The world leader in environmental measurement Vaisala, together with electricity and natural gas energy company Xcel Energy and the National Center for Atmospheric Research (NCAR), have joined forces on a pioneering pilot project in the United States that will take observing and forecasting for wind energy production to the next level.

The goal of the pilot is to explore the use of a new wind observing and forecasting system in Xcel Energy’s wind power generation. The system will provide critical decision-making support for balancing wind power with traditional fossil fuel generation while minimizing costs and improving reliability. A primary focus of the effort is to develop technologies that will better anticipate changes in wind energy output from wind farms. “This is a great opportunity for Vaisala to again demonstrate how we can provide observation systems for weather critical applications,” says Richard Pyle, head of the company’s wind energy market segment.

“We are extremely pleased to enter this pilot project with Vaisala and NCAR, who both are leading players in their fields and can significantly contribute to the development of wind forecasting in energy production,” says Mary Fisher, vice president of strategic technology for Xcel Energy. “Once completed the pilot, if successful, will inform wind farms operators on the means to increase reliability and minimize integration cost.”

Vaisala is providing Xcel Energy with surface weather stations, radar wind profiling capability, and National Lightning Detection Network® data, as well as installation and operating services for a 12-month pilot program. The wind observation network will be located around wind farms in Colorado that total 400 megawatts of installed capacity. The network became operational in November 2009.

NCAR has been contracted to refine a wind forecasting system that focuses on wind ramp detection for the project. Vaisala’s observation data will be integrated with the forecast information in a decision support tool developed by Vaisala in close cooperation with the three parties. To learn more contact Richard Pyle at (303) 589 8772 or richard.pyle@vaisala.com. Visit online at www.vaisala.com.

Ohio Gov. Ted Strickland recently announced that 25 state solar and wind projects will receive more than $13 million in grants funded through the American Recovery and Reinvestment Act’s State Energy Program. The announcement was made last November at Lincoln Electric’s Automation Center of Excellence in Cleveland, highlighting the company’s welding solutions for wind tower fabricators.

Among those projects was $1 million awarded to Lincoln Electric to help install a wind turbine at its Cleveland manufacturing facilities. The plans call for a 2.5-megawatt turbine that will generate approximately 10 percent of the electrical needs for Lincoln’s Cleveland manufacturing operations.

“We are excited to have this opportunity under Ohio’s energy program to demonstrate the value of wind energy by investing in our own installation,” says John Stropki, chairman and CEO. “This project is a continuation of other Lincoln environmental, health, and safety (EHS) programs and green initiatives currently under way in our manufacturing operations to improve our costs and protect our environment. Not only will the wind project provide long-term benefits by reducing our energy costs, it will also showcase the unique benefits that Lincoln products and welding solutions provide to wind tower manufacturers to improve their quality and lower their costs.” Learn more at www.lincolnelectric.com.

By safely channeling harmful shaft currents away from bearings to ground, Electro Static Technology’s new AEGIS WTG™ wind turbine grounding ring prevents bearing damage that could otherwise cause generator failure, unplanned downtime, costly repairs, and lost revenues. Maintenance-free, effective at any RPM, and available for any size wind turbine generator, the ring is designed for OEM installation or easy uptower retrofit.

High-frequency currents induced on the shafts of wind turbine generators can reach levels of 60 amps and 1200 volts or greater. If not diverted these currents will discharge through the generator’s bearings, causing severe electrical damage that results in bearing failure and catastrophic turbine failure, sometimes in as little as six months or less. The AEGIS WTG’s patented conductive microfiber technology effectively steers these currents away from the bearings and safely to ground.

The WTG is engineered to safely divert up to 120 amps of continuous shaft current at frequencies as high as 13.5 MHz and discharge up to 3000 volts (peak). Ideal for use as part of a preventive maintenance program to protect against premature bearing failures, it can be installed whenever bearings are replaced. For more information contact Adam Willwerth at (866) 738-1857 or (207) 998-5140. Send e-mail to sales@est-aegis.com, or go online to www.est-aegis.com.

Byers Precision Fabricators offers highly skilled full-service five-axis laser processing to help reduce costs for manufacturers in the wind turbine and other alternative energy industries. The company provides extraordinary results and exciting new engineering, design, and production opportunities. Byers Precision operates with current laser technology and has the experience necessary to most effectively and efficiently manage customer projects. The company is known for reliable and high-quality work, as well as quick response to customer needs. Outsourcing to Byers Precision reduces cost for customers as no capital expenditure, ongoing operational costs, upgrading costs, or operational changes are required on their part.

Byers Precision utilizes a Prima Rapido 1532 five-axis laser processing center equipped with a 3500-watt CO2 laser capable of cutting of steel, stainless, aluminum, ceramics, plastics, and other materials. Two cutting heads cover a wide range of material thickness. The laser handles simple 2D, as well as more complex 3D jobs. Catia Fastrim software is used for fixture design.

Byers Precision capabilities include cutting and trimming of hydro-formed, spun, deep drawn, and stamped parts. Thus providing a more economical trimming solution than additional tooling or trim dies. Capabilities include producing features at an angle close to the horizontal and in areas inaccessible by other machining methods. 3D part contouring services are offered as well. Available rapid prototyping services provide quick production of prototype parts based on provided model data. Modification services include addition of new features to existing parts. Scanning and modeling capabilities are also available. Byers Precision is equipped with a multitude of work centers allowing solutions ranging from cut and ship to turnkey parts manufacturing. For more information call (888) 693-7411 or visit online at www.byersprecision.com.

Having recently inaugurated a newly-built high-tech lab in Ismaning, Germany, PRUEFTECHNIK Alignment Systems—LUDECA’s principals—strengthens its technological prominence and abilities in measurement technology.

The lab includes two large granite tables (20 ft. x 6-1/2 ft. and 36 ft. x 1½ ft.) weighing 12 and 11 metric tons, respectively, and a 1½ ton 3D motion simulator. The requirements for the measurement and test lab are stringent to the extent that the new optical tabletops have been mounted on a vibration and shock free foundation isolated from the building ensuring that any environmental movement is not transmitted to the tabletop. Tight environmental conditions within the measurement and test room are met. Lighting requirements are provided by 150 LEDs. The installed air conditioning plant regulates the incoming and return air through an elaborate piping system. An accurate equalization of flow ensures that identical environmental conditions exist at every point within the laboratory. The air temperature is stable at 71.6° F (22º C ± 0.1º C). The humidity is maintained at 40 percent. This new high-tech lab allows development of new sensors, lasers, and measurement systems that will further enhance and guarantee the quality of the production units used in maintenance of rotating machinery. It will also satisfy the ever increasing requirements for sub-micron measuring accuracies.

LUDECA is a vendor of preventive, predictive, and corrective maintenance tools including laser alignment, vibration analysis, and balancing, as well as software, services, and training. For more information call 305) 591-8935, e-mail sales@ludeca.com, or go online to www.ludeca.com.

Enertech, Inc., announces the formation of Rio Viento Development Corp., a wholly-owned subsidiary offering multidisciplinary development, consulting, and O&M services. The new venture compliments Enertech’s existing wind turbine manufacturing business by providing customers with the technical and professional services needed to develop wind projects under 20 mw. “Enertech is a ‘one-stop shop’ for community, institutional, agricultural, commercial, and industrial wind projects,” says Dale Jones, president and CEO. “Rio Viento provides Enertech customers with solutions to financing, permitting, and interconnection needs.”

Rio Viento is comprised of professionals with backgrounds in law, planning, and project management. Its services include site selection, site leasing and acquisition, site development, project management, construction management, economic modeling, feasibility studies, land use and environmental permitting, financial consulting, state and federal incentive consulting, grant-writing, utility negotiations, PPA and interconnection agreements, O&M management, remote monitoring, instruction, and training services.

“Wind project development is a complicated process,” Jones says. “Enertech is committed to the mid-sized wind market, and Rio Viento offers the experience and expertise needed to take projects off the drawing board and turn them into reality.”

Enertech, Inc.—based in Newton, Kansas—is an established name in the wind industry. Enertech manufacturers and markets wind turbines for the mid-sized market, with particular interest in community, institutional, agricultural, commercial and industrial projects. A wholly-owned subsidiary, EncoreWind, offers refurbished and remanufactured wind turbines and components. To learn more contact Scott B. Poor at (800) 701-2888 or spoor@enertechwind.com. Visit the company’s Web site at www.enertechwind.com.

Parker Hannifin Corporation, the leader in motion and control technologies, has released the first two-phase cooling system to manage the heat of high-power electronics safely and efficiently. Parker’s Precision Electronics Cooling System Technology, developed at Parker’s Climate Systems Division, allows power electronics’ design platforms to have up to twice the power density in half the space, perfect for a wide array of renewable energy applications.

This new maintenance-free system is ideal for decreasing the size of a wind turbine’s power system or extending the range of a hybrid vehicle. Using a vaporizable dielectric fluid, the system boils this fluid across the base of the silicon chip, converting the fluid into a gas and stabilizing the system’s high temperatures. This process shatters the cooling limits once imposed by traditional water-based systems.

“Because the liquid changes to a gas, we are able to remove two to four times more heat from the system,” says Scott Gill, business unit manager for Parker’s Advanced Thermal Systems Business Unit. “Thermal management is one of the primary barriers limiting high power electronics today and this provides the design engineer an unprecedented leap in thermal performance. By using a dielectric (non-conductive) fluid, our system is safer than the traditional water-based approach and will never damage sensitive electronics.”

“The timing couldn’t be better,” according to Dave Saums, a thermal consultant in Amesbury, Mass. “This technology is applicable to any of the new energy platforms such as hybrid and electric vehicles, wind turbine power systems, uninterruptible power supplies, and just about any high-power platform for industrial, medical, and military applications.”

With annual sales exceeding $12 billion, Parker Hannifin is the world’s leading diversified manufacturer of motion and control technologies and systems, providing precision-engineered solutions for a wide variety of commercial, mobile, industrial, and aerospace markets. For more information contact Dale Thompson at (260) 418-0503 or dale.thompson@parker.com. Also go to www.powersystemscooling.com.

HPM America has unveiled its newest product line—wind turbines. In introducing this line the company will be addressing the needs of homeowners, businesses, schools, and universities, governmental institutions, and other applications. The marketing campaign will be utilizing the slogan “1 to 1—Your Total Community Wind Provider.”

The new wind turbines will be available from a small 1kW unit to 1MW. They will incorporate Axial Flux Permanent Magnet (AFPM) technology, which achieves more-efficient wind power generation and is able to produce more power at lower wind speeds due to its coreless technology. The ability of HPM generators to eliminate traditional cogging issues makes it the ideal candidate for wind turbine applications. This new technology eliminates the need for a gearbox to be used as part of the wind turbine drive train, thereby minimizing downtime and reducing maintenance costs over the life of the system.

In AFPM generators a coil is wrapped around a specially designed disc at the center axis. Magnetic discs then rotate on the sides of the coiled disc and generate electricity, consistent with Faraday’s Law. This kind of power generating technology is therefore ideal for wind power generation because its initial operation torque (cut-in speed) is lower than the current Radial Flux Permanent Magnet (RFPM) method.

AFPM power generation is classified into two configurations; the inner and outer type. In the inner-type configuration only the magnetic disk rotates, while the generator housing remains fixed. In the outer-type configuration the whole generator body rotates by fixing the magnetic disk to the body. Both configurations can be provided depending on the application specifications. When the generator is operating and producing electricity, it produces heat. As the heat increases, generator efficiencies decrease. To solve this problem HPM’s generators include a patented liquid-cooling system. This drastically reduces the associated wear that high temperatures can cause, and thus improves the lifespan of the generators.

HPM America manufactures and supplies extrusion systems, injection molding machines, and die casting equipment, along with providing contract manufacturing from its headquarters in Mount Gilead, Ohio. To learn more contact Gerard J. Sposato, VP of sales and marketing, at (419) 949-2206 or gsposato@hpmamerica.com. Go online to www.hpamerica.com.

Vestas has received an order for an offshore wind power plant with a total capacity of 165 MW. The wind power plant, Bligh Bank Offshore Wind Farm, consists of 55 units of the V90-3.0 MW wind turbine and will be located 46 km off the coast of Zeebrugge, situated in the zone dedicated by the Belgian government for the construction of wind farms. The order has been placed by Belwind N.V., owned by a consortium of Belgian and Dutch investors. The order comprises design, delivery, installation, testing, and commissioning of the 55 wind turbines, as well as a five-year service and availability agreement. Dutch contractor Van Oord Dredging and Marine Contractors bv are responsible for engineering, procurement, and construction.

“We are proud to be supplying turbines for the Bligh Bank Offshore Wind Farm. Furthermore, we are very pleased to see this group of investors showing their confidence in the potential of offshore wind and we look forward to securing them a successful implementation of the project,” says Anders Søe-Jensen, president of Vestas Offshore. “Vestas is a leading, global player in the wind market, and we have been driving the offshore wind industry from the very beginning. Being in the offshore market requires some very specific knowledge and skills—both of which Vestas possesses—and the Bligh Bank Offshore Wind Farm order truly shows Vestas’ dedication and commitment to remain strongly focused on this market.”

Delivery and installation of the turbines, including full power production, is expected to take place during 2010, whereas final completion of the offshore wind farm is expected in early 2011. “This 165 MW wind farm is the first phase of the 330 MW Belwind project,” says Frank Coenen of Belwind N.V. “We look forward to working together with Vestas and Van Oord on the construction of the project, which is a major step forward in realizing the Belgian renewable energy targets. We are proud of our investors and banks, who enabled us to realize this investment in difficult financial times.” To learn more call +45 9730 0000, send e-mail to vestas@vestas.com, or visit online at www.vestas.com.

Carl Zeiss Industrial Measuring Technology (IMT) has introduced the new ACCURA®. By systematically implementing customer requests, it has developed a multi-sensor capable measuring system that permits fast, economical, precise, and flexible measurements.

Measure dynamically, precisely and safely: Thanks to the steel and aluminum components, the new ACCURA measuring machine bridge is extremely rigid and thin. The CARAT® coating (Coated Ageing Resistant Aluminum Technology) on the aluminum parts ensures long-term stability of guideway behavior. The low weight of the moving parts improves the dynamics. This allows the ACCURA to achieve a maximum vectorial travel speed of 800 millimeters per second—50 percent faster than its predecessor—in the Performance Package configuration. This speed demands increased protection measures. Therefore, the Performance Package contains a special safety system: laser scanners monitor the protection zone around the measuring machine during the high-speed mode. If the safety system registers movement within this zone, the machine speed is automatically lowered within one second. Once the disruption passes, ACCURA reaccelerates to the original measuring speed. The enhanced air bearings also play a key role in the dynamic behavior of the bridge. Thanks to the thinner air gap, they are more rigid and require less compressed air than previous air bearings.

Foam insulating technology enables higher temperature independence: The ACCURA bridge features a new, high-performance insulation—foam insulating technology. At minimal thickness, the housing covers ensure temperature resistance. This guarantees the required precision even on the shop floor.
Freely selectable temperature range (20-26°C): Measuring machines must be operated at constant temperatures to avoid temperature-dependent deformations. A fixed measuring lab temperature of 20°C is standard. The new ACCURA can be operated with the same precision at other temperatures between 20 and 26°C. The measuring lab temperature can therefore be set appropriately and you save air conditioning costs.

Tailored to customer demands: As with a versatile modular system, customers can configure the ACCURA to fit their requirements. Based on their current tasks, they select the ideal configuration, i.e. sensors. Special software, such as GEAR® PRO for gears and HOLOS® NT for freeform surface measurements, is integrated along with CALYPSO®, the standard CAD-based measuring software from Carl Zeiss. Subsequent modifications can be made very easily. The ACCURA is available at a very economical price for this performance class. If requirements change, different sensors and software can be easily added. Whether cut, shaped, or molded parts, plastic or steel—all options of coordinate measuring technology are available. The ACCURA also permits the integration of MASS® technology from Carl Zeiss. Combined with an RDS articulating probe holder, MASS permits the fast, measuring program-guided change between contact sensors and the ViScan® and LineScan optical sensors during a CNC run. The contact measuring sensors of the VAST® family and the DT single-point sensor can also be used in various configurations.

The new ACCURA is currently available in four sizes, each of which offers a large measuring range—even with an integrated stylus changer. For more information contact Chris Grow at (763) 744-2400 or cgrow@zeiss.com. Go online to www.zeiss.com.

The U.S. wind energy concluded the world’s largest wind conference held May 4-7 in Chicago, which hosted 1,280 exhibiting companies and more than 23,000 attendees. “The size and breadth of this show are a clear indicator that the wind energy industry is a hub of business activity even in this hesitant economy,” says AWEA CEO Denise Bode. “What we heard loud and clear from the industry assembled here in Chicago was a call to enact a national Renewable Electricity Standard (RES) to secure a stable and growing market for renewable energy.”

A poll released by AWEA at WINDPOWER showed that more than 75 percent of Americans, including 71 percent of independents and 62 percent of Republicans, support an RES requiring that 25 percent of the nation’s electricity be generated from renewable energy by 2025. Show highlights include:

• Siemens announced it will open a wind turbine nacelle manufacturing facility in Hutchinson, Kansas. Investment in manufacturing facilities in the U.S. has accelerated over the past two years, with over 55 wind turbine and wind turbine component manufacturing facilities announced, added or expanded in 24 states in 2008(see page 12);
• Exhibitors from 48 states, and representatives from all 50 states and from 70 countries were present at WINDPOWER, demonstrating the industry’s national and international scope;
• The exhibition hall exceeded 290,400 square feet—more than the 2008 (168,700 square feet) and 2007 (92,500 square feet) WINDPOWER shows combined.
• WINDPOWER welcomed over 23,200 attendees, up from 13,000 in 2008, 3,600 in 2004 (which was also held in Chicago), and 1,000 in 2001;
• Five Governors (Chet Culver of Iowa, Jim Doyle of Wisconsin, Jennifer Granholm of Michigan, Pat Quinn of Illinois, and Ted Strickland of Ohio) addressed the conference. The Governors of Kansas and Pennsylvania were also present. States and their offices of economic development are competing to attract wind turbine supply chain companies and create good jobs. At least 19 state or regional economic development offices were exhibiting at WINDPOWER.
• Secretary of the Interior Ken Salazar, Energy Secretary Steven Chu (via a taped speech), and Federal Energy Regulatory Commission Chairman Jon Wellinghoff also addressed the conference. Secretary Salazar pointed to new rules for offshore wind farms that open the way for the U.S. to become a leader in offshore wind power. Both noted the value of a national Renewable Electricity Standard in creating jobs, helping hold down costs for consumers, and diversifying the nation’s electricity portfolio. “At no time in our history has the time for a new energy policy been so urgent. This is an opportunity that Americans cannot afford to miss,” Salazar said.
• T. Boone Pickens, who planted wind energy firmly in the public consciousness with his high profile campaign, again pointed to the need to get off foreign oil by using more renewables to produce electricity and more natural gas for transportation. He predicted Congress will eventually pass comprehensive legislation, including an RES, because the American people support it.

AWEA is the national trade association of America’s wind industry, with more than 1,900 member companies, including global leaders in wind power and energy development, wind turbine manufacturing, component and service suppliers, and the world’s largest wind power trade show. AWEA is the voice of wind energy in the U.S., promoting renewable energy to power a cleaner, stronger America. The WINDPOWER 2010 Conference & Exhibition will take place May 23-26 in Dallas, Texas. To learn more go to www.awea.org.

For the second year, Wanzek Construction, Inc., has held a position on Engineering News-Record (ENR) magazine’s list of the Top 400 Contractors in the United States. The list ranks the 400 largest general contractors in the United States according to the previous year’s revenue. In 2008 Wanzek appeared on the list for the first time, holding position number 345. This year the company took a 168-point jump into position 177, after doubling revenues to more than $400 million. In 2008 Wanzek’s national portfolio of heavy/civil and industrial construction projects included, most notably, the installation of approximately 1000MW of wind energy generation capacity.

Wanzek Construction, a MasTec company, specializes in heavy and industrial projects throughout the country for the market sectors of power, renewable energy, industrial process, heavy/civil, and wind energy construction. For more information contact Jason Kaufman, vice president of business development, at (701) 282-6171 or jkaufman@wanzek.com. Visit online at www.wanzek.com.

Trelleborg Sealing Solutions supplies a specially engineered sealing configuration to AVN Energy A/S, a leading hydraulic actuator manufacturer for wind turbines. Meeting the dynamic criteria due to constant movement of the actuator, the sealing system offers maximized seal life, contributing to minimal turbine maintenance requirements.

Stall machine turbines being replaced by continuous pitch systems has put extreme demands on hydraulic actuators. The position of stall machines would shift only once every 10 minutes, but in continuous pitch wind turbine systems the nacelle and angles of the blades constantly change in small amounts once every rotation, 15 times per minute on average. This means that instead of producing six long strokes per hour, the turbine’s hydraulic actuator must now initiate 900 short strokes in the same period, 24 hours a day and seven days a week, for a targeted 20-year period.

“Customers have high expectations from our products, and the number-one requirement of the wind turbine manufacturers is reliability,” says Poul Kristensen, export sales manager at Denmark-based AVN Energy A/S, one of the world’s leading suppliers of actuators for wind turbines. “Maintenance of turbines is difficult and costly. On land it is hard enough, but offshore it is really tough. And when the windmill is switched off for maintenance, it is not producing energy and losing income. On top of that, operators are often penalized if supply targets are not met. So a primary objective for them is to minimize routine downtime, while stoppages due to component failure have to be avoided at all costs.”

Having worked with Trelleborg Sealing Solutions on stall machines, AVN approached it to jointly develop a sealing system to meet the challenging requirements of continuous pitch systems. The specified solution is a complex arrangement of seals ranging from O-Rings to specialist Turcon® PTFE based geometries and Slydring® in Orkot®. The unique configuration is specially engineered to enhance lubrication and optimize friction characteristics, while preventing any external leakage. For more information contact Donna Guinivan at +44 121 746 3621 or donna.guinivan@trelleborg.com. Visit online at www.tss.trelleborg.com.

Snap-on Industrial has announced the launch of a torque certification program designed specifically to meet the needs of the growing global wind industry. Snap-on Industrial, a division of Snap-on Inc., is a global leader in the design, manufacture, and distribution of hand and power tools, specialty tools, storage solutions, and training to meet the needs of industry.

“Torque certification is particularly sensitive in the wind-power industry because mistakes can be both expensive and time consuming,” says Frederick Brookhouse, business and education partnership manager. “In developing this training program, our goal is to outline a curriculum that builds on what Snap-on has learned in certification programs it has spearheaded in the automotive market. As a company we’ve learned what works and what doesn’t work in creating an effective training program.”

Torque is the turning motion used to tighten or secure a fastener around an axis point. The amount of force used in a particular task is measured in Newton meters, or foot pounds. The Snap-on torque certification program, developed in collaboration with educators, explores both torque theory and proper use and application of equipment; testing for certification focuses on equipment use.

The 16-hour certification course is designed as a component to an existing wind-power technician training course. The Snap-on torque certification program will be integrated into wind-power technician courses currently available at Lakeshore Technical College in Cleveland, Wisconsin; Gateway Technical College in Kenosha, Wisconsin; Texas State Technical College in Sweetwater, Texas; Cerritos College in Cerritos, California; and the multi-campus Frances Tuttle Technology Center in Oklahoma.

The torque curriculum includes modules on theory, technique, mechanical torque wrenches, electronic torque wrenches, hydraulic torque wrenches, torque multipliers and safety. It is designed to cover every aspect of torque, from the basics through master-level skills. Current wind-power curriculum incorporates the study of electrical and electronic components, electrical safety, working in confined spaces and working at height.

“The understanding and proper application of torque is a mission-critical element of a viable and sustainable wind-power industry in the U.S.,” Brookhouse says. “This industry needs strong training programs to meet the burgeoning demand for manpower. Snap-on Industrial is uniquely positioned to provide this customized, specialized training and we’re working to apply that knowledge today.”

To learn more contact Dale Alberts at (262) 656-6559 or dale.l.alberts@snapon.com. Go online to www.snapon.com.   

Klüber Lubrication, a worldwide manufacturer of specialty lubricants, showcased three innovative, specialty lubricants for the wind power industry at WINDPOWER 2009: Klüberplex® BEM 41-141, Klüberplex® AG 11-462, and Klübersynth® GEM 4-320 N.

Klüberplex BEM 41-141 is high-performance grease with a special blend of base oil and additives to cover the different lubrication requirements of the individual bearing applications within wind power stations. The beige grease is ideal for pitch and yaw bearings (high stresses, oscillations, vibrations), main bearings (low rpm, high stresses, vibrations), and generator bearings (high rpm and temperatures). Klüberplex BEM 41-141 can be used in all bearing applications which allows consolidation of lubrication inventory.

Another unique product is the priming and operational lubricant, Klüberplex AG 11-462 an effective lubrication for open gears. Klüberplex AG 11-462 is esthetically neutral because it is white in color and provides excellent adhesion as well as superior protection against high loads and corrosion.

In addition to its grease products, Klübersynth GEM 4-320 N is outstanding, synthetic oil for enclosed gear drives subject to a wide range of service temperatures. Compared to standard oil, Klübersynth GEM 4 N shows excellent wear protection for gears and bearings, ageing and foaming resistance, cleanliness, and greater efficiency. Klüber’s “ADDED value” program has made it easy for manufacturers and operators to simplify their lubrication program. For more information please visit www.klubersolutions.com/wind.

Siemens intends to build a new production facility for wind turbines in the United States. Initially, 400 new jobs are expected to be created in the new wind turbine production facility in Hutchinson, Kansas. When production begins at this facility, Siemens will be able to even more effectively meet the strong demand for wind turbine equipment in North and South America in the future.

“The United States already is and will continue to be one of the world’s fastest growing wind energy markets. We are thus intensifying our commitment to this green technology to further expand our leading global position in this field,” says Peter Löscher, CEO of Siemens AG. “We are already the leading green infrastructure giant, and by making these investments we will become even greener.”

With revenues totaling EUR19 billion in fiscal year 2008, Siemens now has the world’s largest portfolio of environmental technologies. Construction of the 300,000 square-foot nacelle production facility is scheduled to begin in August 2009. The nacelles to be produced in Kansas will weigh 90 tons and the first nacelle is expected to be shipped in December 2010. All nacelles produced in Hutchinson will be used in the company’s reliable 2.3-MW wind turbine product family. Initially, the factory’s planned annual output is approximately 650 nacelles, or 1,500 megawatts (MW).

“Just two years ago we opened a rotor blade manufacturing facility in Fort Madison, Iowa. By expanding our investment in Kansas we are strengthening our presence in the U.S. and, at the same time, we are increasing the proximity to our U.S. customers. This new location will enable us to serve them more rapidly and cost-effectively,” says René Umlauft, CEO of Siemens Energy’s Renewable Energy Division.

Hutchinson is near the geographic center of the continental United States and offers a viable workforce and excellent transportation logistics. The factory will include direct loading onto rail, which will provide easy access to project locations throughout the U.S. and Canada. Shipments can also be made utilizing the barge facilities at the port of Catoosa, located 250 miles from the plant. Kansas also has excellent wind conditions. In terms of wind energy potential, this centrally located state ranks third in the U.S.

Since entering the wind industry in 2004, Siemens has greatly expanded its worldwide manufacturing network. In addition to opening and consequently expanding the wind turbine blade manufacturing facilities in Fort Madison, Iowa, and Engesvang, Denmark, the Danish facilities in Brande and Aalborg have been expanded, and a new R&D center in Boulder, Colorado, was established. Siemens’ global wind power business has grown from approximately 800 employees in 2004 to more than 5,500 today, which equals an increase of approximately 650 percent. To learn more visit www.siemens.com/energy.

Stanley Proto Industrial Tools has expanded its already-extensive line of combination wrenches with the addition of 23 new extra-large combination wrenches. The new wrenches are designed to meet the needs of users in heavy industries.

These big wrenches are the epitome of heavy duty. They come in standard and metric sizes, with openings that range from 2 9/16 to 4 in., and from 55 to 80 mm. Lengths go up to 3 ft., giving users the leverage they need to work on stubborn fasteners. Heads are made from drop-forged steel for strength and durability. Open ends are precisely machined for a firm grip on fasteners, while 12-point box ends help users work quickly and help improve accessibility (a 12-point head need only be lifted and turned 30 degrees to re-engage the fastener, while a six-point head requires a 60-degree turn.) The inside edge of the box end is countersunk around its entire circumference to ensure that it slips easily onto fasteners. Wrenches with opening sizes up to  2 ¾ inches or 70mm come with a satin finish, protecting them against corrosion and providing a slip-resistant grip. Larger sizes have a non-reflective black oxide finish for use where non-plated products are required.

Stanley Proto Industrial Tools has been making durable, high-quality hand tools for more than 100 years, having grown from a small machine shop to a worldwide supplier. Its tools are developed according to strict ergonomic standards, with features that let users work faster and easier, including enhanced shock absorption and reduced slip. For more information contact E. (Lenny) Acuna, project coordinator, at (609) 208-2684 or (800) 800-TOOL. Send e-mail to elinore.acuna@directgroup.net. Go online to www.stanleyproto.com.

Samsung Heavy Industries is to enter the wind energy market with the support of technical solutions and product engineering company Romax Technology. Romax has been selected by Samsung to assist in the development of its first product, a large-scale onshore wind turbine.

The Korean company is determined to bring Samsung’s brand of quality design, expert manufacture, and high value to the wind industry. As one of the world’s largest shipbuilders and with vast experience of heavy industry, Samsung is well placed to enter the wind energy market and realize its ambitions to become one of the leading suppliers of wind turbines. The turbine will be their first product for the wind energy market.

A number of specialist companies will work on the turbine concept, coordinated by Samsung’s engineering team in Korea. Romax have been identified for their experience in gearbox design and expertise in drivetrain systems engineering. The UK-based consultancy will provide dynamic analysis of the drivetrain as well as consultancy services for the development of key drivetrain components to ensure the final design is efficient, robust, and achieves a long life.

Romax will use its advanced simulation and analysis software, RomaxDesigner, to aid them in the development of the drivetrain components and will support Samsung through the certification process. Throughout the project Romax will be working closely with other companies involved in the project, including fellow UK consultancy Garrad Hassan, who are developing the turbine concept and supplying load data.

As a new entrant into the global wind turbine market, Samsung needed to ensure its new product will get to market quickly. “Time is a critical factor for our success in wind energy and that is one of the key reasons we selected Romax. Not only for their expertise in gearbox design and drivetrain analysis, but also for their ability to work effectively and quickly within our existing engineering team,” says Dr. Jaedoo Lee, Samsung project manager.

“It is a great privilege for Romax to work with Samsung on their first venture in wind energy,” says Andy Poon, director of renewable energy at Romax Technology. “Samsung is a globally recognized company and well known for quality and technically advanced products—values that align well with the Romax philosophy. We are looking forward to delivering Samsung quick and effective solutions that will help them realise their ambitions in wind energy.”

For more information about Samsung Heavy Industries go to www.shi.samsung.co.kr/eng. Visit Romax Technology at www.romaxwind.com.

Following its successful debut in Europe and Asia, GE Energy has announced that its 2.5-megawatt (MW) wind turbine is coming to America. The 2.5xl, which is the latest evolution of the company’s wind turbine technology, will be launched in North America in 2010. More than 100 of the 2.5-MW machines already have been installed in seven countries and have compiled more than one million operating hours. In addition, GE has received more than one gigawatt of commitments over the next year and a half to provide the 2.5xl wind turbine for projects across Europe—enough clean, wind-generated electricity to meet the needs of more than a million households.

The 2.5xl represents GE’s most advanced wind turbine technology in terms of efficiency, reliability, and grid connection capabilities. The 2.5xl is designed to yield the highest annual energy production in its class and builds upon the success of GE’s 1.5-MW wind turbine, the world’s most widely deployed wind turbine with more than 12,000 now installed. The electrical system design of the 2.5xl, which includes a full-power converter, is 50 and 60 Hz compatible, which will facilitate the launch of the 2.5xl in North America. In addition, the 2.5xl design allows it to be transported with similar equipment as the 1.5-MW. Most of the 2.5xl machines for European projects have been manufactured at GE Energy’s wind turbine facility in Salzbergen, Germany, which recently was expanded to help meet Europe’s growing demand for wind turbines. The 2.5xl units for North America will be assembled in Pensacola, Florida.

“Despite the economic downturn, we continue to see opportunities for continued growth in the U.S. wind industry and that growth can be accelerated as our customers gain greater access to the federal economic stimulus funds,” says Victor Abate, vice president or renewables for GE Energy. “Adding the 2.5xl wind turbine to our technology portfolio for North America greatly expands our capabilities to meet the diverse needs of our customers in these challenging times.”

GE Energy is one of the world’s leading suppliers of power generation and energy delivery technologies, with 2008 revenue of $29.3 billion. Based in Atlanta, Georgia, GE Energy works in all areas of the energy industry including coal, oil, natural gas and nuclear energy; renewable resources such as water, wind, solar and biogas; and other alternative fuels. Numerous GE Energy products are certified under ecomagination, GE’s corporate-wide initiative to aggressively bring to market new technologies that will help customers meet pressing environmental challenges. Learn more at www.ge.com/energy.

Loss of clamp load and fatigue are common failure modes for bolted joints subject to dynamic loads. These conditions are the result of insufficient bolt tension during installation tightening, as well as the inaccuracy of typical torque/tension methods used to complete periodic in-service fastener checks. Critical bolted joints on wind turbines—such as tower, bearing, hub, and blade connections—are subjected to complex cyclic loads throughout their 20-year life.

By insuring fastener tension is maintained within +/-5 percent of design specification, RotaBolt® load-monitoring fasteners assure equipment reliability and safety while providing increased operation uptime and reduced maintenance cost benefits over the life of wind turbine bolted joints.
EGC Enterprises, Inc., manufacturer of RotaBolt fasteners for North America, has published a study covering bolted joint tightening and maintenance for wind turbines. The study illustrates the cost and time savings benefits, as well as operating efficiency improvements achieved via use of RotaBolts. The time and cost required to complete typical slew-ring bearing bolt in-service checks using standard torque/tension maintenance checks (+/-30 percent accurate) are compared to RotaBolt fingertip load monitor in-service checks (+/-5 percent accurate).

It is clearly shown that by introduction of RotaBolts as standard hardware for important and frequently maintained wind turbine connections, the results are increased operating uptime and greatly reduced time to perform in-service fastener tension checks. RotaBolts allow 100 percent tension verification in less time than it takes to complete a typical 10 percent torque check of standard fasteners. To request a copy of the study contact Brian Newcomb at (800) 342-0211 or

briann@egc-ent.com. Go online to www.egc-ent.com.