Assembly of Wind Turbines at the Amontada Wind Power Complex – CE
24/10/2014 - By Press Office
Setting up the towers
Stages in setting up a wind turbine tower
This process requires quite complex logistics and engineering. A well-designed project and a highly competent and engaged team are essential for its success.
The bottom part of a concrete wind turbine tower alone weighs 80 tons. Considering that a popular car weighs 1 ton, this weight equals that of 80 cars.
First of a total of 30 pieces of a wind turbine tower
To assemble a 100-meter high wind turbine tower, 30 different pieces, each weighing 14 to 80 tons, are placed on top of each other. The tower’s total weight is 1200 tons, the same as 1200 cars piled up.
And the complexity of the process does not end here. The last pieces of a wind turbine tower weigh 14 to 20 tons, and when the wind reaches 15 meters per second (54 km/hour), it becomes impossible to place the parts with the necessary precision and safety. The solution then is to work when the wind is lighter, which is usually at night.
The towers can only be assembled when wind speeds are below 10 meters/second
One by one, the challenges are overcome and the result is achieved: the towers are assembled, ready to receive the turbines and blades.
100-meter assembled wind turbine towers
Teamwork + competence + engagement = results
Assembly of the first nacelle, blades and rotor at the Icaraí de Amontada – Ceará wind farm
Queiroz Galvão Energias Renováveis (QGER) has built its first wind turbine. The construction, completed on 10 August 2013, was an important milestone in the consolidation of QGER as an agent in the Brazilian renewable energy generation market. See the whole assembly process in the photos below.
Positioning the crane
Lifting and positioning the nacelle (wind turbine)
Lifting and positioning the blades
Assembled wind turbine
Assembling the blades
Just as we look for times with lighter winds to assemble the towers, the remaining equipment also requires extremely safe conditions to be assembled. Therefore, once again this process usually takes place late at night, when, in the region of Icaraí de Amontada, Ceará, the wind is not so strong.
The wind turbine rotor consists of three blades and a hub (the part that connects the three blades). Each blade weighs 13 tons and the hub weighs eight tons, so the set of three blades and one hub weighs 47 tons. Each blade is nearly 50 meters long, which means the assembled rotor is around 100 meters in width.
Operations can only start after the wind has been blowing for at least 30 minutes without gusts and below the critical speed of 12 meters per second. These parameters are crucial to ensure the total safety of the work.
The figures above are important to give us an idea of the complexity of the operation. To further illustrate this, the photos below show the assembly operation at a Queiroz Galvão Energias Renováveis wind farm.
Starting to lift the 47-ton equipment
Overview with all required equipment
The rotor is lifted to 100 meters
Fine-tuning to fit the 47-ton equipment, with winds below 40 km/h
Placing the rotor in the vertical position – Icaraí Wind Farm, Ceará
Video showing the rotor being placed in the vertical position
First operational test
A historic moment for Queiroz Galvão Energias Renováveis. Founded in 2012, the company started testing the generation of clean, renewable energy at 5:30 am on 4 December 2013.
Video of the test
Video of the test
This is Queiroz Galvão Energias Renováveis, operating in accordance with its social responsibilities, values and employee engagement to build a better world.