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June 2015

Editor’s Desk

Stephen Sisk
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Editor’s Desk

No, I don’t mean the four-letter “s-word” that likely comes to your mind. In fact, this “s-word” isn’t profane at all. It’s profound. It shaped my life and career choice from an early age, and it has the power to shape the future of the U.S. wind energy industry.

The word? Story.
I’ve written on the subject of story on several occasions, most recently in a similar column for our sister publication Gear Solutions.
The following is an excerpt from that column:

Do croaking frogs still make you want to drink beer? Did they ever make you want to drink beer? Did you name your children Bud, Weis, and Er?
Chances are, this has been the first time you’ve even thought about those little fellas in a decade. And while you may look back on them fondly, it’s easy to discern the shift in marketing strategies with the passing years.

Advertisers now understand they have to convey their messages in a relatable manner in order to influence the audience. A bond must be forged.
Puppy separated from his family? The audience relates, engages, and demands the reunion.
It’s storytelling — a return to the orthodox communication methods used by mankind for millennia.

We are conditioned from youth to engage with and respond to stories. They are present in every aspect and every stage of our lives — from bedtime stories to tawdry office gossip; documentaries to action thrillers; lessons learned to lessons taught.
In his keynote presentation at WINDPOWER 2015, Jonah Berger, New York Times bestselling author of “Contagious: How Things Catch On” underscored the importance of using stories as a “vessel” for communicating messages that engage and influence audiences, in turn generating “word of mouth.”
“Stories,” Berger said, “are the currency of conversation.”

The overarching conversation at WINDPOWER 2015 centered around the future of the industry. Where do we go now? This was fueled by the release of the Department of Energy’s updated Wind Vision Report, which outlines its vision for the wind energy industry through 2050.

Among the report’s key findings, the DOE states that wind energy will continue to be widely available and affordable, and will have positive effects on reducing emissions and boosting jobs and local economies.
Those points, while individually beneficial, add up to a profound benefit when taken as a whole. They’re the small talk, if you will, that takes place in the context of the greater conversation.
None of us in this industry are experts in everything. We all have our own nests of small talk and spheres of influence.
But together, we do tell the whole story and communicate the entire message.

Thanks for reading,

MidAmerican Launches $900 Million Wind Farm Development Plans

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MidAmerican Launches $900 Million Wind Farm Development Plans

MidAmerican Energy is in the process of obtaining necessary permits and easements for the construction of wind farms at two new sites. Pending IUB approval, the company plans to begin construction in spring 2016, with completion scheduled for the end of 2016. Total cost of the project is approximately $900 million. Bill Fehrman, president and CEO of MidAmerican Energy said, “We are very excited about building additional wind farms that will produce clean, carbon-free energy.”

Fehrman said the company continues to focus on developing wind projects because wind generation offers many clear benefits for MidAmerican Energy customers. “Wind continues to be a factor in keeping our customers’ electricity rates among the lowest in the nation.”

Iowa Gov. Terry Branstad noted that MidAmerican Energy’s efforts have helped the state become a national leader in wind generation. “Iowa derives a greater percentage of its electricity from wind than any other state, and we’re second in the nation in the number of people employed in the wind industry,” Branstad said. “Thanks to our low electricity prices and commitment to renewable energy, major tech companies and other energy-intensive businesses are interested in locating and expanding facilities here, which is good economic news for all Iowans.”

Increasing the company’s investment in wind turbines gives MidAmerican Energy the ability to reduce its reliance on coal, which helps protect customers from rising costs associated with meeting stricter environmental standards.

“If we look back a little more than a decade ago, we did not own any wind generation resources across our system,” said Fehrman. “As a company, we made a commitment to developing wind as a resource for our customers, and we’re proud to say we’ve followed through with and expanded upon that commitment. Once the proposed projects are completed, we’re projecting that 57 percent of our total retail load could be served with energy from these turbines. This puts us in a strong position to comply with future carbon emissions limits without placing the significant financial burden of that compliance on our customers.”
MidAmerican Energy customers have expressed their support for renewable energy, and today, wind makes the most economic sense for Iowa and the Midwest.

“We have abundant wind resources in Iowa and community leaders and landowners who want wind development in their areas,” Fehrman said. “Over the next 30 years, an estimated $1.5 billion in property taxes and lease payments will flow to local communities as a result of our wind projects.”

Since 2004, MidAmerican Energy has invested approximately $5.8 billion building wind projects in Iowa, placing the company far ahead of all other rate-regulated utilities in the nation in terms of wind ownership. With the addition of the two projects announced today, MidAmerican Energy’s wind assets will include approximately 2,000 turbines, more than 4,000 megawatts of wind generation capacity and a total investment of approximately $6.7 billion.
 
— Source: MidAmerican Energy Company

Centerbridge Partners Close Senvion Acquisition Deal

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Centerbridge Partners Close Senvion Acquisition Deal

Wind turbine manufacturer Senvion SE, previously part of the Indian group Suzlon Energy Limited, has changed owners. Centerbridge Partners, L.P. , through its Centerbridge Capital Partners private equity investing strategy, has successfully completed the acquisition of Hamburg-based Senvion. All the necessary administrative, legal and financial preparations for the transfer of ownership are now completed. The relevant antitrust authorities have approved the transaction.

Senvion will remain headquartered in Hamburg, Germany.

Following the acquisition, the Supervisory Board members mandated by the old owner have stepped down from their positions. The new Supervisory Board consists of four shareholder representatives (Stefan Kowski, Steven M. Silver, Todd Morgan, and Martin Skiba) and two present employee representatives (Bernhard Band and Thomas Rex).

Senvion put in place a new 950 million euro guarantee and credit facility from a consortium of 15 international banks and credit insurances (issued in April 2015 in a significantly over-subscribed syndication). The new facility is 100 million euro larger than the company’s previous facility in order to support further growth under the new owner.

More than half the transaction capitalization will be funded with equity.

“We are very excited to welcome Centerbridge as our strong new partner,” said Andreas Nauen, CEO of Senvion. “Together, we will take even greater advantage of our potential in the wind energy market. With its leading product portfolio, market position and by leveraging Centerbridge’s strong network, Senvion is now very well placed to benefit from the continued shift towards renewable energy and to continue our course of profitable growth. We will continue to expand our onshore market share, both in our top five markets of Germany, the UK, Australia, Canada and France and in other target markets and will also cement our strong position in the offshore market.”

“Senvion is a highly innovative company with outstanding technology, a leading market position and an experienced, committed workforce and strong prospects,” Stefan Kowski, Managing Director at Centerbridge said. “By working closely with the management, we want to help to further accelerate the company’s growth plans by investing in product development, service excellence and expansion in new markets.”

— Source: Senvion SE

ZF To Acquire Gearbox Business From Bosch Rexroth

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ZF To Acquire Gearbox Business From Bosch Rexroth

ZF Friedrichshafen AG will take over the large gearbox business of Bosch Rexroth AG with more than 1,200 employees. For ZF, the acquisition is an entry into the business with industrial gears that are used in oil rigs, mine vehicles, tunnel drilling machines, or cableways, for instance. In addition, the technology company is strengthening its wind turbine gearbox business. The acquisition agreement signed on May 13 is still subject to the approval of antitrust authorities. The companies agreed to not disclose financial details.

“Strengthening our non-automotive segment is an important objective of our long-term corporate strategy,” said ZF CEO Dr. Stefan Sommer. “The acquisition of the industrial gears and wind turbine gearbox segments of Bosch Rexroth AG is an excellent supplement to our Industrial Technology portfolio and opens up new customer groups.”

In 2014, Bosch Rexroth generated sales of approximately EUR 300 million with the large gearbox business. In the same year, ZF generated roughly 12 percent of its Group sales with the Industrial Technology division in which the company bundles its off-road activities. This share is expected to grow in the long term.

ZF is taking over the two production locations of Bosch Rexroth AG in Witten (North Rhine-Westphalia, Germany) with almost 900 employees and in Beijing (China) with more than 300 employees, as well as the service location in Lake Zurich (USA) with approximately 15 employees — totaling more than 1,200 employees. The primary plant in Witten is not only home to production, but also to the administration, development, and sales departments for large gearbox technologies (industrial gears and wind turbine gearboxes); in Beijing, Bosch Rexroth exclusively produces wind turbine gearboxes. At both locations as well as in Lake Zurich, the company offers its customers support services.

“We are confident that our large gearbox business will benefit from ZF’s transmission expertise, and be able to make the best possible use of its growth opportunities in the new unit to be created at ZF,” said Karl Tragl, Chairman of the Executive Board of Bosch Rexroth. He added that Bosch Rexroth has successfully advanced the business in recent years. “We have specifically broadened our product range with the development of the new wind turbine gearboxes for the weak wind segment,” said Tragl. Going forward, Bosch Rexroth will focus more intensively on the core business with industrial and mobile applications.

“We are looking forward to working together with experienced staff with more than 30 years of development and production know-how for wind turbine gearboxes and even over half a century of expertise in industrial gears,” said Wilhelm Rehm, responsible for corporate materials management, and industrial technology on the ZF Board of Management. “We take account of this by making Witten the headquarters of our new Industrial Drives business unit.”  

— Source: ZF

Clean Line, Texas Co-Ops Ink 50 MW Ownership Option

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Clean Line, Texas Co-Ops Ink 50 MW Ownership Option

Clean Line Energy has reached an agreement with the East Texas cooperatives that provides the cooperatives with an option to own up to 50 MW of capacity on the Plains & Eastern Clean Line and a portion of the project’s assets. The Plains & Eastern Clean Line will deliver more than 3,500 MW of low-cost wind power from the Oklahoma Panhandle region to utilities and customers in Arkansas, Tennessee, and other markets in the Mid-South and Southeast. The East Texas cooperatives include four generation and transmission cooperatives throughout East Texas — East Texas Electric Cooperative (ETEC), Northeast Texas Electric Cooperative (NTEC), Sam Rayburn Generation and Transmission Cooperative (SRG&T), and Tex-La Electric Cooperative of Texas (Tex-La)  — and collectively serve ten not-for-profit distribution cooperatives serving approximately 330,000 member-owners. For many decades, the East Texas Cooperatives have made it possible for thousands of residents and businesses in their service territories to take advantage of the lowest-cost, reliable energy available.

“The agreement with Clean Line allows us to potentially realize the benefits from owning important new energy infrastructure while maintaining our commitment to provide long-term, reliable and affordable electric power to our members,” said Edd Hargett, general manager of ETEC.

The Plains & Eastern Clean Line represents a $2 billion investment in infrastructure that will provide low-cost renewable energy to the Mid-South and Southeast regions of the United States, areas currently lacking access to renewable, affordable energy. The Plains & Eastern Clean Line will help unlock more than $6 billion in investments in new wind farms that could not otherwise be built due to the limitations of the existing electric grid. The infrastructure project will create demand for thousands of jobs in manufacturing, construction, and operations while meeting the increase in demand for additional electric transmission capacity to deliver renewable energy.

“We are thrilled to sign an agreement with the East Texas Cooperatives allowing the option to own a part of the Plains & Eastern Clean Line. As the permitting and regulatory processes advance, we look forward to welcoming more participants in the project,” said Michael Skelly, president of Clean Line. “This is a great step forward for the Plains & Eastern Clean Line, and we commend the East Texas Cooperatives for their commitment to adopting innovative infrastructure in order to improve clean energy delivery while keeping costs low.”

Construction of the Plains & Eastern Clean Line is estimated to begin in 2016 and will require approximately two to three years to complete. The Plains & Eastern Clean Line is expected to begin delivering electricity as early as 2018 and will provide clean power to more than one million American homes, providing public benefits for years to come.  

— Source: Clean Line Energy Partners

Improving LCOE By Training The Human Assets

Shawn Lamb
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Improving LCOE By Training The Human Assets

When I worked for large international wind companies, like GE and Nordex, I saw entire infrastructures — engineering, EHS management, spare parts warehousing, SAP specialist, IT support, O&M schedulers, remote monitoring, process writers, etc. — created to support the operation. However, very few people actually climbed the turbines to do maintenance and troubleshooting.  I have always considered the techs in the field to be the “all-stars” of the wind energy industry. But even the most experienced technicians need to be trained and re-trained on an ongoing basis. Without constant skills development, the rapid advances in wind technology will quickly surpass the expertise of even the most skilled technician.

Even the best turbine on the market — equipped with the most proven technology and boasting the longest and most reliable track record —  can suffer catastrophic failures if the technician and support team don’t know what they are doing. For example, when critical failures occur, as operators we are very good at pointing fingers at sub suppliers — like gearbox and bearing manufacturers — while overlooking the obvious O&M issues associated with that component. Maybe we should ask ourselves if the root cause was our own failure to keep the drivetrain correctly aligned, or if ignoring a “too high oil temperature” alarm for several months could have caused the failure instead.

Action at a Distance

The world’s best work instructions (usually checklists) and technical support (sometimes thousands of miles away from the turbines) only become efficient and functional if you have technicians with the right attitude and skills to execute them correctly.  In my experience, the engineering and remote support personnel can only describe at a distance what they want checked or performed on site.  It is up to the site technicians to understand the turbine technology well enough to finish up on site and get the issue resolved.  The communication and language between the back office and the field techs must be aligned in order to maximize the efficiency of the teams.  Harmonizing the understanding of technology between engineering, operations, and the site techs can only be accomplished through training, and it is vital for feeding back and forth improvements and information, which gives quicker response times.

Generation Mindset

Having the “generation mindset” to understand not only the technology, but the entire wind farm operation, is important for a technician.  Understanding the business model of the wind farm and what is best for the bottom line is also important for those who are on the turbines every day, not just those in the office.  Many times the technicians will make day to day decisions that can affect downtime and generation availability.  For example, if there is a non-critical warning about a filter that needs changing, but the turbine is producing well with a good feed in tariff, it makes sense to wait until a lower wind day to plan the replacement.  Training staff to understand ways to make decisions like this, enables them with the generation mindset.

Technicians with the true generation mindset are usually hard to find and even harder to retain since management views them as ideal candidates. Given that there is a major “brain-drain” in the U.S. power generation industry, it may be a better option to hire and train entry-level techs into the generation mindset.

Developing Our Human Assets

Technicians are taking on a huge responsibility when working on a multi-million-dollar power production facility. It isn’t fair for a company to send a worker to these highly automated, robotic power plants and expect them to be just “arms and legs” on-site. The reality is that they have to be trained and developed over many years. In doing so you are building their confidence and equipping them with the knowledge and resources to do their jobs — for years to come. It’s often difficult for those in the wind industry to clearly see how developing their “human assets” will have a direct and quantifiable return on investment.

In such a low-margin and reactive industry as wind, the idea of spending money on training technicians (beyond safety requirements) seems like an afterthought.  In order for this industry to mature and take its place with other worker-centric industries we have to address the workforce development component.

The reality is that site specific training can save money and increase performance on these assets.  It has been shown that per-unit turbine performance and LCOE can be improved by teaching technicians how to operate, maintain, and troubleshoot the turbines in the most efficient way.

Condition-Based Training

As far as I know, the only place that uses a methodology of “condition-based training” is the Danish Wind Power Academy, an independent training organization from Middelfart, Denmark.  I think that this concept is so unique and effective that it is worth sharing.

The process starts by uncovering the need for training at a particular site.  This is done by analyzing the site performance for one year and deriving the top-10 downtime errors. Afterward, a skill-set analysis of the staff and technicians on site is done either through self-evaluations or testing.  The training is then customized around the “skills gap” of the operators as compared to the needs of the turbine. This training plan may include classroom, online, and on-turbine training.  Most of time spent on the project is analysis and development.  Only about 25 percent of the time is spent in actual training — whether in a classroom or on the turbines. There is also a continual learning component, where the instructors will follow the progress and changes (personal turnover) on-site to track progress in the O&M skills.

Case Study: Condition-Based Training

This “Condition-Based Training” has been a proven and successful technique for over a decade with various wind owners and operators around the world.  For example, when the Danish Wind Power Academy set out to work with E.ON Climate & Renewables on its Papalote and Champion sites in Texas, the company was looking for an improvement in per-unit performance on over 460 MW of assets.  The project included training the operational staff: risk, asset, operation, site management, lead techs, and assistant techs.  The training was done with turbine-specific theory classes and with on-turbine training.  The classes focused on the top downtime errors for each particular site and how to quickly fix or mitigate them.

By analyzing the performance before and then after, it was shown that there was a marked decrease in production loss within just six months after training.  By optimizing the techs’ skills towards what the turbine needed, the unplanned outage loss was minimized and the maintenance downtime was reduced. This type of team-based training also helped to boost morale on site, synchronize communication between teams, and contribute to employee retention.

Conclusion

In this new industry, it is important not to confuse technology for technicians.  Even with the advancement in turbine technology, optimization techniques, and SCADA analytics, the turbine never performs better than those who are tasked with maintaining them.  The workers that climb each day need to keep up with the increasing complexity of the wind turbines and aftermarket improvements.  This can only be done by training them both in the classroom and on the turbines.

It has been shown that by employing a “condition based training” strategy on-site, operators can focus their staff on the specific errors that cause the most downtime and address them.  This methodology will also help to develop a “generation mindset” amongst the technicians on site, which will ultimately lower the LCOE and improve performance.

Working Safely In The Blazing Summer Heat

Walter Christmas
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Working Safely In The Blazing Summer Heat

You wouldn’t leave your dog in a car on a hot, sunny day. So, why would you leave your wind technician in a turbine to roast in the summer sun? Okay, seriously, heat stress is a very real concern that should not be taken lightly. Public service announcements warn us that a car can reach temperatures of 140° F within an hour in the sun. A wind turbine nacelle can get just as hot, especially when you consider that the gearbox can serve to heat things up from the inside out while solar energy works from the outside in.

According to the Center for Disease Control (CDC), “On average, 675 people die from complications related to extreme heat each year in the United States — more than tornadoes, hurricanes, floods, lightning or any other weather event combined.” Heat cramps, heat exhaustion, and heat stroke affect thousands of Americans every year.

Company EHS policies often dictate safety measures that must be taken during these hot months. If these measures are officially written into the EHS policy, then OSHA requires that they be followed, even if they exceed official OSHA requirements. Shawn Lamb, CEO of Danish Windpower Academy Americas, said he remembers the Florida heat while rebuilding roofs for the disaster relief effort after Hurricane Charley. “We could only work 20 minutes at a time in shifts.” Lamb, also a former instructor for GE Wind, said, “Palm Springs was the only GE site that would allow technicians to wear shorts.” Shorts, normally considered to be less-than-ideal attire in terms of safety in a wind turbine, can be considered to be a hazard mitigation tool for dealing with extreme heat.

Three Stages of Heat Emergencies
While in charge of multiple crews as the Operations Manager for BIS Salamis and Resources Technician for Vestas, Ecotech Institute’s Wind Energy Program Director, Auston Van Slyke kept a close eye on the technicians under his authority. “Remember, it starts with cramps and starts getting dangerous with exhaustion. If you reach heat stroke, permanent damage has already been done.” As a part-time American Red Cross First Aid/CPR/AED instructor, Van Slyke trains wind turbine technicians how to recognize the three stages of heat emergencies:

Heat Cramps — The first stage of a heat emergency, heat cramps, are quite simply recognizable by the victim as muscle pain and tightness. Since these are also symptoms of a really effective workout at the gym, previous recreational activity, or overtaxing muscles during a work shift, it can be easily overlooked as a heat-caused issue. Such an oversight might allow the heat emergency to escalate to the next stage.
Treat heat cramps by moving to a cooler environment, resting, and drinking water and electrolytes at a slow but steady pace. Cramped muscles can be massaged and stretched for relief. The victim should not rule out seeking medical attention.

Heat Exhaustion —  According to the American Red Cross (http://www.redcross.org/prepare/disaster/heat-wave), in addition to heat cramps, the second stage of a heat emergency can include any or all of the following symptoms:
• dizziness
• headache
• irritability
• extreme thirst
• nausea or vomiting
• pale skin
• heavy sweating
• fainting

In most cases, treat heat exhaustion the same way that you would heat cramps, but definitely seek medical attention right away. If the victim is vomiting or has fainted, do not make them drink water until these symptoms have passed. Heat exhaustion can escalate quickly to a potentially fatal condition.

Heat Stroke — Heat stroke is the most serious of the three stages of heat emergencies. In addition to all of the symptoms noted for heat exhaustion, the American Red Cross advises that heat stroke can include the following:
• body temperature over 105° F
• irrational behavior
• confusion
• rapid, shallow breathing
• rapid, weak pulse
• seizures
• loss of consciousness

A victim of heat stroke should be considered to be in a very serious condition. Call 911 immediately! The victim’s body is past the point of having any ability to cool itself through the process of perspiring. While awaiting the emergency response, apply cool, damp cloths to the victim’s neck, face, chest, arms and legs. Ice or cold packs, if there are any around, can be applied to the underarms, wrists and groin. A body temperature at or above 105° F will often lead to some level of brain damage and possibly even death, so it is critical to help the victim to reduce his to her body temperature while waiting for help to arrive.
Preventing heat stress

Awareness — Knowing the risks and watching for the signs of heat stress in both our coworkers and ourselves is key to working safely in a hot environment. Be especially aware of the onset of symptoms experienced by new employees. OSHA reminds us that it can take some people two to three weeks to acclimatize to a hotter environment as well as to the strenuous labor of working on wind turbines. New employees will often overwork themselves to prove themselves to veteran technicians; summer heat can turn this effort into a dangerous situation quickly. Assign less strenuous tasks for the new guys and gals until they can be trusted to work safely in the heat. Similarly, carefully watch even experienced coworkers who are returning from a two to three week vacation where they possibly spent their time enjoying cooler temperatures.

Hydration — Veteran turbine troubleshooter and wind energy instructor, Derek Johnson, has seen a common pattern amongst wind technicians. “So often you see wind techs neglect hydration because they are so focused on the task at hand,” Johnson comments. OSHA recommends four cups (32 ounces) of water every hour. One cup every fifteen minutes is preferable to guzzling the full 32 ounces on the hour. Do not exceed six cups per hour as this can deplete your body of electrolytes and cause other health complications that, if extreme, can be fatal. Mixing water with an electrolytic sports drink can help with this. Small hydration packs of powdered electrolytes, like the ones made by Sqwincher™, can be carried in a worker’s pocket and mixed with water when needed. Alcohol and caffeine may dehydrate a body more than they help to hydrate one. Avoid alcohol consumption in general during the hottest periods of the year, and choose decaffeinated drinks instead. Did I lose you there, dear reader?

Reduce Workplace Temperature – Contrary to popular belief, fans do not cool the air. They do however increase evaporation from the skin, which has a cooling effect on the body. Placing some fans strategically in the nacelle to circulate air is a very easy measure with a huge reward. Be advised, however, that if a heat stressed person has reached the point that they stop sweating, a fan will have little effect, and at this point medical attention is past due. Ensuring maximum natural ventilation through a nacelle can help, so open any hatches that don’t pose their own hazards to technicians such as any that a technician could fall through. If you’ve ever felt the air rush up a tower when the roof hatch of a nacelle has been opened, you can appreciate what a relief this can be. Also, whenever feasible, shutting down a turbine early to let the gearbox cool is a measure that comes with a small but worthwhile production price tag. Scheduling strenuous tasks for the early morning or evening hours is a common practice for many sites. Many companies will require or advise site managers to schedule the workday much earlier in the day during the summer months. Reporting for work at 5 a.m. may not sound like fun, but clocking out in the early afternoon is a nice perk.

Reduce Body Temperature — Everyone knows that standing in front of a fan is the place to be on a hot day. Take short breaks frequently to cool off; You won’t be seen as a workplace hero by skipping breaks if it results in you being lowered to the ground in a rescue procedure. For that matter, encourage your coworkers to take cooling breaks as well. Workers can buy neckbands and pads with dried polymer crystals inside. These crystals swell to a gel in cold water that cools the skin and blood vessels within. Some bands and pads are made specifically for industry and construction workers and, when used according to the manufacturers, will not interfere with the effectiveness of personal protective equipment (PPE)

Monitoring the Risk
OSHA offers a free app for smartphones and tablets to monitor the heat risk level with real-time updates of current temperatures. The app also provides the signs and symptoms listed earlier in this article as well as advised treatment for each of the three conditions. OSHA’s app also provides a calculator to combine temperature and humidity to determine the heat index often denoted by the term “feels like”. For example, if the thermometer reads 108° F and humidity is at 83%, the heat index will tell you it “feels like 212° F” which is the temperature at which water boils at sea level. Ouch!
If the site has a technician or manager monitoring the SCADA system and watching for thunderstorms, this person can also keep an eye on outside temperature readings. The SCADA-watcher should engage in frequent communication with technicians in the turbines to remind them to rest and drink water, check nacelle heat readings, and to be ready for the distress call that might come.

At some point, common sense and a concern for safety will compel a site manager to simply shut down all repairs and maintenance for the day. When that happens, go home, stick your face in the freezer for a minute, drink a frosty non-alcoholic beer or decaffeinated iced coffee, and enjoy your time watching the Weather Channel to see what tomorrow will bring.  
 

Moventas Opens Multi-Brand Service Shop In Minnesota

Wind Systems staff
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Moventas Opens Multi-Brand Service Shop In Minnesota

Moventas, one of the world’s leading wind gear manufacturers and service providers, has opened a wind gearbox service workshop in St. Paul, Minnesota, answering the growing demand for multi-brand expert wind drivetrain service in the Midwestern U.S.

Moventas is expanding its network of high quality wind gearbox service centers in North America. With the addition of the St. Paul facility, Moventas is now within a day drive from nearly all of the installed North America fleet with locations in Oregon, Texas, Canada, and now Minnesota.

“Our four existing service and manufacturing facilities in North America are all located in the main wind energy corridors to offer our customers fast and responsive services,” said Mike Grunow, vice president of sales and marketing at Moventas Americas. “We are excited to be investing in the Midwest with our St. Paul facility, where we are now local and able to apply our 35 years of experience as a leading wind industry service provider.”

The investment is part of Moventas’ service strategy, aiming to localize its operations and minimize wind farm owner lifecycle costs. Moventas services its own brand as well as most gearbox brands in the market and will be able to serve clientele in the rapidly growing Midwest area with full capability.

Plans for an open house and customer tours of the new facility are scheduled for this summer. In addition to its workshop service capabilities, Moventas plans to co-locate a custom Mobile Service Unit in the Midwest to carry out cost efficient up-tower field repairs. The self-contained, climate-controlled mobile service units are available for field work, including full helical and planetary replacements with specially fabricated Moventas tooling.

— Source: Moventas

Profile: 3M Wind Energy

Stephen Sisk
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Profile: 3M Wind Energy

At the dawn of the last century, a group of investors pooled their resources and starting a mining operation in Minnesota. The group was looking for corundum, a valuable mineral used in abrasives.
The mining efforts fell short of expectations when it turned out the mine contained anorthosite — a different mineral which didn’t fit the intended applications.

Instead of corundum, the investors were left with a conundrum. The group had to re-focus and innovate, or face financial ruin. Over the next decade or so, the company actively sought out the applicational needs of its customers in the abrasives industry and implemented a problem-based approach to meeting those needs.
That spirit of innovation and application-based approach are still apparent today for the company orginally known as Minnesota Mining and Manufacturing Company, now simply 3M. Throughout more than a century, the company has grown into a $30 billion-plus global giant, with a product portfolio ranging from high-tech health care to home arts-and-crafts to the wind energy industry.

“We are a materials company. We come up with material solutions for the customer,” said Santhosh Krishna Chandrabalan, technical business development leader with 3M’s Renewable Energy division. “When there is a particular need with a customer, we partner with the customer to understand what their needs are, and we can actually develop the right materials or solutions for them for that particular market.”
The renewable energy division of 3M was built on that philosophy. While the company’s products had been used by customers in the renewable energy field for some time, in 2009, near the onset of rapid growth in the wind industry, the company saw the need to have a dedicated segment of its organization specifically to serve the needs of those customers.

“We are always looking at new technologies and new markets — areas where we can add significant value,” Chandrabalan said. “Even though we were active in the renewable energy area for a very long time, we wanted to bring focus to this market area. In 2009, the Renewable Energy division was started, bringing all different pieces together.”
Renewable energy is one of 3M’s 27 business divisions. Although it may seem to some that it would be easy to get lost in the shuffle and bureaucracy of a multinational corporation, Chandrabalan said the division’s customers have quite the opposite experience. This is because the company’s divisions operate with a high degree of autonomy.

“We are a very large company. However, every division is run mostly on its own,” Chandrabalan said. ”We do have direction. We have a global strategy. But many times, for example, if the renewable energy division is launching a product, that is actually done by my division. It is not going beyond there. We are able to act quickly to a customer need, and we are able to solve those problems much easier than a very large company where the decisions need to go to the corporate level.”

It’s that kind of collaborative mindset — both with customers as well as with the many other divisions within the company — that allows 3M to continue along its long-held tradition of innovation.

“We partner with others in the industry — all the way from turbine manufacturers to the wind farm owners — to solve a particular problem,” Chandrabalan said. “We are an industry leader in leading edge protection. When there’s a problem, we don’t go and just fix it, too. We educate the market. In leading edge protection, we were the pioneers to understanding leading edge erosion, its effects on the blades, and possible outcomes. We were able to come up with a solution to those issues. This is just one example of how 3M is far more than a materials supplier. We partner to be able to solve a particular need, and then we go from there.”
3M’s products and applications for the wind energy industry are generally separated into three categories: blade, nacelle, and tower.

Rotor blades make up largest category of these products, and represent the renwable energy divisions primary focus. These products are further subdivided into surface solutions, manufacturing process aids, and structure solutions. Individual products include specialized tapes, foam tapes, coatings, fillers, adhesives, and threadlockers.

Many of these products are cross-category in nature, and have similar applications in the nacelle and on the tower. These include electrical splices, electrical tape, wire management, and sealants, among others.
For a complete listing of 3M’s products for wind energy applications, see the sidebar that accompanies this article.

For more information about 3M’s solutions for the wind energy industry, visit http://solutions.3m.com/wps/portal/3M/en_US/Wind/Energy/.

3M Wind Energy Products

Operations & Maintenance
• Wind Protection Tapes
• Wind Fillers
• Acrylic Foam Tape
• Clean Sanding System

Manufacturing & Design
• Wind Blade Protection Coating W4600
• Wind Protection Tapes
• Wind Blade Bonding Adhesive W1101
• Wind Structural Adhesives
• Wind Threadlockers
• Dry Layup Adhesive
• Wind Sealants
• Acrylic Foam Tape
• Diamond Cutoff Wheels
• Clean Sanding System

Installation
• Cold Shrink Splices
• Cold Shrink Terminations
• Premium Electrical Tapes
• Cable Grounding Kits
• Wire Management and Marking Supplies
• Detectable Buried Barricade Tapes
• Locators and Markers

Safety
• Safety-Walk™ Materials
• Filtering Facepiece Respirators
• Half and Full Facepiece Respirators
• Powered and Supplied Air Respirators
• Hearing Protection
• Eye Protection
• Head and Face Protection
• Peltor™ Communications
• Fall Protection
• Speedglas™ Auto-Darkening Filters and Helmets
• Sorbents

— Source: 3M

Shermco Staffer Pens Electrical Maintenance E-Book

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Shermco Staffer Pens Electrical Maintenance E-Book

John Wiley Publishing, known for its extensive For Dummies collection of ‘how-to’ books, has published “Electrical Systems Maintenance for Dummies” by Lynn Hamrick, PE, from Shermco Industries.

The book is a primer for any company, facility or industrial entity that needs to ensure that its electrical systems are properly maintained. From high-voltage substations down to distribution panel boards, control equipment and motors/generators within facilities, companies, utilities and commercial buildings are often required to maintain and test their equipment to keep it functioning at its very best. This book is an introduction to best practices for maintaining these systems, so that money can be saved from costly repairs, replacements and downtown to operations.

The book covers:
• Safety basics for working with electrical systems
• Testing and maintenance procedures  to help avoid expensive equipment failures
• Maintenance tips for prolonging the life of expensive electrical systems
• How to put together a proper maintenance plan to train new employees and ensure consistency

Hamrick is the business development manager at Shermco Industries, where he is based in Marion, Iowa. He manages the development and implementation of NFPA 70E and NFPA 70B activities for clients, including electrical safety training, arc flash hazards analysis, and electrical preventative and predictive maintenance.

To download the free e-book, visit www.shermco.com/newsevents/shermcoinprint, or for a free printed copy, email info@shermco.com.

— Source: Shermco

PSI Repair Services Ships 20,000th Repaired Wind Part

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PSI Repair Services Ships 20,000th Repaired Wind Part

PSI Repair Services, Inc., a subsidiary of Phillips Service Industries and an independent service provider to the wind energy industry, has announced that it recently shipped its 20,000th repaired wind turbine part to a prominent wind energy company. Since 2009, PSI has provided economical repairs, as well as industry-leading engineering services that include product upgrades, for the largest wind farms in the United States.

“PSI is very proud to be a trusted resource to the largest wind farms in the U.S.,” said Mike Fitzpatrick, general manager of PSI Repair Services, Inc. “We are constantly adding new services and capabilities to meet the strong, ongoing demand from our wind energy customers, so come talk to us at the Windpower Conference.”

PSI Repair Services offers component repair and engineering services for GE, Vestas, Gamesa, Siemens, RePower, and Clipper wind turbines. PSI covers the critical electronic, hydraulic and precision mechanical components that drive the turbines’ pitch and yaw systems and down-tower electronics.

Commonly repaired components include printed circuit boards, pitch drive systems, inverters, IGBTs, PLCs, VRCC units, AEBIs, proportional valves, hydraulic pumps, pitch and yaw motors, encoders, slip rings, transducers, yaw modules, 3-phase bridge rectifiers, blade bearing automatic grease dispensers, active crowbars, line reactors, oil level sensors, battery chargers, cold climate converters, and more. PSI uses the latest diagnostic tools to detect failures down to the microchip level.

— Source: PSI Repair Services

Case Study: Broadwind Energy and Sentient Science

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Case Study: Broadwind Energy and Sentient Science

Life extension of a single-stage planetary gearbox
Reduction in contact stresses due to geometry changes and improvements in material quality led to quantified fatigue performance improvement

SUMMARY
Challenge — Broadwind was seeking to quantify the effect of its DriveMAX® enhancements on a European single stage planetary design gearbox to help their customers calculate the value and ROI.

Solution — Broadwind turned to Sentient Science using the company’s developed DigitalClone® prognostic models of the planetary stage to determine the effect on gearbox life due to DriveMAX® modifications under the same severe Class 1 site operating conditions.

Results — Early failures were predicted on the sun gear and planetary bearing on the OEM specification. The DriveMAX® upgrades were shown to improve the sun gear by a factor of 3x and improve the planetary bearing life by a factor of 1.65x.

CASE STUDY DETAILS
Challenge
The goal was to quantify the effects of DriveMAX® enhancements for one of the largest deployed wind turbine gearboxes in the U.S. wind industry.  As more wind turbines come off warranty, operators are seeking solutions to make decisions on how to service, maintain, and replace gearboxes in their fleet today to meet their long-term financial objectives. Graph 1

The planetary stage is known to be a leading cause of premature failure in these gearbox models for 1.5MW wind turbines that can cost an operator up to $350,000.
To address this, Broadwind provides remanufacturing and upgrades of components to extend gearbox life.  For example, Broadwind can complete full planetary stage remanufacturing up-tower.  Wind turbine operators are increasing seeking to quantify the effect of remanufactured gearing enhancements on future expected component life and ROI before making a buying decision.

Solution
Broadwind provided Sentient Science with thereverse engineered design specifications on the original design and their updated configuration of sun gears, planetary gears, ring gears, and planetary bearings.  Sentient Science developed DigitalClone models of each configuration under a severe Class 1 wind regime. Broadwind chose the DigitalClone models because they simulate material performance at the micro-structure level.  With this level of fidelity, the model can accurately calculate crack initiation and small crack growth and perform “What If” comparisons considering geometry, operating conditions, lubricant properties, material microstructure, surface finish, and residual stresses among others. Recent validations in the marketplace have made Sentient the leading provider of predictive maintenance and decision support solutions for some of the largest wind operators who control over 40% of the US fleet.  
 
Through a process of ‘computational testing’ – device testing done using computer simulations – Broadwind and Sentient Science assessed how the each planetary gearbox system would perform in the same ‘apples-to-apples’ severe Class 1 operational conditions.  

Result
The computational testing results showed that, based on the severe turbine loading profile, early failures were predicted on sun gear and planetary bearing.  Broadwind DriveMAX upgrades were shown to improve the sun gear fatigue performance by a factor of 3x and the planetary bearing life by a factor of 1.65X.  These improvements in Broadwind gearbox components fatigue performance were mainly due to improvements in material quality and reduction in contact stresses due to geometry changes. Graph 2

Life extension can provide a positive net present value if it eliminates a gearbox replacement before the expected end of life, or allows a wind turbine to operate for a few more years. This can add as much as $200k-$1M of power production if a PPA is extended by 1-5 years or eliminate the need for another $350K gearbox replacement before the wind farm end of life.  

DigitalClone gearbox enhancement models can be made available to operators within DigitalClone Live so operators can quantify the expected life extension and ROI for specific turbines in their operating conditions. There is a varying response to life extension and ROI of enhancements based on the current turbine state, site wind regime, etc.   

— Source: Broadwind Energy; Sentient Science

www.bwen.com  www.sentientscience.com

GE Optimization Service Targets Wind Farm Efficiency

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GE Optimization Service Targets Wind Farm Efficiency

When planning a wind plant, collector cable systems play a critical role in how efficiently power can be delivered from the point of generation to the grid. An optimal collector system design can help minimize electrical losses, cable and trenching costs and substation configuration costs. The new Wind Collector Optimization Service from GE’s Digital Energy business uses grid intelligence to help utilities, developers and contractors better plan the layout of their wind farm by providing an in-depth look at possible collector cable configurations and the benefits and drawbacks of each. With this information, system design can be optimized to reduce start-up costs and improve operational efficiency.

Traditional manual collector cable design processes can be labor intensive, hard to adjust and can have long lead times. The result is a time-consuming, costly, non-optimized design with little flexibility to change the project after implementation has begun. GE’s new service provides customers with a collector system design that optimizes cable routing and sizing and addresses the challenges associated with traditional design methods. It provides customers in the wind renewable energy segment with a comprehensive optimization service — from initial consultation to a completed and validated design. The Wind Collector Optimization Service incorporates GE’s extensive experience in bringing over 4,000 MW of renewable energy online and more than 40 years of substation engineering, procurement, and construction expertise.

“With our new Wind Collector Optimization Service, we meet with customers early on in the process to establish what features and parameters are important to them and are required for their specific project,” said Bob Turko, general manager of GE’s High Voltage Solutions business. “From there, we utilize our leading, proprietary design tool — which includes multi-variable analysis — to design an optimized wind plant collector system, reducing the design cycle time and lowering the total cost of ownership for our customers.”

With GE’s Wind Collector Optimization Service, the optimal route is determined between the turbines and the substation resulting in improved efficiency and a more resilient network. The solution provides a preliminary cable table with the ampacity of each collector circuit outlined in an easy-to-view, mapping file that can be viewed using Google Earth. In addition, the service includes trenching and cable cost estimates and provides insight into how efficiency can be improved through reduced power losses, optimized designs of cable sizes and trenching path configurations.
Using this optimization software, GE can reduce the cost of rationally designed collector systems, providing potential savings of greater than 20 percent while also reducing design cycle times by 60 percent.  

— Source: GE Digital Energy

IEA Stresses Technology Boost To Meet Climate Goals

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IEA Stresses Technology Boost To Meet Climate Goals

A concerted push for clean-energy innovation is the only way the world can meet its climate goals, the International Energy Agency stated upon the release of its flagship energy technology report.
The report, Energy Technology Perspectives 2015 (ETP 2015), shows that despite a few recent success stories, clean-energy progress is falling well short of the levels needed to limit the global increase in temperatures to no more than 2 degrees C. Moreover, it will be challenging for the world to meet its climate goals solely through the UN negotiation process that is expected to yield an agreement this December in Paris. That leaves the development and deployment of new, ground-breaking energy technologies as key to mobilizing climate action, and the report urges policymakers to step up efforts to support them.

“The stakes are high for the energy sector, but it is also no stranger to profound technological change. An incredible chain of innovations in the energy sector has been at the vanguard of social and economic transformation for over a century, and it is exciting to see the progress being made by solar panels and fuel economy improvements for passenger cars today, to name but two,” said IEA Executive Director Maria van der Hoeven.

“But we cannot be complacent,” she continued. “We are setting ourselves environmental and energy access targets that rely on better technologies. Today’s annual government spending on energy research and development is estimated to be $17 billion. Tripling this level, as we recommend, requires governments and the private sector to work closely together and shift their focus to low-carbon technologies.”

ETP 2015 provides a comprehensive analysis of long-term trends in the energy sector, centered on the technologies and the level of deployment needed for a more environmentally sustainable, secure, and affordable energy system. Recent success stories clearly indicate that there is significant and untapped potential for accelerating research and development in clean technologies.

Yet research and development alone are insufficient for moving new technologies from ideas to commercial products. Governments have a key role to play in creating the initial market opportunities that send a signal to innovators and drive investment. One success story involves public support for renewable energy technologies: while it has not always been efficiently targeted, it has transformed the market outlook for wind and solar to the extent that they are now the lowest-cost source of power in a number of regions.

“This result, unthinkable only a decade or so ago, is the power of innovation,” van der Hoeven said. “Given our current climate realities, more of that power must be unleashed on the world.”
ETP 2015 does not make long-term forecasts. Instead, it is built around economic modeling scenarios — each of which shows what mix of energy technologies would need to be deployed to obtain a specific climate outcome. The main scenario of ETP 2015 — the 2-Degree Scenario, or 2DS — illustrates a transformed global energy system in which cumulative carbon emissions from fossil fuels are reduced by 40 percent relative to the “business-as-usual” scenario, or 6DS.

ETP 2015 analysis shows that the 2DS does not just allow global climate goals to be met but also enhances energy security. Best of all, it makes economic sense: for every dollar invested in the clean-energy technologies that drive the 2DS, nearly three dollars in fuel costs are avoided by 2050.

ETP 2015 includes the annual Tracking Clean Energy Progress report, which for the first time looks at progress in storage and hydrogen technology.
ETP 2015 analysis says that fostering innovation of low-carbon products and processes in industry is essential to meeting global decarbonization goals. The report demonstrates the opportunities and challenges across the entire innovation chain of various sectors for global industrial actors. In the 2DS, almost 30 percent of direct industrial CO2 emissions reductions by 2050 hinge on processes that are in development or demonstration today.

Finally, the report says that building and maintaining strong innovation capacity in emerging economies will be key to successful deployment of sustainable energy technologies where they may have the largest impacts. Domestic innovation of low-carbon technologies in emerging economies is increasing, with some countries – especially China – closing the gap in key areas.

For obvious reasons, van der Hoeven stressed, the ETP 2015 can only model existing technologies. But she noted that the right support to innovation, coupled with effective public-private partnerships, can provide the energy technology breakthroughs that could amplify or hasten the low-carbon transition.
“The shale gas and shale oil boom of the last few years was virtually unthinkable at the dawn of this century,” van de Hoeven said. “If we only stick to the beaten path of today, we will miss the game-changers of tomorrow.”  

— Source: International Energy Agency

Lufft Wind Sensor Classified For Offshore Use

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Lufft Wind Sensor Classified For Offshore Use

The Lufft Ultrasonic Anemometer VENTUS successfully completed the test at the International Technical Inspection Agency TÜV SÜD and now has the Protection Class IP68. This confirms officially that VENTUS is one of a few Ultrasonic Anemometers, protected from infiltration of dust as well as from extended submersion in water. This demonstrates again that VENTUS is perfectly suited for installations on offshore wind turbines as well as on ships or buoys. The sensors are tested and certified to provide accurate data in the harshest conditions of vibration, dust, ice and now extremely wet and corrosive offshore environments.
The Lufft VENTUS is designed for harsh conditions including operation on wind turbines in cold weather and offshore environments. The VENTUS is able to integrate into any existing wind turbine control system given its extreme flexibility of communication.

In a recent call for bids, Lufft was named the winner for the renewal and extension of ultrasonic wind sensors in the maritime monitoring network of the German Weather Service , the ultrasonic wind sensor Ventus from the Fellbach-based manufacturer of environmental measuring equipment won against all competitive products.

The weather service made the decision with the aid of a large number of very strict exclusion criteria. Only a few companies in the world are able to meet these criteria with their products and were therefore short-listed for the tender.

Among other requirements for offshore use, the ultrasonic anemometers had to be very robust and have a closed system.

“Since the sensors will be used exclusively in the maritime sector, they must be particularly well protected against extreme weather conditions and bird attacks. The Ventus ultrasonic wind sensor consists of a seawater-resistant aluminum alloy, which is also used on ship propellers. The sensor therefore withstands the corrosive conditions without any problem. In addition, thanks to its enclosed design the sensor has already proved itself many times over with regard to bird attacks, whereas each year a large proportion of the open measuring systems from other manufacturers fail for this reason and give rise to correspondingly high repair costs. Therefore, in its tender specifications the DWD demanded a closed system,” said Udo Kronmüller, sales representative for the wind and weather segment. Technical problems caused by animals such as bird attacks are not uncommon in environmental equipment.

Therefore, Lufft GmbH decided on a closed system for measuring wind speed and wind direction at an early stage. This makes it almost impossible for birds to damage the sensor.

Since the advantages of this design inevitably lead to the impairment of measurement uncertainty, detailed minimum standards were required for wind speed and wind direction. In order to test these and other requirements, specific tests were conducted in the DWD wind tunnel.  

— Source: G. Lufft GmbH

Acciona Opens Turbine Assembly Plant In Brazil

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Acciona Opens Turbine Assembly Plant In Brazil

Acciona Windpower, the Acciona subsidiary dedicated to the design, manufacture, and sale of wind turbines, has opened a turbine assembly plant at Simões Filho, Bahia, Brazil. The facility has already producing all the 3 MW machines for the Brazilian market.
An opening ceremony commemorating the event was presided by the Governor of Bahia, Rui Costa dos Santos, who was accompanied by State Secretary for Industry, Trade and Mines, James Correia. ACCIONA was represented by Group President José Manuel Entrecanales, the CEO of the Energy Division, Rafael Mateo, and the Executive Director of ACCIONA Windpower, José Luis Blanco, together with senior managers in Brazil.

The Simões Filho plant has a production capacity of 100 turbines per year (300 MW), which can be increased to 200 units (600 MW) depending on demand. The facility has created 150 direct jobs and around another 500 indirect jobs, and it manufactures the hubs that ACCIONA Windpower previously produced at a location very close to the present one.

“This plant shows our industrial commitment to Brazil, today becoming a reality in Bahia, and is a testimony to the great reception given to our most advanced product — the 3 MW wind turbine — from wind power developers in the country,” Entrecanales said at the opening ceremony.
The entry into service of this plant, which assembled its first turbine in December 2014, is a direct result of the positive reception given to the AW3000 (3 MW) in the Brazilian market, evidence of its adaptation to the wind conditions of the country and its high level of competiveness.

Since it started marketing turbines in Brazil in 2012, ACCIONA Windpower has signed contracts for 1,020 MW. Over the period, the company has fulfilled the requirements for the gradual production in Brazil of components established by the BNDES (National Economic and Social Development Bank) under the FINAME regulations. This process enables wind power developers to gain access to finance on more favorable terms than those offered in the market.

At present, there are two wind power complexes in service in Brazil, with 3-MW turbines from AWP totaling 210 MW. Another two are under construction, totaling 201 MW, and those pending implementation represent 609 MW.

All these contracts have been signed for turbines with rotor diameters of 116 and 125 meters mounted on 100- or 120-meter-high concrete towers. The company is now supplying machines with a rotor diameter of 132 meters and a tower height of 137.5 meters.
In addition to the new wind turbine manufacturing facility, the company has a plant to manufacture sections for concrete towers located at Areia Branca (Rio Grande do Norte).

ACCIONA Windpower has a workforce of 288 people in Brazil at present. The company’s operations have created (or consolidated) more than 1,000 direct and indirect jobs in the country.

The ACCIONA Group has been present in Brazil since 1996. It has carried out major infrastructures projects, among them part of the Metros of São Paulo and Fortaleza, the Mario Covas ring road around São Paulo, the extension and concession of the BR-393/RJ highway in Rio de Janeiro and the installation of a wastewater treatment plant and pipe network in São Gonzalo.

— Source: Acciona Windpower

Optimal Performance From Thermal Management Products

Gary Steiger
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Optimal Performance From Thermal Management Products

Heating and cooling devices in enclosures are designed to protect electrical and electronic components from low and high temperatures, as well as moisture.  However, even with the appropriate equipment and controls, problems may arise due to incorrect positioning within the cabinet.

Heating
As the requirement of heaters for the prevention of condensation formation becomes more widely acknowledged, engineers and design teams must consider the equipment placement in an enclosure along with the devices they are intended to protect.  It is not uncommon to find systems added after the fact, fitted into whatever space remained.  While this may be the only solution available, it could potentially be the cause of other problems such as creating “hot spots” or “heat nests” near temperature sensitive electronics.

Ideally, most heaters will perform optimally when mounted near the bottom of an enclosure and used in conjunction with a separate controller such as a thermostat and/or hygrostat.  With the controller located in an area of the cabinet that is representative of the average temperature or humidity requirement, the heater should then be placed in a position near the bottom but not directly beneath the controller (see Illustration 1).  This placement will ensure that the controller is not influenced by direct heat from the heater.

For smaller areas such as shown in Illustration 1, convection heaters will generally provide adequate heating power to maintain temperature and humidity control.  For example, a 36”x 24”x 24” free-standing, insulated stainless steel enclosure with a desired interior temperature of 45°F with an ambient temperature of 25°F will require a 100W heater:

Power (W) =  (enclosure surf. area)  x  (delta T)  x  (heat transmission coefficient)

    =  (28.8 sq. ft) x  (11.1 K) x  (0.325 W/sq.ft K)

    =  104W

In the case of Illustration 2 shown below, with all other parameters remaining the same, the height has been increased to 72” thereby increasing both the air volume and the surface area.  Accordingly, the required heating power has also increased:

Power (W) =  (encl. surf. area)  x  (delta T)  x  (heat transmission coefficient)
    =  (50.4 sq. ft) x  (11.1 K)  x  (0.325 W/sq.ft K)

    =   182W

For larger cabinets with greater heating power requirements, convection heaters are not a practical solution.  As Illustration 2 shows, the most effective heat distribution is accomplished by a fan heater with greater air circulation to ensure rapid and efficient control of the temperature and/or humidity.

However, as mentioned previously, space for a tall heater is not always available.  Packing densities have increased as more equipment is designed into smaller spaces.  In the case of the enclosure shown in Illustration 1, only 100W of heating power is required, but as shown below in Illustration 3, the high packing density limits the available space for a convection heater.

The alternative is a compact fan heater positioned to provide adequate heat distribution throughout the cabinet. The position of the controller can vary depending on the air flow and temperature gradient, providing that it is not impacted by direct heat.

In any circumstance where a heater is required, the location of all other equipment relative to a heater should be carefully considered.  Most heater manufacturers recommend a minimum distance of 2” (50 mm) from components inside an enclosure.  However, the temperature sensitivity of each component should be assessed along with the heater temperature profile to ensure no damage will occur.

Cooling
Enclosure cooling solutions range from louver plates to heat exchangers and high performance air conditioning systems.  In all cases, the intent is to remove excess heat from the cabinet interior.  Whether naturally or mechanically achieved, the basic principle of heat rising is utilized.

One common and simple method is by using forced air ventilation, which is most effectively achieved with filter fans.  Since outside air is introduced into a clean sealed environment, high efficiency filters are required to maintain that integrity.  An example of a typical layout is shown in Illustration 4.

This arrangement with the filter fan (air intake) at the bottom and the exhaust filter near the top is highly effective by using cooler ambient air to displace the warmer air inside the enclosure.  The exhaust filter is typically mounted as close to the top of the cabinet as possible to take advantage of natural convection forces, and should also be located as far as possible from any heat producing components.  If designed properly, the air path created by the filter fan system will pass through critical areas that are to be cooled, allowing for maximum cooling efficiency.  Ideally, a control thermostat should be located in one of the critical areas where it will turn the fan on and off when temperature set points are reached.

Many other arrangements are possible, even so far as letting ventilation occur naturally.  One such system would allow for passive cooling by letting the warmer air escape through a roof-mounted vent.  Again, the key is that cooler air is used for displacement, so an intake filter would be required near the bottom of the cabinet.

Designing the layout of cabinets and enclosures that house sensitive electronic components is a challenging task.  While it may seem a less important consideration than many other aspects of proper control system design, the suitable placement of heating and/or cooling components can have a major impact on system operations.  Following these simple guidelines will help ensure system functionality and long service life.  

Conclusion
Designing the layout of cabinets and enclosures that house sensitive electronic components is a challenging task.  While it may seem a less important consideration than many other aspects of proper control system design, the suitable placement of heating and/or cooling components can have a major impact on system operations.  Following these simple guidelines will help ensure system functionality and long service life.  
 

Alterra Taps Mortenson To Build Shannon Wind Project

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Alterra Taps Mortenson To Build Shannon Wind Project

Mortenson Construction’s Wind Energy Group recently announced that it entered into a contract for construction of the Shannon Wind Project located near Windthorst, Texas, which is owned and managed by Alterra Power Corp. (Alterra). Vancouver-based Alterra acquired the project from Horn Wind, LLC, a north Texas wind developer that has successfully developed two other wind projects in the region — both constructed by Mortenson. This will be the second wind farm Mortenson will construct with Alterra following the completion of the Dokie Wind Project located in Chetwynd, British Columbia, in 2011.

Mortenson will be responsible for the construction of the access roads, foundations, turbine erection, and underground electrical collection system, as well as substation and transmission line installation. The 204 MW project will utilize GE turbines, and at completion will deliver power sufficient for approximately 61,000 households.

Mortenson commenced construction on the project under a limited notice to proceed in 2013 and completed a number of foundation excavations and carried out site road construction in both 2013 and 2014.

Approximately 250 jobs will be created during the construction, and millions of dollars will be infused in the local community and surrounding areas as a result of construction spending and living expenses from Mortenson crews and trade partners.

“We are very excited to again partner with Alterra,” said Tim Maag, vice president and general manager of Mortenson’s Wind Energy Group. “We are honored to play a part in the growth of their business and expansion into the United States while also continuing to expand our local presence.”

To date Mortenson has completed construction on 26 wind projects and three solar facilities across Texas. In 2014, the company established an office in San Antonio dedicated primarily to energy and infrastructure.

“We are very happy to work with Mortenson on our first U.S. wind project and appreciate the depth of experience they bring to the table,” said Paul Rapp, VP Wind and Geothermal Power for Alterra.

Construction on the Shannon Wind Project is expected to be completed in late 2015.
 
— Source: Mortenson Construction

Construction Insurer Zurich Supports U.S. Focus On Safety

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Construction Insurer Zurich Supports U.S. Focus On Safety

A shimmering skyscraper, a world-class stadium and an expansive suspension bridge are impressive architectural achievements, but every structure comes with serious risks faced by the construction workers who build them. More than 80,000 construction workers suffer an injury on job sites each year across the United States.

Zurich North America a U.S. construction insurance provider, joined the construction industry in supporting U.S. Industry Safety Week (May 3-9), as well as the Occupational Safety & Health Administration’s National Safety Stand-Down (May 4-15), which aims to reduce falls at construction sites.

“Life is far too valuable not to make safety the top priority on job sites,” said Eric Lambert, National Customer Solutions Director at Zurich North America. “Any single incident is one too many. It’s important for all of us in the industry to take the time to collectively raise the awareness of construction safety.”

Zurich recommends that construction firms take action toward safer environments by following these six safety tips to help reduce falls:

1) Assess site hazards to determine the appropriate equipment needed for a job
2) Invest in proper equipment, ensuring it’s used appropriately and with caution
3) Inspect and remove any fall exposures while securing materials so they don’t fall
4) Train employees on fall protection and equipment inspection, having accountability in place for ignoring safety precautions
5) Document safety-training activities and non-compliance with protocols
6) Before starting work, discuss the day’s tasks, required tools and potential hazards

“Falls from heights are a major concern on construction sites, ranking as the leading cause of death in the industry,” said Scott Rasor, head of Construction at Zurich North America. “More than 200 U.S. construction workers are killed each year from falls. Taking some time to bring safety front and center is important for our industry.”

Zurich aims to provide solutions for the risks that construction firms face today and in the future. By combining traditional and specialized insurance with customized analysis and risk management services, Zurich works with construction companies to help reduce the total cost of risk. Zurich’s highly trained staff brings years of experience to the operational and technical aspects of construction while demonstrating leadership and influence in key construction and insurance industry associations.

“We try to inspire everyone in the construction industry to be leaders in safety,” Lambert said. “It’s a philosophy and strong team approach that can lead to safer projects. It can be as simple as employees meeting before each shift to discuss hazards and ways to prevent them.”
 
— Source: Zurich American Insurance Company

Boise State Team Claims 2015 Collegiate Wind Competition

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Boise State Team Claims 2015 Collegiate Wind Competition

Seven teams of students from across the country gathered at the National Renewable Energy Laboratory’s National Wind Technology Center from April 29 – May 1 for a fierce blade-to-blade wind turbine rematch. At the Department of Energy Collegiate Wind Competition 2015 Engineering Contest, teams of undergraduates tested original designs of model wind turbines in an on-site wind tunnel and presented their technical designs to wind technology experts.

The full Collegiate Wind Competition, comprised of engineering, business, and deployment tasks is held during even numbered years and is designed to challenge undergraduate students from a variety of disciplines to develop unique solutions to complex wind energy problems. Teams that participated in the inaugural 2014 competition in Las Vegas, Nevada were invited back to improve upon their designs and technical solutions during last week’s contest.

Competing teams included the University of Massachusetts at Lowell, Colorado School of Mines, Pennsylvania State University, California Maritime Academy, Boise State University, Northern Arizona University, and Kansas State University.

As teams gathered at the NWTC, the sense of camaraderie that swept through the competition was underpinned by the bonds that teams had formed with one another during the previous year’s competition. The air was thick with excitement as each university unpacked and assembled their individual wind turbine designs, protecting their trade secrets so as not to give away information that could benefit a competitor. Standing at a hub height of two feet, each team’s turbine was a unique scale design inspired by the modern wind turbine.

Throughout the day, teams were overheard swapping tools and spare parts and trading guesses over what this year’s surprise challenge would be. Under the eye of some of the industry’s brightest innovators, teams made last minute adjustments and shared stories of design blunders and successes.

1st Place Boise State team, at the 2015 Collegiate Wind Competition held at NREL’s National Wind Technology Center just south of Boulder, Colorado. (Photo by Dennis Schroeder / NREL)

However, joviality was set aside once the competition began. University of Massachusetts, Lowell raced against the clock as they waited for a replacement part to arrive in the mail so that they could compete.  During their first test in the wind tunnel, Kansas State’s turbine controller went up in smoke due to a faulty wiring configuration.

This year there was the addition of a surprise challenge. Teams were given a set of criteria that included the location of transmission lines, access roads, local demand, and integration facilities, and tasked to use their knowledge of wind energy systems to determine the perfect location for a new wind plant that would produce energy at the lowest cost possible. Every team could be seen making last minute adjustments and repairs to ensure their turbines would operate at peak performance.

While each team excelled, Boise State University was named the winner of the Collegiate Wind Competition 2015. Cal Maritime placed second and Penn State, last year’s champion, finished third and also won the surprise challenge.

Since the Collegiate Wind Competition is intended to inspire and equip the next generation of wind professionals, the involvement of the wind industry is critical. The Energy Department collaborated with Siemens Wind Power, Vaisala, Renewable Energy Systems – Americas, ReGenerate, Invenergy, KidWind, and the National Renewable Energy Laboratory to make the Collegiate Wind Competition 2015 Engineering Contest a success. The Energy Department’s Wind Program leads the nation’s efforts to accelerate the deployment of wind power technologies through improved performance, lower costs, and reduced market barriers.

—  Source: U.S. Department of Energy, EERE

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