DNV GL recently published its first Energy Transition Outlook (ETO): Renewables, Power and Energy Use. The industry implication report is part of DNV GL’s new suite of Energy Transition Outlook publications. The report reviews global energy demand and energy supply and summarizes the implications for the power and renewables sector and large industrial energy users.
An era of abundant and cleaner energy lies ahead, according to DNV GL’s modeling of the world energy system. The key findings of the report emerging globally over the forecasting period include:
Electricity consumption increases by 140 percent by 2050, becoming the largest energy carrier, followed by gas. Other energy carriers such as coal experience significant reductions, while oil and gas consumption increase only slightly.
85 percent of global electricity production in 2050 comes from renewable sources — Solar PV will provide around a third of the world’s electricity by 2050, followed by onshore wind, hydropower, and offshore wind, in that order.
Despite this optimistic outlook, the report finds that the world is not on course to achieve the climate objectives of the Paris agreement.
DNV GL forecasts that humanity will exhaust the 2 degrees C carbon budget (the amount of CO2 that can be emitted without triggering dangerous climate change) by 2041, pointing toward a global warming of 2.5 degrees C above pre-industrial levels by the end of the century, a level which is likely to force dangerous climate change.
An era of abundant and cleaner energy lies ahead, according to DNV GL’s modeling of the world energy system. (Courtesy: DNV GL)
The growth of electricity consumption is one enabler to speed up the global decarbonization. This includes the rapid uptake of electric vehicles, generating energy savings and emissions reductions. DNV GL forecasts that electric vehicles will achieve cost parity with internal combustion vehicles in 2022 and, by 2033, half of new light vehicle sales globally will be electric.
“Our report shows that the energy industry, more than any other, has the power and knowledge to manage the world’s carbon budget in a smarter way,” said Ditlev Engel, CEO at DNV GL-Energy. “Until 2050, the electricity share of energy demand will grow from 18 percent to 40 percent, yet this transformation is not happening fast enough. Speeding up the acceleration by decarbonization of heat and transport will be one vital measure to put the brakes on global warming. In fact, all industries should maximize the decarbonization of their operations. But the climate challenge is not only an engineering challenge, but also one of governance. We call upon all stakeholders to maximize the decarbonization of their operations.”
To achieve the target of a low-carbon world, there is no single solution. Instead, multiple achievable actions must be taken both locally and globally, involving collaboration within the energy sector and across industries:
Action1: Greater and earlier adoption of renewables.
Assist the growth of offshore wind.
Drive uptake of data analysis to optimize performance of wind, solar, grids, and energy use.
Invest in testing and verification of systems to secure robust electricity supply.
Provide flexibility, balancing, and cost-effective integration solutions.
Optimize grids to facilitate growth of renewables.
Action 2: Greater and earlier electrification of heat and transport.
Drive the uptake of decarbonization of heat.
Broader adoption of electric vehicles contributing to energy savings and emissions reduction.
Action 3: Greater improvements in energy efficiency.
Invest in strategic energy management.
Action 4: Change in personal behavior.
Increase the level of public acceptance to shape consumer behavior.
Availability of subsidies.
DNV GL’s ETO report was prepared by a dedicated research team, which received input from hundreds of energy experts from inside and outside the organization.
The report arms all relevant sectors with a wealth of factual ammunition to adapt strategies, and be bold in making evidence-based decisions to transform energy systems.
Companies in the American wind-energy industry recently announced they will donate $1 million to Hurricane Harvey repair and rebuilding as keystone partners of Habitat for Humanity’s Habitat Hammers Back initiative.
Participating companies include Apex Clean Energy, Blattner Energy, Duke Energy, EDF Renewable Energy, EDP Renewables, Enel Green Power North America, Inc., E.ON, Goldwind Americas, Hannon Armstrong, Invenergy, Leeward Renewable Energy, MAP Royalty, Pattern Energy, TPI Composites, and the American Wind Energy Association.
The money will support repairs and rebuilding efforts in areas affected by the storm, which first made landfall August 25 near Corpus Christi, Texas. The wind companies had also planned to send volunteers to help with the rebuilding effort. Texas has a quarter of U.S. wind-power capacity and more than 22,000 Texans work in the industry, among 102,500 wind jobs nationwide. The state’s more than 12,000 wind turbines themselves emerged unscathed from the storm.
“The EDF group has 400 employees in Houston serving various sectors of the energy industry, including our regional wind-project development team,” said Tristan Grimbert, president and CEO of EDF Renewable Energy. “As Texas wind is an important contributor to our nation’s energy mix, and Houston in specific is the center of energy diversity, we are committed to the ambition to offer our resources in the recovery and rebuilding efforts.”
Money donated by the wind industry will support repairs and rebuilding efforts in areas affected by Hurricane Harvey, which first made landfall August 25 near Corpus Christi, Texas. (Courtesy: NOAA)
“Our thoughts and prayers continue to go out to everyone along the Texas Coastal Bend and in Houston who was impacted by this storm,” said Patrick Woodson, chairman of E.ON North America. “Several E.ON employees around our Papalote Creek Wind Farm lost their homes, and even more saw their communities devastated when the hurricane made landfall. Habitat for Humanity will play a critical role in helping people rebuild their homes and communities. With Texas as the nation’s leader in wind energy, it is only right that we and the wind industry be a leading force to help Texans rebuild and recover.”
“More than 22,000 wind workers are in the state of Texas, so this has hit very close to home for us,” said Steven C. Lockard, president and CEO of TPI Composites. “We all feel the need to help with this rebuilding effort. I am especially proud participating companies from across the United States and their associates are committed to volunteer their time in addition to financial resources.”
“Habitat for Humanity is committed to helping families recover from Hurricane Harvey, and we wouldn’t be able to do it without the support of our partners like these American wind-energy companies,” said Habitat for Humanity International CEO Jonathan Reckford. “Their gift is an investment in the long-term recovery of these communities.”
Habitat is already at work responding to Hurricane Harvey, helping families clean up and prepare for the rebuilding effort to come. Habitat will work with its local offices throughout the hurricane-affected regions to assess the shelter and housing needs and develop response options. In addition to long-term housing repair and construction, Habitat’s response includes organizing volunteers and resources to help with the cleanup of homes damaged by wind and flood waters.
Gearbox Express (GBX), the only independent company in North America focused on providing down-tower, multi-brand wind gearbox remanufacturing services, recently announced it has signed a framework agreement with Eickhoff Bochum to become its preferred North American partner for all up- and down-tower service both in and out of warranty, parts supply, and new replacement gearboxes.
“Currently, Eickhoff has more than 800 wind-turbine gearboxes in service in North America, and this partnership gives Eickhoff much needed service capabilities,” said Bruce Neumiller, CEO of Gearbox Express. “Gearbox Express will serve as their North American service and repair partner, ensuring the Eickhoff gearboxes keep running. We look forward to working together as partners for many years to come.”
Gearbox Express will become the preferred North American partner for all up- and down-tower service both in and out of warranty, parts supply, and new replacement gearboxes for Eickhoff Bochum. (Courtesy: Gearbox Express)
Eickhoff has been in the gearbox business since 1864, and takes the care and maintenance of their product seriously.
“We had to prove our capabilities to handle the work,” Neumiller said. “The GBX team is highly trained; our equipment and parts are state of the art, and our quality of service sets the industry standard.”
The collaboration is in line with Eickhoff Bochum’s strategic goal to provide service all around the globe.
“We are looking back on many years of cooperation with GBX and value them as a reliable and experienced partner,” said Christina Gierga, head of service at Eickhoff Bochum. “The official collaboration is a logical step toward our goal of meeting the needs of our customers in the USA with high quality standards and OEM spares made by Eickhoff.”
Siemens Gamesa Renewable Energy (SGRE) has been selected by NextEra Energy Resources to repower two wind farms in Texas. The newly repowered wind farms are expected to deliver up to 25 percent more annual energy production, boost reliability and efficiency, and extend service life.
The two wind farms feature Siemens SWT-2.3-93 model turbines. The repowering program will upgrade them to the SWT-2.3-108 model. Project completion is expected by year-end, and the wind farms will remain operational during the repowering process.
The SWT-2.3-108 model turbine will be used to upgrade two Texas wind farms. (Courtesy: Siemens Gamesa)
“We are very pleased to continue our work with NextEra Energy Resources,” said Jacob Andersen, head of Onshore North America for Siemens Gamesa Renewable Energy. “Through Siemens Gamesa’s repowering program, we’re making it possible to optimize our customers’ assets and extend their service life — maximizing the value of their investments.”
Harnessing its expertise in both turbine technology and turbine operation and maintenance services, SGRE has developed a comprehensive and customizable repowering program. The program offers solutions in all phases of a repowering project including siting guidance, financing, planning, construction, service, and operation. SGRE further offers a turbine overhaul option designed to upgrade the electrical and electronic components of wind turbines from other turbine suppliers, improving performance and increasing energy production.
“Siemens Gamesa is a valuable partner, and we look forward to working with them on these important projects,” said Armando Pimentel, president and CEO of NextEra Energy Resources.
Merging ZF’s extensive experience in developing innovative designs with advanced digital technology, results in a modular gearbox solution approach for geared wind turbines.
With more than 55,000 gearboxes shipped, ZF’s installed base exceeds 100 GW covering 25 percent of the globally installed base. This makes the company a leading partner in the wind-power sector.
ZF powers more than 50 percent of the global 3-MW onshore installations and is the first supplier with a serial production of more than 8-MW gearboxes for offshore installation. A 9.5-MW upgrade is being developed.
ZF Wind Power officials said they are convinced that in the future wind energy will become even more pivotal than it is today. “We will need bigger, better, and more powerful turbines to provide the world with affordable electricity.”
ZF’s Modular Gearbox Solution
“With the development of our modular gearbox solution, ZF can now cover new turbine platforms in the 3- and 4-MW range,” said Jan Willem Ruinemans, head of ZF Wind Power Business Unit. “We assure that new generation wind turbines can grow significantly in torque requirements, within the same nacelle dimensions. And thanks to our integrated intelligent performance solutions, our gearboxes can automatically sense the best way to optimize energy generation and improve turbine economics for any wind-site condition.”
Service for Wind Energy in Motion
ZF offers a strong, global partnership and enhanced multi-brand full service for wind turbine gearboxes and drivelines, enabling its customers to successfully stand ground amongst the competition.
“Our full offering combining on-site, ZF and non-ZF mechanical drive-train repair, and insight engineering partnership is fundamental in leveraging our global knowledge base to reduce costs and downtimes,” said Antti Turunen, head of Global Wind Power Service. “As a further evolution in service, ZF sees an important role for connected devices to actively control gearbox performance and health status during operation. As part of this vision, ZF offers an intelligent gearbox retrofit as a new method to reduce service bills.”
In the sleepy town of Lunderskov, Denmark, there’s a 22-meter-long room that is climate controlled at minus-30 degrees Celsius. Dubbed the Ice Lab, it’s a place where LM Wind Power engineers can study the effects of freezing weather conditions on wind-turbine blades and determine how best to mitigate them.
As wind energy gains prominence around the globe, major wind-turbine manufacturers are researching strategies that would allow their technologies to work in the coldest of climates. Because of their high winds and increased air density — not to mention their lower populations — colder regions are ideal for wind-energy production.
Challenges abound, though, and in 2002, the International Energy Agency (IEA) Wind Task 19 began gathering and coordinating recommended practices on cold-climate wind energy. One area on its radar is blade icing, a problem that has been tackled by a number of manufacturers in recent years. For when ice builds up, energy production goes down, and it can even come to a halt altogether.
Many Ways to Get Rid of Ice
You’d think it would be easy to keep ice from building up on a wind-turbine blade. Try a little anti-freeze coating. Paint the blade black. Maybe try salting the blade like they do on icy roads. Unfortunately, none of these much-researched “easy” fixes has actually worked, according to the October 2012 edition of IEA Wind Task 19’s State-of-the-Art of Wind Energy in Cold Climates.
Instead, many manufacturers have turned to electro-thermal heating, a conductive mat or mesh usually made of carbon fiber added to the blade’s surface. The mat heats up when electricity is applied. These systems apply heat precisely to the ice layer, and they can be used in harsh environments.
Several other companies went a different direction, however, to a hot-air system — a technology many believe offers lower maintenance and greater reliability compared to electro-thermal heating.
Here’s how the hot-air technology from LM Wind Power works: A heater fan unit is located at the root of the blade. Because all LM Wind Power blades are custom designed, the heater fan size can vary, depending on the blade size. An insulated duct sends the hot air through the blade’s interior, all the way to the tip. Holes in the leading edge (LE) web direct hot air onto the blade shell. The holes are placed according to design needs, and flow and heat distribution can be tailored to local heat transfer conditions. The length of the de-icing zone varies, too, depending on requirements. Finally, the air returns through the LE cavity and an insulated return duct, the length of which is chosen based on the length of the desired ice mitigation zone and power requirements.
Compared to electro-thermal technologies, LM Wind Power’s ice mitigation systems don’t increase manufacturing cycle time. In addition, there’s less chance of damage because all components are internal.
Finally, electro-thermal technologies are conductive, which can attract lightning and potentially damage the blades, and the warming technologies aren’t extended to the blade tip for that reason. With a hot-air system, since no metal components are used beyond the blade root, there’s no impact on lightning protection, making it possible to remove ice very close to the tip.
As wind energy gains prominence around the globe, major wind-turbine manufacturers are researching strategies that would allow their technologies to work in the coldest of climates. (Courtesy: LM Wind Power)
Devil in the Details
Numerous studies have shown that ice builds up at the LE and the tip more than in other areas, but these also are the most critical areas to aerodynamic performance. One challenge with hot-air technology: If the heater fan unit is at the root, the tip is the hardest area to reach, and the air can cool by the time it reaches there. The smaller internal area at the tip means that pressure losses are high by the time the air reaches there as well.
LM Wind Power was able to maintain a high air temperature by using an insulated supply duct. In addition, engineers increased the internal heat transfer coefficient by increasing the local velocity and turbulence of the air, using methods such as impingement holes to direct the hot air flow at the LE and other procedures to increase turbulence locally. For a hot-air system that heats the inside of the blade, it is essential that the heat transfer through the blade shell matches the heat transfer from the blade to the air. The most efficient system will exceed this slightly to keep surface temperatures just above zero.
Additional design enhancements come with each customization. LM Wind Power works with its customers to design a blade for their particular turbine, and the company puts a lot of effort into determining where the hot air is most needed every time. Each turbine has different requirements, and the geometry of the blade can greatly affect air flow. Creating just the right design is critical to efficiency.
Design Developments Continue
Many manufacturers begin their design research using analytical models. LM Wind Power’s sophisticated flow model uses compressible flow equations to accurately model flow distribution, but turbulence and other local flow effects aren’t captured with this model. A global heat-transfer model can estimate power requirements, while a local heat transfer model estimates local ice buildup potential and is used for structural calculations.
Another design method is computational fluid dynamics, or CFD, which basically splits a volume of space into sections to simplify a complicated 3D flow into a series of simpler flow analyses. For instance, CFD can be used to simulate external flow to determine heat-transfer requirements and internal flow steady state and transient analyses, to calculate surface temperature distributions, impingement from web holes, and internal heat transfer coefficient distribution. A number of these analyses might be used for a new blade design, depending on how novel the design or application is compared to previous designs.
The goal of any ice mitigation system is to get the blade surface hot enough to either melt ice or prevent it from forming. (Courtesy: LM Wind Power)
Enter the Ice Lab
With its Ice Lab, LM Wind Power takes its research an additional step. Located 14 kilometers from the company’s headquarters in Kolding, Denmark, the lab can be used to study the effects of cold climates on the most critical part of the blade — the tip. Instrumented with temperature, pressure, and sensor flows, the lab can provide data logging for transient analyses and is used to validate CFD and analytical models and to test new designs.
For most of LM Wind Power’s new designs, the main focus is on maximizing heat transfer in the tip region. The goal of any ice mitigation system is to get the blade surface hot enough to either melt ice or prevent it from forming. The heat transfer requirements toward the root are generally much easier to achieve, so the company is concentrating on the tip.
With hot-air technology, it’s hard to target specific areas, and LM Wind Power has focused on matching the flow and temperature distribution to local heat transfer requirements, she said.
LM Wind Power is also challenged by scaling effects, because as the blades get longer and slenderer, it is harder to get enough flow at a high enough temperature at the tip.
And there is another consideration:
Hot-air technology uses more energy than the electro-thermal technique, so it is important to optimize this as far as possible.
The battle against ice on blades will continue as wind-energy markets expand into colder regions. (Courtesy: LM Wind Power)
Upgrading to Anti-Icing
The blade typically is stopped while de-icing takes place — up to several hours per blade — depending on conditions. Anti-icing technology, on the other hand, literally prevents the ice from building up in the first place, so the turbine continues to run. Since heavy icing sites can have ice accumulating up to 70 days per year, anti-icing technology has the potential for annual energy production gains at these locations.
With hot-air technology, researchers are using CFD analysis to determine the heat transfer required to keep the blade surface water in a liquid state. Compared to a de-icing blade, an anti-icing blade needs more insulation to maintain higher temperatures, an increased heat transfer coefficient at the tip, a higher flow rate overall, and an especially higher flow rate at the tip, which means a larger fan is needed to provide more flow and greater pressure gain.
Up to the Customer
The battle against ice on blades will continue as wind-energy markets expand into colder regions. When entering a new region, blade manufacturers need to work closely with customers, alongside meteorologists, to deepen their understanding of the weather conditions blades will face throughout their 20-year lifetime. Demand for systems to combat ice is growing, and the pressure to decrease the levelized cost of electricity (LCOE) from wind will drive ongoing improvements in the cost and efficiency of the technology.
To continue to compete in colder climates, research is key. So, as long as the winter winds blow outside, engineers will be found inside LM Wind Power’s Ice Lab developing the next generation of de-icing and anti-icing technologies.
In any industry, value is often in the eye of the beholder. What works for one company may cost another significantly.
The total replacement cost for gearboxes needs to be reduced to make wind a more sustainable technology. (Courtesy: Shutterstock)
Five years ago, Gearbox Express (GBX) introduced Revolution for the Sle platform because a majority of those turbines were 5 to 8 years old. The theory was these assets would run 20-plus years in a market where power-price increases would be the norm and reliance on the Production Tax Credit (PTC) would phase out.
Fast forward to today and:
Wind has become very competitive. According to Make Consulting, LCOE (levelized cost of electricity) is expected to fall below $35/MWh within the next five years, outstripping both coal and natural gas.
Current development boom being fueled by the phase out of the PTC. PPAs (power purchase agreements) are coming in extremely low (sub $20/MWh in many circumstances). This underscores long-term importance of OPEX (operating expenses).
Given low power prices, independent power producers in a post-PTC environment (after year 10) find it difficult to justify gearbox and or main-bearing replacement.
Regulated utilities have a rate base used to justify upgrades and increased reliability. They continue to develop and expand wind largely as a long-term hedge against other forms of power generation while the PTC remains nice to have.
A major “repower” wave is surging through the more than 8-year-old turbine market, exclusively driven by the PTC 80/20 rule. Over 7 GW is expected to undergo some sort of repower activity, qualifying for a second 10 years of PTC providing relief to OPEX pressures.
The total replacement cost for gearboxes needs to be reduced to make wind a more sustainable technology. Yes, power prices are likely to rise, but for wind to be sustainable long term, these costs have to be fundamentally lower while at the same time not sacrificing reliability. Owners of post-PTC turbines not repowering could be lured into chasing a low cost /used gearbox, only to quickly find out the value of its reliability is not there.
Traditional cranes are expensive. Wind is maturing, and newer technologies are now on the market that are cutting the in-and-out cost in half. Newer, self-hoisting systems can do the job for $75,000 to $100,000 while a traditional crane would cost $125,000 to $175,000. As acceptance in the industry increases, up-front capital cost will reduce, and the in-and-out cost could be as low at $50,000 to $75,000.
Predictive maintenance is key. It is possible to use condition monitoring as a tool to manage time between failures with de-rating strategies. Turbines can produce power safely until it makes sense to perform the change-out, avoiding costly down time. Furthermore, economies of scale can be realized on the crane mobilization by lumping multiples together.
Make smart investments. Certain wear debris sensors have become cost effective. They now cost a third to half the price of a traditional full-blown vibration system.
Material fatigue can cause serious wear, limiting the lifespan of a used gear vs. new. (Courtesy: Gearbox Express)
Reduce the cost of the gearbox repair while understanding the reliability tradeoffs.
A full set of replacement gearing represents approximately half the costs of a complete remanufacture. Reusing gears therefore presents a significant opportunity to save cost.
Used gears can be successfully used if properly inspected to ensure within backlash tolerance and reground to 100 percent clean up (meaning it looks like a new gear). Using gearing as-is or without proper inspection is a recipe for disaster. This is the crux of the material aspect of any warranty: ensure the language is clear, as any gray area implies assumed risk. Make sure suppliers providing a guarantee are transparent with their specifications.
It’s reasonable to expect a properly reconditioned used gear will run another five to 10 years while a new gear would be expected to last 20 years. For example, if a turbine is 11 years old and the goal is to run beyond 20 years, additional investment must be made up-front so new material can be used. If the goal is only to run another nine years (to year 20), recertified gearing may be a better option. As an example, if the upfront purchase cost of a gearbox with all new gearing was $180,000, a gearbox using recertified used gearing could be $120,000.
Bearings represent about a quarter to a third of the cost of a complete remanufacture. Paying 20 percent to 30 percent more for upgraded bearings in a few of the positions (planets, high speed, intermediate) will only marginally increase the cost of the gearbox (approximately 5 percent), but substantially improve reliability.
The remaining cost of the gearbox relates to labor, lube system, seals, and a load test leaving little room for additional savings.
Value is often in the eye of the beholder. As an owner, value takes on different definitions over the life of the turbine. The good news is innovation and industry maturity has brought additional options, and more importantly, transparency, so all risks can be weighed and the true value found.
Senvion, a leading global manufacturer of wind turbines, has signed contracts to supply 20 wind turbines with a total output of 62 MW for four projects in Lower Austria. The contracts have been signed with Windkraft Simonsfeld AG, which has had an established business relationship with Senvion since 2011.
The two companies have previously worked together on four projects in Austria with a total output of approximately 65 MW.
With the orders for the four wind farms, Hipples II (MM100), Dürnkrut II (3.2M122), Poysdorf- Wilfersdorf V (3.4M140) and Prinzendorf III (3.2M114), Senvion shows the strength of its broad turbine portfolio, which enables optimized solutions for different wind regimes from strong-wind all the way to low-wind scenarios. The wind turbines will be installed at hub heights ranging from 100 meters to 160 meters to suit the local conditions and further optimize the yield of the wind farms. In doing so, Senvion will be celebrating two firsts in Austria: The Senvion 3.2M122 will be making its debut on the market during the projects and will be installed at hub heights of 119 meters and 139 meters. The 3.4M140 low-wind turbines will be installed at a hub height of 160 meters for the first time.
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“We are very much looking forward to these projects,” said Jochen Magerfleisch, Managing Director of Senvion EU Central. “They will further reinforce our partnership with Simonsfeld. The projects demonstrate that flexibly adapting the turbines from location to location is the way to achieve the highest yield. With a combination of low-wind and strong-wind turbines from the Senvion portfolio at various tower heights, we are helping Simonsfeld to implement the most efficient solutions for all four locations.”
“We are delighted to continue the excellent partnership with Senvion that we have built up over the last five years and expect the new turbine generation to deliver performance just as stable and productive as in the past,” said Markus Winter, head of wind-power engineering at Simonsfeld.
“With the planned electricity production from the new wind farms, we will be able to increase our overall production by more than half in the next few years,” said WKS CEO Martin Steininger. “That will help us to contribute to the process of expanding renewable energy and achieving climate targets.”
For all four projects, Senvion has signed full-service contracts lasting 15 years with extensions for up to 20 years. The wind farms are expected to be constructed between 2018 and 2021.
Vestas’ progress in India continues with a 100 MW turnkey order.
Leveraging Vestas’ extensive experience from more than 100 turnkey projects across the globe, the order includes delivery, installation, and commissioning of 50 V110-2.0 MW turbines as well as the project’s civil and electrical works. The order follows the inauguration of Vestas’ blades factory in Gujarat and the 54 MW Periyapatti order earlier this year, adding to Vestas’ continued progress in India.
The order also includes a 10-year Active Output Management 4000 (AOM4000) service contract and VestasOnline® Business, its unique SCADA system for data-driven monitoring and preventive maintenance.
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“This order underlines the broad range of capabilities and offerings that Vestas has to offer in the Indian market now and in the future,” said Clive Turton, president of Vestas Asia Pacific. “Our extensive experience from around 4 GW of turnkey projects across the globe has been key in securing this order, which is another significant step forward in a key market.”
Turbine delivery is expected to start in late 2017, with commissioning by first half 2018.
At the customer’s request, the customer and project names have not been disclosed at this time.
Dong Energy has been awarded a contract to build its Hornsea Project Two offshore wind farm, at the lowest-ever price for offshore wind in the U.K.
At GBP 57,50/MWh, the strike price for the Contract for Difference (CfD) is 50 percent lower than the previous round of CfD allocations just two years ago, demonstrating the rapid reduction in cost across the industry.
With a massive capacity of 1,386 MW, enough to power more than 1.3 million U.K. homes, Hornsea Project Two will become the world’s biggest wind farm, even surpassing the 1,200 MW giant Hornsea Project One which Dong Energy is currently constructing.
Hornsea Project Two will be built 89 kilometers from the Yorkshire coast and is expected to be operational in 2022.
Hornsea Project Two will contribute significantly to Dong Energy’s ambition of reaching a total offshore wind capacity of 11-12 GW by 2025.
“We’re delighted to be awarded a Contract for Difference for Hornsea Project Two, which is another important step towards fulfilling our vision of making offshore wind the most competitive form of electricity generation,” said Samuel Leupold, executive vice president and CEO of Wind Power at Dong Energy. “We have always promoted size as a key driver for cost. The ideal size of an offshore wind farm is 800-1,500 MW, and therefore it is natural that Hornsea Project Two will deliver record-low costs to society. At the same time, the low-strike price demonstrates the cost saving potential of developer-built offshore grid connections, which in the U.K. is included in the project scope.”
“We remain fully committed to financial discipline, and Hornsea Project Two will be value creating to our investors,” he said.
“This is a breakthrough moment for offshore wind in the U.K. and a massive step forward for the industry,” said Matthew Wright, managing director for Dong Energy U.K. “Not only will Hornsea Project Two provide low cost, clean energy to the U.K., it will also deliver high quality jobs and another huge boost to the U.K. supply chain.”
The Hornsea Project One. (Courtesy: ABB)
“Successive governments deserve great credit for providing the certainty for continued investment in offshore wind, enabling it to become the thriving renewable industry it is today,” he said. “Costs are falling rapidly, long-term and highly-skilled jobs are being created across the North of England, and the U.K. supply chain is going from strength to strength. We’re now really seeing the benefits of this commitment to offshore wind, and there is still so much more to come. Indeed, it has the potential to play a key part in the realization of the U.K.’s industrial strategy.”
Dong Energy already is constructing Hornsea Project One and has started the consultation process for Hornsea Project Three, underlining the huge potential of this area of the North Sea for offshore wind.
Cost-drivers enabling the bid for Hornsea Project Two include:
Scale: Dong Energy’s pipeline of construction projects across the U.K. (Race Bank and Walney Extension in 2018, Hornsea Project One in 2020, and Hornsea Project Two in 2022) creates economies of scale. And with 1,386 MW, Hornsea Project Two has the scale required to secure low costs per MW of construction, and low costs per MWh during a lifetime of operations and maintenance.
Risk reduction: Dong Energy already has several years of experience from developing Hornsea Project One in the North Sea. This reduces construction and operation risk of Hornsea Project Two.
Synergies: Operations and maintenance on both Hornsea projects will be conducted from Dong Energy’s new hub in Grimsby, which also serves other Dong Energy offshore wind farms on the U.K. east coast.
Maturing industry and technology: Innovation of offshore wind turbines, new installation equipment and methods, continuous improvements of foundation design, improved cables with higher capacity, and a growing and competitive supply chain.
With the allocation of the CfD, Dong Energy has now taken a final investment decision on Hornsea Project Two.
EDP Renováveis, S.A. (EDPR) and ENGIE recently announced that Moray Offshore Windfarm (East) Limited, a joint venture company owned by EDPR (77 percent) and ENGIE (23 percent), has been awarded a 15-year Contract for Difference (CfD) for the delivery of 950 MW of offshore wind generation at £57.50/MWh (in real 2012 terms). The contract was awarded by the U.K.’s Department for Business, Energy & Industrial Strategy (“BEIS”) following its latest CfD auction.
EDPR and ENGIE are jointly developing this project, which is off the northeast coast of Scotland. Upon conclusion of the development phase and the selection of all partners and suppliers for the different stages of construction and operation, the project would then move toward the construction phase. Completion and the commencement of commercial operation is expected in 2022.
“With (the) announcement, EDPR increases its growth options in offshore wind in an attractive market, thereby enhancing and diversifying the company’s long-term profitable growth options while maintaining a balanced risk profile,” said João Manso Neto, CEO of EDPR. “EDPR’s sustained commitment to the U.K. offshore wind market through Electricity Market Reform and the transition to CfD auctions has enabled dramatic cost reduction from £150/MWh in 2014 to £57.50 /MWh today.”
“This auction has demonstrated the real progress in cost reduction, and our result shows how affordable offshore wind can be compared to other technologies, including new thermal generation,” he said. “The U.K. needs more low carbon generating infrastructure to maintain security of supply against an increasingly uncertain future. EDPR has demonstrated what can be done at this site. It is in the UK’s interests to enable us to continue this achievement at other sites”
“We are delighted that the Moray East offshore wind farm has received this CfD, which is an important step in taking this project forward,” said Wilfrid Petrie, CEO for ENGIE in the U.K. and Ireland. “This will be ENGIE’s first offshore wind development in the U.K. and complements our growing global offshore wind portfolio with projects in France, Portugal, and Belgium, as well as our existing renewables operations in the U.K.”
“ENGIE is committed to investing in sustainable energy solutions and innovative services in the U.K., including renewable energy generation,” he said. “Moray East will make a significant contribution toward helping the U.K. meet its decarbonization targets, and it will also support ENGIE’s ambition for 25 percent of its global energy portfolio to be renewable by 2020.”
“Moray East’s success in this auction will enable us to bring a high-quality, high-value offshore wind project to the U.K., and I would like to thank all of the organizations, individuals, and communities with an interest in the Moray Firth with whom we have worked to reach this vital milestone,” said Dan Finch, managing director of Moray Offshore Renewables. “Moray East also brings major economic opportunities to our supply chain. Innovation and co-operation have enabled the cost reduction which ensured success in this auction. Electricity from Moray East will be produced at the lowest cost of any offshore wind farm around the U.K., with exceptional benefits to consumers.”
CWind, a leading provider of services to the offshore wind industry, recently announced it has been awarded a contract by Dong Energy, to install new and retrofit existing gates on the transition pieces (TPs) at the Gode Wind and Borkum Riffgrund offshore wind farms in the North Sea off the coast of Northern Germany.
CWind, which is part of the Global Marine Group and delivers the company’s power capabilities, will use its own crew transfer vessels, assets, and engineering expertise to help ensure the project is completed successfully and on time.
CWind will retrofit the TP Gates at Borkum. (Courtesy: CWind).
The CWind Phantom, a 27.4m catamaran, will undertake the work on Gode Wind’s 97 turbines and Borkum Riffgrund’s 77 turbines. Work began September 1, with the first phase expected to be completed in eight weeks.
The entire project has been scheduled for completion within one year and will call upon the skills of eight of CWind’s experienced electrical engineers and mechanical technicians, all of whom have benefited from training at the company’s in-house facility, the NWFTC (National Wind Farm Training Centres). Extensive navigational lighting and cable rerouting will be required to accommodate the new gates, demonstrating CWind’s electrical engineering capability and capacity.
“We have worked with Dong Energy for many years, including extensive prior work at Gode Wind, and we are pleased to continue our close business relationship,” said Lee Andrews, managing director of CWind. “The decision to utilize the same site team for the new project, to ensure consistency, has been well received by the client. Our aim is to always deliver successful projects with excellent customer service. The fact that Dong Energy has returned to CWind demonstrates our can-do attitude and our ability to get things right first time.”
The delivery of two 2.5 MW wind turbines to Fortech represents Lagerwey’s first steps into the Belgian market. The two L100 turbines, which have a hub height of 99 meters, will be at the Goeiende wind farm next to the E17 motorway near Zele. The aim is to have the park operational at the end of 2017.
Using the motto “what’s not inside, cannot break down,” Lagerwey has developed a wind turbine with fewer components compared to normal turbines. Lagerwey turbines are characterized by their direct drive technology, excellent grid compatibility, and high availability.
Lagerwey turbines are characterized by their direct drive technology, excellent grid compatibility, and high availability. (Courtesy: Lagerwey)
“Lagerwey is delighted to realize its first wind project in the Belgian market,” said Ronald Boerkamp, sales director for Lagerwey. “We would really like to thank Fortech and Triodos Bank for their cooperation, and for the fact that they share our passion for engineering, simplicity and innovation.”
“When realizing our projects, we want wind turbines that offer advanced technology and are capable of maximizing energy production within the scope of the license,” said Chris Derde, manager with Fortech. “Lagerwey’s wind turbine emerged as the best option from our evaluation. In addition, we found a very committed team of specialists within Lagerwey, who shared our values.”
“Wind energy supplied by the turbines will be distributed to families, (agricultural) businesses, and municipalities in the region by the Wase Wind cooperative,” said Kris Aper, chairman of Wase Wind. “It is also possible for cooperative members to participate financially in the wind farm. For instance, a dividend of 5.5 percent has been paid in recent years.”
Terex Cranes recently introduced a new addition to its growing tower crane family, the Terex® CTT 472-20 flat top tower crane. This new Terex 22-ton class crane expands maximum jib length to 80 meters (262.5 feet) and increases load charts over previous models offering the same lift capacity on the whole jib length, with a maximum load at the full length of the jib tip of 4.4 tons.
“Fresh off the introduction of our new hammerhead tower crane at CONEXPO-CON/AGG, we offer our customers the new CTT 472-20, an extremely versatile and robust flat top tower crane with great features requested by our customers,” said Marco Gentilini, vice president and general manager for Terex Tower Cranes. “The CTT 472-20 gives the market a flexible solution to meet complex lifting challenges. With Terex fully committed to the tower crane business, we are accelerating new tower crane product development to meet our customers’ needs. This includes a new tower crane cabin that will advance operating efficiency and comfort for our new CTT 472-20 crane.”
Offering a 470 ton-meter load moment, the new CTT 472-20 crane delivers extremely high lift capacities throughout its load chart and 11 different jib configurations from 30 to 80 meters (98.4 to 262.5 feet) to meet varying jobsite needs. Its hoist, slewing, and trolley speeds allow operators to quickly and precisely move and position heavy loads. All jib sections come preassembled with a lifeline for quick, safe installation at height, while galvanized jib walkways deliver long-lasting quality.
The Terex® CTT 472-20 flat top tower crane. (Courtesy: Terex)
The CTT 472-20 can be configured with H20, HD23, and TS212 Terex mast section thanks to the transfer masts with the combination of them.
“Here, Terex offers superior value for the customer, as this gives companies operating multiple Terex tower crane models the ability to efficiently manage component inventory and cost effectively meet their tower needs,” Gentilini said.
The CTT 472-20 flat top tower crane offers a competitive maximum freestanding height to reduce erection time and lower costs. Optimized for transport, these tower segments come preassembled with aluminum ladders for fast erection and increased durability.
The CTT 472-20 is the first tower crane model to include the new Terex cabin that will be installed on all flat top, hammerhead, and luffing jib models. It puts the operator in a fully adjustable comfort seat and has joystick controls with a short stroke length, providing a pleasant and comfortable working environment. The large full-color 18-centimeter (7-inch) display with anti-glare screen provides critical operating data and information required for troubleshooting. Built-in heating and air conditioning maintains consistent cabin temperature.
A new control system offers expanded configuration options to meet different jobsite needs. Offering quick set-up, the new controls boast the exclusive Terex Power Plus feature that can temporary increase the maximum load moment under controlled conditions (e.g. smooth hoist movements) giving the operator extra lifting capacity, by an additional 10 percent, when needed. Power match allows the operator to choose between operating performance or lower consumption to fit lifting needs. An optional radio remote control expands crane-operating efficiency by giving the operator a choice in how he wants to work.
Offshore Energy Support Vessel (OESV) operator Seacat Services has secured a contract with Beatrice Offshore Windfarm Limited (BOWL) to support the construction of Scotland’s second major offshore wind farm. The contract comprises a 730-day logistical support charter for the 26-meter catamaran, Seacat Intrepid, that began September 25. Intrepid will be joined by its sister vessel, Seacat Courageous, early next year.
BOWL is owned by SSE (40 percent), Copenhagen Infrastructure Partners (CIP) (35 percent), and Red Rock Power Limited (25 percent). Under development in the Outer Moray Firth in the north of Scotland, the wind farm will produce 588 MW of power. It will receive onshore support from the new operations and maintenance (O&M) hub at the Port of Wick, currently undergoing construction.
With considerable planned investment and opportunities in the Scottish offshore wind sector, the industry is seeking to maximize the benefit of lessons learned and transferrable knowledge accrued in the wider U.K. and European markets. As the first deepwater utility-scale projects come online in challenging waters off the Scottish coast, assembling an experienced project team is a key focus for asset developers and owners.
The Seacat Intrepid is a 26-meter catamaran. (Courtesy: Seacat Services)
Having previously established a long-term relationship with project stakeholder SSE at the Greater Gabbard wind farm off the coast of East Anglia, and with vessels under contract supporting construction and O&M activity at project sites throughout U.K., German, and Danish waters, Seacat Services is well-placed to support BOWL throughout the time and resource-intensive construction phase.
In practical terms, at 26 meters, Seacat Intrepid and Seacat Courageous are at the larger end of the OESV scale, providing them with high capability, without compromising on maneuverability and responsiveness. Both vessels benefit from extensive fuel and cargo-carrying capacity, and operate at a service speed of up to 26 knots.
The proven versatility and reliability of these vessels will be essential in driving the efficiency of crew and equipment transfers, while the technicians’ familiarity with the vessels will ensure their safety and enable them to complete their jobs to the best of their ability.
More broadly, the deal between Seacat Services and BOWL provides further evidence of the strength of support delivered by the U.K. maritime supply chain to offshore wind developers and operators.
“Beatrice is our first Scottish project, and we’re looking forward to setting a benchmark for future wind farms in the region,” said Ian Baylis, managing director, Seacat Services. “In doing so, we’ll be aiming to benefit from lessons learned on U.K. projects, further strengthen collaboration and long-term relationships, and support opportunities for the regional economy. We currently have 13 vessels and their crews operating off the east coast of the U.K., and will always look to recruit locally where possible.”
Trelleborg’s engineered products operation is growing its portfolio of offshore floatover solutions, with a custom designed skirt pile gripper. Add to this its grout seal, diaphragm closure, and grout packer products, and Trelleborg customers can now specify a total sub-structure leg can system from one source.
The skirt pile gripper (SPG) is welded onto the upper section of a platform’s jacket skirt pile sleeves and is designed to create a temporary connection between the pile and jacket during the grouting process. With unique biting teeth for increased contact area, Trelleborg’s innovative design delivers a firmer grip. This fixing method reduces risks during platform installation, as it guarantees stable working conditions, even in inclement weather.
A skirt pile gripper. (Courtesy: Trelleborg)
“Jacket installation of a substructure into the seabed is an operation that requires product reliability and on site expertise,” said J.P. Chia, engineering manager for Trelleborg’s engineered products operation. “Until the grout between pile and jacket has set and the installation is completed, the SPGs hold the jacket’s piles firmly in place to provide temporary retention of the jacket’s elevation position during levelling operations and grout setting. By growing our portfolio to offer a total leg can system solution, customers can benefit from streamlined procurement, reliable functionality, and interfacing of the entire system from purchase through to delivery from one solution provider.”
Trelleborg’s custom-made SPGs can be designed to have a holding capacity of between 500 and 3,000 metric tons and are compatible with all offshore oil and gas and windfarm HVDC jackets. Working at operating pressures of 200 bar and higher according to customer testing requirements, and water depths to 250 meters, Trelleborg’s SPGs exceed all relevant client standards and is DNV GL certified.
Trelleborg’s SPGs are fully developed and tested in-house at its facility in Singapore. Full scale testing, biting teeth friction testing and pressure holding testing are all carried out and exceed client specified standards to ensure Trelleborg’s SPGs perform during the critical grouting process.
In 2007, when Jiminy Peak installed a $4 million 1.5 MW wind turbine on the western flank of its mountain, many thought the 70-year-old resort was taking a huge financial risk.
But 10 years after the switch was thrown, Brian Fairbank, chairman of The Fairbank Group that runs the resort, looks back at a risk worth taking. The 253-foot high turbine paid for itself in seven years, and today, combined with a 12-acre 2.3 MW solar field and 75 kWh cogeneration unit at the slopeside, Country Inn at Jiminy Peak in Hancock, Massachusetts, can claim to be one of the few resorts in the U.S. powered 100 percent by renewable energy.
When asked whether a second turbine is planned, Fairbank said they already have all the electricity they need.
“We’re now focusing on drastically reducing our carbon footprint and greenhouse gas emissions,” he said. “Conservation is the most cost-effective form of energy-use reduction, cost control, and containment.”
The installation of the turbine was met with great fanfare, music, flags, and speeches. Rotor bearings were replaced about 45 days into its service life, but since then, the turbine has run without major issues.
Today, the “Zephyr,” as it’s nicknamed, is the first megawatt-size turbine at a ski resort and remains the largest. It has become a symbol of the resort, as much as the barn is to Steamboat Ski Area, or the snowfields are to Sugarloaf.
Zephyr is also a social media star, a veritable selfie magnet, with a strong online presence. Employees wear turbine pins and school groups visit to tour the site and view an educational documentary called “Forever Green.”
Dependable Power Producer
“It has been an exceptional, dependable power producer for us,” said Jiminy’s Jim Van Dyke, vice president of environmental sustainability, and a veteran 43-year employee. “The turbine handles 33 percent of our energy needs on an annual basis, up to 66 percent in the winter when the winds blow strongest.”
“As far as electricity is concerned, we’re already at 100 percent renewable power,” he said. “We’re good. Excess power not needed by the resort goes out on the national grid, for which the resort receives credit to use when the turbine is working at less than full capacity or when the resort’s need exceeds the turbine’s capacity.”
“Our focus now is upon reducing our carbon footprint,” Van Dyke said. “We’re still burning gasoline and diesel to run snowcats, still using propane to heat, and on busy weekends, 1,500 cars are in the parking lots, most with internal combustion engines.”
To that end, he points to a number of steps already underway to further reduce the resort’s impact on the planet. These improvements include:
Installation of a 2.3-MW community solar project with Massachusetts-based project developer and owner Nexamp, Inc. The solar field, near the base of the mountain, significantly expands Jiminy Peak’s renewable energy commitment while extending the environmental and cost-saving benefits of solar energy to the community.
Replaced the entire 450-gun snowmaking arsenal with energy-efficient Snowgun Technologies “Sledgehammer” snowguns. The new guns convert more water with less air and at warmer temperatures than traditional snowguns. This means the resort runs air compressors for fewer hours, consuming less electricity, while producing 100 percent more snow (assuming Mother Nature cooperates).
Jiminy Peak has equipped two PistenBully groomers with digital mapping and GPS to tell drivers exactly how much snow is beneath their treads, blades, and rollers. The maps are based on aerial photography captured during summer, and are accurate to within two inches (5 cm).
“Rather than eyeball it, the SNOWSat technology allows us to more precisely gauge depth and place more snow where the cover is thin, and less where the cover is already sufficient for skiing or riding. This means fewer passes by groomers,” Van Dyke said, noting that Jiminy Peak is one of only a few resorts in the U.S. using the new technology.
Cat’s Meow
Speaking of groomers, Jiminy Peak is purchasing the new energy efficient Pisten Bully 600 E+ snowcat, one of three in use in the Northeast. Built by the German company Kassbohrer, Pisten Bully’s “Green Machine” 600E+ is the world’s first groomer with a diesel-electric drive. One of the most significant advancements in snow-grooming technology over the past two decades, the 600 E+ uses a diesel engine to drive two electric generators, which power electric motors that turn the tracks and the snow tiller.
It reduces the emission of nitrogen oxides and carbon dioxides by 20 percent, produces 99 percent fewer sooty particles, and registers a 20 percent fuel savings over its standard 600 model.
Other energy savings include:
Installation of four EV charging stations, working with an Albany, New York, EV Drivers Club, with support from Tesla. Van Dyke said EV car owners, in addition to saving on fossil fuels, will be recharging with renewable electricity generated by both solar and wind.
More than 230 slope-side lights have been replaced with lighter, brighter, more energy-efficient LED lighting covering 60 percent of the mountain. The difference has been likened to that between a manila envelope and a white envelope.
By using propane for both hot water and electricity, the Country Inn’s 75 kWh cogeneration unit eliminated one propane burner. At the same time, 658 lights in the Country Inn were converted to LEDs to be more efficient.
Excess heat from two snowmaking compressors is used to warm three Village Center buildings, a total of 34,000 square feet, thus reducing propane and electricity consumption.
“We’re getting down to the granular level, including waterless urinals in all base lodges. Each one saves 40,000 gallons per year,” Van Dyke said. “Conservation makes perfect business sense today, just as the turbine did 10 years ago. We save money, besides which, it’s the right thing to do.”
“Massachusetts’ beauty and health are an integral part of our business,” he said. “We live here so working to maintain it comes naturally.”
Working at height requires movement. Workers need to connect and reconnect their snap hooks dozens — or even several dozens of times — a day. The new 3M™ DBI-SALA® Comfort Grip Connector from 3M™ Fall Protection improves connecting and disconnecting while providing flexibility to anchor efficiently and comfortably in multiple orientations.
“The search for a connector that can be tied off in multiple directions is over,” said Nate Safe, product development specialist at 3M Personal Safety Division. “Many of the hooks on the market can be a nuisance to open where the operator’s hand is placed right in the opening creating a pain point. The Comfort Grip Connector opens and closes easily and comes with a hand guard so knuckles are protected while making a connection.”
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Designed and certified to arrest a fall when loaded in multiple orientations, the Comfort Grip Connector helps provide a 5,000-pound tensile strength as well as up to 3,600 pounds in transverse and gate strengths. When connected to a vertical or transverse application, such as a pipe, the hand-guard pin shears in the event of a fall to allow the connector to align with the direction of the fall and remain securely anchored.
The 3M DBI-Sala Comfort Grip Connector is available on some of 3M Fall Protection’s most popular products, including:
Miki Pulley’s CS Electromagnetic actuated clutches are durable, versatile and have excellent torque transmission features.
CS Clutches provide an efficient connection between a motor and a load providing low inertia, minimal drag, and quiet operation. They function using the magnetic force generated by the energized coil providing engagement of input and output members of the clutch.
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Available with three different armatures, Miki Pulley CS Clutches consist of a clutch stator, rotor, and armature assembly. They feature an integrated bearing design making mounting fast and easy while ensuring application concentricity and excellent system runout. CS Clutches operate well in temperatures from 14°F to 104° F (-10°C to 40°C).
Available in bores ranging from 10 mm to 15 mm, with brake torques ranging from 3.687 ft. lbs. to 236.02 ft. lbs. (5 Nm to 320 Nm). The CS Clutch uses corrosion resistant materials and is RoHS compliant like all other Miki products.
“Miki Pulley’s CS Clutches stand apart from competitor’s models, in that they incorporate specialized composites and alloys promoting durability and longer operational life,” said Jon Davidson, Miki Pulley sales specialist. “Miki Pulley’s friction-type design operates smoothly and quietly, making them an ideal choice for digital printing systems, and similar equipment requiring near noiseless operation.”
Ty-Met™ stainless steel retained-tension ball-lock cable ties, new from Thomas & Betts® (T&B®), a member of the ABB Group, feature specially formed spring crimps that help maintain consistent tension on the tie after installation.
Consistent tension enables the cable tie to remain in position, even under high-vibration conditions.
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“Ty-Met retained-tension cable ties won’t slide down the bundle of cables after installation,” said Ralph Donati, product marketing director, Installation Products, at ABB Electrification Products. “The spring crimp was engineered to provide positive clamping in high-vibration applications, such as manufacturing, heavy equipment operation, oil and gas processing, renewable energy generation, and shipbuilding.”
The formed channel provides a path for trace wire that protects against crushing and short circuits. Other features include the ball-lock fastening mechanism that is easily assembled and adjusted for tension. Ty-Met stainless steel retained-tension ball-lock cable ties are available in Type 304 stainless steel and marine-grade Type 316 stainless steel.
Ty-Met stainless steel retained-tension ball-lock cable ties can be installed with T&B DAS-250 application tools.
ZF’s Modular Gearbox Solution
Challenges abound, though, and in 2002, the International Energy Agency (IEA) Wind Task 19 began gathering and coordinating recommended practices on cold-climate wind energy. One area on its radar is blade icing, a problem that has been tackled by a number of manufacturers in recent years. For when ice builds up, energy production goes down, and it can even come to a halt altogether.
