Windpower Engineering & Development

Hexion’s new BP 535 for wind turbine rotor blades combines higher mechanical strength and fatigue performance with a long open time.

Hexion Inc., a supplier of epoxy resins, curing agents, and bonding pastes to wind turbine blade manufacturers around the world, introduces the EPIKOTE MGS Resin BP 535/EPIKURE MGS Curing Agent BPH 538 bonding system. This new bonding paste, developed specifically for today’s larger, high-performance rotor blades, combines outstanding strength and fatigue performance with the long processing time needed to manufacture lengthier blades.

As the wind energy industry migrates to larger turbines with longer, heavier rotor blades, a variety of production challenges have emerged. One drawback of conventional bonding paste has been that it can only remain exposed to air for a limited time before its adhesive performance suffers due to surface film formation, or carbamation. Manufacturers often found that they didn’t have time get the entire blade processed before the bonding paste would lose its efficacy—often in a little over an hour.

In response, Hexion developed a paste that would not form a film until after four hours of open time or longer, even at 70% relative humidity, allowing manufacturers additional time to lay down the paste and assemble the parts.

“As a recognized leader in resin systems for wind energy applications, we work closely with customers to develop innovative solutions to their particular product and process challenges,” says Johannes Meunier, Hexion Global Segment Leader, Composites. “BP 535 is an excellent example of a collaborative solution to the manufacturing problems posed by larger, heavier rotor blades.”

In addition to long processing time and high tolerance for environmental humidity, the EPIKOTE BP 535 resin system displays outstanding fatigue performance, improved by one order of magnitude over benchmark BP 435. It also exhibits good sag resistance at elevated temperatures, making it ideal for adhesion of vertical surfaces and across wide gaps. This adhesive resin does not bleed from vertical gaps even if parts are immediately cured at high temperatures (up to 80° C). This attribute, as well as the system’s solid T_G after curing for only four hours, offer possibilities for cycle time reduction. Other process enhancing characteristics of this new bonding paste are a long pot life and a low exotherm.

Hexion Inc.
www.hexion.com

Windpower Engineering & Development

Abrahan Puente, Engineering Manager, AUGE Industrial, www.auge.com.mx

The corrosion protection of hot dip galvanization can lead to hydrogen embrittlement which weakens the steel anchor bolts. A recent improvement to the process avoids the problems of hydrogen embrittlement.

It is no surprise that a common goal among the wind industry’s participants is to lower the total cost of ownership associated with wind farms while not sacrificing on health, safety, and environmental issues.

To help reach the goal, this article focuses on the significance of removing entrapped hydrogen from bolt steel and how an innovative approach minimizes the risk of hydrogen embrittlement without cutting back on quality or safety.

Seismic regions around the world require hardened high-tensile strength anchoring systems. These must have a minimum 1,040 MPa tensile strength (Reference ISO 898-1).

Making such materials comply with this stress value requires hardness usually above 35 HRc, because these are thermally treated by means of quenching and tempering. Wind-turbine OEMs require hot-dip galvanization to avoid the natural phenomenon of corrosion.

Hot-dip galvanizing typically consists of three steps per the American Galvanizers Association, including surface preparation, galvanizing, and inspection. During surface preparation, the steel is dipped in acidic solutions such as sulfuric acid or hydrochloric acid as a way to remove surface impurities and oxides.

The problem arises when coating a high-strength hardened alloy by hot-dip galvanizing. During this first step, there is a high probability of a phenomenon called “Environmental Hydrogen Embrittlement” occurring because the material contacts the acid medium.

Here’s what goes on at an atomic level: Hydrogen embrittlement results when metals literally absorb hydrogen. It is the smallest molecule in nature. When it diffuses along the grain boundaries, hydrogen atoms are absorbed into the metal lattice and diffused through the grains, tending to gather at inclusions or other lattice defects.

Disassociated hydrogen ions take little space, but when hydrogen ions combine to form hydrogen molecules they take up tens of thousands of times more space.

This applies stress on a granular level and may form cracks, thus causing the part to fail when additional outside stress is applied during use. Also, this usually results in a loss of ductility or load carrying capacity, which may cause catastrophic brittle failures at applied stresses well below the yield strength. Failures occurring in service are serious and may be costly.

Hydrogen must be in the atomic form to impose damage to steel. Because hydrogen has the smallest atomic mass, it can enter the molecular structure of the steel. This is not true when two hydrogen atoms combine to form a stable H2 molecule. Hydrogen in molecular form is too dense to penetrate a steel structure.

Because hydrogen is exceptionally mobile, it quickly penetrates any recently formed cracks, lesions, or material surface discontinuities, and creates high stress areas within the steel structure. When embrittlement failures occur, they often significantly increase costs and lead times associated with the development of a project.

To prevent this phenomenon, it is common to use alternative methods of cleaning such as sand blasting or air blasting instead of using acid solutions. Also, it may be recommended to use post-baking for dehydrogenation.

To ensure risk reduction, our company has developed AUGE Rhino, an alternative cleaning method consisting of an alkaline de-scaling process. The results are in full compliance with ASTM A153 and EN 10684 (thickness, adhesion test, etc.). Upon completion of laboratory testing and customer approval, the company applies hot-dip galvanized anchoring systems safely, through a process free of acidic solutions. This process allows reducing cost and lead-time by reducing the need for baking the steel.

Windpower Engineering & Development

Hempel offers a new combined primer and mid-coat designed specifically for wind towers.

International coatings supplier Hempel has launched a new combined primer and mid-coat designed specifically for wind towers. The new coating, HEMPADUR 4774D, will be used in Hempel’s well-known two-coat anti-corrosive system for wind turbine towers to address previous UV stability issues.

Hempel’s two-coat wind tower protection system dries up to 30% faster than equivalent three-coat systems, helping to eliminate production bottlenecks, increase throughput, and reduce drying hall costs. Since it was first launched in 2008, the system has effectively become the industry standard within two-coat paint systems for wind towers, and today around 70% of producers using a two-coat system for wind towers choose Hempel.

Anders Voldsgaard Clausen, Group Wind Power Segment Manager at Hempel, comments: “By shifting to our two-coat system, wind tower producers can put a tower through the production process roughly 30% quicker, enabling them to produce more towers in each shift. The two-coat system also means lower VOC emissions and less paint and waste, which all contributes to reducing the overall cost of wind tower production.”

Developed specifically for wind towers, HEMPADUR 4774D will replace the combined primer and mid-coat currently used in Hempel’s two-coat system and will improve the system by addressing previous UV stability issues.

“Unlike the exterior, a wind tower interior usually only requires one or two coats with a primer/mid-coat. The interior is often exposed to UV rays while awaiting erection and previous epoxy primer/mid-coats could lose their white colour. HEMPADUR 4774D has been designed to maintain its color in these conditions.” Anders Voldsgaard Clausen explains.

Hempel is the leading coatings supplier to the wind energy sector and supplies coatings to more than 50% of all wind turbines, towers and blades produced around the world.

According to Anders Voldsgaard Clausen, the improved two-coat system is the result of many years of experience in the industry. “Our new two-coat system has been developed through close work with some of the industry’s leading companies in order to reduce the overall cost of wind energy production.”

HEMPADUR 4774D was released in April 2015 and is available worldwide.

HEMPEL
www.hempel.com

Windpower Engineering & Development

The W-1100 coating has been rain erosion-tested on whirling arms at 300 mph (135 m/s) in 1 inch per hour rain for 24 hours, with no visible damage on the surface.

The leading edges of turbine blades take a beating as they sweep through air that is not always clean. Dirt in the air along with crop dust and rain eventually wear the leading edge away, and if it does not receive proper attention, the blade will deteriorate to the point of needing replacement. Coating developer Hontek has developed a new series of blade coating for the wind turbine blades.

The company says the blade coating, ReNEW W-Series, is superior to the tapes and coatings currently available on the market.  The W-1100 coating has been rain erosion-tested on whirling arms at 300 mph (135 m/s) in 1 inch per hour rain for 24 hours, with no visible damage on the surface.

ReNEW W-1100 also shows sand erosion resistance when tested at 300 mph (135 m/s), using 177-240 micron sand.  The weight loss of W-1100 is 3.5 times less than a well-known competitive coating, which was tested side by side (below-left).

Side-by-side comparison of the weight loss of W-1100 versus a well-known competitive coating.

On the ASTM D4060 Taber Abrasion Test,  Hontek ReNEW coating showed 11 to 71 times lower weight loss than the current blade coatings on the market.

The Company says ReNEW coating exhibits great resistance to hydrolysis degradation in outdoor humid environments.  In an accelerated hydrolysis test, developed by the U.S. Air Force Coating Technology Integration Office, Hontek ReNEW scored the highest on rain erosion and hydrolysis resistance.  All other coatings tested by the U.S. Air Force showed signs of coating reversion.

Hontek’s ReNEW Erosion Coatings can be sprayed, rolled, brushed, or cast in mold, suitable for both OEM and field repair applications.

More information can be obtained by contacting info@hontek.com.

For related articles, refer to links below:

• Algorithms simplify and predict blade maintenance
• New report encourages military’s objective to expand renewable energy program

Windpower Engineering & Development

Multi-jackbolt tensioners are a solution when companies experience bolting problems such as leakage, thread galling, unsafe working conditions, or when using expensive methods and find it difficult to properly bolt the joint.

Although wind turbines vibrate enough now, more of it will come as engineers introduce designs with longer blades to capture more wind energy. Increased vibration levels may also loosen some tower fasteners which calls for occasional re-tightening. Hence, most trends in this area have tool designers looking for better ways to measure tension (rather than torque) and prevent corrosion. Other trends are toward lighter tools and a future trend is collaboration between construction workers and turbine engineers that will build design features that make it easier to tightening bolts outside the hub.

The best-way debate: There is a discussion in the bolting-tool community regarding a best way to produce or measure bolt tension. Standard procedure has been to measure pressure in hydraulic tools or current in electric tools, parameters that indicate having reached a torque that corresponded to a required bolt tension. The accuracy to the tension value generated is considered by some to be too low. According to one study, actual bolt tensions can vary as much as ± 40%.

One wrench manufacturer says the margin for torque error is a lot less with an electric wrench because the tools can be “locked” to a particular torque value. Such manufacturers say their tools work with ±3% accuracy. Additional wrench features include setting several torque limits at one time for different jobs workers may encounter that day.

To provide a closer measure of torque, one tool manufacturer provides a socket head with a built in strain gage. The tool can be used on all torque generators, hydraulic and electric alike.

Lighter and smarter wrenches are another bolting trend. Of course, lighter is a relative term. One bolting supply company took it upon itself to design an electric powered tension pump that clients were requesting. It’s 65% smaller than competing units.

In addition, bolting work requires accountability – knowing that each bolt is tightened to a prescribed level. More wind-turbine manufactures require proof that each bolt has been installed and applied to appropriate torque levels to maintain the manufacturer’s warranty. Recent electric torque wrenches allow collecting such data. On-board data loggers can report how many bolts have been torqued along with failed torques and over torques. One project manager estimates that electric torquing takes about 33% less time than by other methods.

Coatings and corrosion protection. The offshore industry is encouraging development of bolt coatings. The coatings are developed to protect industrial structures and equipment in corrosive conditions, referred to as C4 and C5, where saltwater and high humidity corrode unprotected steel. Chemist are giving zinc flake materials attention. One zinc flake material has passed ISO 12944 by tolerating 1,440 hours of salt spray without substrate corrosion. Another, Hempel’s Hempadure AvantGuard activated zinc primers include patented chemistry that they say provides better anti-corrosion protection than zinc epoxies without AvantGuard.

To ensure risk reduction of hydrogen embrittlement, AUGE bolting has developed an alternative cleaning method consisting of an alkaline de-scaling process. The results are in compliance with ASTM A153 and EN 10684 (thickness and adhesion tests). The process applies to hot-dip galvanized anchoring systems, through a process free of acidic solutions. The process allows reducing cost and lead-time by reducing the need for baking the steel.

Recommended future trends: If tool manufacturers would like new product ideas, ones that could start future trends say construction workers, build lighter tools. Holding a 45-lb tool overhead for hours is a lot to ask of a normal person, says one worker.

For example, a common 1.6 MW turbine with 100-m rotor sports 940 bolts not counting the 140 odd base bolts. Try tightening those in a day, he challenges tool makers. Then consider those outside-blade bolts (bearing to hub) on some machines. With no platform to stand on, no handles, no waist or chest high anchors, just the modest sized tie-off rail to stand on, and no access to the front of the nose cone, you quickly see these machines are not as worker friendly as they could be. Then add the weight of the torque gun, which may not have a lanyard-connection point, and a long electric-and-data cord and frequently encountered grease, and it becomes immediately obvious that lighter tools are needed along with safer access to outside bolts.

A recommended trend would be more collaboration between turbine OEMs or even major wind associations and tool manufacturers to address the issue.

Windpower Engineering & Development

While coatings today provide protection and other static functionality, a new generation of technologies is making them “smart” – able to change in response to their environment. There’s significant potential for this capability to impact industries from military and aerospace to wind energy, according to Lux Research.

“Smart coatings are coming and will open the way to more dynamic, higher performing products,” said Anthony Schiavo, Lux Research Associate and lead author of the report “Surfaces Get Smarter: Scouting Emerging Coatings, Markets and Functionalities.”

“However, many of these innovations are still at the lab stage and face technical and developmental challenges before they can make an impact in the market,” he added.

Lux Research analysts evaluated the technical and market potential of both functional and smart coating technologies and developers. Among their findings:

• Partnerships, scale are key to hydrophobic coatings. Clear winners emerging in the hydrophobic coatings space are set apart not by performance metrics but by their ability to form partnerships and scale technology. In automotive coatings, Nanogate Technologies is far above the field, followed by Diamon-Fusion; P2i and HZO lead in electronics.
• LiquiGlide leads in liquid-infused coatings. Liquid-infused coatings have rapidly emerged on the back of low cost – less than $1/m2 – and are now positioned to impact packaging. The two main start-ups in this space – LiquiGlide and SLIPS Technologies – employ similar technology but LiquiGlide has the edge because of its greater maturity and a partnership with Elmer’s.
• Self-healing coatings are still sluggish. Self-healing coatings have suffered from slow growth but market pull and patenting activity indicate a future for this technology. Key products in the market include Nissan Motor’s self-healing car paint and LG Electronics’ self-healing back coating for its G Flex 2 smartphone.

“Surfaces Get Smarter: Scouting Emerging Coatings, Markets and Functionalities,” is part of the Lux Research Advanced Materials Intelligence service and can be downloaded here.

Lux Research
www.luxresearchinc.com/

Windpower Engineering & Development

Offshore wind towers are another market for Tesla NanoCoatings’ corrosion protection products.

Tesla NanoCoatings announces the appointment of Norwegian Drilling Group (NDG) as sales agent and distributor for its Teslan products in Europe, the Middle East and Africa.

Tesla NanoCoatings and Norwegian Drilling Group will launch a new class of corrosion protection coatings targeting the oil and shipping industries.

Offshore wind towers are another market for Tesla NanoCoatings’ corrosion protection products.

Corrosion in the oil, shipping and offshore wind industries is a major maintenance issue that can severely hamper operations. Tesla NanoCoatings’ products utilize carbon nanotechnology to prevent corrosion and extend the life of platforms and equipment as well as ships and turbine towers.

“We are very excited to partner with Norwegian Drilling Group to change the corrosion landscape,” said Todd Hawkins, Tesla NanoCoatings president and CEO. “NDG’s considerable resources will allow us to quickly penetrate the oil drilling markets in Europe, the Middle East and Africa.”

“Teslan, which is a two-coat process rather than the traditional three-coat process, will enable us to significantly reduce our customers’ maintenance costs. In the current environment of lower oil prices, maintenance savings is critical,” said Egil Lauvsland, NDG’s Group CEO, Norway and the U.S.

Tesla NanoCoatings and Norwegian Drilling Group will work to introduce Teslan coatings to NDG’s customers like BP and Saudi Aramco.

Tesla NanoCoatings
www.teslanano.com/

Windpower Engineering & Development

Oxifree Global offers a sprayable polymeric-resin coating for the protection of metallic components that contains organic corrosion inhibitors and provides protection against all corrosive contaminants — making it ideal for offshore wind components.

Oxifree Global has secured funding from UK venture capital firm Octopus Investments letting it invest in expanding its offering within the offshore wind industry. This will also let the company roll out additional resources to support its global distribution and end user base. The business will supplement existing well-established operations in Houston, Texas with additional facilities in Europe and the Far East.

Oxifree is a global provider of solutions to complex corrosion and contamination situations in many sectors. Offshore wind farms are exposed to constant salt water and salt mist, causing corrosion of moving and serviceable metal parts and reducing the operational efficiency and longevity of the installation. Oxifree metal encapsulation and anti-oxidizing properties will extend serviceable longevity of metal parts, enabling cost savings and greater economic return from offshore wind farms, which is an area of particular importance to the sector.

Oxifree currently has presence in over 30 countries across seven continents.

Ed Hall, one of the Founders and MD of Oxifree, comments: “We are delighted to announce this significant investment by Octopus which will enable us to expand our services within the offshore wind industry. Since we began trading in 2009, Oxifree has grown significantly and we intend to use this investment and support from Octopus to help accelerate us on the path to become a leading player in the corrosion prevention industry. We are also excited by the opportunity this investment gives us to provide additional support to our excellent Global distributor and end user base.”

Oxifree’s principal business activity is providing patent protected polymeric resin coatings and installation equipment for clients where existing solutions are not sustainable long term or financially viable.

Some of the key characteristics that together make Oxifree significant include it being wholly organic and environmentally friendly, quick to apply, highly durable, easy to remove, reusable, requires minimal surface preparation, is long lasting and contains active corrosion inhibitors within its formula.

Jane Vinson, a member of the Ventures team at Octopus Investments, comments: “At Octopus our goal is to find strong, talented management teams, with an innovative product, operating in a large market — and this is the case with Oxifree. What’s more, in this business we see a strong potential to expand into complementary markets, making this precisely the type of business we look to back. The worldwide sales already being achieved by Ed, Nigel Thomson the Group Sales Director and their team are promising, and we look forward to working with the business closely in the coming years.”

Oxifree’s management team and vendors were advised by JDC Corporate Finance and Mills & Reeve. Octopus completed the transaction with support from Shoosmiths, Mazars and Armstrong Transaction Services.

Dave Howes, Director at JDC Corporate Finance, comments: “I am delighted to have advised the shareholders and management team on this exciting deal. JDC’s expertise allowed us to run a competitive process to find an investor in Octopus with an excellent fit to meet the objectives of Oxifree. The investment will enable the Group to further accelerate its growth and capitalise on the large market opportunity that exists for its products and services.”

Oxifree
www.oxifree.com

Windpower Engineering & Development

Studies consistently demonstrate that even minor blade erosion can lead to an AEP loss of at least 4%, and up to 20% in more severe cases.

Santhosh Chandrabalan | Development Leader | 3M Technical Business

To maximize wind-farm efficiency and related investment returns, the wind industry is paying increasing attention to the wear and tear of turbine blades. From high winds and rain to damaging hail and salt spray, turbine blades face a wide variety of weather and environmental challenges. Exposure to these conditions over time commonly leads to erosion in the form of pitting, gouging, and delamination on the leading edge of blades.

This damage compromises the integrity of a blade and impacts its aerodynamic efficiency, causing a significant loss in annual energy production (AEP). Recent studies from several sources consistently demonstrate that even minor erosion can lead to an AEP loss of at least 4%, and up to 20% or more in the case of severe erosion.

The best approach to blade erosion is a proactive one, addressing the issue before it becomes one. Several materials can help prevent blade damage before it’s a problem that affects a turbine’s production and ROI. Protecting blades Today’s utility-scale turbine blades often extend more than 40-m long and are made of lightweight materials, such as fiberglass, epoxy, polyester, and core materials, depending on the manufacturer. The longest blades can achieve tip speeds of more than 200 miles-perhour, so even the smallest bits of sand or moisture can cause damage over time, regardless of the brand, material, location, or hub height.

Protecting blades
Today’s utility-scale turbine blades often extend more than 40-m long and are made of lightweight materials, such as fiberglass, epoxy, polyester, and core materials, depending on the manufacturer. The longest blades can achieve tip speeds of more than 200 miles-per-hour, so even the smallest bits of sand or moisture can cause damage over time, regardless of the brand, material, location, or hub height.

One of the most common products for leading-edge erosion is blade-protection tape. Originally developed for helicopter blades and aircraft radomes, tapes are constructed with durable, abrasion-resistant polyurethane elastomers. The material is tough enough to shield a blade’s leading edges and surfaces from pitting, wear, water ingression, and environmental erosion, while protecting against punctures and tears.

When evaluating blade-protection tapes, consider a product that’s UV stable without hazardous pollutants. Also check whether special tools are needed for application. Several tapes on the market are designed for use in the factory or in the field by rope or platform access. Protection tape is often one of the best choices for repairs in the field because it provides a simple and consistent solution with a uniform thickness and finish. Unlike a chemical coating, blade tape isn’t affected by weather conditions, such as humidity or temperature, and provides a more reliable application process for quick fixes and corrections.

Polyurethane coatings provide another option for blade protection, offering a layer of defense against damage caused by sand, rain erosion, and minor impacts. But careful and proper application by brush or casting is necessary for full protection, so coatings are best applied in controlled conditions, not in the field.

Blade manufacturers also often use epoxy or polyurethane fillers to fix surface defects after de-molding or to create a smooth transition between blade halves. In these cases, the filler becomes an integral part of the leading edge of blade. Because blades are designed to flex significantly during operations, fillers must allow for some bend while providing enough durability to prevent surface cracking.

A variety of fillers are available so before deciding on a product users should factor in the application method required, the repair time available, and the performance expectations in the field. Also, review the instructions to ensure proper mixing and adhesion to the substrate of a blade to decrease the possibility of application errors and waste.

Fillers technically become the base of the leading edge of a blade, so they significantly influence how that leading edge resists erosion. Coatings and blade protection tape are also used to effectively prevent erosion, so it is important to choose a reliable filler that works in combination with other protection products.

Upgrading designs
An ageing fleet occasionally leads turbine operators to implement design upgrades to improve the aerodynamic efficiency of turbine blades. In these cases, it’s imperative to use a tough, reliable bonding solution when adhering composite blades or securing aerodynamic attachments.

Depending on the project, several bonding products are available for turbine blades and proper application will increase reliability. With the right combination of leading-edge protection, operators can boost wind-farm performance, power generation, and ROI.

Surface preparation
Preparation is key to successful blade protection. Before selecting a blade-protection product, double-check the degree of damage or repair on the blade. Serious chips or damage to the leading edge of a blade can mean a filler is needed prior to coating. After choosing the appropriate product, read the application directions and follow the recommendations including whether maintenance or repairs are best completed in the factory or in the field. Most often, the surface intended for the protection tape or coating significantly influences an adhesive’s reliability and performance. A clean and dry surface is usually required to obtain high-strength structural bonds. WPE

Windpower Engineering & Development

Parker Hannifin Corporation, a developer of motion and control technologies, has enhanced their tube fittings and adapters with ToughShield (TS1000) plating, which keeps fitting rust free up to 1,000 hours, according to ASTM B117 neutral salt spray tests. The superior coating is the result of years of investment in metallurgical and surface analysis capabilities. “The plating will be of interest to the budding U.S. offshore wind industry, and marine industries,” said Parker Tube Fitting Division Technology Development Leader Dr. Dawn Zhu. 

The ToughShield (TS1000) plating keeps fitting rust free up to 1,000 hours, according to ASTM B117 neutral salt spray tests.

Parker’s TS1000 plating retains torque values, coefficients of friction, pressure ratings, color and other critical specifications important to customers, while improving fitting corrosion-resistance in harsh conditions. Parker’s differentiation is robust plating chemicals and processes that outperform other fitting manufacturers.

Parker TS1000 also fights additional critical issues that can lead to loss of time and revenue in mobile and industrial applications, including:

• System contamination
• Potential leaks
• Fitting connection problems
• Aesthetic quality concerns
• Maintenance difficulty

For more information on TS1000 visit ravagesofredrust.com or
contact Wendy-Davis Moore at WDMoore@parker.com

Windpower Engineering & Development

KISCO Ltd., an international supplier of high-quality materials and services, has announced its acquisition of Specialty Coating Systems (SCS), a global provider of Parylene coating services and technologies.

Parylene is a thin coating often used on circuit boards that can go into moist environments. Both well-recognized brands, KISCO has been operating in the Parylene market for over 18 years and has a strong background in materials science and development. SCS also has notable roots back to the origination of Parylene and has been a leading contributor in the expansion of the worldwide Parylene market.

Over the coming year, the merged Parylene organization will begin to operate globally as Specialty Coating Systems, a KISCO company. The acquisition represents a significant milestone in the industry that builds on a combined 63 years of experience and positions the company as an industry leader with enhanced manufacturing capabilities, with unmatched research and development applications.

“We are pleased to welcome Specialty Coating Systems into the KISCO family,” said Takekazu Kishimoto, President of KISCO Ltd. “The management teams at KISCO and SCS are committed to continuing our strong leadership positions in the industry by providing high-quality Parylene services and technologies to our customers through a combined 21 regionally positioned facilities throughout the Americas, Europe, and Asia. We are also committed to expanding the market by developing and commercializing new, cutting-edge materials, processes, and technologies, which will be made possible by the consolidation of our highly successful engineering teams.”

Terry Bush, SCS President & CEO, added: “This is an exciting time for our company and customers. I am proud of what Specialty Coating Systems has accomplished in the market throughout our company’s long history and am confident that the consolidation of our two companies will create an even stronger entity to better serve our customers in the future. SCS and KISCO remain committed to the highest level of quality products and customer service experiences, and we are excited about the opportunity to offer customers additional resources, locations, and coating options to help make their innovations successful.”

Specialty Coating Systems
www.scscoatings.com

Windpower Engineering & Development

Parker Hannifin Corporation, a developer of motion and control technologies, has enhanced their tube fittings and adapters with ToughShield (TS1000) plating, which keeps fitting rust free up to 1,000 hours, according to ASTM B117 neutral salt spray tests. The superior coating is the result of years of investment in metallurgical and surface analysis capabilities. “The plating will be of interest to the budding U.S. offshore wind industry, and marine industries,” said Parker Tube Fitting Division Technology Development Leader Dr. Dawn Zhu. 

The ToughShield (TS1000) plating keeps fitting rust free up to 1,000 hours, according to ASTM B117 neutral salt spray tests.

Parker’s TS1000 plating retains torque values, coefficients of friction, pressure ratings, color and other critical specifications important to customers, while improving fitting corrosion-resistance in harsh conditions. Parker’s differentiation is robust plating chemicals and processes that outperform other fitting manufacturers.

Parker TS1000 also fights additional critical issues that can lead to loss of time and revenue in mobile and industrial applications, including:

• System contamination
• Potential leaks
• Fitting connection problems
• Aesthetic quality concerns
• Maintenance difficulty

For more information on TS1000 visit ravagesofredrust.com or
contact Wendy-Davis Moore at WDMoore@parker.com

Windpower Engineering & Development

KISCO Ltd., an international supplier of high-quality materials and services, has announced its acquisition of Specialty Coating Systems (SCS), a global provider of Parylene coating services and technologies.

Parylene is a thin coating often used on circuit boards that can go into moist environments. Both well-recognized brands, KISCO has been operating in the Parylene market for over 18 years and has a strong background in materials science and development. SCS also has notable roots back to the origination of Parylene and has been a leading contributor in the expansion of the worldwide Parylene market.

Over the coming year, the merged Parylene organization will begin to operate globally as Specialty Coating Systems, a KISCO company. The acquisition represents a significant milestone in the industry that builds on a combined 63 years of experience and positions the company as an industry leader with enhanced manufacturing capabilities, with unmatched research and development applications.

“We are pleased to welcome Specialty Coating Systems into the KISCO family,” said Takekazu Kishimoto, President of KISCO Ltd. “The management teams at KISCO and SCS are committed to continuing our strong leadership positions in the industry by providing high-quality Parylene services and technologies to our customers through a combined 21 regionally positioned facilities throughout the Americas, Europe, and Asia. We are also committed to expanding the market by developing and commercializing new, cutting-edge materials, processes, and technologies, which will be made possible by the consolidation of our highly successful engineering teams.”

Terry Bush, SCS President & CEO, added: “This is an exciting time for our company and customers. I am proud of what Specialty Coating Systems has accomplished in the market throughout our company’s long history and am confident that the consolidation of our two companies will create an even stronger entity to better serve our customers in the future. SCS and KISCO remain committed to the highest level of quality products and customer service experiences, and we are excited about the opportunity to offer customers additional resources, locations, and coating options to help make their innovations successful.”

Specialty Coating Systems
www.scscoatings.com

Windpower Engineering & Development

3M will highlight its expanded wind portfolio of adhesives, sealants, and personal protection equipment at this year’s AWEA WINDPOWER event in New Orleans.

As the wind energy industry continues to grow at an exponential pace, there has been a renewed importance to build and maintain wind turbines that achieve a maximum return on investment (ROI). For more than 40 years, 3M has been a leader in the renewable energy industry due to their expertise in product innovation, development and manufacturing.

This year, 3M will highlight its expanded wind portfolio – from adhesives and sealants to personal protection equipment – at the American Wind Energy Association (AWEA) Show from May 23 to 26, in New Orleans.

This year, visitors to the 3M booth will learn more about the company’s soon to be released product – 3M Wind Protection Tape W8750 – designed to significantly reduce the effects of leading edge erosion, extend maintenance and service levels and provide a fast and easy application process. During the show, 3M will also demonstrate its complete line of wind energy products, which will include:

• Wind Blade Protective Coating W4601
  • Designed to help protect wind turbine blade leading edges from damage caused by sand and rain erosion and minor impact, this two-component polyurethane coating provides excellent erosion protection in a single or multiple layer(s).
• PU Filler W3610
  • A tough, flexible two-part epoxy polyurethane filler ideal for finishing and smoothing wind turbine blade surfaces and leading edges.
• Dry Layup Adhesive W7900 2.0
  • A sprayable, synthetic elastomer based adhesive for bonding and holding glass fabrics, and roving other reinforcements and materials in place during the infusion process.

“3M is proud to be an industry leader in renewable energy by ensuring that our full line of products enhances reliability, improves performance and provides the highest level of safety,” said Santhosh Chandrabalan, Global Business Manager, 3M Wind Energy. “Through our partnerships, resources and expertise, we are able to provide unparalleled technical support and supply products anywhere in the world.”

Through their commitment to provide wind OEMs everything they need in the field, 3M recently announced the acquisition of Capital Safety, which brings more than 70 years of expertise in fall protection strategies. Highlighted products from the 3M Personal Safety Division will include:

Windpower Engineering & Development

RELEST repair product line has been especially designed and developed for the wind-power industry.

WINDSOURCING.COM GmbH, a component and materials provider for wind turbines, has announced a new supply partner, BASF Coatings. BASF’s RELEST rotor-blade repair products are now available on WINDSOURCING.

“We are proud that another big brand manufacturer has qualified and chosen us as distribution and logistics partner,” stated Stefan Weber in a recent press release. Weber is the Managing Director for WINDSOURCING.COM.”

He added: “The RELEST product line is an important component in our product range, and helps us to further expand our portfolio which already consists of more than 20,000 items. This development is highly pleasing, and we are currently conducting further negotiations with interesting Suppliers to present further product innovations also in the future.”

Windpower Engineering & Development

From the base foundation to the tip of the blades, Sika offers a full range of wind-turbine products and solutions capable of withstanding the toughest climatic conditions.

Sika Corporation, supplier of innovative, sealing, bonding, reinforcement, and protection solutions announced its participation as an exhibitor at the AWEA WINDPOWER Conference and Exhibition, from May 23 to 26 at the Ernest N. Morial Convention Center in New Orleans.

Sika will present its full range of sealants and structural adhesive solutions for wind turbines — from the tip of the blades to the base of the foundation— including the unique SikaForce-7800 Red & Blue two-component polyurethane structural repair adhesives and SikaDur Blade Repair Kits.

In addition, Sika will present Sikaflex polyurethane sealants and adhesives, Sikasil silicones; and SikaFast two-component MMA structural adhesives. Sika’s wind-turbine solutions offer the wind industry rapid, reliable, and cost-efficient products for manufacturing, installation, and repair applications. “

The wind industry is a very dynamic and challenging environment. The utility companies are demanding OEMs produce more durable, lower cost units, that generate greater energy output,” said Tony Martin, Vice President, Transportation and Appliance & Components, Sika Industry.

He added: “In addition, the wind repair market is the fastest growing segment in the renewable energy industry. The sealants and adhesives required to properly repair the wind blades and turbines are not the products you buy off the retail shelves. It is important that Sika educates and provides the best repair solutions that expedite getting the turbine units back on line.”

Sika has serviced the wind energy industry globally for over 25 years with high-performing products and solutions to meet our customers’ challenging applications. A member of the American Wind Energy Association, Sika will be exhibiting at booth 5139.

Sika Corporation
www.sikausa.com

Windpower Engineering & Development

BÜFA Composite Systems’ bonding paste series, BÜFA-Bonding Paste 0110, is used to bond the two shells of the blades.

As a traditional manufacturer of specialties for the composites market, the German company BÜFA Composite Systems has an extensive experience in supplying systems – polyester and vinyl-ester resins, gelcoats, topcoats, and bonding pastes – for the wind power industry.

All this know-how may soon be also available in Brazil, according to Jose Moralejo, regional business manager of the company. “We want to monitor the evolution of the wind sector but, for that, we need surely to expand our internationalization,” he said. “This is one of our main challenges for the upcoming years, and Brazil has a very interesting market, with good growth prospects. In addition, many of our global clients are already producing in the country.”

For wind blades molded with vinyl-ester resins, BÜFA Composite Systems supplies the bonding paste series BÜFA-Bonding Paste 0110. The product is used to bond the two shells of the blades.

“As for polyester nacelles and spinners, we have several certified and accredited products,” explained Moralego. “This is the case, for example, of the series BÜFA-Standard gelcoats and topcoats for indoor and outdoor applications. They have been used for many years by European manufacturers that supply to the main wind-turbines producers.”

Another highlight of BÜFA Composite Systems’ portfolio is the series called BÜFA-Firestop, which is intended for applications that require flame retardant properties. Manufacturers of wind turbines in Europe have been incorporating this type of fire protection in the internal parts of the nacelles, where the generator is located.

“We managed to offer flame retardant protection without changing the mechanical properties of the laminate, the production process of the piece and with a lowest impact on its final cost.”

Today, the wind energy sector consumes approximately 10% of the annual production of BÜFA Composite Systems. According to the company’s regional manager, this share is expected to grow between 5% and 10% annually.

Windpower Engineering & Development

Power generation from renewable sources is a key part of Covestro’s sustainability concept, says the company. This applies above all to wind power, which is one of the most promising renewable energy sources due to its global availability and the technical progress already made.  Polymer manufacturer Covestro (formerly Bayer MaterialScience) focuses on the production of high-tech polymer materials and the development of solutions for products used in many areas of daily life.

In collaboration with partners, Covestro recently created the first ever large polyurethane rotor blade in China. It is 37.5-meters long and dimensioned for an output of 1.5 MW. This is important evidence that the resin is suitable for industrial production

Wind power capacity is seeing double-digit annual growth across the globe. Cost-efficient processes for manufacturing wind turbines are in greater demand than ever to enable further expansion. Once in operation, the aim is for turbines to be used over a lengthy period with the lowest possible maintenance requirements. This is particularly true of offshore turbines, some of which are exposed to extreme environmental conditions.

Global expertise
Covestro’s innovative and sustainable material solutions improve the efficiency of wind turbine manufacture and support the creation of further onshore and offshore wind farms with a long service life.

The company has its own competence center in Otterup, Denmark, to coordinate its global wind energy activities. “Our aim is to use creative and sometimes unexpected solutions to make the world a brighter place – and power generation is part of this,” said Kim Klausen, who is in charge of Covestro’s global wind energy program.

Covestro will be showcasing its latest developments at the K 2016 plastics trade fair. One example is a special infusion resin for the cost-efficient manufacture of rotor blades. When used with reinforcing glass fibers and an efficient production process, this resin enables short cycle times. “This is a clear cost advantage for manufacturers,” said Klausen. “After all, rotor blades account for around a quarter of the total cost of new wind turbines.” The resin also exhibits very good mechanical properties.

Covestro has developed a cost- and time-efficient solution for the coating of steel towers and rotor blades. With Pasquick technology; the number of coats can be reduced compared with the conventional process. What’s more; the coatings cure faster.

The half-shells for the rotor blades are efficiently manufactured using the vacuum infusion process. This involves placing the core materials and glass fiber fabrics in a mold and sealing the structure hermetically with a film. Once the vacuum has been created, introducing the liquid resin starts the infusion process. A version of the process optimized for polyurethane resins was developed by HÜBERS in collaboration with Covestro.

Short cycle times
Thanks to the vacuum, the process only requires a relatively short amount of time and prevents the formation of cavities. The advantage that polyurethane resin has over epoxy resins is that it flows more easily and ensures better wetting of the glass fibers used for reinforcement. The curing process starts when the mold is heated and is faster than when using epoxy resins.

Covestro recently created the first ever large polyurethane rotor blade in China. It was manufactured at the Shanghai FRP Research Institute in collaboration with HÜBERS and glass fabric manufacturer Chongqing Polycomp. International Corp. (CPIC). The blade is 37.5-meters long and dimensioned for an output of 1.5 MW. This provides important evidence that the resin is suitable for industrial production. In collaboration with industry partners such as glass fabric supplier Saertex, Covestro is planning to produce further prototypes.

Economic significance
The company has also developed a cost and time-efficient solution for coating steel towers and rotor blades. With Pasquick technology, the number of coats can be reduced compared with the conventional process. What’s more, the coatings cure faster. Both factors help to further reduce the cycle time and the manufacturing costs of wind turbines.

The corrosion protection is just as long-lasting and high in quality as with the standard process. This is an important prerequisite for turbines with long service lives and minimal maintenance requirements and thus for the cost-effective use of wind energy.

The same applies to the rotor blades: During a windstorm, even raindrops can act like bullets at a height of 90 meters – especially at the tips of rotor blades. And offshore turbines face the added problem of saltwater. Polyaspartic coatings offer perfect protection here as well. The low-solvent coatings also set standards when it comes to sustainability. The company says leading manufacturers of wind turbines therefore have already embraced the Pasquick technology.

Durable cable protection 
Maintenance at sea can be associated with huge costs, especially for operators of offshore wind farms. Subsea cables that are permanently exposed to strong currents are particularly susceptible to damage. Covestro elastomers based on the Baytec and Desmodur polyurethane systems are ideal for protecting cables and have long been used for this purpose. The protective systems benefit from excellent impact strength and decomposition resistance. Unlike steel and concrete, components require no further processing, which saves a significant amount of time and money when building offshore wind farms.

Tekmar Energy Ltd. is one company that recognizes these benefits. The European manufacturer of subsea cables is making exclusive use of Covestro’s products for the construction of offshore wind farms in China. The two companies recently signed a collaboration agreement to address the increasing demand in the Chinese market.

Meet the company at the K 2016 plastics trade fair from October 19 to 26 in Düsseldorf, Germany, Hall 6, Stand A 75. For more: at http://www.k2016.covestro.com/.

Windpower Engineering & Development

This abstract comes from an article by Günter Binder, Federal Waterways Engineering and Research Institute, Karlsruhe, Germany. The complete 11- page article is here: https://corrosion-offshore.iqpc.de/mediacenter

What is the best method for finding out appropriate corrosion protection systems for steel structures?
Coated hydraulic structures for example undergo stresses from impacts, abrasion provoked by transport, erection and use as well UV-aeration, osmoses, and cathodic protection current.

The selection criteria generally are reduced to check the coatings by defined laboratory test procedures especially by measuring the rusting of the substrate at an artificial scribe after a certain time of corrosion loads in cabins. The advantage is obvious: short time of testing and getting a definite value of rusting for comparing it with the threshold value or forming ranking.

From that a further question arises: Which real stresses for coated steel structures are there and how they may be reproduced in laboratory test procedures? With the help of a variation diagram the rusting measurements of diverse coating systems may be checked for the correlation between field and laboratory results.

A first step for that is to compare rusting at a scribe and by that it is necessary to get rusting values from different protection systems from both the test procedures mentioned above (salt spray or cycle test procedures e.g. and long term trials in nature i.e. field tests). It is advantageous to subdivide the field test trials in immersion, water changing, and splash water zone.

The research carried out by BAW sometimes shows significant positive correlations with a certain statistic security. The results also show, that field test results are more reliable than laboratory tests and that protection systems work at best with special formulated primers.

This benefit also can be observed when protective coatings are tested to the resistance to electric protection currents: Systems with special primers generally show better results, which can be measured by the uptake of protection current and the grade of blistering. It should be mentioned that cathodic corrosion plants work especially in the immersion zone, where otherwise the corrosion stresses are low as shown.

Hydraulic and offshore steel structures often suffer by mechanical stress reasoned by transport and erection of the buildings. This kind of damages can be imitated by impacts to the coated panels. To make the damages by resulting micro fissures visible the panels in addition to the falling weight test where loaded by the salt spray test. The first results shows the positive effects of zinc-dust primer systems in combination with elastic binders, mainly single pack polyurethanes.

The rest of the 11-page article is available at the url above.

Windpower Engineering & Development