Home May 2015

May 2015

DHi Receives UL Certifications For Pitch Control Slip Rings

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Virginia-based Defense Holdings, Inc. (DHi) recently announced it has received unrestricted certification from Underwriters Laboratories for its pitch control slip rings with HiPerCon Brand metal fiber brushes.
With this significant accreditation, DHi becomes: only the second company to achieve a UL listing for WTG pitch slip rings; and the first and only company to achieve UL certified and listed WTG pitch slip rings using metal fiber brush technology.
DHi’s UL Certified pitch control slip rings are currently available for use in all GE1.X, GE2.X and Suzlon S88 WTGs. The company’s “T00XXXX” series pitch slip rings are pre-certified to provide design flexibility for current and future slip ring demands for other OEM designs, as well as being capable of incorporating many other features including but not limited to high quality multi-GigaBaud signal transmission capabilities (>100MBPS/channel), high quality transmission of signal over power (PLC requires capable monitoring and control methodologies), and other aftermarket needs such as; blade de-icing or tip illumination, and advanced blade monitoring and control.
DHi entered the wind industry with its revolutionary patented Metal Fiber Brush (MFB) technology in the spring of 2011 under the mentorship of H&N Wind (A Timken Brand Company). Due to the general lack of knowledge throughout the wind industry of the existence and nature of DHi’s HiPerCon Brand MFBs, legacy pitch slip ring carcasses were used in a program through which customers were provided slip rings refurbished with DHi’s metal fiber brushes.
The primary goal was to familiarize the industry with the multitude of benefits associated with HiPerCon Brand patented metal fiber brushes as compared to carbon-based, metal-graphitic, or other metal brush technologies in use at that time. A secondary and very important goal was to demonstrate reductions of operations and maintenance (O&M) costs and increased operational availability.
“We are excited to set new industry benchmarks by becoming the first company in the world to provide the first unrestricted UL certified carbon-free slip rings to the wind industry,” DHi president and CEO Rich Martin said.

— Source: Defense Holdings, Inc.

Moventas Seeks To Ease Cost Burden Of CMS Retrofits

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Moventas North America has introduced an innovative financial solution with their Condition Monitoring Lease Program that converts the upfront installation costs for condition monitoring into an affordable monthly payment for wind farm owners. Additionally, this financial innovation translates condition monitoring from a hardware-only business to a complete life-cycle service.
Developed by Moventas, CMaS condition monitoring service maximizes gearbox life with early detection of mechanical problems through remote, real-time monitoring of gearbox vibration, oil condition, and temperature. A strong majority of all new wind turbines are sold with advance condition monitoring on the drivetrain. Unfortunately, a large majority of the existing fleet of 40,000 wind turbines were built without this valuable technology, and owners find it difficult to afford and deploy.
“The lease payment removes barriers to the deployment of condition monitoring hardware, 24/7 analysis by expert technicians, nationwide multi-brand boroscoping and a complete suite of lower cost multi-brand up-tower repairs for the North American fleet,” said Mike Grunow, vice president of Sales and Marketing, Americas at Moventas. 
Currently, wind farm revenues are down due to lower electricity prices, and these farms typically cannot afford the upfront costs to retrofit the existing fleets with condition monitoring capability.  However, today’s low interest rates enable low cost operational leases of this kind of equipment. Leveraging the innovative leasing structures that are prevalent in other industries spreads the cost out over multiple years for the wind farm owner.
“Outside of Moventas’ comprehensive offering, a wind farm owner would have to contract with at least four separate entities for condition monitoring, the lease, follow on boroscope inspections, parts and repairs. Having all of these under one roof enables access to lower cost repair savings and less downtime for wind farm owners,” said Grunow.
Moventas currently monitors over 2 GW of wind turbines globally and has repaired over 1500 multi-brand wind turbine gearboxes in North America alone.

— Source: Moventas

Maximizing Wind Build Returns Through Meticulous Planning

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Although the U.S. wind fleet is relatively new, rapid growth in turbine size and hub height has resulted in an evolution in the necessary resources to successfully complete efficient turbine erection. According to the Global Wind Energy Council, the U.S. was in the top three countries with the largest amount of installed capacity in 2014. Globally, the wind industry set a new record for annual installations in 2014 with a 44 percent increase in the annual market. In this competitive climate, wind farm construction contractors have had to increase efficiencies to reduce construction time, generating higher returns for developers, owners and operators.
Wanzek Construction, Inc., which has installed over three thousand turbines across North America, focuses on a proactive approach to balance organic growth with customer requirements. With solid experience in installing a variety of turbine types and sizes, Wanzek has developed efficiency processes that directly impact construction schedules and project costs.
 “Our approach is to identify risks and reduce qualifying conditions,” said Arnold Jelinek, vice president of Wanzek. “It comes down to optimizing design, analyzing sites and a strong quality assurance program. And communication throughout a project is crucial. Planning, organization and communication before, during and after site work is essential to each project’s success,” Jelinek said.
During preconstruction services, Wanzek works with customers to optimize the civil and electrical system design as well as determine the implication of environmental requirements. For a project that requires larger turbines, site civil design can directly impact turbine delivery rates, crane moves and project cost. By analyzing site requirements, effectively managing turbine deliveries and organizing optimal crew size, qualifying conditions are minimized.
“As wind turbines have increased in size and complexity, our quality assurance process has expanded as well.” Jelinek said. “We use lean continuous improvement methodologies to optimize all aspects of construction and operations. From inspection of each component as it is received to final walk-down, Wanzek’s quality assurance team measures every step of the process. This focus allows us to work smarter and be more competitive.”
Wind projects are very fast paced. Once a contract has been signed and a plan has been finalized, there is no downtime until the project has been completed. Construction companies are relying more heavily on technology to improve efficiency and productivity. One method Wanzek is beginning to employ is a paperless quality assurance system for wind turbine erection. The system is wireless, compiles data automatically, allows the customer to view progress in real time and saves many man-hours of administrative work.
Wanzek focuses on four core roles for technology including streamlining job site documentation, enhancing collaboration between corporate and field team members, workflow improvement and job site mobilization. According to Jelinek, use of technology can turn a standard field office into a smart job site office.
“Technology allows us to integrate our teams, evaluate our processes and develop effective solutions for successful project completion,” he said.
Implementation of safety programs and training are another part of identifying risks and maintaining an efficient job site. Wanzek offers its employees 64 safety courses taught by safety professionals, including ENSA Height and Rescue training, as well as over 400 courses in safety and regulatory compliance.
“Our focus on safety starts long before we mobilize to the field. It is a crucial part of reviewing and finalizing proposals, continues through project planning and crew mobilization and provides the opportunity for employees to be engaged in our safety program through an employee observation and feedback process,” Jelinek said.
With an efficiency program firmly in place and a commitment to continuous development and improvement, Wanzek has established a work process that supports the continued growth of the U.S. wind industry.

For more information on Wanzek Construction, call (701) 282-6171, email constructors@wanzek.com, or visit www.wanzek.com.