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FLANGE MACHINING

MONOPILES & TRANSITION PIECES

CNC Onsite flange-facing machine offers precise milling for transition pieces and monopiles of up to 12 meters for improved reliability, service life and maintenance costs.

When monopile and transition piece flanges are welded to the structure during manufacturing, the heat input can cause twisting and bending in the flange. Sometimes the result is flatness outside the tolerance. This is increasingly challenging, especially in offshore wind turbines where the flanges for jackets, monopiles, transition pieces and bottom tower sections are becoming ever larger while tolerances are being tightened.

With our proprietary precision machine, “Goliath”, fine tolerances can be achieved by post welding milling, meeting the required structural fit.

Machining is in most cases faster than traditional methods like heat straightening while the achievable tolerances are much better.With global flatness tolerances of 1 millimeter and local flatness tolerances of 0.5 millimeter for an 8-meter flange, our Goliath machine offers industry leading tolerances.

Our fully automatic CNC-controlled machine can mill flanges of up to 10-meters in standard configuration and can be configured for diameters up to 12-meters. The fine tolerances allow designers to create smaller diameter flanges that offer the potential to use maintenance-free bolt connections, which ultimately reduces both CapEx and OpEx for the the wind turbine manufacturers.

REDUCED CAPEX & OPEX

Precise milling of flanges ultimately results in reduced CapEx and OpEx for offshore wind farms.

HSE ADVANTAGES

If combined with precise bolt tensioning methods, the precise flange tolerances achieved with Goliath can help reduce the need to retighten bolts and eventually lead to maintenance free connections – reducing OpEx and improving Health, Safety and Environment (HSE).

LIFETIME EXTENSION

Precision-milled monopile flanges can contribute to a longer service life

CUSTOMER SATISFACTION

Integrating our flange milling into the manufacturing process will help producers meet end-customer requirements.

CONTACT US

Our team of experienced professionals will guide and advice you towards
the best possible solution that takes time, economy and durability into consideration.

Hans Løvlund Toft


CTO

+45 53 57 00 47 | hlt@cnconsite.dk

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PROCESS

FROM CHALLENGE TO SOLUTION

Quotation
Precision milling of a monopile flange.

The manufacturer contacts CNC Onsite to discuss specifications for the monopile flanges.

Our technical sales team will analyse the project and customer schedule. We will issue the quote based on the customers need and timeline.

The customer issues the purchasing order.

Planning
A large CNC machine used for wind turbine maintenance and repair.

We plan the technical part of the project, which includes preparation and programming of Goliath, the precision machine that will perform the milling.

We plan staff availability and timing, including flexibility to accommodate potential changes to the schedule.

Implementation
Technicians installing Goliath, a precision milling machine, at a customer's facility.

Our technicians will conduct the precision milling of the flanges at the customer’s factory.

Alternatively, CNC Onsite will train the customer’s own technicians for the operation of the machine.

The team will use the Goliath machine to mill the flange faces, leaving them flat to within one millimeter.

Handover
CNC Onsite checklist and thumbs-up symbol, representing the efficient rotor lock repair process using in-house developed machines

After machining measurements are made, a measurement report is issued to the customer.

Alternatively, the customer or a customer-contracted third party conduct the measurements.

Once the measurement are complete, the customer signs off the work.

Follow-up

We offer follow-up meetings with the customer. 

CNC Onsite’s follow-up program is part of our high quality standards.

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PRECISE FLANGE MILLING


Goliath, which can work both horizontally and vertically, can cope with features on large flanges such as double-tilted flanges and requirements for parallelism of the flange surfaces. Our Goliath machine can manage the many new complex flange designs, making it probably the most advanced and precise flange milling tool on the market

 

Søren Kellenberger, Sales Director

 

LEARN MORE ABOUT GOLIATH

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