Home November 2012

November 2012

Construction Profile: Alternative Energy Institute

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Recognized around the world for its research and testing, the Alternative Energy Institute (AEI) at West Texas A&M University is celebrating its 35th anniversary in education, training and development of renewable energy systems.

Formed in 1977, AEI based in Canyon, Texas, conducts turbine and sensor tests at its Nance Ranch Wind Test Center in partnerships with NRG Systems and the Small Wind Certification Council (SWCC). Beyond on-site testing, AEI performs work for private land owners, developers and the state of Texas in wind research.

“In the 70s, some of our physics professors were doing research on wind energy and renewables. It was about the same time of the 1973 oil embargo where prices went through the roof. The public became much more interested in renewable energy at that point and three professors, Vaughn Nelson, Earl Gilmore and Robert Barieau started the institute as an outgrowth of the research they were already doing,” said David Carr, associate director of AEI.

Carr now manages testing, resource assessment and other programs with a staff of full-time workers and undergraduate and graduate students from the institute’s main hub and 40-acre wind test center.

With initial funding from the State of Texas followed by grants and private contracts with communities and businesses, the institute now specializes in wind data collection and analysis, evaluation of wind turbines, research and development, workshops and training programs, consulting and educational programs and classes.

“We have datasets going back to the 80s for wind and solar in Texas, New Mexico and Oklahoma providing historical data in various areas for wind farm development,” he said. “We took data from various towers across those three states and that data is a big value for our partners in doing predictive assessments for long term wind analysis. We created the first detailed GIS maps for the state of Texas and provided that information to NREL so developers and others in the industry could look at the land and learn the potential for wind farm development.”

The institute also continues to be involved in GIS and WAsP data analysis for developers regionally as well as along the east coast and as far away as Kenya. Carr was involved in working with the group in Kenya as it installed its first site.

Carr says turbine testing is another major part of the work conducted by AEI. “We test turbines up to 50 kW and we test to AWEA standards,” he said. “We also do custom testing on our site for small-to-large-scale turbine models. Between 2009 and 2010, we installed 14 test pads that are ready to go at any time. Test pads are available with 480 volt three phase and 240 volt setups to accommodate many different types of turbines. Manufacturers ship their turbines to us. We can set it up, or their personnel can, and we test to the standards or custom requirements.”

The site is also capable of conducting small wind and custom prototype testing and enjoys Class 4+ winds, which Carr says generate faster results for users, and the construction and maintenance personnel on staff are knowledgeable and available at the site each day.

The AEI Wind Test Center is one of three preferred testing organizations from around the world recognized by the Small Wind Certification Council. Chosen from more than 20 testing centers, the SWCC designation indicates AEI provides quality engineering and testing practices.

With its affiliation to West Texas A&M University, AEI’s programs include classes, seminars, workshops, training programs, and specialized educational opportunities for its Windy Land Owners, which includes seminars and presentations on wind farm installation, operation, contracts and wind assessment information.

West Texas A&M also offers two- and four-year degree programs in engineering technology with an emphasis in renewables, including solar, wind and biomass.

In addition to education, community outreach programs and manufacturing relationships, the center specializes in training and is an official training center for NRG Systems, where workers are trained on 50, 60 or 80 meter tilt-up towers.

“I don’t know if there is anything else like us in the industry all in one place.” Carr said. “We also offer international internships where students learn how to work, not only in wind, but also on our 48 kW solar system. Our entire test site is a net positive producer of energy. We use solar hot water to heat our workshop and solar hot air is pumped into the building for heating.

“We offer very specialized testing, training and data analysis for the wind industry, and we have the capabilities to serve many more developers and manufacturers,” Carr said. – S.M.

For more information visit www.windenergy.org or call 806-651-2295.      

Maintenance Profile: Air Sentry

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Controlling particulate and moisture contamination from lubricants in the fluid reservoirs of gearboxes is a critical aspect in preventing equipment downtime, premature failure and lost production time.

In any industrial application where moving parts are lubricated or powered with fluids, the reservoir vents air as the fluid levels rise and demands additional air as those levels fall. Many traditional air venting methods provide minimal contamination control. Most OEM filters will prevent ingress of particles down to about 40 microns, which means that dirt particles large enough to cause severe damage are able to enter the fluid causing wear and tear, premature equipment failure and more frequent maintenance. Those particle filters do nothing to keep out equally damaging moisture, which changes the lubricity of the fluids, breaks down essential additives, and leads to corrosion inside the headspace of the gearbox.

By using desiccant breathers to replace existing breather caps or air vents on fluid reservoirs and gearboxes, it is possible to extend the useful life of the lubricant and keep the fluid cleaner longer, according to Scott Dunbar, Vice President at Air Sentry®. “Air Sentry contamination control breathers provide the first line of defense in contamination control with 2-micron absolute filtration and highly effective moisture removal,” he said.

A division of Whitmore, a leading maker of specialty-lubricants, coatings and sealants, Air Sentry offers contamination control products for a broad variety of industries, including wind energy.
Introduced in 1997 to help its customers increase fluid cleanliness and lower maintenance costs, the breathers include two 2-micron filters with a desiccant chamber to trap moisture before it reaches the fluid.

“To understand the scale of contamination that is prevented, consider that an average human hair is about 80 microns across. If you cut that hair into 40 even slices, they would be two microns wide. Typically as you get tighter and tighter tolerances on bearings and other meshing gears, you are looking at a one-to-three micron boundary layer, which is basically the fluid layer of oil between the mating surfaces passing over one another. Particles in the lubricant larger than this boundary layer lead to metal wear on gear teeth and bearings, and that metal wear is exacerbated because you now have two rough surfaces passing over one another. It’s a downward spiral of metal wear with more and more metal particles floating in the lubricant. Keeping that from happening is essential to the longevity of the fluids and the life of the gearbox.”

Dunbar said the wind industry in particular has been more receptive to looking for ways to improve reliability because of the expense involved in the equipment, the remote locations where wind farms are often situated and the difficulty to access those remote locations in emergencies for maintenance situations.

Air Sentry desiccant breathers utilize an indicating dye on their silica gel desiccant that starts out as bright orange and becomes dark green when fully saturated, or absorbed. By providing a clear visual indicator of the condition of the drying agent, maintenance personnel know when to change the filter.
“Most of the studies we’ve seen are conservative in estimating that you will double the life of your lubricant and more than double the life of your equipment by using these contamination control devices and other reliability centered maintenance procedures,” Dunbar said.

Air Sentry® was the first company to integrate check valves into desiccant breathers, which extends the life of the breather by blocking ambient air from reaching the desiccant, and allowing only the air drawn into the fluid reservoir to be treated – this can extend the life of a breather by a factor of two to five times, depending on the condition of the ambient air.

The company now offers the new Guardian™ series of breather that takes the many Air Sentry innovations to the next level. The Guardian™ is constructed of Tritan™, a material that is more resistant to chemicals, extreme temperatures and impact than other plastics. It is also BPA free and recyclable. The check valves in the reusable top cap prolong the life of the desiccant while the reversed check valves in the reusable metal reinforced base exhaust outgoing air to the atmosphere rather than back through the desiccant. An optional Isolation Check Valve at the bottom of the replaceable cartridge prevents oil mist and splashing fluids from potentially coating the desiccant limiting airflow, which could damage delicate seals.

Air Sentry is ISO 9001 and ISO 14001 certified and available through the company’s worldwide distributor network. Extending lubricating fluid life, improving productivity and reducing maintenance costs help make wind energy operations more profitable. – S.M.     

For more information, visit www.airsentry.com or call 855-242-2792.

Manufacturing Profile: BlueScout Technologies, Inc.

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Formerly known as Catch the Wind, Ltd., BlueScout Technologies recently changed ownership and management with a new vision to bring its groundbreaking wind measurement technology to market.

“Our name, BlueScout, is about the future,” said Jo Major, President and CEO of BlueScout. “We are using this rebranding to show our customers, investors, and partners our commitment to helping turbines reliably produce cleaner, renewable energy. We intend to use our technologies and skills to help our customers understand and manage their wind resources more effectively.”

The BlueScout OCS-210 is a next generation turbine control system designed for utility-scale wind turbines. By placing the system on top of the nacelle, the optical unit measures wind speed and direction in the approaching inflow and can employ predictive control architectures to increase energy production and reduce the harmful effects of wind turbulence on wind turbines.

The OWS-150 is a lightweight, portable, all-weather wind assessment tool that can be used up to 300 meters above the ground for wind prospecting, wind resource assessment and turbine performance assessment. This unit is designed to provide engineering analysis data on the same rugged fiber optic platform as the OCS.

“What’s happening now is the industry uses a conventional anemometer positioned behind the rotor,” Major said. “And because there is so much turbulence, it is less representative of the actual wind resource and it limits the quality of data that can be measured and used for control. Everyone in the industry acknowledges that anemometers mounted behind the rotor have a lot of problems. They’ve spent years and years working to control wind turbines with that data, but in the end analysis, the performance of the turbine is limited by the quality of the data coming in. What we do, in a sense, is very focused and elegant. We measure the wind before it hits the turbine and base the control of the turbine on the unperturbed air that is going to strike. There are a lot of valuable things we can do by measuring the wind in front of a turbine.”

By using this pre-strike wind turbine data, BlueScout’s optical control system allows for precise control that generates more power and cleaner operation with less wear and noise.

“There are a lot of economic benefits in knowing the characteristics of the wind before it hits the turbine,” he said. “There is a lot of focus in the industry on dynamically adjusting pitch for optimal performance. Currently, after the wind hits the blades they detect heavy wind either through deflection of the blades or increased torque on the generator and then the blades change pitch. We know where the wind is going and what the wind characteristics are going to be three, four or five seconds before it hits the wind turbine so controls can adjust the blade to the proper pitch for the wind that will be hitting the blades, as opposed to reacting to what has already happened. If you adjust after the fact, it is based upon the assumption that the wind is going to be the same after it hits as when it hit. Our approach is much cleaner. We simply say, ‘well, the wind is going to increase in velocity by 20 percent so we need to proactively change our pitch. ’ ”

“The wind moves on the order of 10 meters per second and our system can see the wind 50 to 100 to 150 meters out in front of the turbine, so you are looking at us being able to tell the turbine what the wind velocity will be in five seconds and in 10 seconds,” he said. “The blades can adjust their pitch rapidly, so there is plenty of warning for these pitch control systems to adapt.”

With the increased acceptance of LIDAR in the industry to measure wind velocity with optical beams, the BlueScout system should be familiar to wind industry. The BlueScout OCS units have an improved telescope to capture more light, a better heating system to prevent icing, and significantly improved signal processing. Major said “improving the system while lowering costs was a challenge for BlueScout engineers, but was necessary to bring the new OCS unit to market for a wider audience.”

“The vast majority of our work is on active turbines, so we’ll send out an installation team and they go up on the turbine and install the OCS,” Major said. “After operating the system for a while, we’ll flip the switch and integrate into the control of the turbine. We are big believers in being collaborative with our customers, so there is a complete sharing of data on how much power is being generated. We provide the owner wind speed, wind direction, power curves and other data that gives the wind farm owner a complete turbine control analysis.”

Major says BlueScout’s technology is in test with the National Renewable Energy Laboratory (NREL) and installed and collecting thousands of hours of data in the field with current customers. – S.M.     

 

For more information, call 703-956-6554 or visit www.bluescout.com.

Conversation with Dane Overfield

Who is Exele Information Systems?

Exele Information Systems started in 1978 in East Rochester, NY. We became and integrator and distributor for an early data historian software product for the oil industry that later expanded to power, chemicals, oil and gas, and paper. While integrating and customizing this software for customers, a few products emerged which we now sell as “off-the-shelf” products. In addition to these products, we also offer various integration services and are heavily involved with environmental and emissions monitoring and reporting.

As product development lead for Exele Information Systems, Inc., what products do you offer for the wind energy market?

Many of our products satisfy a need that crosses many industries, including the wind energy market. One is a process calculation engine that is also heavily used in the refining and power industries, allowing engineers to easily create logic and calculations involving process data. TopView is a software product that monitors user-selected process measurements for abnormal conditions or events, notifies responsible parties, and makes details of the data and events available through various presentation tools.

How does TopView work?

TopView is an alarm management and notification product that allows customers to address the universal need to let people monitor, notify, and record specific unexpected or abnormal process events. Sometimes the events are simple limit violations, but TopView also allows more complex event detection involving multiple inputs or behavior over time.  Once the events are detected, we record, notify, and distribute this information through a variety of channels.

We started with the ability to monitor data from a single vendor. Our customer base expanded when OPC emerged since it allowed a client application such as TopView to monitor data regardless of process data vendor. More recently, we added the ability to monitor data stored in relational databases. Today, TopView can be used with most PLCs, SCADA systems, control systems, process historians, and relational databases

What are the main features of the software?

TopView started in 1997 as a way for people to visually and audibly monitor current process conditions from one vendor’s database. Once we released the product, people began to request more features such as email notification, voice call-out and pager notification, and various other monitoring and reporting activities. We also added remote operator consoles to allow real-time monitoring and acknowledgement of alarms as well as the querying of alarm history and the execution of alarm analytics. We keep adding great features to the product as technology and trends change.

How do customers customize for their needs?

We want the user to apply their process knowledge to the configuration of the product and we rarely get involved in the detailed customization of an installation. The interesting thing about our customers is that they often have a unique list of needs, but they all use the same TopView product because they can pick and choose the features that bring them the most value. The challenge for us is to create a feature-rich product that is easy to configure. We have a Configuration tool to address this task, and so far the feedback has been very positive. We also provide a real-time administrative tool to help the user “look under the hood” and monitor the current running state of the product. We try to empower the user by providing good tools.

Who are your customers?

Our customer industries span from wind farms to power plants, refineries, data centers, pharmaceuticals, water/wastewater, and more. The initial interest in TopView is often from a process engineer, process data analyst, or system integrator looking for real-time monitoring event detection, and notification software. Once installed, the users expand to those with interest in the data and events including maintenance, control operators, engineers, managers, and even suppliers and vendors.

For more information, visit www.exele.com or sales@exele.com for pricing.