a new market-niche, being able to assembly towers with height currently not possible due to current mobile crane limitations.
With the development of this crane, HWS aims to be a worldwide reference in the ASSEMBLY of (Full or Hybrid) CONCRETE TOWERS by using their own patented and so-called “AIRCRANE SYSTEM”, offering customers (wind-turbine manufacturers and wind farm exploiters) to assemble their turbines on wind farms all over the world.

The MAIN OBJECTIVE of the project is to complete, qualify, set standards and demonstrate in real working conditions the “AIRCRANE erection and ASSEMBLY SYSTEM”.
The 2nd OBJECTIVE of the project is to open a new niche in the market. Aircrane system makes possible to reach upper rotor heights, bringing cost efficiency, low carbon footprint, reliability, time saving, quality and workers safety.

Work performed

During the first year of the project, HWS has been working on the design of the AIRCRANE system, as well as the definition of the testing and demonstration to be performed in real operational conditions. In order to achieve this objective successfully, HWS has been in constant discussions with the main stakeholders: wind turbine manufacturers, wind park developers, crane manufacturers and suppliers…In addition, stablishing a good relationship with TÜV-Rheinland, the certification body, has been important for setting the right design standards and criteria from the beginning of the project.
The design and development of the Aircrane responds to the wind market needs:
AIRCRANE is designed to work in windy areas with speeds of up to 20 m/s. The places (“wind farms”) where the new towers will be installed are obviously windy locations. Conventional cranes do not operate with winds higher than 10 m/s. Consequently, increasing the number of operational days leads into a less delays, faster construction and more reliable project management.
All the elements of the Aircrane system are designed to be commercial or standard in the market. This makes the crane a low-cost machine, easy to repair and maintain.
Due to the simplicity of the system and its low operational limitations, AIRCRANE SYSTEM costs can be reduced to 90% of the costs of conventional cranes.
Five trucks are only needed to transport the AIRCRANE, compared to the 30-70 trucks required for existing cranes. AIRCRANE is easier and quicker to move and assembly avoiding problems in transportation and logistic infrastructure. Moreover, it requires less assembly area, which means less civil works, less occupied area…which makes the AIRCRANE environmental-friendlier solution.
As it climbs along the tower and gains altitude in parallel to its support structure, AIRCRANE has no height limitations. Additionally, its lifting capacity is the same at any height.
While the AIRCRANE is operational, there is no need of great platform-parking spaces around the turbine, or any qualification of the soil around the foundation.
The work carried out to achieve a disruptive product, is aligned with the main objective of the wind sector for the next 10 years: reduce drastically the LCoE (Levelized Cost of Energy) reducing the costs of onshore Wind Turbines to reach 1 Million € per 1 MW-installed.

Although the results obtained this first year of the project are not directly exploitable yet, some of them will help to achieve the main outcome of the project: to build and validate the first real scale Aircrane system and have it ready to the market.
The results of this first year of the project are:
- First phase of engineering design finished: having the engineering design of the Aircrane ready, is allowing HWS to show it to potential clients, partners… External parties see it as a more tangible product. Additionally, the drawings and specifications from this design can be used to talk to the supply chain about future needs, potential collaboration…

- Test definition: this document is helping HWS to analyze where and how the Aircrane wants to be tested. The Aircrane will have to comply with all the safety standards in order to be ready to commercialize it. The testing that has been defined will ideally be performed in close collaboration with a potential partner/client.

- Communication & dissemination plan: a significant work has been carried out in contacting potential customers and moving forward in the potential collaboration, win-win relationship. The contact list has been expanded to EPC (engineering procurement and contractor) firms and developers, leading to a higher probability of success and higher share in the market.
Involving the potential clients from the beginning of the project, will make easier the entrance of the Aircrane into the market. That is why, the exploitation of this first year results can be critical for a successful implementation of the Ai

Final results

The OUTCOME of the project will be the completed and validated AIRCRANE Assembly SYSTEM in real working conditions. After the necessary trial on-site, AIRCRANE will be ready for commercialization and building of terminated concrete towers for the interested customers. The final project TARGET is to sign a first sales agreement.

The implementation of the Aircrane could bring savings of up to 20% for tower installation, and 45% for wind turbine assembly, both of which lead to a relevant LCoE reduction. Additionally, its higher availability due to its low-cost, and operability in higher wind speeds, will assure a big impact in the wind energy market. Moreover, its easy adaptability to offshore and maintenance services, expands the applicability fields of the machine.

Successful project completion represents a significant business opportunity for HWS, with expected REVENUES of millions of euros in 5/7 years. In addition, the successful market introduction of the AIRCRANE SYSTEM is expected to create over 98/167 new Direct Jobs, and 176/307 new Indirect jobs.

Website & more info

More info: http://www.hwstowers.com/.