Wind Energy Customer Presentation

™™Titan Technologies Titan Technologies Superior Bolting SolutionsSuperior Bolting Solutions™™

forforWind TurbinesWind Turbines

Wind energy generating capacity installed, U.S.: 11,603 MW (end of 2006) Total installed U.S. wind capacity at year's end 2007 was 16,818 MW, or enough to serve the equivalent of over 4.5 million average U.S. households.

That’s 1.5 million households more than just one year ago

Wind energy generating capacity, worldwide: 74,223 MW (end of 2006, Global Wind EnergyCouncil).



Globally, over 20,000 MW of new wind capacity was added in 2007. Current installed capacity worldwide at the end of 2007 was over 94,000 MW• Denmark, Spain, and some regions of Germany now generate 10% to 25% of their electricity with wind power

Over 5,200 megawatts of wind generation – enough to serve the equivalent of 1.5 million American households annually – was installed in the United States in 2007alone.



• Nearly 48 billion kWh of electricity will be generated by wind power in the U.S. in2008 (based on AWEA estimates)

• That is enough electricity for the equivalent of 4.5 million average American homes • A single new 1-MW turbine generates enoughelectricity for 250 to 300 homes



How is a wind Turbine farm built?

IT IS BOLTED TOGETHER

Lets take a look at the process and how Titan Technologies makes it all come together.



Setting-up & Tooling:

Most Wind Farm Developers prefer to separate Erection & Commissioning (E&C) from Maintenance Tool packages

1. Erection and Commissioning tool package.

• One to two packages per project of 30 to 40 towers each package will include 4 x Hydraulic Torque Wrenches and a Pump (possibly 2 x Titan T1’s (3/4” drive) & 2 x Titan T3’s + Pump) Additionally a number of Hydraulic Bolt Tensioners for tensioning the base section.

• Some developers use Hydraulic Bolt Tensioners ; most will use torque tools only.

• This E&C tooling package will eventually be priced into the job and handed over to the project owner. (in some cases the developers would rent the tools rather than purchase).



On-going periodic maintenance package.

• This is an identical package to the E&C package identified above.

• Most developers would consider a package for every 8 to 10 towers; this translates to a number of tools. These tools are purchased exclusively for the project.

• Titan is a major supplier to the industry because of product performance, suitability, availability, serviceability and pricing.

• Titan offers product sale and operating leases to the developers.

• 3 to 5 year custom contract packages are available



• 1st thing is you need to get the tower sections and related hardware, tools etc to the site.



Transportation of each tower section is not easy. Every precaution is taken to ensure the tube is not damaged during transport.

The spreader jig is bolted on upon arrival at the erection pad and the tube is readied to be located on the concrete pad.

This will become a work platform inside the tower; the ladder leads up to the top (the Nacelle and the Hub).



And we have LIFT-OFF. The two cranes work simultaneously to lower the base and raise the top of the tube over the concrete pad.



Wind Tower Base4300 MM

The reinforced concrete foundation is usually an octagonal shape.

In this case the top surface is 6300mm across.

The tower base is 4300mm.

Two sets of bolts hold the base section of the tower 160 each x M42 Bolts in total.



Photo demonstrating the length of the studs that will be embedded in concrete.

Once the Studs are lowered into the prepared site, the reinforced steel is formed around the studs and this anchors the stud frame into the concrete foundation which is around 100 cubic meters in area.

Depth embedded in reinforced concrete

Wind Tower Base



Wind Tower Base

Footings before concrete is poured. Approx 100 cubic meters of concrete is poured to support the wind tower.

The studs are approximately 42mm x 2400mm.

After the concrete is poured only 150 mm are exposed.



Wind Tower Base

The base section is lowered over the concrete pad using a 300T hydraulic boom crane.

Some damage can occur to the studs because of narrow tolerances between stud diameter and hole diameter.



Wind Tower Base

4 leading studs allow the base section to line up over the remaining 76 external studs.

There are 80 internal and 80 external studs that hold the base section into place.



Wind Tower Base

Titan assisted in the tensioning of the base section studs with the use of Titan Foundation Bolt Tensioners.

Field Training and hands-on assistance was provided during the installation of the first wind tower for this project located at Hallett in South Australia.

In this case a set of 20 x Titan Foundation Bolt Tensioners were sold to Suzlon with a full set of high pressure hoses and a Hydraulic Tensioner Pump.



Wind Tower Bolting Arrangement

Sect A

160xM36 Bolts [Torque 2800Nm}

Sect B

256x M36 Bolts [Torque 2800 Nm]

Sect C

300xM36 Bolts [Torque 2800 Nm]

Sect D

224xM42 Bolts [Torque 4500 Nm]

Sect E

160xM42 Bolts [Toque 2800 Nm]



The second section is put into place and the bolts are torque using a Titan Model T5 Hydraulic Torque Wrench and 70mm Titan Impact Socket.

Tower Bolting



Hoisting Tools and materials from the Top section of the tower into the Nacelle is done manually – there is no winch in the Nacelle. Technicians have to hoist this tooling manually.

Tools and Pump need to be relatively light and compact. Titan Hydraulic Wrenches have the best torque to ratio in the industry

Tower Bolting



Tower Bolting

Work space is very confined and generally two technicians are assigned to inspect and service each Wind Tower.

Noise generated by the Hydraulic wrench or Tensioner pump must have relatively low dBA

Titan EXE Hydraulic Wrench Pumps and EXE 2000TT Hydraulic Tensioner pumps run very quiet



Torquing the Rotor Blade Hub Bolts on a Vestas Wind Tower with a Titan T-1



•Houston based Titan Technologies International, Inc., is the fastest growing company in the bolting technologies industry with global representation.

•Titan offers one stop bolting solutions and has dramatically changed the Wind Turbine bolting landscape with the introduction of four new and radically innovative technologies.

•The revolutionary new bolting technology is sold and serviced through Titans worldwide network of Sales Representatives and Stocking Dealers.



Titan Technologies is introducing new technology firsts for Wind Turbine Erection and Maintenance

Titan SmartTite™ automatic cycling Hydraulic Wrench Pump System

Titan EXE 2000TT™ Electric Hydraulic Tensioner Pump

Titan AutoTite™ Automatic H9 Bolt Tensioner System

Multiple patents granted & pending



Titan has set a new and unrivalled performance benchmark with the introduction of the SmartTite™ Auto Cycle Hydraulic Wrench Pump Tensioning system.

•It is often the case that when a wind farm developer targets a specific site; gainful employment for local workers is offered as an enticement to secure the approval of the local government authorities.

•While this is a desirable and worthy incentive it is sometimes problematic as under-skilled or unskilled workers are given a sophisticated and expensive Hydraulic Wrench system and with minimal training are expected to properly torque nuts using the Hydraulic Wrenches.



Wind turbine erection companies and the wind turbine manufacturers themselves have requested Hydraulic Wrench manufacturers to provide them with automatic cycling Hydraulic Wrench pump that can be operated correctly with minimal level of expertise



• Heretofore the art involved using a combination of flow and pressure sensors which were used in combination.

• The trick was that the system needs to recognize that pressure buildup within the system was a result of the Hydraulic Wrench being at the end of its stroke or was the pressure within the system realized because torque had been achieved on a threaded fastener. • •Problems with heating of the oil and voltage and amperage variations and other problems commonly found on-site, have made the technology problematic. None worked properly in all field conditions. Until now…



Titan SmartTite™ Automatic Cycling Hydraulic Torque Wrench system.

Titan exclusive product

Available in Titan EXE MAXTitan EXE MINI EXE Whirlwind models



The process of returning the piston for another stroke is instantaneous as the tool no longer has to reach a preset pressure to allow the flow & pressure sensors to work.

There are no flow and pressure sensors which can fail and necessitate costly repairs and downtime on the job.

Titan SmartTite™ AUTOCYCLE

Hydraulic Wrench & Pump System



The Titan SmartTite™ features unique and multiple patent pending technologies.

It uses a sensor within the Hydraulic Torque Wrench that determines when the tool is at the end of its stroke.

The sensor is in communication with a processor with in the Hydraulic Torque Wrench Pump. When the tool is performing the tightening process, the sensor tells the pump when to retract the tool piston and make a successive stroke.



The operator simply depresses a button, the tool cycles until the nut is tightened to a predetermined torque and he goes on to the next nut and repeats the process.

The result is faster tightening of the nuts resulting in time savings and integral joint make up with minimal skill level needed.



Titan SmartTite™SUPERIOR BOLTING SOLUTIONS™



Titan Standard Wind Turbine

Pumps ™SUPERIOR BOLTING SOLUTIONS™



Titan Hydraulic Torque Wrenches

Highest Torque/Weight ratio

Designed by FEA

Make it Stronger

Patented& Uniquefeatures

More durable

Simpler operation

Automatic option

SmartTite™Technology

available with

Titan Technologies introduces new and revolutionary ELECTRIC /Hydraulic

Tensioner Pump for use in Wind Turbine Erection and Maintenance




• The EXE2000TT™ Electric Tensioner Pump provides hydraulic pressure to bolt stud Tensioners used on various applications throughout the Turbine erection and maintenance. Such as:

• Assembly of Blade to Bearing• Assembly of Bearing To Hub• Base Bolt Tensioning




• The Titan EXE2000TT™ was designed from the ground up for wind turbine tensioning applications.



EXE2000TT™ Electric Tensioner Pump




• The Titan EXE2000TT™ Electric Tensioner Pump features a unique technology which delivers up to 2000 bar, is powered electrically and will hold up to the usage required of it at those pressures

• It is a two stage pump. The 1st stage provides high flow to an intensifier which takes the low pressure high flow and converts it to high pressure at a lower flow. This pump is designed for use with all 1500 bar tooling and represents the best TECHNOLOGY to deliver fast payback and performance.




• It is a high flow delivery pump, important where speed of operation is essential and as such is excellent when using multiple Tensioners in such applications as the assembly of blade to bearing and assembly of bearing to hub application. It is easy to use and made to last. Titan is backing up that claim by offering an 18 month warranty with purchase.




The Titan EXE-2000TT Series is available for delivery now and is comes in both 115VAC and 230VAC versions.







Superior

BoltingSolutions™



More cutting edge technology from the leader in engineered bolting solutions



TitanH9 Bolt Tensioners

Double Stacked H9 Tensioners

Single piston H9 Tensioners




Titan Technologies introduces new and revolutionary AutoTite Bolt Tensioner System for use in Wind Turbine for use on 10.9 Bolts.

Windpower 2008, Booth 3150

Applications

Blade to Bearing

Bearing to Hub




A wind turbine Tensioner system with an integral motor for simultaneous nut-tightening while tensioning.

• No longer will your workers have to subject themselves to the dangers of tightening the nuts within the confined area of the blade hub area




UNSURPASSED SAFETY

• The AutoTite system can work with any number of Tensioners giving unsurpassed versatility and can be customized to your tooling budget




• Segmented systems available for maximum speed and easy set up.




Available with either

Hydraulic motor for nut rundown

Pneumatic motors for nut run down

Electric Motors for nut run down




The nuts are rundown automatically while tensioning

The operator is not in proximity with the high pressure hoses while tightening the nuts or pressurization takes place.




The whole tightening process is done from the safety of the nacelle or other REMOTE

location






Shown with optional nut run-down mechanism

Titan Foundation Tower Base Bolt Tensioner System

• TITAN™ Foundation bolt Tensioners are commonly used for wind turbine tower base bolts, bridges and other civil engineering applications.




• TITAN ™ Tensioners are designed using Finite Element Analysis and 3D solid modeling combined with extensive testing. Key features include:




• Optional spring return

• Durable - Minimum 10,000 pressure cycles on all designs

• CE marked. Conforms to International standards.

• Optional single or twin connections




• Long-life composite seals for easy retraction and leak free operation

• LOWER total cost of ownership • FAST and easy to use • Pressure TESTED and CERTIFIED • STANDARD & CUSTOM Tooling available




• OVER- STROKE prevention devise • Highly visible stroke indicator • Optional ROBUST GEAR DRIVE for fast nut run

down • Optimal size, weight and load capacity • plus a full range of 1500 bar Electric, Air/Hydraulic

and Manual Pumps & a full range of flexible hoses and fittings






Titan ETite™Electric Torque Wrenches

• Featuring the PLUS Series TORQUE & ANGLE TOOLS




Excellent for T Bolts on GE Wind Turbines

Gear Bearing Bolts and Main Bearing bolts

• The Torque and Angle Capability of the Titan ATEip 2200-P16 PLUS provides quick work of the T-bolts (blade to blade bearing) to 413 ft/lbs plus 120 degrees rotation.

• On this turbine there are 60 bolts per blade on the inside of the nose cone.




Special Reaction fixtures are available for the ETite™ or Titan Hydraulic Torque Wrenches for your application.




• Shown is a special reaction for the gear bearing (each side 4 bolts M36 HV/ SW 60) and the main bearing (each side 6 bolts M39 / SW 60) on the 1.5 MW GE Wind turbine.






VESTAS WIND TECHNOLOGY TORQUE TOOLING REQUIREMENT

ITEM LOCATION TOWER ERECTION TOWER REPAIR & MAINTENANCE

Titan TOOL REQUIREMENT

1 SECTION E (BASE SECTION)

160 X M42 2800NM TORQUE

FULL WELDED AND EMBEDDED IN CONCRETE

NOT REQUIRED N/A

2 SECTION D (LOWER SECTION) 224 X M42 4500NM TORQUE

TORQUE TOOL + PUMP + SOCKET

SAME T5 + PUMP + 1 ½ DV X 42 SOCKET

3 SECTION C, B, A (UPPER SECTIONS) 716 X M36 2800NM TORQUE


SAME T3 + PUMP + 1”DV X 36 SOCKET

4 NACELLE ROTOR BLADES / HUB


SAME T1 + PUMP + ¾”DV X 32 SOCKET

5 NACELLE TRANSMISSION PEDESTAL MOUNT BOLTS



6 NACELLE GENERATOR PEDESTAL MOUNT BOLTS



7 NACELLE DRIVE SHAFT FLANGE / COUPLING





ITEM LOCATION TOWER ERECTION TOWER REPAIR & MAINTENANCE

TOOLING REQUIREMENT

1 SECTION E (BASE SECTION)

160 X M42 2800NM TORQUE

Titan Foundation Bolt

TENSIONERS

SAME 20 UNITS + PUMP + HOSES, ETC.

2 SECTION D (LOWER SECTION) 224 X M36 4500NM TORQUE

TORQUE TOOL + PUMP + SOCKETS


3 SECTION C, B, A 716 X M36 2800NM TORQUE



4 NACELLE ROTOR BLADES / HUB


SAME T1 + PUMP + ¾” DV X 32 SOCKET

SUZLON ENERGY TITAN TOOLING REQUIREMENT



9001 Jameel Road, Suite 180Houston, TX. 77040 USA

Tel: 281-449-9994

Toll free in North America866-345-8484

Fax: 281-449-9996Email: [email protected]: www.TitanTi.com

mailto:[email protected]

http://www.titanti.com/



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