USOO8813534B2

(12) United States Patent (10) Patent No.: US 8,813,534 B2

Barr (45) Date of Patent: Aug. 26, 2014

(54) METHOD FOR REMOVAL OF DENTS FROM (58) Field of Classification Search
WIND TURBINE MASTS USPC .................... 72/370.04, 705, 392, 457, 481.2
See application file for complete search history.
(75) Inventor: Hugh C. Barr, Brownwood, TX (US)
(56) References Cited
(73) Assignee: Barr Fabrication, Brownwood, TX
(US) U.S. PATENT DOCUMENTS
-r 1,033,687 A * 7/1912 Fish ................................ 72,392
(*) Notice: Subject to any disclaimer, the term of this 1837,690 A 12/1931 Sunde
patent is extended or adjusted under 35 2,687,763 A * 8, 1954 Perkins ........................... 72,392
U.S.C. 154(b) by 0 days. 2.916,076 A * 12/1959 Young ............................. 72,392
3,625,046 A 12/1971 Van Gompel
(21) Appl. No.: 13/586.857 4,004,444. A * 1/1977 Pollart ....................... T2/370.08
4,555,926 A 12/1985 Bieli-Moschlin
1-1. 4,803,881 A 2/1989 Dudley
(22) Filed: Aug. 15, 2012 5,826,457 A * 10/1998 Eagles ............................ 72,392
O O 6,000,260 A 12/1999 Price
(65) Prior Publication Data 7,246,991 B2 7/2007 Bosche
ck
US 2012/0304434 A1 Dec. 6, 2012 8,245,558 B2 * 8/2012 Barr ................................ 72,392
* cited by examiner
Related U.S. Application Data
- - - Primary Examiner — Faye Francis
(62) Division of application No. 12/784,120, filed on May (74) Attorney, Agent, or Firm — Strasburger & Price, LLP
20, 2010, now Pat. No. 8,245,558.
(60) Provisional application No. 61/216,748, filed on May (57) ABSTRACT
21, 2009, provisional application No. 61/253,236, A method for removal of dents from wind turbine masts uses
filed on Oct. 20, 2009. a dent pushing tool. The dent pushing tool includes a self
aligningram assembly with a central ram cylinder and remov
(51) Int. Cl. able adjustable length arms. At the end of one arm is a curved
B2IC 25/02 (2006.01) base. At the end of the other arm is a dent pusher plate.
B2ID I/08 (2006.01) Removal of the dent is caused by extension of the central ram
(52) U.S. C. cylinder.
CPC. B2ID I/08 (2013.01); YIOS 72/705 (2013.01)
USPC .......................................... 72/370.04; 72/705 3 Claims, 2 Drawing Sheets

100

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U.S. Patent Aug. 26, 2014 Sheet 1 of 2 US 8,813,534 B2
U.S. Patent Aug. 26, 2014 Sheet 2 of 2 US 8,813,534 B2
 US 8,813,534 B2
1. 2
METHOD FOR REMOVAL OF DENTS FROM SUMMARY
WIND TURBINE MASTS
A system and method for consistently and accurately
CROSS REFERENCE TO RELATED removing dents from the walls of wind tower masts is dis
APPLICATIONS closed herein.
The disclosed system and method is enabled by a dent
This divisional application claims the benefit of non-pro pushing tool. The dent pushing tool includes a self aligning
visional U.S. patent application Ser. No. 12/784,120, filed ram assembly. The self aligning ram assembly includes a
May 20, 2010, issued on Aug. 21, 2012, under U.S. Pat. No. central air over hydraulic or electric over hydraulic central
8.245,558, that claims the benefit of Provisional U.S. patent
10 ram cylinder. Extending outwardly from the central ram cyl
application No. 61/216,748 filed on May 21, 2009 and Pro inder are removable first and second adjustable length arms.
visional U.S. patent application No. 61/253,236 filed on Oct. The lengths of the first and/or second arms are adjusted by the
20, 2009, which all applications are incorporated by reference use of inserts placed either within or at the ends of the arms.
in their entity for all purposes. Attached to the outboard end of the first adjustable length arm
15 is a curved base. Attached to the outboard end of the second
STATEMENT REGARDING FEDERALLY adjustable length arm is a pusher plate.
FUNDED RESEARCH AND DEVELOPMENT Use of the dent pusher to properly remove a dent from the
wall of a wind turbine mast begins by assessing the size of the
The invention described in this patent application was not dent and formulating a plan for its removal. Once the plan for
the subject of federally sponsored research or development. removal of the dent has been formulated, the dent pushing
tool is put in place within the hollow portion of the wind
FIELD OF INVENTION turbine mast. The pusher plate is placed against the dent. The
curved base is placed against the wall of the wind turbine mast
opposite from the dent. The self aligning ram assembly and
The present invention pertains to a system and method for 25
the extension arms are located to lie along an internal diam
removing dents from a substantially circular hollow metal eter of the wind turbine mast. The adjustable length extension
structural Support column in either a vertical or horizontal arms are sized by the use of inserts to be a sufficient length to
orientation. More particularly, the present invention is hold the dent pushing tool in place within the interior of the
described according to its use in removing dents from the wind turbine mast.
masts used to Support wind turbine driven electrical energy 30
With the dent pusher tool in place within the wind turbine
generators. mast, the process of removing the dent from the wall of the
wind turbine mast begins. Dent removal begins at a predeter
BACKGROUND mined end of the dent. The central ram cylinder portion of the
self aligning ram assembly is extended so that the dent is
Those traveling in the Western part of the United States 35 pushed outwardly toward the external wall of the wind turbine
have noticed the growing presence of wind towers for pro mast. The force from the central ram cylinder is monitored by
viding renewable energy to generate electricity. These wind the use of a pressure gauge. As the dent starts to come out of
towers have several large blades which are turned by wind the wall of the wind turbine mast, the dent pushing tool is
energy. The large blade assembly turns an electrical generator relocated to another location along the dent so that the pusher
or an alternator and thereby converts wind energy into elec 40 plate is effectively walked along the dent until the dent is
trical energy. Supporting the large blade assembly above the removed. After each application of force against the dent, the
ground is typically a Substantially circular single hollow size and orientation of the dent is re-assessed to assure that the
metal structural Support column or mast. dent is reacting as predicted to the applied force. The condi
The rapid growth of the use and construction of wind tion of the dented metal is monitored closely with non-de
towers to harness the energy of the wind and convert the 45 structive metal testing techniques as the dent is pushed out.
energy of the wind into electrical energy is well known. Not Removal of the dent is assured by measuring the area where
so well known is that the walls of the large hollow metal masts the dent was located to assure that the dent has been com
which both support and position the rotating blades in the pletely removed. In certain circumstances progress toward
wind are subject to damage. Such damage may occur in many removal of the dent is assured by taking pictures of the dent of
ways Such as: blade strikes; transportation damage; construc 50 each step during the dent removal process.
tion damage; inadvertent collision with other equipment Such
as a truck or a crane; and other types of unforeseen damage. BRIEF DESCRIPTION OF THE DRAWING
Typically, the damage is in the form of a dent in the mast wall. FIGURES
Operators of wind towers have found that when dents in the
walls of the masts of wind towers occur, it is generally advis 55 A better understanding of the system and method for the
able to remove the dent to assure the structural integrity of the removal of dents from wind turbine masts may be had by
mast as opposed to replacing the entire mast. reference to the drawing figures wherein:
Because of the large size of the wind tower masts and the FIG. 1 is a plan view of the dent removal tool placed within
location of the dent on the wind tower mast, removal of a dent a wind turbine mast having a dent in a side wall;
from the wall of a wind tower mast is not an easy thing to do. 60 FIG. 2 is a perspective view of the dent removal tool; and
This task is further complicated by the fact that no two dents FIG.3 is an exploded elevational view of the dent removal
are exactly the same. Specifically, dents have a unique size, tool.
shape, orientation and location with respect to the wind tower
mast. Because of the complexity of removing a dent from a DESCRIPTION OF THE EMBODIMENTS
wind tower mast there is a need in the art for a system and 65
method for consistently and accurately removing dents from As may be seen in the drawing figures the system and
the walls of wind tower masts. method of the present invention is enabled by a dent pushing
 US 8,813,534 B2
3 4
tool 10. The dent pushing tool 10 is an elongated self-aligning receive at least 40 hours of classroom and practical instruc
ram assembly 20. This elongated self-aligning ram assembly tion on dent removal and use of the dent pushing tool. Fol
20 is sized to fit with the diameter of the hollow metal struc lowing the completion of the instruction those using the dent
tural Support column by adjusting the length of the pipe pushing tool 10 are tested and certified. Thus, before any job
sections 22, 24 which extend from the central ram or actuat is undertaken to remove a dent from a wind tower mast, a
ing cylinder 26 between the two ends of the self-aligning ram check is made to assure that all personnel have been certified
assembly 20. This length adjustment is accomplished by the in the use of the dent pushing tool 10 and the procedures for
use of inserts 28 placed either within or at the ends of the pipe dent removal.
sections 22, 24. To assure maximum surface contact with the Wind towers are located in may diverse locations. Each
inserts 28, the contact Surfaces of the inserts are machined as 10
location has its own physical characteristics and operating
are the surfaces with which the inserts 28 come into contact.
The force applied by the self-aligning ram assembly 20 is procedures. Further, each location has its own safety proce
dures. When certified dent removal technicians arrive at the
obtained from a central ram cylinder 26 which is either an air site where their dent removal expertise is required, the certi
over hydraulic or an electric over hydraulic cylinder between
the ends of the self-aligning ram assembly. Such air over 15 fied dent removal technicians are given a site orientation and
hydraulic or electric over hydraulic cylinders are sold under a safety briefing.
the EMPAC brand and are well know by those of ordinary Following the site orientation and the safety briefing a Job
skill in the art. In actual use, it has been found that if the Safety Analysis is initiated during the review of the actual
disclosed self-aligning ram assembly 20 is able to exert up to damage to the hollow mast portion of the wind tower. This Job
about 50 tons of force against a dent 102 in the wall 100 of a Safety Analysis is documented in writing and a copy is pro
hollow metal structural Support column most dents can be vided to the on-site safety personnel.
pushed out. The actual amount of force needed to remove a Before any work starts on the removal of the dent from the
dent is determined by the size, the orientation, the location, wall of the hollow mast portion of the wind tower, the dent is
and the shape of the dent. During the dent removal process, thoroughly inspected and measured with lasers, levels,
the amount of force being placed on the dent is monitored by 25 straight edges, calipers, etc. to determine the depth and con
one or more pressure gauges connected to the central ram figuration of the dent to be removed.
cylinder 26. Pictures may be taken of the damaged area of the wind
Various different types and shapes of dent pushing plates tower mast during the initial inspection to thoroughly docu
30 may be used against the inside of the dent depending on the ment the “before condition of the dent as well as the dimen
size and orientation of the dent. Typically, the dent is “walked 30 sions of the dent.
out; that is, the dent is pushed out in Small steps from one end Once the dent has been measured and photographed, the
of the dent to the other until the dent has been completely dent pushing tool as described above is moved into the inte
removed. rior of the hollow mast for assembly and proper positioning.
On the opposite end of the ram from the dent is an arcuate As will be understood by those of ordinary skill in the art, any
support or curved base 40. The arcuate support or curved base 35 misalignment of the dent pushing tool within the hollow mast
40 provides abroad foundation for support of the self aligning could create either an unsafe condition or could cause addi
ram assembly and assists in assuring that the self-aligning tional damage to the mast wall.
ram assembly is properly lined up along the diameter of the Before the dent pushing end of the dent pushing tool is
hollow metal structural support column. In the preferred placed against the dent, a further evaluation of the dent is
embodiment, the arcuate support or curved base 40 is made 40 made. Such evaluation encompasses all aspects of the dam
from a one inch thick aluminum section. The softness of the aged area to include: the general direction of the damaged
aluminum as compared to the rigidity of the steel used con area with respect to the wall of the wind tower mast, the
struct the wind tower mast enables the aluminum to flex to the overall size of the damaged area; and the type of damage to
shape of the interior wall of the mast. the wall of the hollow mast Such as sharp edges or creases,
The purpose of the disclosed procedure is to minimize the 45 shallow rounded deformities, etc.
distortion of the hollow metal support mast portion 100 of a When the extent of the damage to the wall of the hollow
wind tower. As indicated above, the dent pushing tool 10 mast is understood, a plan is formulated for removal of the
described therein includes an arcuate Support or curved base dent. Such plan will include at least the starting point and the
40. The curved base section 40 is used to disperse the force ending point of the repair and the points therebetween as most
applied to the dent on the oppositeside of the hollow mast 100 50 dents generally have to be walked out of the mast wall. It is
from the dent 102. these critical details that will enable repair of the damaged
On the other end of the dent pushing tool 10 from the area of the mast wall without over-pushing the dent to create
arcuate support or curved base 40 is the dent pusher plate 30. an external bulge or an out-of-roundness condition on the
The dent pusher plate 30 concentrates the forces on the dent exterior of the wind tower mast.
102 by the use of a pusher plate 30. The pusher plate 30 is both 55 Non-destructive testing metal testing techniques may be
shaped and positioned to align the force applied by the dent used during the dent removal process. For example, magnetic
pushing tool 10 either on the apex or apexes of the dent or at particles may be used to either evaluate or watch for surface
some other point on the dent to be removed from the wall of cracks in either the interior the exterior of the mast wall.
the wind tower mast. As previously indicated, the wind tower Ultrasonic or electromagnetic wave evaluation techniques
mast may be on the ground if a dent is to be removed before 60 may also be used to look for internal cracks within the wind
the wind tower is erected. In other situations, the wind tower tower mast wall. And, strain gauges may be placed on the dent
mast may be vertical. When the wind tower mast is vertical, to assure that metal of the mast wall never exceeds its yield
the dent pushing tool 10 is rigged and lifted upwardly within strength during the dent removal process. Each step during
the mast to the level of the dent. the dent removal process may be photographed for study.
Because of the sensitivity of the removal of dents from the 65 Operation of the dent pushing tool 10 and monitoring of the
walls of the hollow masts of wind towers, those who use results of the non-destructive metal evaluation procedures are
actually remove the dents from the walls of wind tower masts often accomplished with use of a remote control 50 or at a
 US 8,813,534 B2
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remote location because of the large forces needed to remove placement of a dent pushing tool against the dent, said dent
a dent from the wall of a wind tower mast. pushing tool including:
Certain dents may require the use of spider bracing within a self-aligning, remotely actuatable ram assembly
the mast to localize pressure in the dent removal area. Such including a central ram and first and second adjustable
spider bracing prevents distortion of the hollow mast wall and 5 length arms extending from said central ram;
will maintain the roundness of the hollow mast following the a curved base attached to the end of said first adjustable
dent removal process. length arm, said curved base constructed and arranged
When a dent or a flat area is being repaired, the wall for placement on the interior wall of the substantially
material is not deformed or stretched. Rather, the wall mate circular hollow metal structural Support column
rial is restored to its original contour. Such restoration occurs 10 across from the dent; and
by the application of force from the dent pushing tool on the a dent pusher plate attached to the end of said second
damaged area. The effect of the application of force on the adjustable length arm, said pusher late constructed
dent is continually monitored. No heat is ever used as the and arranged for placement against the dent on the
grainstructure of metal of the mast wall is not to be altered. It interior wall of the substantially circular hollow metal
has been found, however, that in very cold climates, it may be 15 structural Support column;
necessary to warm the area of the dent to reduce brittleness aligning said dent pushing tool Substantially along an inte
within the metal thereby enabling better control over the dent rior diameter of said substantially circular hollow metal
removal process. structural Support column so that said pusher plate is in
As the application of force causes the size of the dent to be contact with one end of said dent and said curved base is
reduced, lasers, levels, straight edges calipers, etc. are applied in contact with the wall interior wall of said substantially
to the dent to closely monitor the effect of the applied force on circular hollow metal structure across from said dent;
the dent. At the same time the mast wall opposite the dent actuating said ram assembly to cause force to be placed on
being removed is closely monitored and may be photo the dent by said pusher plate:
graphed to assure its integrity during the dent removal pro moving said dent pushing tool along the dent from one end
CCSS, 25 to the other and repeating the forgoing procedure until
Once the dent has been removed from the wall of the the dent has been removed from the wall of the substan
hollow wind tower mast, pictures of the damaged area may be tially circular hollow metal structure, wherein said step
taken again. The damaged area is remeasured. The measure of evaluating the dent includes determining a direction
ments, together with the pictures, verify and document the of the dent, a size of the dent, a depth of the dent, and a
removal of the dent from the wall of the hollow wind tower 30 type of damage to the wall where the dent is located.
maSt. 2. A method for removing a dent from the wall of a sub
Once the dent has been satisfactorily removed from the stantially circular hollow metal support structural support
wind tower mast wall, the dent removal tool is disassembled, column, said method comprising the steps of
removed and transported to another job site. measuring the size of the dent;
Before leaving the job site, the crew that repaired the dent 35 formulating a plan for removal of the dent;
completes a report including the before and after dimensions placement of a dent pushing tool against the dent, said dent
of the dent, the condition of the wind tower mast, the equip pushing tool including:
ment used to remove the dent and any before, during and after a self-aligning, remotely actuatable ram assembly
pictures. including a central ram and first and second adjustable
Those of ordinary skill in the art will also understand that 40 length arms extending from said central ram;
the system and method of the present invention may also be a curved base attached to the end of said first adjustable
used to repair flat spots or out-of-round conditions in the length arm, said curved base constructed and arranged
flanges which appear at the ends of wind tower masts or for placement on the interior wall of the substantially
between sections of wind tower masts. Because of the shape circular hollow metal structural Support column
and thickness of these flanges, it may be necessary to create 45 across from the dent; and
special plate 30 to contact the interior edge of the flange. a dent pusher plate attached to the end of said second
Because of the unique nature of a flange, extensive measure adjustable length arm, said pusher late constructed
ment of the flange is necessary before a flat spot or out-of and arranged for placement against the dent on the
round condition can be repaired. Such measurements may interior wall of the substantially circular hollow metal
include the diameters of the exterior and interiors of the flange 50 structural Support column;
as well as the diameter of the bolt circle. Depending on the aligning said dent pushing tool Substantially along an inte
thickness of the flange, it has been found that forces up to rior diameter of said substantially circular hollow metal
about 100 tons may be needed to reshape a flange. structural Support column so that said pusher plate is in
While the present invention has been disclosed according contact with one end of said dent and said curved base is
to its preferred and alternate embodiments, those of ordinary 55 in contact with the wall interior wall of said substantially
skill in the art will realize that other embodiments of the circular hollow metal structure across from said dent;
disclosed invention may be made and may have utility in actuating said ram assembly to cause force to be placed on
other applications. Such embodiments and use in other appli the dent by said pusher plate:
cations shall be included within the scope and meaning of the moving said dent pushing tool along the dent from one end to
appended claims. 60 the other and repeating the forgoing procedure until the dent
has been removed from the wall of the substantially circular
What is claimed is: hollow metal structure, wherein the dent is measured during
1. A method for removing a dent from the wall of a sub the dent removal process while a condition of the dent is
stantially circular hollow metal Support structural Support monitored using one or more non-destructive metal evalua
column, said method comprising the steps of 65 tion techniques being selected from a group including Surface
evaluating the dent; magnetic particles, ultrasonic testing, electromagnetic wave
formulating a plan for removal of the dent; testing, and strain gauges.
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3. The method as defined in claim 2 wherein the plan for
removal of the dent is adjusted following each measurement
of the dent after each application of force against the dent.
k k k k k