After eight months of testing and verification, FusionDrive®, the industry’s most advanced gear and generator combination is now a validated drivetrain. The smallest and most lightweight combo in the market has proven to reach 96.6 percent efficiency, leading to an excellent energy yield.

The gear and generator combination, in commercial production for DeWind, is a joint effort of Moventas and permanent magnet generator supplier The Switch.

FusionDrive enables higher drivetrain efficiency due to a better power curve and overall efficiency. It has a lower drive train mass and requires less material and its compact design allows lighter overall turbine layout.

Added to great serviceability and potential for up-tower repairs, which reduce maintenance and repair costs, all FusionDrive benefits help reduce the LCoE (Levelized Cost of Energy) by a total of 6 percent comparing to a  3MW onshore turbine with conventional drivetrain concept.

FusionDrive with 3000kNm shaft torque carrying capacity has recently completed comprehensive factory verification process at the Moventas R&D center in Jyväskylä, Finland. FusionDrive’s overall efficiency exceeded all expectations; a 96.6 percent efficiency was reached already in 65 percent of the operation nominal.

The full load tests of the FusionDrive showed good dynamic behavior and an overall sound power level of < 96 dB(A) in all operation phases. The combo’s vibration tests also exceeded expectations
In addition to normal testing phases including component, climate chamber and load testing, the verification process was modified to verify also one of the design priorities—FusionDrive’s excellent serviceability that will revolutionize wind power maintenance costs. 

A complete FusionDrive service without an external crane is now proven to be possible. This significantly reduces maintenance and repair life cycle cost—according to Moventas’ calculations—by as much as 15 percent. Moventas specializes in challenging up-tower repair methods as well as preventive maintenance, the spearhead of which is the CMaS Condition Management System that overlooks turbines with as many as seven key parameters.

For more information, visit www.moventas.com, www.theswitch.com, and www.dewindco.com. 

The Energy Department’s National Renewable Energy Laboratory (NREL) has released its assessment of leading utility green power programs. Under these voluntary programs, residential and commercial consumers can choose to help support additional electricity production from renewable resources—such as wind and solar—that diversify our nation’s energy portfolio and protect our air and water.

“Participating in utility green power programs allows consumers to support renewable energy above and beyond what utilities are procuring to comply with state renewable portfolio standards,” NREL Analyst Jenny Heeter said. “These utilities are offering first-rate programs that give their customers an opportunity to support renewable energy deployment.”

Using information provided by utilities, NREL has developed “Top 10” rankings of utility green power programs for 2012 in the following categories: total sales of renewable energy to program participants: total number of customer participants; the percentage of customer participation; green power sales as a percentage of total utility retail electricity sales; and the lowest price premium charged for a green power program using new renewable resources.

Ranked by renewable energy sales (megawatt hours /year), Portland General Electric (Oregon) overtook Austin Energy in Austin, Texas, in 2012, selling the largest amount of renewable energy in the nation through its voluntary green power program. Dominion Virginia Power and Oklahoma Gas & Electric are new to the top renewable energy sales list. Ranked by the percentage of customer participation, the top utilities are City of Palo Alto Utilities (California), followed by Portland General Electric, Madison Gas and Electric Company (Wisconsin), Sacramento Municipal Utility District, the City of Naperville (Illinois) and Pacific Power (Oregon). In addition, six utilities provided green power supply that included at least 2 percent solar. (See http://greenpower.energy.gov for rankings).

Green power sales of the top 10 utility programs by sales exceeded 4.2 million MWh in 2012, up from 3.9 million MWh in 2010. Wind energy represents approximately 85% of electricity generated for green energy programs nationwide.

Utility green pricing programs are one segment of a larger green power marketing industry that counts more than 1.8 million customers, including Fortune 500 companies, government agencies and colleges and universities among its customers, and helps support more than 11,200 megawatts of renewable electricity generation capacity.

For more information, visit www.nrel.gov.

Smalley Steel Ring Company is a leading manufacturer of Spirolox® retaining rings and wave springs for the power generation industry. What makes Smalley different is that they coil the ring or spring in place of stamping it, meaning no tooling is required for manufacturing.

Spirolox retaining rings have No Ears to Interfere® with mating components in an application and are compatible with standard snap ring grooves. They have no gap or lugs allowing for tight radial applications.

Smalley wave springs reduce operating height by up to 50 percent with the same force and deflection as coil springs, allowing them to fit in applications other springs cannot. Wave Springs are manufactured to satisfy precise operating conditions, including the tight radial and axial spaces, found in many applications.

Smalley’s standard Wind Power Series is available in up to 120” diameters. Standard materials sizes are stocked for production, with delivery in as little as two weeks. Over 10,000 parts are available from stock, 1/4” to 16”, in both carbon and stainless steel. Ask a Smalley engineer about this new series.

Smalley prides itself on its commitment to the highest quality and performance standards. Each retaining ring and wave spring is engineered with their No-Tooling-Charge™ process allowing for endless possibilities in dimension and material to suit your application needs.

Having worked with wind turbine designers, Smalley Engineers are available to assist with application specific retaining ring and wave spring design. Contact a Smalley engineer today with your design requirements.

Free CAD downloads and part samples are available to facilitate fast and efficient prototyping.
With offices in both the US and abroad, certified to ISO 9001, ISO/TS 16949, AS9100 and ISO 14001, Smalley is able to offer customers worldwide unprecedented service and quality. Smalley Steel Ring Company is an ITAR (International Traffic in Arms Regulations) registered facility.

For more information, visit www.smalleywindpower.com or call 847-719-5900.

Next generation SKF Multilog IMx on-line monitoring systems introduce advanced technology for a wide range of machine condition monitoring applications. These robust and programmable solutions equip users with a 24/7 monitoring system providing timely and true simultaneous measurements of various operating parameters to guide in improving machine reliability, availability, and performance. All IMx systems are engineered to detect faults early, integrate automatic recognition to correct existing or impending conditions, and ultimately contribute to condition-based maintenance program objectives.

IMx technology additionally offers an opportunity to convert and upgrade outdated systems and interface with compatible SKF @ptitude Analyst and Observer software to realize a highly comprehensive approach to condition monitoring.

IMx systems include units for extremely tough industrial environments and models designed specifically for turbo machinery, wind turbine, vehicle, or railway applications, as well as portable versions ideally suited for temporary installations and troubleshooting.

Depending on model, SKF Multilog IMx units incorporate 16, 32, or 64 analog signal inputs configurable for a variety of sensors to ascertain acceleration, velocity, and displacement, among other parameters, such as acceleration enveloping. Individual warning and alarm levels controlled by machine speed or load can be set for each measurement point and built-in auto-diagnosis can check all sensors, cabling, and electronics for any faults, signal interruption, shorts, or power failure and then automatically alert when problems are found.

IMx systems can run on an existing LAN or WAN and network with computers, printers, and servers, or over the Internet.

For more information, visit www.skf.com/us/products/condition-monitoring/surveillance-systems/on-line-systems/monitoring-systems/index.html.

The ZOV Series of metal oxide varistors is a series of epoxy coated square varistors with sizes from 23mm to 60mm. These high-energy varistors come in a single disc, double, triple and quadruple disc versions with pulse current capabilities of up to 80kA. This series offers energy handling up to 4100 Joules with working voltages up to 680 Vrms and 895 Vdc. The ZOV can be supplied with epoxy coating and rigid terminals, with rigid terminals and no coating, and with a bare metallized disk.

In general, they are used in SPD protection modules for Type 1 and Type 1+2 surge protection applications. This type of protectors are suitable for the first level of protection in incoming power distribution panels. These devices are capable of protecting all equipment from direct lightning strikes and are suitable for industrial, commercial and residential applications. Wind and solar power generation is becoming more and more attractive and the ZOV is a good solution for these applications also.

The ZOV is available in 1K and 500 pcs quantities depending on size in bulk packaging. Pricing varies with size, voltage, and terminal/coating configuration and ranges from $1.70 to $9.80 each in full package quantities. Contact Stackpole or one of our franchised distributors for volume pricing.

For more information about Stackpole products, call 919-850-9500 or visit www.seielect.com.

International coatings manufacturer Hempel announced the launch of HEMPADUR 47300, a new NORSOK-approved epoxy mid-coat that can reduce drying times for offshore wind tower manufacturers by up to 25 percent and help drive down production costs.

Specially formulated for offshore wind towers, HEMPADUR 47300 is a new low-solvent epoxy mid-coat that offers vastly improved curing times for manufacturers. The coating can be handled just four hours after application at 68°F, compared to an average of five hours for standard equivalent coatings.

According to Anders Voldsgaard Clausen, Group Power Generation Segment Manager at Hempel, the new product enables manufacturers to reduce production line bottlenecks and increase line speeds—which could lead to significant cost reductions.

“The offshore wind energy industry is looking to lower costs in every part of the value chain, including productivity in the tower manufacturing stage,” he explained. “The curing time of HEMPADUR 47300 means manufacturers can achieve a faster production flow. As a result, they can coat more towers each shift and use less energy to dry the towers—which will help drive down the cost of each unit.”

HEMPADUR 47300 is approved and certified according to NORSOK M-501, system 1. It can be applied with airless spray and has a volatile organic compound content of just 190 grams per litre, which means very little VOC is released during application. For more information, visit www.hempel.com.

ZF Services, LLC announced the completed installation of the 2.5MW test bench at its Vernon Hills, Ill. Wind Service Center. The project, which began with construction in September 2012, is the result of a $1.6 million grant.

The recently completed test bench will be able to test over 200 gearboxes annually. ZF Services, LLC launched this new project with an open house on May 8th—coinciding with WINDPOWER 2013—while hosting their customers and local vendors at the Vernon Hills facility to showcase the test bench, redesigned facility and extensive portfolio of technical possibilities. The recently completed test bench and redesigned facility now allows the company to offer an even wider range of services, providing a tailor-made one-stop shopping approach for multi-brand gearbox and mechanical drive train repair.

ZF has been present in the region for over the past 35 years, and customers can continue to anticipate great customer service. The centrally located facility has a 20-man wind service team dedicated to servicing customer needs, including field technicians for on-site up-tower repairs. Through a close link to the ZF Wind Power research and development team in Lommel, Belgium, ZF Services, LLC has access to continuous ongoing developments to support customer requirements in repairs and gearbox enhancements. The regional wind service center at ZF Services, LLC will be stocking genuine spare parts and exchange gearboxes covering the full product range of ZF Wind Power.

With more than 7,000 ZF gearboxes installed in North American, ZF designed the wind service facility with the intent to service this large installed base of ZF gearboxes as well as other multi-brand products. The ZF Services, LLC Vernon Hills facility is now one of ZF’s 8 wind service locations worldwide; with 6 having load testing capabilities. For further questions please contact your ZF representative.

“The ZF Services Vernon Hills service organization continues to grow as evidenced by our recent investments in the facility, equipment, and personnel over the past three years.  Our North American wind industry customers will have the same great service experience that our other industry customers received in this region over the past 35 years,” said Scott Gardiner, director of wind services for North America.

For more information, visit www.zf.com/na.

Siemens Energy has been awarded an onshore wind power order for the Sere wind power plant on the west coast of South Africa. This is already the second wind power order for Siemens from South Africa. The Sere project is a flagship project for the customer ESKOM, which is one of the world’s largest utilities. The scope of supply includes the delivery and installation of 46 wind turbines of the type SWT-2.3-108, with an output of 2.3MW, a rotor diameter of 108 meters on 115 meter towers each. The deal also includes a five-year-service agreement. Installation of the wind turbines is scheduled to begin in the second half of this year, with the start of operations expected during first half of 2014.

“South Africa has outstanding conditions for the utilization of wind energy and has set up a remarkable renewable energy program with the Independent Power Producer Procurement Program. We are proud to contribute to the development of wind power in South Africa with our technology, and especially proud that ESKOM has chosen to rely on us for their first large project,” said Felix Ferlemann, CEO of the Wind Power Division in Siemens Energy.

 The first wind power order from South Africa was awarded to Siemens by Mainstream Renewable Power Limited, Globeleq, and local B-BBEE investors Thebe Investments, Enzani and Usizo for the Jeffrey’s Bay onshore wind power plant with a total capacity of 138MW.

For more information, visit www.siemens.com.

The Nordex Group posted a 30.6 percent increase in sales to EUR 259.0 million in the first quarter of 2013 (previous year: EUR 198.3 million). This performance was underpinned by strong business in the core European region, which contributed 94 percent of sales. On the other hand, business in America contracted by a substantial 57.6 percent, accounting for only 5 percent of consolidated sales, while Asian business remained persistently weak.

The greater volume of business was also reflected in production and installation activity. Thus, Nordex produced 60 percent more turbines in the first quarter, completing more than twice the capacity of the same period of the previous year.

This performance together with reduced structural costs in the United States and China, which had previously operated below capacity, resulted in a substantial improvement in operating earnings. As a result, the loss at EBIT level came to EUR 0.6 million as of March 31 (previous year: loss of EUR 9.0 million) and was therefore fully in line with budget. The consolidated net loss was reduced by 40 percent to EUR 8.4 million (previous year: loss of EUR 14.0 million).

Due to increased purchasing and production activity, the working capital ratio widened to 11.8 percent (December 31 2012: 8.7 percent), with cash and cash equivalents declining by 29.3 percent to EUR 194.2 million (December 31 2012: EUR 224.3 million). Net cash outflow from operating activities amounted to EUR 60.0 million (Q1/2012: inflow of EUR 34.8 million).

Order intake continued to climb in the first three months of 2013. At EUR 327.9 million, new business rose by 5 percent, compared with the high level of the same period last year (Q1/2012: EUR 312.3 million). This performance was driven by sales successes in Northern Europe, particularly in the domestic German market, as well as successful marketing of the N117/2400 low-wind turbine. Thanks to the best first quarter since 2008, firmly financed orders grew to EUR 1,141 million (previous year: EUR 837 million), thus creating a solid basis for the company to achieve its full-year sales target.

The Management Board of Nordex SE confirms its forecast for 2013 and expects a further increase in sales to EUR 1.2 – 1.3 billion (2013: EUR 1,075 million). Given slightly weaker capacity utilisation in the first half of the year compared with the second half, management expects operating earnings to improve in the final quarters, resulting in a full-year EBIT margin of 2 – 3 percent.

For more information, visit www.nordex-online.com/en.

Siemens has signed 15-year contract extensions with RES Americas to continue providing service and maintenance at two wind projects in North America. Siemens will provide long-term service f.or the 26 SWT-2.3-93 wind turbines operating at RES Americas’ Whirlwind Energy Center. Long-term service will also be provided by Siemens for the 72 SWT-2.3-93 units in operation at RES Americas’ Hackberry Wind Farm. Both projects are located in Texas. This is Siemens’ first wind service contract signed with a duration of 15 years in North America.

Siemens currently has an existing five-year agreement with RES Americas for both sites. Under the new agreements, Siemens will provide 15 additional years of service, maintenance, and warranty along with an availability guarantee. The extensions will help both projects perform at high levels of efficiency and availability for years to come, and most notably, over the entire estimated 20-year lifecycle of the units. Siemens’ advanced remote monitoring and diagnostics are included along with the company’s Advanced Grid Performance (AGP) upgrade at both sites.

With a combined output of approximately 226MW, the Whirlwind and Hackberry wind projects, located in West Texas, produce enough electricity to power an estimated 68,000 Texas households annually.

For more information, visit www.siemens.com.

Renewable energy consultant AWS Truepower LLC has announced it is further strengthening its position in the global renewable market by establishing a partner consultancy in Istanbul, Turkey. This office will provide the Turkish renewable energy market with access to AWS Truepower’s 30 years of experience in technical consulting, advisory services, software and data for wind and solar technologies.

The new consultancy will be led by Ahmet Gurel and employs several staff with experience in renewable energy technology and has a well-established network of customers and partners.

“We look forward to working with Mr. Gurel and his team to expand our global footprint with their local presence,” said Joan Aymamí, vice president of international business. “Having a local office in Turkey will help the company build and grow relationships, and address and respond to the unique needs of the market.”

Demand for renewable energy is growing rapidly in Turkey as growth in energy demand outpaces economic expansion. Projections show that by the end of 2023 the country could have 18GW of new wind capacity. Turkey has the potential to install 40 GW of onshore windpower capacity, with 11GW megawatts of wind projects already licensed.

AWS Truepower will offer services such as renewable resource and energy assessments, infrastructure support services, independent engineering and due diligence studies, energy forecasting, grid integration studies, operational assessments and other services to support successful renewable energy projects. These services will help the Turkish market maximize system performance and better plan renewable energy delivery.

For more information, visit www.awstruepower.com.

DEUS Rescue has announced that it has become ISO 9001 certified for the manufacture, assembly and supply of fall protection equipment. The company has been registered to the ISO 9001:2008 standard signifying that it has developed a quality management system (QMS) that focuses on continual improvement of customer satisfaction by delivering quality products.

DEUS Rescue’s QMS processes include areas such as purchasing, shipping and receiving, production, employee training, records control and more.

In addition, the company has direct control over third-party testing and certification of its products to industry standards such as NFPA, ANSI, CSA, EN and others.  More than a one-time achievement, a significant ongoing component of the DEUS Rescue QMS is to regularly monitor supply chain efficiency and customer satisfaction by measuring a number of key objectives such as on-time deliveries and, most important, product conformance. Consistent with that is the company’s continuous commitment to maintaining and improving its quality standards.

“This is really about DEUS Rescue making a full-court commitment to readiness and quality for our customers,” said Shain Rae, president of DEUS Rescue. “Receiving our ISO certification is not only a statement about our having achieved the highest level of quality manufacturing today, but also our commitment to continuously raising our standards in every aspect of our business. This boldly states to our customers that when they deal with DEUS Rescue, they receive the highest assurance that we will do whatever it takes to deliver a quality experience—across the board—now and in the future.”

For more information, visit www.DEUSrescue.com or call 866-405-3461.

The National Center for Atmospheric Research (NCAR), building on a pioneering wind energy forecasting system that saved millions of dollars for Xcel Energy customers in eight states, has entered into a new agreement with the utility for even more sophisticated weather forecasts.

In the next two years, NCAR scientists and engineers will develop custom forecasting systems to predict sudden changes in wind, shut down turbines ahead of potentially damaging icing events, and even predict the amount of energy generated by private solar panels. The systems will be used by Xcel Energy control centers in Denver; Minneapolis; and Amarillo, Texas.

The cutting-edge forecasts will help Xcel Energy, and potentially other utilities, to provide reliable power to their customers and reduce costs while moving to greater use of wind and solar.

“This is pushing the state-of-the-art still further, using the latest science to enable Xcel Energy to generate energy from the atmosphere more effectively,” said NCAR program director Sue Ellen Haupt, who is overseeing the new project.

Xcel Energy officials say the more accurate forecasts are critical as they increase their use of renewable energy.

“The importance and value of accurate renewable energy generation forecasts increases with the size of our renewable energy generation portfolio,” said Ben Fowke, chairman, president and CEO of Xcel Energy. “Xcel Energy has been the largest utility provider of wind energy for the last nine years and we are continuing to grow our renewable energy portfolio.”

The new project represents the latest venture by NCAR into renewable energy. In addition to the lab’s earlier work with Xcel Energy, NCAR is also spearheading a three-year, nationwide project to create unprecedented, 36-hour forecasts of incoming energy from the Sun for solar energy power plants.

“By creating more detailed and accurate forecasts of wind and sun, we can produce a major return on investment for utilities,” said Thomas Bogdan, president of the University Corporation for Atmospheric Research, which manages NCAR on behalf of the National Science Foundation. “This type of cutting-edge research helps make renewable energy more cost competitive.”

Xcel Energy has been utilizing increasing amounts of energy from renewable sources, especially wind. But this shift means relying on resources that are challenging to predict and manage.

Energy generated by a wind turbine, solar panel, or any other source must be promptly consumed because large amounts of electricity cannot be stored in a cost-effective manner.

If an electric utility powers down a coal or natural gas facility in anticipation of wind-driven energy, those plants may not be able to power up fast enough should the winds fail to blow. The only option in such a scenario is to buy energy on the spot market, which can be very costly.

In order to help utility managers anticipate wind energy more reliably, NCAR began designing a wind energy prediction system for Xcel Energy in 2009 that saved the utility’s customers more than $6 million in 2010 alone. The specialized system relies on a suite of tools, including highly detailed observations of atmospheric conditions, an ensemble of powerful computer models, and artificial intelligence techniques to issue high-resolution forecasts.

For more information, visit ncar.ucar.edu or xcelenergy.com. 

Over the last 50 years, HYTORC has become the most trusted name for industrial bolting. Leading the industry with groundbreaking innovations, HYTORC has set new standards in the field. HYTORC’s stretch-to-load bolting system is in use by major manufacturers in the windpower industry in areas all over the world. This patented technology gives users the highest level of safety, speed, and accuracy available today. It is the only bolting system in the world that can achieve consistent bolt load accuracy within 5 percent, without time-consuming bolt measurement.

The HYTORC Avanti, shown here, can be used for standard torque or upgraded for Stretch-to-Load with additional drivers. This system eliminates the need for reaction arms and backup wrenches, which makes the job faster, by eliminating arm placement and the need for extra personnel, and safer, by eliminating dangerous pinch points. Furthermore, the HYTORC Nut, a Stretch-to-Load fastener, completely eliminates bolt damage, preventing the need for replacement bolts during maintenance.

Aside from the increased safety and speed, the major advantage of the Stretch-to-Load system is the tremendous accuracy that is attainable on a consistent basis. On pressurized vessels, the system has been so successful that it is backed by a zero leakage guarantee—something that many maintenance workers and contractors previously thought to be impossible. On jobs subject to vibration and movement, the system outperforms all others in accuracy and endurance. The system uses a counter-nut effect to prevent unintentional loosening, even on equipment with extreme vibrations such as railroad tracks and gyratory rock crushers.

A free on-site survey is available by request to help determine your needs. Stretch-to-Load fasteners are available in a number of different materials to cover all application needs. Please contact info@hytorc.com or call 1-800-FOR-HYTORC for a quick answer to your questions.

Drawing on the success of prior generations of the ExoFit Harness lines, DBI-SALA/Capital Safety offers what they claim to be the most advanced harnesses available in the industry—the ExoFit NEX.
Marketed as “The Ultimate Full-Body Comfort Harness,” the “NEX” implies that this is the next generation in harnesses. The ExoFit NEX expands on the features and benefits that the at-height workforce has come to rely on in the ExoFit and ExoFit XP products by incorporating ongoing research, new materials, and innovative features into the design and manufacturing processes.

At the heart of the ExoFit NEX are the company’s three-pronged commitment to comfort, function, and durability.

Among the features and benefits are:

• 420 lb. Capacity—Large capacity adds to tool carrying options and jobsite flexibility.
• Revolver Vertical Torso Adjusters—Simple and fast adjustments that eliminate loose ends and lock into place, preventing slippage.
• Hybrid Comfort Padding—Lightweight, moisture wicking and breathable padding won’t move or slip, always keeping the wearer comfortable.
• Tech-Lite™ Aluminum D-Rings—Extremely lightweight alloy commonly used in military and aerospace offers a higher level of security and comfort.
• Integrated Trauma Straps—Provide an adjustable, continuous loop for post fall, minimizing suspension trauma.

Duo-Lok™ Quick Connect Buckles—Lightweight one-handed use with memory-fit web-lock ensures fast, non-slipping connections.

• Protective Shoulder Caps—Provide protection and comfort when carrying heavy materials.
• Molded Lanyard Keepers—Easy holstered snap hooks break away to avoid trip hazard.
• Reflective Material—For greater visibility in dark and dangerous environments, reflective material is integrated on legs, chest, shoulders, and back.
• Built-In Carrying Pocket—Conveniently holds and protects a cell phone, camera, or other items.
• Removable Tool Loops—Allows various tool carrying options.
• Repel Technology Webbing—Water repellent to reduce attraction of mold and dirt—also has up to 5 times more abrasion resistance.
• Stand-Up Dorsal D-Ring—Patented spring-loaded design automatically stands-up, ensuring fast, easy, and safe connections to your fall arrest system.
• Superior X-Design—A single piece of material in the shape of an X wraps around the wearer for the ultimate in comfort, security, and no-tangle donning.
• Radio Holster—Conveniently holds and protects a radio, cell phone, or other item like a Lad-Saf™ sleeve.
• Ultra-Soft Edging—Moves with you. Doesn’t rub or chafe.

ExoFit NEX Wind Energy harnesses, lanyards, and accessories meet OSHA/ANSI/CSA/CE requirements for global compliance.

For more information, visit www.capitalsafety.com.

Gearbox Express, is introducing its Revolution gearbox upgrade. Revolution is a set of upgrades and a new thought process for wind energy gearboxes from 1.5MW up to 2.3MW. Developed by the team at GBX, Revolution addresses the most common premature failure modes of gearboxes.

“The Gearbox Express team has seen many gearbox failures, and a majority of them have the same premature failure characteristics,” said Bruce Neumiller, CEO of Gearbox Express. “We saw a huge opportunity to address these common reasons by integrating upgrades that will provide significantly longer gearbox life.  Revolution is a technical product unlike anything else in the industry and it creates a paradigm shift in the wind industry with a direct, commercial impact on our customers’ business.”

Revolution features:
• 5-year, no-risk warranty
• Case-carburized ring gear
• Timken® case carburized and coated cylindrical roller bearings in the HSS, IMS, and planet positions
• Water-Lok maintains low water concentration
• GBXtreme Filter to six micron while maintaining high flow at 1,000 beta
• Non-desiccant, GBX Water Blocker Breather System
• Factory filled with Amsoil EP55®, ISO 320 oil

Revolution gearboxes are built in Gearbox Express’s 43,000 square-foot, climate-controlled facility in Mukwonago, Wisc., which also offers a highly-flexible, technologically-advanced 3.1MW test stand. In addition to Revolution, Gearbox Express technicians also remanufacture gearboxes to the latest revision level.

“When we started operations in 2012, we had a vision on how to help wind farm owners protect and manage their assets,” said Neumiller. “Our growth has exceeded expectations and Revolution is another vital component to our business model that is based on keeping investments running.”

Three wind industry veterans founded GBX, and succeeded in attracting millions of dollars of investment capital along with a $3.4 million low interest, revolving loan from the Wisconsin State Energy Program. Additional investments are forthcoming as GBX pursues its next growth phase.

“We are a company built by gearbox guys,” said Neumiller. “We saw an absolute hole in the wind industry for an advanced company providing dedicated gearing, bearing and gearbox expertise. We have the best people, equipment, and parts. I’m looking forward to what we announce in the future.”

For more information, visit gearboxexpress.com.

Awareness is growing in the wind industry about the severe impact that erosion on the leading edge of wind blades can have on turbine output. Erosion can lead to a significant loss in annual energy production, costing owners and operators thousands of dollars. Blade repair and protection can help provide significant annual energy production improvements, reduce costly downtime, and protect the integrity of the blade.

3M™ Renewable Energy Division introduced an innovative solution for wind turbine blade protection at WINDPOWER 2013 on May 6. 3M Wind Blade Protection Coating W4600 is a two-component polyurethane coating that provides excellent erosion protection properties to help prevent and repair leading edge erosion on wind blades.

3M has a proven history of providing highly durable solutions in the industry with its 3M Wind Blade Protection Tape. This product has provided significant reductions in leading edge erosion, and has also helped extend maintenance and service intervals. Designed to offer game-changing performance and protection, 3M Wind Blade Protection Coating W4600 further expands 3M’s portfolio of erosion protection solutions. The coating is designed for application in OEM facilities and can be easily applied via brush or casting.

“3M has performed extensive testing on this product, and customers will see that it provides superior performance for a critical industry need,” said Christian Claus, business development manager, 3M Renewable Energy Division. “We are proud to expand our product offering to the wind industry.”

For more information, visit www.3M.com.

Vestas has secured a firm and unconditional order for the delivery of 166 V100-1.8MW wind turbines along with a 20-year service and maintenance agreement for the 299MW Blackspring Ridge Wind Project, a joint venture of EDF EN Canada, Inc. and Enbridge. It marks the largest order for Vestas wind turbines in Canada.

Deliveries for Blackspring Ridge, located near Lethbridge, Alberta, are scheduled for the second half of this year and commissioning is expected to occur by mid-2014.

“We appreciate these two global energy companies making a long-term commitment to Vestas. Our partnership with EDF EN Canada and Enbridge shows their confidence in our ability to deliver turbines safely and on time,” said Chris Brown, president of Vestas’ sales and service division in Canada and the U.S. “This project also will increase our market leadership position in Canada and further builds on our strong service business in Alberta.”

The 20-year service agreement—the longest in Vestas’ history in the U.S. and Canada—features the Active Output Management (AOM) 5000 service option. AOM 5000 features an energy-based availability guarantee to ensure the turbines are operational when the wind is blowing. This service option includes the VestasOnline® surveillance system that remotely controls and monitors the turbines and predicts potential maintenance issues. This allows Vestas to plan maintenance so the turbines are operational for the maximum amount of time.

“Blackspring Ridge is an important addition to Enbridge’s fleet of renewable projects as it significantly expands our wind energy portfolio in the Alberta market, which we first entered nearly a decade ago with our Magrath and Chin Chute wind farms,” said Don Thompson, Vice President, Green Energy, Enbridge Inc. “Alberta is an attractive environment for wind investments due to its high wind capacity factor and access to transmission. We welcome this opportunity to continue expanding our renewable energy assets into Western Canada and are pleased to continue our relationship with EDF EN Canada and Vestas.”

Vestas’ U.S. factories in Colorado will be involved in manufacturing components for Blackspring Ridge, which will become Canada’s sixth wind power plant to use V100-1.8 MW turbines. Overall, more than 600 V100-1.8 MW turbines are producing energy at 13 sites across Canada and the United States.

EDF EN Canada and Enbridge will develop and own Blackspring Ridge. Once commissioned, it will be the largest wind power plant in Western Canada with the capacity to provide electricity to nearly 140,000 households.

“EDF EN Canada looks forward to our first opportunity to install Vestas turbines in Canada as part of the Blackspring Ridge project,” said Al Kurzenhauser, COO for EDF EN Canada.  “Alberta is a promising market that allows us to expand our wind development success into Western Canada. The project further builds on our relationship with both Vestas and Enbridge, demonstrating our business model to optimize assets throughout North America.”

Vestas installed its first wind turbines in the Canadian market in 1997 and since has become the leading wind-turbine supplier in the country and in Alberta.

For more information, visit www.vestas.com or www.edf-en.ca.

U.S. Deputy Secretary of Energy Daniel Poneman on April 10, detailed President Barack Obama’s $28.4 billion Fiscal Year 2014 budget request for the Energy Department. Poneman emphasized the President’s continued commitment to an all-of-the-above energy strategy that prioritizes investments in innovation, clean energy technologies, and national security. The Department’s budget request is part of the administration-wide effort to strengthen the American economy with energy that is cleaner, cheaper and creates sustainable jobs. The FY 2014 budget request represents tough choices aimed at focusing taxpayer resources on areas that will yield the greatest benefit over time.

“The United States faces one of the greatest challenges ahead, the opportunity to lead the global clean energy race.  We must continue to out-innovate, out-educate and out-build the rest of the world to meet this challenge,” said Deputy Secretary Poneman.  “This budget reflects strong commitments to fiscal responsibility and shared sacrifice, while embracing the President’s all-of-the-above energy strategy which expands both oil and gas production and investments in new clean energy technologies, while advancing our national security.” Specifically, the President’s FY 2014 budget request for the Department of Energy:

• Invests in innovative research to lead in research, development, deployment, and production of clean energy technologies;
• Establishes a new goal of doubling American energy productivity by 2030;
• Calls for Congress to establish an $2 billion Energy Security Trust;
• Creates a new Race to the Top for Energy Efficiency and Grid Modernization;
• Helps consumers and businesses save money and improve their energy efficiency through the President’s Better Buildings Initiative;
• Supports groundbreaking basic science research and innovation to solve our energy challenges and ensure the U.S. remains at the forefront of science and technology

For more information, visit www.energy.gov or www.whitehouse.gov.

Wind energy grew 28 percent in the United States in 2012, setting a new installation record and confirming its status as a mainstream energy source, according to the American Wind Energy Association’s U.S. Wind Industry Annual Market Report for 2012, released in April.

In its best year ever, the U.S. industry topped all energy sources with 42 percent of all new U.S. electric generating capacity. Over 6,700 new wind turbines were erected, which produce enough electricity to power the equivalent of 3.5 million homes. Overall, America finished the year with 45,100 wind turbines that can power 15.2 million homes.

The bumper crop of wind energy benefited the U.S. economy across all 50 states, through $25 billion in private investment in new U.S. wind farms, tens of millions of dollars paid to landowners and local communities in lease payments and property taxes, and billions in projected savings for electricity consumers.

“We had an incredibly productive year in 2012,” said AWEA interim CEO Rob Gramlich. “It really showed what this industry can do and the impact we can have with a continued national commitment to renewable energy. We’re doing what Americans overwhelmingly say they want: making more clean, renewable energy, and creating good jobs in U.S. factories.” The report found that more than 550 factories across the nation provide parts and services for the wind energy industry, which accounted for more than 80,000 American jobs in 2012.

While jobs numbers were hampered as the year went on by Congress’s delay in renewing the primary incentives for American wind power—the production and investment tax credits—their extension on Jan. 1, 2013, for projects that start this year has sent the industry back to work.

Among project developers, NextEra Energy Resources installed the most new U.S. wind energy capacity in 2012, amassing 1,505MW. Iberdrola Renewables came in a distant second with 716MW of new installed capacity. EDF Renewable Energy, Caithness, and Duke Energy rounded out the top five, with 658MW, 640MW, and 620MW, respectively.

Geographically, Texas extended its lead among states generating wind energy. It also led all the other states in new wind energy installations. The Lone Star State realized the addition of 1,826MW of wind energy, and exceeded 12,000MW of capacity—accounting for more than a fifth of the nation’s wind energy installations. California eclipsed Iowa for second in total installed capacity with the addition of 1,656MW of wind energy capacity. Kansas (1,441MW), Oklahoma (1,127MW), and Illinois (823MW) followed in new 2012 capacity.

On the global scale, the record year for new U.S. wind energy installation narrowly edged the new installations in China (13,000MW), but accounted for just less than 30 percent of global wind energy installations in 2012. New wind energy installations globally in 2012 amounted to 41,236MW.

General Electric maintained its top position as the world’s leading turbine manufacturer, installing 3,003 turbines (5,014MW), amounting to a 44.5 percent market share in number of turbines (38.2 percent share of capacity). Siemens, Vestas, Gamesa, and REpower (Suzlon) rounded out the top five.

In addition to the industry’s record growth last year, a growing trend augured well for its future: new purchases of wind power by 74 electric utilities, along with at least 18 major industrial consumers and 11 school and universities—all taking advantage of the chance to diversify their energy portfolio and stabilize and lower energy costs, typically on long-term, fixed-rate contracts. Rising utility interest has been seen again this year since the PTC extension, with at least seven utilities issuing new requests for proposals to purchase over 1,000MW of wind power.

Top 2012 wind energy industry facts, by the numbers:

• 13,131 – The amount of installed capacity, in megawatts, installed during 2012 in the U.S.
• 60,007 – The amount of total installed capacity to date, in megawatts, in the U.S.
• 25 – The total investment, in billions of dollars, in U.S. wind energy projects during 2012
• 890 – The number of utility-scale wind projects currently operating in the U.S., consisting of more than 45,000 turbines

AWEA Business Members can download their copy of the complete U.S. Wind Industry Annual Market Report by logging onto the Member Center at www.awea.org.

*Source: American Wind Energy Association; American Wind Energy Association U.S.
Wind Industry Annual Market Report Year Ending 2012.