Home June 2014

June 2014

Editor’s Desk

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Through the years, he had a number of different jobs and short-lived private enterprises. I don’t know the details, but the one I remember hearing about the most from family members was “the Truck.”

It was a general store on wheels—difficult to imagine today, but commonplace back then. His customers were rural blue-collar workers and farmers—busy folks whose ability to travel into town to purchase towels, razors, or flatware was limited by daylight, distance, and in some cases, dollars.

The Truck allowed Papaw Wade to serve what I believe was his true occupational calling. In his chest beat the heart of a natural salesman.

Now, when I say “salesman,” I don’t mean the slick, fast-talking pitch men on late-night cable television. His customers had essential needs, and he was able to both clearly identify and compassionately meet those needs. In turn, he was able to meet the needs of his family.

There’s a unique, romantic simplicity to that story that gets lost these days. In response, I’m sure many would stand firm on the fact that “you’ve got to change with the times, or you’ll get left behind.”

True. But if the core value of meeting needs gives way to fulfilling wants (want for my company; want for my shareholders; want for myself), then the intended mutual benefit is lost.

That struggle has existed for centuries, and continues today… even in the wind power industry.

I think perhaps that’s why we anticipate AWEA’s WINDPOWER event every year. It’s not simply a business function. Granted, we’re all there because of our business—our occupation, our livelihood. Wind Systems is a business that needs to make money. Substitute your employer’s name there also.

But every year at WINDPOWER, we’re also reminded that there’s more at stake. Sustainability. Environmental responsibility. Preservation of precious natural resources. These are among the many mutual benefits we strive for in our industry.

If we keep those benefits at the core of our operations—just like we learned in Las Vegas—the prosperity will naturally follow.

Upon retirement from Montgomery Ward, Papaw Wade’s work ethic couldn’t handle all the free time. He occupied himself with little projects in the workshop-slash-playhouse he had erected in the back yard. But it didn’t take. While visiting him once, he told me: “I’m going back to Basic,” referring to a sales job at a home furnishings store.

In my initial confusion, I thought he said: “I’m going back to basics.”

In a sense, he was. He was going back to the career that had sustained him, his family, and his customers, for decades.

If our industry can adopt that idea of getting back to basics, we can prove that there’s plenty of room for earning green while being green.

Thanks for reading.

Three Big Takeaways from WINDPOWER 2014 You Should Know

Every year news is made at the WINDPOWER Conference & Exhibition, and that was as true as ever this time around. If you were at WINDPOWER 2014, which happened May 5-8 in Las Vegas, Nev., hopefully you took in much of the news, not to mention got a little business done and perhaps even socialized with some of the nearly 8,000 other participants.

But organizing the massive amount of information and happenings that come participants’ way during North America’s largest wind industry gathering can be tough. So for both those who were in Vegas and those who couldn’t make it, here are three key industry developments and takeaways from WINDPOWER 2014.

New Wind Vision
The U.S. Department of Energy (DOE) shared details for the first time of its Wind Vision initiative, launched last year at WINDPOWER. The key benchmarks announced: 10 percent wind energy on the U.S. power grid by 2020; 20 percent by 2030; and 35 percent by 2050.

More than doubling wind’s penetration from 4 percent to 10 percent by 2020 will require as much growth in the next six years as the past 40. Jose Zayas, Director of the Wind and Water Power Technologies Office at DOE, outlined the benefits: $520 billion saved for electric consumers between now and 2050 (when electricity will cost 3 percent less than it otherwise would); 336 billion gallons of water saved by 2050; 140,000 industry jobs by 2020 and 400,000 jobs by 2050, plus spinoff jobs benefits.

The Wind Vision calls for approximately 10,000 MW a year to be deployed over the next several years, including substantial offshore wind starting to come online by the latter part of this decade.

Wind as Leading Solution to Climate Change
With recent reports underscoring the urgency of tackling climate change, industry leadership underscored its readiness to be a top solution. “The urgent need to dramatically reduce global carbon emissions brings incredible opportunity to our industry,” said Susan Reilly, CEO of RES Americas, and new Chair of the AWEA Board of Directors.

Forty percent of all carbon emissions in the U.S. come from the electric power sector. Scientists say “decarbonizing” electricity is critical to holding carbon dioxide to a safer level in the atmosphere, and avoiding the worst impacts of climate change cost effectively, Reilly said.

“The facts are clear: After energy efficiency, wind energy is the fastest, cheapest way to get the biggest carbon reductions in our energy portfolio,” Reilly said. “So wind energy is no longer an ‘alternative’—it is an imperative.”

DOE Advances Three Demo Offshore Projects
DOE announced the three winning offshore projects for Phase 2 of its Advanced Technology Demonstration Project Initiative. The winners, chosen from a group of seven projects that comprised the initial phase of the program, are now eligible to receive up to an additional $46.7 million each to advance their projects, all of which are focused on next-generation offshore technology. The winners include projects from Dominion Virginia Power, Fishermen’s Energy of New Jersey, and Principle Power of Washington. All three projects use direct-drive turbines. Proposals from the University of Maine and the Lake Erie Energy Development Corp. were named as alternates for Phase 2.

The demonstration projects are part of an effort at accelerating the deployment of more efficient offshore wind power technologies by improving performance and lowering cost. The projects are slated to be deployed as grid-connected systems in federal and state waters by 2017.

More on the three projects: Fishermen’s Energy will install five XEMC 5-MW direct-drive wind turbines approximately three miles off the coast of Atlantic City, N.J. The project will feature an innovative twisted-jacket foundation that is simpler and less expensive to manufacture and install than traditional offshore wind foundations.  

Principle Power will install five 6-MW direct-drive wind turbines approximately 18 miles off the coast of Coos Bay, Ore. The U.S.-developed WindFloat semi-submersible floating foundation will be installed in water more than 1,000 feet deep, demonstrating an innovative solution for deep water wind turbine projects and lowering costs by simplifying installation and eliminating the need for highly specialized ships.

Dominion Virginia Power will install two 6-MW direct-drive wind turbines 26 miles off the coast of Virginia Beach, utilizing a U.S.-designed twisted jacket foundation. Dominion’s project will demonstrate installation, operation, and maintenance methods for wind turbines located far from shore. Additionally, the Dominion project will install and test a hurricane-resilient design.

(202) 383-2500 www.awea.org info@awea.org
AmericanWindEnergyAssociation @AWEA american-wind-energy-association
www.aweablog.org

 

DNV GL advises on transmission line project in Kenya

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DNV GL recently demonstrated its commitment to modernizing and developing power in Africa by advising on the construction of a 400kV high voltage overhead transmission line and substations in Kenya. Designed to strengthen the Kenyan grid and build a connection between the capital, Nairobi, and one of the largest wind farms in Africa, Lake Turkana Wind Power, the 420 kV AC transmission line runs from the national grid at Suswa to Loiyangalani.

The 400kV Kenyan transmission line is supporting the government initiative to harness the country’s rich renewable resources to boost the economy and respond to consumption needs in the capital. Without transmission lines such as this one, the future development of reliable wind and geothermal sources will be limited and Kenya will be forced to rely on more expensive fossil fuels serving power plants in the coastal region.

DNV GL was selected to advise on the transmission line by Kenya Electricity Transmission Company Limited (KETRACO), a government owned organization established to develop new high voltage electricity transmission infrastructure. DNV GL provides in-depth technical expertise and critical insights to KETRACO, in addition to developing the specification for the project, supervising construction work and providing training on asset management.

The project also involves advice for the construction of a power transmission substation at the Loiyangalani project site and a terminal substation at Suswa.

Thank you for making Windpower 2014 a success!

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Wind Systems would like to thank all WINDPOWER 2014 attendees who helped make our conference a success by visiting our booth in Las Vegas. Our staff was working diligently to answer your questions and share our vision of becoming your primary source for the latest, most insightful wind energy industry information available. WIINDPOWER 2014

In what has become a longstanding tradition at WINDPOWER, Wind Systems held daily giveaway drawings on May 6-8. Visitors to the booth who singed up for a free subscription to Wind Systems were automatically entered to win either a DBI-SALA ExoFit NEX harness from Capital Safety, or a Snap-on toolbox.

Toolbox winners were GE’s Daniel Olson, and Chris Elko of ITH Engineering. ExoFit NEX harnesses went to Mark Winward of GE, David Fuller of EDF Renewable Energy, and Moiseis Pineda, a student at Oklahoma State University–Oklahoma City.

Congratulations, winners! Thank you for coming by and participating in our drawing. If you came by our booth during the conference, but weren’t one of our lucky winners, please visit us next year at WINDPOWER 2015 in Orlando!   
 

Women of Wind Energy recognizes award winners

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The winners of the Women of Wind Energy (WoWE) Awards were announced on Thursday May 8 at the annual luncheon held at AWEA’s WINDPOWER 2014 Conference & Exhibition in Las Vegas. The awards put the spotlight on professionals at the pinnacle of the industry as well as on the up-and-coming next generation of leaders. All three winners provide examples of achievement, creativity and courage.  

“Highlighting and recognizing the stories of incredible women and men like this year’s WoWE Annual Award winners is critical not only to recognizing and appreciating their successes but also to help other women in the sector see role models and new career pathways,” said Kristen Graf, WoWE Executive Director.

2014 WoWE Award Winners
Rising Star award—Kylah McNabb is currently a program manager and wind development specialist at the Oklahoma State Department of Commerce/State Energy Office. She started her career working for the Oklahoma Wind Power Initiative, and then worked as a project manager for Horizon Wind Energy before achieving her current post. She is a very directed, determined person, building this unique career upon her roots of a Bachelor’s in geography and an MBA—both from the University of Oklahoma. She is a 2011 graduate of the National Renewable Energy Laboratory’s Executive Energy Leadership Program, which she claims among her proudest accomplishments.

McNabb has experience in private wind development, wind industry research and development, oversight, and financial management of over $70 million in federal funding programs, loan program development and management, and policy analysis.

Champion award—Dr. James Walker is vice chairman of the board of EDF Renewable Energy, a leading developer, owner, and operator of wind projects, which is a wholly owned subsidiary of EDF Energies Nouvelles. Walker has more than 30 years of experience in energy in public and private entities, including positions at MCR Geothermal and Edison Mission Energy. He pioneered wind project development in Greece, Turkey and Mexico.

“Jim has provided true vision and leadership not only for the wind industry, but for each individual he comes across.  His endless energy for new ideas is contagious, and his drive for constant evolution on how to approach challenges is an inspiration to those around him.  He can wear many hats from a mentor to professor to leader to excellent dinner seatmate,” said WoWE Board Member, Liz Salerno. “After meeting Jim, you will quickly find out there is always a great story behind his knowledge and experiences.  Despite the amazing accomplishments and stature Jim has earned over the years, he never fails to be incredibly generous with his time and knowledge.”

Woman of the Year award—Trudy Forsyth has been a leader in wind energy and renewable energy for the past two decades. She was the U.S. Department of Energy’s Golden Field Office liaison and coordinator of NREL’s technical support for the Small Wind Turbine Field Verification Project, overseeing testing of small turbines to International Electrotechnical Commission (IEC) standards. She co-authored the IEC technical standards and served as an IEC secretary for the second and third revisions of the IEC small wind design and safety standards.  Forsyth led the development of AWEA’s Small Wind Roadmap—published in 2002.

For many years, she was a leading NREL voice on the Wind Powering America initiative (now called Wind Exchange) working to break down barriers to installing wind turbines.

Forsyth has served on the Boards of the Small Wind Certification Council, the American Solar Energy Society, the North American Board of Certified Energy Practitioners, and the Distributed Wind Energy Association. She has also been a true champion and mentor for other women and girls in the industry and in science technology and life in general; the range of her activities include being the first “official” Board Chair for Women of Wind Energy for the past four years and working with the Girls Scouts.  Forsyth has worked tirelessly throughout many years to foster the engagement of girls and women in engineering, aerospace, and the renewable energy sector.

Preserving Integrity in Composite Components

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Composite repair is an art, relying on high-tech tools and processes—in the hands of skilled technicians—to extend product life.

While composites are strong and durable, they are not immune to damage. Composite parts on everything from boat hulls to wind turbines can be impaired through collisions, lightning strikes, environmental exposure and other causes. In addition, as parts age fatigue may also be a factor. With applications for advanced composites ever increasing, so too is the demand for repair services and experts.

While the basic principles of repair have not changed much recently, the size and complexity of the repairs have. For example, last December a team of Boeing engineers and technicians repaired an Ethiopian Airlines 787 Dreamliner that was damaged extensively by fire. It was the first major repair to an airliner made largely from carbon-fiber-reinforced plastic. In the wind market, technicians are challenged to perform maintenance on increasingly larger wind blades, some as long as 250 feet.

The repair of advanced composite parts follows a standard series of steps: damage assessment/ inspection, preparation, repair, curing, final inspection, and finishing. But in the field, each damaged part poses unique requirements based on the type of composite material and the manner and extent of the damage. Each repair requires its own solution that must be uniquely engineered, particularly if the structural integrity of the part has been compromised.

Step one: Damage assessment/inspection
Since the repair’s design is driven primarily by the type of damage incurred, proper assessment and inspection is critical. Beyond a preliminary visual inspection, there are a range of nondestructive inspection techniques available in the repair technician’s tool kit.

Manual audio sonic testing, or “tap testing,” is the most straightforward method to detect voids, degradation, and delaminations in a composite structure. Tap testing used to be as simple as taking out a coin or tap hammer and listening for a change in tone where the laminate is damaged or has delaminated from the core material. Now repair technicians use digital tap hammers to more accurately identify and measure the damaged area. Along with ultrasonic A-scan methods to determine the depth and size of damage, these are the workhorses of inspection.

Louis Dorworth, division manager of direct services for Abaris Training Resources Inc., a provider of composites repair training, notes that repair technicians are increasingly using higher-tech methods for inspection. “Thermal imaging (thermography) is performed with infrared cameras to measure different levels of heat transfer, indicating where defects within the composite part are located,” he says. “More sophisticated, yes, but environmental factors can affect heat transfer, making thermography just one more tool in the repair technician’s toolbox.”

Abaris also teaches the use of laser shearography as a diagnostic tool. “Using a camera, an interferometric image of the part’s micro-surface is taken in an unloaded state,” says Dorworth. “The part is then exposed to loading with heat or weight or vacuum, and the image is compared. Information about the differences between the two photos is extracted, revealing surface strains associated with subsurface defects, anomalies and damage to the internal structure—as minute as one nanometer.”

Inspection of damage to wind turbines poses a unique challenge: height. “We have high-powered camera lenses to photograph the blades from the ground,” says Gary Kanaby, director of sales for MFG Energy Services. “We are just now seeing the use of remote drones with attached cameras for inspection—a much less expensive approach than raising platforms or using technicians on ropes.” Drone cameras can regularly track the progress of minor dings or cracks, enabling owners to make informed decisions on when to make a repair.

With detailed inspection information in hand, the technician or engineer drafts a repair plan. “This is a critical step,” says John Busel, vice president of the American Composites Manufacturers Association’s Composites Growth Initiative. “The plan must take into account the loads and how this repair will provide continuity to the original structure. Understanding the materials, cure temperatures, and rates are all factors in a successful repair.”

Step two: Preparation
Removing the damaged material and debris from the compromised part may require the technician to cut out or grind out the various layers of laminate plies and inside core. During preparation, the technician also confirms the composite and core material, determines whether the repair is in a critical, highly loaded section, and confirms the axis of the unidirectional, bidirectional or multiaxial fibers or fabrics.

Sophisticated preparation technology currently in use, particularly for aerospace composites repairs, includes computer-controlled milling for removal of damage and laser pretreatment to enhance the surface for bonding of the repair. The benefits of these more automated tools include improved consistency, removal of the least laminate necessary, accurate tapering to accept the new laminate plies or prepreg composite fiber materials, and less opportunity for human error, as well as the opportunity to integrate the automated inspection, preparation, and repair tools to form a manufacturing repair cell.

Step three: Repair
Repairs should replicate the original laminate and core, matching the original strength, stiffness, and weight. If the damage is extensive, reaching through the outer ply and into the structure, then the core and outer skin need to be addressed. In the most challenging scenario, damage to the inner skin plies, structure, and outer skin plies require repair.

“The Lamborghini promise is to ensure that the carbon fiber repair is 100 percent the same quality as the original part,” says Casper Steenbergen, head of composite repair for the high-end automaker. Lamborghini’s team of repair specialists—called “flying doctors”—travel to dealerships to assess damage and perform repairs. The company modeled its flying doctor program after a similar strategy used by Boeing, says Steenbergen. “The aircraft manufacturer has been working with traveling specialists for some time and has developed a system for execution of carbon fiber repair work using extremely compact equipment,” he says.

Some repairs first require the core to be rebuilt matching the specifications from the original core, such as balsa, or, in the case of wind turbine blades, foam. “We use foam in prescored sheets to make it easy to pack anywhere from 100 x 100 millimeters to several square meters for a major repair,” says Kanaby. The core is later vacuum packed to ensure a complete bond.

The decision to use wet layup or a prepreg repair for the skin depends on the composite material and the original part design. Matching the direction of the composite fibers to each ply of the original design is most critical to duplicating the fiber axial load capability in the structure.

According to Henry Elliot, an instructor at the IYRS School of Technology and Trades, wet layups for skin repair remain the most common method for laminate skin marine applications. “We do see prepregs being used more often now for racing boat repair,” Elliot says. “But prepreg must be used in an environment where temperature, humidity and contaminants can be controlled.”

With wind turbine repair, the environment dictates wet layup. “Prepregs require storage in a cool place to control curing. Since wind turbine repair usually takes place outside in warm weather, we use wet layups 99 percent of the time,” says Kanaby. “Fibers are oriented at 45 degrees in one direction and 45 degrees in the opposite direction for biaxial strength for the skins while unidirectional is used in the structure.”

Dorworth summarizes the complex process of making and bonding repairs: “Once the edges of the damaged part have been tapered or scarfed to accept the repair, a series of replacement plies are cut to size. The fiber material is wetted with a laminating resin that will bond to the existing structure. Alternately, prepreg material, which is already pre-impregnated with just enough resin to bind the fibers together, will require an adhesive interface to bond the laminate. Systematically orienting the direction of the fibers in each repair ply to match the original axis of the corresponding original ply ensures the repair can efficiently transfer loads back into the structure.”

Remaining steps
Once a composite part is repaired, it is cured, inspected, and finished. Though these processes are the essentially same ones used for initial fabrication of parts, they are critical. “The curing step is incredibly important,” says Busel. “Without curing, the repair is garbage: Just think of using a glue to paste two things together that never really bond.”

Finishing the part can be as simple as sanding and cleaning to sealing and painting with epoxy- or polyurethane-based coatings. For aircraft and wind turbines, conductive coatings that provide lightning strike protection are likely required.

Trained technicians
The effectiveness of repairs depends on the skilled hands of technicians. In the past, composites repair technicians learned through trial-and-error or on-the-job training, says Dorworth. Composites manufacturers assigned repairs to their most skilled personnel. But now they recognize the importance of training dedicated composite repair technicians. Aerospace companies, including Boeing and Airbus, have led the way in repair technology and training. “Many aerospace OEMs are actively sharing best practices with other users of advanced composites,” says Dorworth.

He adds that the most popular course offered at Abaris is Advanced Composite Structures: Fabrication & Damage Repair Phase I. ACMA offers the Certified Composites Technician – Wind Blade Repair (CCT-WBR) to meet growing demand for training technicians in servicing and repairing wind turbines. To date, more than 100 people have earned the certification.

“We are now seeing community colleges and other training organizations offering composite-related repair curriculum,” says Dorworth. “It’s been 25 years in the making, but best practices are evolving around many industries, with aerospace technologies leading the way.”

** This article was originally published in the May/June 2014 issue of Composites Manufacturing, the official publication of the American Composites Manufacturers Association. It has been reprinted here with permission from the copyright holder. For more information on the ACMA’s Certified Composites Technician – Wind Blade Repair course, email Caitlin Felker at cfelker@acmanet.org.

(703) 525-0511 (703) 525-0743 (fax) http://www.acmanet.org/

 

Nordex to invest heavily in rotor blade capabilities

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Nordex SE has announced it will invest EURO 50 million in series production of modern, large-dimensioned rotor blades.

This investment will initially involve the expansion and modernization of its own plant in Rostock, Germany.

The greater dimensions of the products and tools necessitate modifications to the existing production halls. In addition, an entirely new hall for rotor blade finishing will be built. The resultant physical separation of basic production and finishing removes the need for complex production steps in cabins and facilitates quality assurance.

Nordex plans to implement its blade strategy between 2014 and 2016.

Profile: Dr. Shrink

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One of the core values of the wind energy industry has always been environmental protection—reducing both harmful emissions caused by traditional energy sources and reliance on precious natural resources.

For Dr. Shrink, a 22-year-old business specializing in shrink-wrap for applications ranging from marine to construction to heavy industry, wind energy is a natural fit. Environmental protection is what Dr. Shrink does. Only in this case, the company’s entire business is focused on helping its customers protect their valuable assets from the environment.

In 1992, following several years of experience with shrink wrapping application, Michael Stenberg started Dr. Shrink as a training and distribution operation out of his single-car garage in Traverse City, Michigan.

Stenberg founded the company with the intention of being a single-source to whom customers could turn for any shrink wrapping need, whether it be the shrink wrap material itself, installation products such as tools and accessories, or intangibles like expert advice, information, and training.

“We started out in the marine industry and moved outward into areas such as industrial applications, and disaster relief, among other areas,” Stenberg said. “Shrink wrap works in almost any industry.”

After establishing a presence in industrial markets, the company expanded its reach into other markets, one of which was the wind energy industry. Eight years ago, Dr. Shrink attended the American Wind Energy Association’s WINDPOWER Conference & Exhibition, and began to gain the attention—and business—of wind energy clients.

“We eventually started working with and providing materials for GE, Mitsubishi, Vestas, Suzlon—all of the big manufacturers,” Stenberg said. The company’s involvement in the wind energy industry has evolved and grown in the years since. “As the wind industry has gone up and down, we’ve kept customers, and now we have a fair amount of European business through our distributors in Germany, Norway, and the UK.”

For the most part, wind energy applications consist of covering vital wind turbine components with shrink wrap to protect against harmful elements those components could face either in transit, in warehouse storage, or at the turbine lay-down site prior to erection and installation.

“When wind turbines are completely assembled, they’re totally weather proof,” Stenberg said. “What we do is offer the products for covering blades, tower ends, nacelles—all the different pieces—while they’re being transported and stored. Even if a turbine is put into a lay-down field and is left there for two years, our products would still protect it. We’ll warranty them for two years in any climate.”

The materials used in the premium shrink wrap offered by Dr. Shrink allow the product to be useful in a wide temperature range from 40 degrees Celsius down to negative 40 degrees Celsius. Additional features and enhancements such as dessicants and anticorrosives allow for additional specialized protection.

The goal, according to Stenberg, is to make sure that a customer’s valuable assets are completely protected from damage caused by environmental factors in any climate that they may face.

The shrink wrap process involves unrolling the raw shrink wrap material—which is delivered on long spools, and ranges in width from 12 feet to 60 feet, and lengths up to 229 feet—to the required dimensions; draping the material over the component; trimming to size and creating a seam; and then using a propane fired heat tool to shrink the material to the component.

Looking forward, Stenberg said Dr. Shrink will stay attuned to the needs of the wind energy industry as needs vary.

“We’re always coming up with new products that may work for different industries. Even as the wind industry evolves, they may need different items for longer-term protection. There may be different applications as new materials are being used. We’ll evolve along with them and make new products to meet those needs.”

Dr. Shrink operates out of a 73,000-square-foot facility in Manistee, Michigan, which houses a minimum of one million pounds of product in stock at all times. Additionally, the company carries installation tools, access doors, specialized tape, and full range of all the other accessories associated with shrink wrap applications.

“Whatever is needed to do any job, we have it sitting in stock for immediate shipment,” Stenberg said. “We can ship, generally speaking, about 98 percent of all orders same day.”

Conversation with Steve Kistner

How did Thermo Bond get started in the wind energy industry?

Thermo Bond Buildings has been building Electrical Equipment Shelters and Telecommunication Shelters for nearly 30 years. Many of our energy and utilities customers using our buildings for telecommunications and other applications appreciated the flexibility and vast array of integration options and saw our ability use those talents building substation control buildings. Together with our customers we began designing, engineering and building Substation Control Buildings over 15 years ago.

What products does Thermo Bond offer specifically for the wind market?

Thermo Bond Buildings builds fully integration Substation Buildings, Inverter Buildings and Power Control/SCADA Buildings for the wind market. These buildings can be all steel buildings, precast concrete buildings and prefabricated lightweight buildings in a number of configurations. Thermo Bond Buildings also provides smaller cabinet style enclosures for smaller equipment needs.

What advantages does Thermo Bond offer over other manufacturers?

Thermo Bond Building is not just providing a shell that you can put your equipment in. We pride ourselves on providing a complete solution for each of our customers’ unique projects. We work with each Project Manager to customize our solution to provide a site solution. We can provide the electrical (AC & DC systems), integration, batteries, rectifiers. Doing the integration at our facility reduces field expenses and potential delays at the site.  We are able to help the customer reduce the number of vendors they are managing.

How does the process work?

The customer contacts a Thermo Bond sales associate by phone, email or through our website, which leads to an exchange of information, drawings, questionnaire, etc. to establish the scope of work and design needs (e.g., shelter size, HVAC, electrical, grounding, etc.). A detailed quote that includes shipping cost is prepared by the Thermo Bond associate for the customer to review. A purchase order/contract is submitted by the customer along with a rough sketch of the shelter design for use by the Thermo Bond drafting department in preparing detailed construction drawings of the interior layout, exterior view, cross sections of the wall, roof and floor, skid assembly and foundation. Construction drawings are finalized by the customer and our manufacturing team at Thermo Bond builds it according to specifications. A Thermo Bond representative provides blueprints to the appropriate state agencies, if necessary, and coordinates delivery of the finished building by truck and trailer to its designated location. The completed project is reviewed by the Thermo Bond associate to ensure complete customer satisfaction prior to the invoice being processed.  We continue to support the customer as required after the building is delivered.

Could you cite a specific wind industry installation?

Thermo Bond Buildings constructed, delivered and installed a 15’-0” x 46’-0” x 10’-6” all steel, fully functional, pre-assembled control building to a Nebraska 230/34.5 kV wind energy substation. The building construction was of a heavy duty, non-combustible, rigid framed steel structure that included AC/ DC electrical components, a 125vdc Battery system, HVAC, cable tray, grounding, alarm and other auxiliary equipment. Thermo Bond provided this high quality, cost effective solution within the customer’s mandatory 12 week timeframe, while satisfying all customer required structural, electrical and safety specifications as well as adhering to all state and local regulations and building codes.

(800) 356-2686 www.thermobond.com /ThermoBondBuildings @ThermoBond

 

CASE STUDY: Building One of Chile’s Largest Wind Farms in Three Months

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Wind energy has come a long way in Chile since the first wind farm was inaugurated in 2001, the Alto Baguales, a three-turbine farm that generated 2 MW of energy. Today, Chile has over 300 MW of wind power generation capacity, and the recently inaugurated Valle De Los Vientos park at the northern Chilean region of Antofagasta accounts for 90 MW. Valle De Los Vientos is the first of three wind farms planned for this region. With the other two already approved, the Calama joint wind farm will have 240 MW capacity and a total investment of more than $500 million. To erect this new generation wind farm, developer Enel GreenPower requested lifting services of Gruas Burger and their Terex CC 2800-1 NT crawler crane.

Erecting wind turbines is somewhat a dichotomy: one has to build the turbines where there is wind, but one can seldom perform lifts with strong wind speeds. Complicating the matter even more is the fact that one has to take into consideration the wind sail area when lifting large surface components. If all this comes together, the window to perform the lifts might be small, and lift companies must be ready to act when it opens. When building an entire wind park comprised of 45 turbines, these variables add up and can bog down a project or significantly increase its costs. Figure 1

Gruas Burger came to prominence worldwide relative recently for being the crane rental company that supplied the cranes to rescue the 33 miners trapped at a mine in the north of Chile. Not only has this crane and transport company been around since 1996, but it also is no stranger to the hostile climatic conditions of the Chilean Desert, where hot temperatures and high altitudes are everyday working conditions. It was natural that they were the right company to erect a large wind park in the north of Chile.

Planning and erecting a wind park has its idiosyncrasies. Besides transporting the turbines, building the foundations and erecting them, an often-overlooked aspect for this type of project is site preparation. Access roads, lifting pads, and support facilities need to be built from scratch, often in remote areas like this one. On top of this, the variability in climatic conditions when the turbines can be erected meant that the project has a high potential for delays and cost increases. To mitigate these risks, it was important to be efficient in planning, and be reliable when lifting.

Efficiency in Ground Preparation
“Ground preparation is very important when performing lifts, and it’s an aspect one should never skimp on, but there are ways to minimize costs in projects like this,” said Raul Burger, president and owner of Gruas Burger. “We are very experienced in erecting wind turbines, so we offered the developing company our services with the NT crane so they only needed to build 5.5-meter-wide roads for the crane instead of 10 meters, which is usually needed for a crawler crane. We helped them save a significant amount of money.”

Whereas the track footprint of the conventional Terex CC 2800-1 crawler crane measures over 32 ft (9 m), the track width of the Terex CC 2800-1 NT is only 17.4 ft (5.3 m), allowing Burger’s crews to navigate the narrow roads. Even with the narrow tracks, the crane still offers the high lift capacities customers expect from a 660-ton crane. Large 16.4 ft long x 4.6 ft wide (5  x 1.4 m) front/rear outrigger pads work in conjunction with two hydraulically operated 9.8 x 7.9 ft (3  x 2.4 m) side outrigger pads to give the stability required for lifting heavy loads. Figure 2

Heart-Stopping Construction Pace
The pace at which this wind farm was built was outstanding by any standard, according to Raul Burger. “It was a logistic masterpiece we are proud of. After the access roads and pads were prepared, and the turbine parts in place, we erected each turbine and then crawled with the fully erected crane to the next pad. On average we erected one turbine per day and each turbine required seven lifts. It was indeed a very fast pace.”

The Valle De Los Vientos wind farm is comprised of 45 Vestas V100/2000 2 MW turbines with a rotor diameter of 100m. To erect these type of turbines, the crane had to lift loads up to 100 tons up to a height of 80 meters with a usual working radius of 18 meters.

“After 2 months of hard work, we lifted the last nacelle. It was a wonderful feeling to look back and see how much we contributed towards renewable power in Chile in such a short time,” Raul Burger said.

The Terex CC 2800-1 NT crawler crane offers a high return on investment and is among the most economical and versatile narrow track cranes in the 660 US ton class. Using a selection of specially designed accessories, the crane is convertible from standard heavy lift configuration to a narrow track crane and back, providing outstanding performance in a wide variety of applications, including wind farm sites, where extra heavy load capacity is a necessity. Figure 3

Recognizing the high potential of the onshore wind turbine market and the subsequent need for dedicated equipment in the 660 US ton class, Terex Cranes developed the CC 2800-1 NT (narrow track) crane model from the standard CC 2800-1 version to suit specific wind farm construction requirements. Equipped with its narrow track chassis, the CC 2800-1 NT can be driven from one construction site to the next, even when access is tight, while fully rigged with counterweights, 334.6 ft. (102 m) main boom and LF 2 fixed jib, saving precious time and increasing productivity.

The CC 2800-1 NT version is based on a conventional CC 2800-1 crawler crane, where the standard chassis (27.6 ft {8.4 m} track width) is replaced with the Narrow Track Kit comprising of: chassis track with 5.3 m outer track width and front and rear outriggers, two 16.4 ft long x 4.6 ft wide (5  x 1.4 m) outrigger pads for both front and rear outriggers, two side outriggers with 9.8  x 7.9 ft (3  x 2.4  m) outrigger pads, counterweight suspension frame to lower the center of gravity and control system with remote control unit and full color graphic display monitor at the rear of the crane chassis. To provide stability and quick rigging times, both front and rear outrigger beams remain connected to the carrier.

—Source: Terex Cranes

Full-Field Wind Measurements Can Make Wind Power More Competitive

At present, the efficiency of a wind turbine cannot be accurately measured because of inadequate data on the wind field across the swept area of the rotors. This poor correlation between energy generation and wind conditions conceals the true state of turbines and affects the accuracy of the 24 hours forecast of power output.

Inadequate Performance Evaluation
Turbine performance is usually evaluated using power curves that express electricity generation as a function of wind speed.

The power curve is based on data from the nacelle-mounted anemometer and on the 15-second average power output. However, using the 15-second averaged figure means that the change in actual output cannot be clearly assigned to the measured wind speed (Figure 1). This ambiguity (output in relation to wind speed) can mainly be attributed to the inaccurate and incomplete nature of wind measurements being taken by the anemometer (which fails to take account of shear winds, wind direction, and changes in wind direction). This makes it impossible to determine the actual efficiency of the turbine. This disparity means that, even now, production losses of up to 10 percent cannot be identified with any degree of certainty. The reasons for the loss in efficiency therefore remain undetected, which in turn reduces the competitiveness of the turbine owner/operator.

Indeterminate Energy Yield
Energy yield presents another problem. There are many different reasons why losses occur when wind is converted into energy—one of these being a lack of precision when determining the actual wind direction.

Wind direction is established using a wind vane mounted on the nacelle. But the wind vane—like the anemometer—has a number of shortcomings. On aspect is that first, it is located behind the rotor blades in a turbulent airstream and therefore has to take measurements over a long period of time if it is to supply meaningful data. Moreover, it only measures at one point in the flow field of the swept area, and consequently cannot record all the important data. The wind vane is also affected by the flow conditions prevailing at the nacelle itself and this in turn creates additional measurement errors (Figure 2).

Inadequate Turbine-Output Forecasts
The use of 24-hour wind power forecasting is becoming increasingly popular as more and more wind power is traded on electricity markets.

The forecast consists of a weather report for the turbine site and a calculation of the power output under the forecasted conditions. The forecast for the following day is based on numerical simulations projected on to a grid, which nodal points are some three to eight kilometers apart. Seventy percent of all forecasting errors are connected with this process and relate to the difficulties that arise when trying to accurately predict weather front movements.

The remaining 30 percent of errors are caused by “downscaling,” the process whereby the predicted wind direction at the nodal points is assigned to the actual site of the turbine. To illustrate this, we have taken an NREL forecast (NREL/CP-550-48146) (Figure 3) that compares the yield from a wind farm with the actual air flow measured by a weather station set up in the park.

As the figure shows, the relationship between energy and wind speed at the weather station presents a very fuzzy and ambiguous picture. In fact, when the wind speed is 10 m/s the power output varies between 100 MW and 300 MW. With more precise mapping (creating a link or correlation between the wind-field data at the respective nodal points and the corresponding wind turbine), not only in terms of wind speed but also for shear, turbulence, and changes in wind direction, the error rate associated with downscaling could be reduced.

Full-Field Wind Measurements Based on Blade Deflection
The aforementioned problems could be tackled by taking full-field measurements with a wind sensor. The underlying technology combines measurements of blade deformation with a highly advanced signal analysis and processing unit. Blade deformation is recorded by a digital camera, which tracks the displacement of reflectors embedded deep inside the rotor blades. As the “raw camera signals” are not very meaningful on their own, they are then relayed to a computer in the nacelle for real-time analysis and processing.

A one-year field trial compared flow speed, wind direction, shear wind components, changes in wind direction, and turbulence levels with the values recorded by a continuous-wave LIDAR system installed on the rotor hub. The LIDAR is equipped with a rotating prism that can pivot the laser beam so as to provide a comprehensive description of the prevailing wind field. The field trial found an excellent match between the blade-based wind sensor and the LIDAR. This consistency was based on 15-second mean data, whereby errors and discrepancies could be identified much more easily than with the 10-minute data. Moreover, during the test the wind vane was rotated manually through a precisely measured angle, whereupon the wind sensor was able to detect this deviation within 30 minutes to an accuracy of 0.3 degrees.

More Precise Power Curves
The blade-sensor’s ability to provide a complete and instantaneous measurement of the wind field means that much more precise power curves can be obtained. By gaining immediate access to information about the complete wind-field conditions, it becomes possible to calculate the wind speed but also wind shear, turbulence levels, and wind shift at the moment of power generation. The measured power output can thus be broken down into “bins” (categories) according to wind shear, turbulence, and wind shift, which allows power curves to be generated for each categorized wind-field condition (Figure 4).

Determining Actual Efficiency
Having an accurate and clearly defined power curve, along with information about all prevailing wind-field conditions (bins), allows us to determine the actual efficiency of the turbine. Let us assume that the output of the turbine is below its specified rating. Is this because the installation itself is less efficient than it should be? To answer this question we need to look at the wind-field category (bin) that corresponds to the manufacturer’s power curve. If there is no divergence between the two then the turbine is operating at full efficiency. In such a case the reason has to be sought in the wind field, or more precisely in the bin in which the turbine is being operated most of the time. If there is a divergence here, the data from the wind sensor can be used to carry out a targeted root cause analysis.

More Accurate Mapping Through “Experience”
As stated above, errors in downscaling can be greatly reduced if accurate information is available on the prevailing wind field. The data can be used to achieve much more precise mapping between the values at the computational grid points and each individual turbine. This mapping would then build on the bin values used in the power curve and in practice continuously improve through “experience” (learning from errors between predicted and actual output).

Conclusions and Outlook
Being able to make better assessments of turbine output is a top priority for turbine owners and operators. Wind speed, wind direction, wind shear, changes in wind direction, and turbulence in the wind field can now be measured with real accuracy and this makes for more exact power curves, increased energy production, better 24-hour forecasts, and more accurate blade condition monitoring. This new technology is both cost-effective and extremely reliable. Moreover, it can be used on every turbine and consequently offers significant potential for improving the competitiveness of the wind power industry.

+49 5976 946 0 www.emersonindustrial.com EmersonIndustrialAutomation

 

GE Demonstrates Blade Extension Technology at WINDPOWER 2014

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At WINDPOWER 2014 in Las Vegas, GE demonstrated its new blade extension technology which takes GE wind turbines from a 77-meter rotor to a 91-meter rotor by adding a seven-meter extension to the turbine’s blades. The extension increases the swept area of the rotor by 40 percent and increases the energy production by more than 20 percent.

The technology was implemented in two prototypes that have now been in operation for 10 months. The prototypes were completed with Noble Environmental Power at Noble’s Clinton Wind Park in Clinton, New York.

The technology upgrades GE 1.5-77 turbines to GE 1.5-91 turbines utilizing the entire existing blade asset. The program was developed by GE to help customers achieve significant increase in power output on their existing fleet while maintaining existing product life and acoustics. Throughout the development of the extensions, the GE team filed more than 16 patent applications and developed custom tooling for the extension installation.

“The blade extension program for GE is a great example of the magnitude of technology advancements GE is capable of developing,” said Mark Johnson, engineering leader for GE’s renewable energy business. “At GE, we take big swings to help our customers reach their goals and operate more successfully. Achieving production gains of more than 20 percent for existing units is a challenging task, and with GE’s expertise in engineering aerodynamics, material science, structural engineering and controls, we continue to be able to help our customers operate more profitably and efficiently.”

Advanced technologies developed to make the project a reality include the unique, centrally located insert, improved methodologies and advanced controls for loads mitigation. The extended blades have undergone testing beyond IEC requirements, including static strength tests that are standard for all GE-engineered blades and fatigue tests totaling more than 6 million cycles. The model and process utilize the existing design margins of the 1.5-77 turbine in lower wind speed applications. In addition to the extended blades, modifications were made to controls and parts to adjust for the added loads on the turbine.

Videos be found at www.youtube.com/user/GErenewables.

Vestas Installs Next Generation Low-Wind Protype

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Vestas has installed the first V110-2.0 MW prototype turbine at a test site in Høvsøre, Denmark. The turbine has produced its first kilowatt hour of electricity and will undergo an extensive test and verification program to ensure reliability before full-scale production commences. Initial availability of the V110-2.0 MW is expected by year’s end.

The V110-2.0 MW is built on the proven technology of Vestas’ 2 MW platform and features a larger rotor using 55-meter blades. The turbine is optimized for production on low-wind sites, and increases annual energy production by up to 13.6 percent when compared to the V100-1.8 MW on low wind sites.

“Vestas’ product development strategy is to optimize our products and services to continue to lower the cost of energy for customers,” said CTO Anders Vedel. “The V110-2.0 MW is an extremely competitive product for maximizing energy production at low wind speeds, and over 400 turbines sold demonstrate customers are responding positively to Vestas’ strategy.”

In addition to the larger rotor, the V110-2.0 MW has a strengthened gearbox when compared to previous 2 MW turbines, to withstand the increased force from the wind on the larger rotor. Furthermore, new control features have enabled strengthening of the hub and other parts of the structure without increasing the overall weight.

A Guide to Understanding the Most Common Types of Wind Turbine Generators

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As you drive into work in the morning, you can see that the turbines at your wind farm are spinning and are on-line. They are producing power. But can you tell how much power?  I can’t. Why is that?
   
That’s because the turbine turns pretty much the same speed or revolutions per minute (rpm) when the turbine is producing minimal or maximum power.

How much does your team understand about how the turbine’s generator produces power?  Let’s find out.   

There are many different types of generators used today in wind turbines, but the most common types are asynchronous generators. The two types most commonly used are the squirrel cage induction generator and the wound rotor induction generator—also known as a doubly feed induction generator (DFIG).  

Both types work pretty much the same way, with DIFGs having some additional capabilities.

I will start with explaining the operation of the squirrel cage induction generator and then explain an attribute of the other.

For most turbines today, if the turbine is safe, has no faults or errors, and sufficient wind is present, the turbine will face into the wind and the blades will start to rotate as they absorb energy.  As the rotor turns the gearbox, the generator also rotates.  But as we all know, the turbine is not generating power if it is spinning at less than the connecting speed of the generator. The turbine can pinwheel for hours or days if there is not enough wind to get it up to spinning to the generator connection speed. We know that the turbine—that is, the generator shaft—has to get up to a certain speed before we connect it to the grid by applying power to it. That speed is called synchronous speed and is the speed at which the generator neither consumes power nor makes power (other than reactive power, but that’s a topic for a whole other article).

In reality we could apply power to the generator at any time.  But if we do so before we reach the connecting speed, we will be running the generator as a motor.  If we run the generator as a motor, then we will be consuming energy and that will cost us money. Why is this?

The connecting speed of the generator is determined by the number of poles in the generator.  It is also a function of the frequency of the grid. The frequency in the U.S. is 60hz (or cycles per second). Other parts of the world use 50hz. The generator is constructed is such a way that there is a relationship between the number of poles in the generator and the frequency of the power supplied by the grid.  This relationship is what determines synchronous speed of the generator.  A six-pole generator has a synchronous speed of 1,200rpm @ 60hz, and a four-pole generator has a synchronous speed of 1,800 rpm @ 60hz.  

You may be asking: “What does that all mean?” Synchronous speed means that the shaft of the generator rotates at the same speed of the rotating magnetic field that is formed when the generator has power applied to its stator when it is connected to the grid. If the shaft rotates slower than the magnetic field in the stator, then the generator will be working as a motor and will consume power.  That is why we don’t connect the generator at rpms much lower than the synchronous speed.  We typically connect just under or at synchronous speed—the point at which the turbine is expected to produce power.  When we connect power to the generator just at synchronous speed, the wind tries to push the generator faster than the rotating speed of the magnetic field in the generator.  Instead of the generator spinning faster, the system produces power. If the wind pushes soft against the magnetic field or pushes hard against the magnetic field, the generator maintains pretty much the same rpm but produces more power the harder the wind pushes.

Here is a good practical example of what is happening. The rotating magnetic field in a 4-pole generator rotates at 1,800rpm at 60hz here in the U.S. That magnetic field is basically a wall that prevents the generator shaft from spinning faster. To illustrate this point, choose a wall in your office. This wall will represent the generator’s magnetic field spinning at 1,800 rpm. Go ahead and push against that wall with your hand. Does it move? No. Push harder. You may be able to cause the wall to flex, but it won’t move—no matter how hard you push against it. The same principle applies with the magnetic field in the generator. Once the turbine gains speed and connects to the generator, the wind pushes, but the magnetic field in the generator doesn’t let the generator rotor shaft turn any faster. Instead, power is produced according to how hard the wind pushes. The wind spins the turbine and in turn pushes against the rotating magnetic field of the generator.

If you were to remove the wall and push in the place where it once existed, you would go tumbling forward (presumably into another room. The same thing would happen if you removed the magnetic field from the generator (disconnected the generator). If you removed the magnetic field while the wind is blowing, the blades would still be absorbing energy. That energy has to go somewhere.  In this case, the energy transfer would increase the rotational speed of the turbine, resulting in the turbine entering overspeed.  

A DFIG works the same way as a squirrel cage generator, except that it allows you to move the “wall” you’re pushing against. We can move the generator’s magnetic field by adjusting the power to the rotor through slip ring connections. Instead of the wall being fixed at 1,800 rpm, it can be adjusted electrically. By adjusting the power to the rotor, it can move forward to say 900 rpm and backward to 2,000 rpm. The advantage of being able to move the wall allows us to produce power at lower rpms and to absorb some gust loads by allowing the wall to move back or faster, absorbing the additional load.  The way we move the wall or the magnetic field in the generator is by adjusting the power to the wound rotor with power electronics.

I hope this increases your understanding of how the generators in your turbines produce power, and explains why you can’t tell from looking at the spinning turbines how much power is being produced. I’ll leave you with one last tip about wound rotors. If the turbine experienced a true overspeed, it would be prudent to perform a bore scope inspection of the windings for expansive movement.  At the minimum, the situation necessitates a climb to the turbine to listen to the generator up-close at very low rpms in order to detect rubbing of the rotor windings on the stator. If rubbing is present, the rotor could be damaged, and you could take steps to prevent damage to the stator.

As always work as safe as possible and work to prevent surprises.  
 

Siemens, Pattern Energy Agree to Long-Term Service Contract

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Underscoring growing customer confidence in the valuable benefits Siemens Energy can provide with its flexible, longer term wind service agreements, the company has been awarded 10-year wind service agreements encompassing over 400 onshore wind turbines in the U.S., Canada and Puerto Rico. The customer is Pattern Energy Group Inc., based in San Francisco. Combined, the scope of these long-term contracts represents one of Siemens’ largest agreements with a single customer in North America.

Pattern Energy is a leading independent power company with a portfolio of 10 wind power projects in the United States, Canada and Chile.

“This is an important milestone in the continued maturation of the wind industry in North America,” said Tim Holt, CEO of Service Renewables, a business unit of the Siemens Energy Service Division. “As more and more wind energy is placed into service, our commitment is to provide long-term added value to customers like Pattern Energy in order to help them realize favorable performance throughout the turbines’ lifecycle.”

“As an industry leader with vast experience, Siemens brings long-term reliability and technology enhancements to our wind projects, ensuring improved performance and lower operating cost risks from each and every turbine,” said Mike Garland, President and CEO of Pattern Energy.

Helping Pattern Energy obtain continued reliability, availability and performance of the turbines, Siemens will provide the long-term service and maintenance, as well as technology updates, for six Pattern Energy wind projects located in the U.S., Canada and Puerto Rico with a combined output of over 930 MW.

The current operating projects included in the new service agreements are Pattern Energy’s St. Joseph Wind project in southern Manitoba (138 MW); Spring Valley Wind in eastern Nevada (152 MW); Ocotillo Wind in Southern California with (265 MW); Hatchet Ridge Wind in Northern California (101 MW); and Santa Isabel in Puerto Rico (101 MW). These projects are also slated to receive a variety of modernization and upgrade components representing the latest technological advancements, such as Siemens’ Power Curve Upgrade, a combination of add-on components designed to help improve the aerodynamic performance of installed turbines.

In addition to the projects currently in operation, Siemens has also signed a 10-year service agreement for the Panhandle 2 wind project in Texas (182 MW), which Pattern Energy has agreed to acquire when the project reaches operation later this year.

Spider Provides Turnkey Blade Access with Largest Platform to Date

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Spider, a division of SafeWorks, LLC, recently designed, manufactured and rigged its largest 360° Blade Access Platform (BAP) to date.

The customer, Alstom, required access to the blades of its massive 3.0 MW prototype turbine at the National Renewable Energy Laboratory in Boulder, CO to conduct R&D on a new power performance improvement package. The scope of work required the platform to pass the max chord on the blades and have access to the blades’ root.

In less than four weeks—two weeks ahead of the anticipated production schedule—Spider designed, manufactured and delivered the custom 15 ft x 10 ft BAP—its largest to date—to Alstom.

Additionally, Spider technicians surveyed the turbine to develop a rigging plan that allowed the use of a four hoist platform by routing the rigging slings over the blades in a bunny ear position. With Spider on site daily to handle the rigging needs and provide immediate support throughout the three-week project, Alstom’s blade technicians were able to focus on their scope of work.

“In addition to providing a stable and safe working platform, Spider’s management of design, construction, rigging and on-site support allowed us to complete our project without any issues,” commented Jon Campbell, innovation program manager with Alstom.

GE Unveils Wind Farm Plant Management Suite

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GE recently announced the expansion of its brilliant wind platform to include plant-level wind management software applications to improve overall wind farm output.

Using the power of the Industrial Internet and turbine-to-turbine communications capabilities, GE’s new software allows the turbines within a wind farm to act as a cohesive unit, rather than individual assets. Wind plant wake management is the first farm-level management application launched by GE and enables customers to recapture lost power output from waking effects.

With the wind farm wake management application, turbines balance performance and loads throughout the entire wind farm. In turn, wind farms can achieve greater power output as an overall plant, and customers can expect to see 5-10 percent reduced wake losses and improved mechanical loads due to lower wake turbulence. This translates to up to 8 percent more profit for the wind plant.

GE’s wind plant management applications will be optional features on new projects. For turbines currently in operation, the technology will be integrated into GE’s Wind PowerUp technology platform.

GDF SUEZ to Upgrade 19 Gamesa Turbines in France

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Gamesa has landed a contract from La Compagnie du Vent, a wind energy subsidiary of GDF SUEZ, to upgrade 19 wind turbines in the south of France.

The contract includes the frames’ reinforcement as part of the life extension program of the five wind turbines of 660kW, the implementation of the algorithm improvement software, and the Gamesa premium Availability (GPA) in 14 Gamesa 2.0 MW wind turbines.

This contract bolsters Gamesa’s presence in the operation and maintenance market, a linchpin of the company’s growth potential. Moreover, this activity is a vital tool for creating value associated with the development, availability and profitability of wind energy projects.

The wind turbine life-extension program consists of a series of structural reforms and a monitoring system designed to prolong the useful lives of WTGs made by Gamesa and also by other manufacturers beyond that of the original design specifications, thereby guaranteeing the equipment’s safety and availability, enabling control over O&M costs and streamlining the cost of energy.

ACoS Condition Monitoring System Reduces Cost of Energy

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Cost of energy (CoE) is the key measure of wind turbine efficiency, as well as being a top priority for turbine operators. Condition monitoring systems make an important contribution in this regard, enabling condition-oriented maintenance to reduce operating costs, and therefore the CoE, in a sustainable manner. ACoS, the Advanced Condition Monitoring System from Rexroth, is a world first, combining condition monitoring for all components in the power train of a wind turbine and intelligently networking measurement data from different sensors. A standardized operating interface for all sub-systems speeds up the analysis process and reduces the need for training.

Building on many years of experience with the BLADEcontrol rotor blade monitoring system, Bosch Rexroth AG has now joined forces with technology company DMT GmbH & Co. KG to develop the holistic ACoS condition monitoring system. The system combines monitoring for all relevant function groups by means of a standardized and continuous connection to a control desk, thereby reducing the need for hardware. By synchronizing the data measurement process, the detection sensitivity and data quality are also increased.

The universal system philosophy enables easier operation while simultaneously increasing the efficiency and transparency of the monitoring process, allowing a considerably greater number of turbines to be covered by each monitoring expert. The system reduces turbine monitoring costs, while also improving the ability to plan for maintenance operations.

Operators of onshore and offshore wind turbines are thereby able to reduce their CoE on a long-term basis over the entire service life of the turbine.

Proven measurement and analysis strategies are combined to form a holistic monitoring strategy on an open platform composed of individual function modules. All measurements are synchronized with each other. By combining monitoring of the rotor and power train, abnormalities on one component can be checked and verified by means of cross-comparison with the measurement data of the other component.

In addition to holistic turbine monitoring, ACoS includes GL-certified ice detection on the rotor blades. This option eliminates on-site inspections of wind turbines to ensure that they are free of ice, allowing the turbine to be restarted safely and promptly once the ice is no longer present.

Collegiate Wind Competition winners at WINDPOWER 2014

The clean energy and STEM (science, technology, engineering, and mathematics)-focused competition challenged more than 150 students at 10 universities across the country to design, test, and build a small wind turbine.

Throughout three days of intense competition at the American Wind Energy Association’s annual conference, the teams put their wind turbines through rigorous performance testing, developed carefully-crafted business plans and pitched wind industry leaders on the market opportunities for their turbine designs. As the team with the highest cumulative score, Pennsylvania State’s winning turbine will be displayed at Energy Department headquarters in Washington, D.C.

“Through student challenges like the Collegiate Wind Competition, we are not only engaging college students to develop an interest in clean energy, we are also developing the next generation of clean energy engineers, scientists and business professionals,” said Energy Secretary Ernest Moniz. “I congratulate our first Collegiate Wind Competition champion as well as all of the participating teams on their hard work.”

Jose Zayas (left), director of the Department’s Wind and Water Power Technologies Office, and David Danielson, Assistant Secretary for Energy Efficiency and Renewable Energy, at the Collegiate Wind Competition.

Each Collegiate Wind Competition team was comprised of engineering and business students. Experts including business executives, project and technology developers, scientists, and engineers judged each team.

The competition consisted of three main events, each covering a different segment of involvement in the wind energy industry.

In the first event, teams submitted documents to judges who will assess their concepts and designs for a small, operable wind turbine. Their actual turbines were then tested in a variety of conditions using an on-site wind tunnel.

Teams were then required to deliver a public presentation proposing solutions to market barriers facing the wind industry.

In the final event, the teams were challenged with devising and pitching a cohesive business plan for their turbine to judges and audience members.

The University of Massachusetts Lowell—which developed a transportable wind turbine that charges portable electronic devices—placed third at the Collegiate Wind Competition.

Rounding out the top three finishers was the University of Kansas, in second place, and the University of Massachusetts Lowell, in third. In addition, the following schools were recognized as top finishers in the following categories:

• Market Issue Presentation: Pennsylvania State University
• Business Plan Development: University of Kansas
• Turbine Design and Testing: University of Kansas

Penn State was also crowned as the People’s Choice winner—the audience’s pick for the best business “pitch” presentation.

Other schools participating in the competition were Boise State University, California Maritime Academy, Colorado School of Mines, James Madison University, Kansas State University, Northern Arizona University, and the University of Alaska-Fairbanks.

For more information about the Collegiate Wind Competition and how the Energy Department is advancing the state of wind energy technology, visit www4.eere.energy.gov/wind/windcompetition/home and www.energy.gov/eere/renewables/wind.