Windpower Engineering & Development February 2019

M E E T T H E E N H A N C E D G LO B A L W I N D T R A I N I N G STA N DA R D S / /

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The technical resource for wind profitability

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Take two:

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HERE’S WHAT I THINK

the case for cleaner airports starts with renewables SURPRISINGLY, weather was blameless when a blackout delayed more than 1,000 passengers in Hartsfield-Jackson Atlanta International Airport in December 2017. A fire — later traced to a failed switchgear — was the culprit, knocking out the airport’s electricity for some 11 hours that day. The airport’s primary and backup power cables ran through the same tunnel and the fire destroyed both, leaving many travelers (including a good friend of mine) stranded and in the dark.

This event came to mind nearly a year later when awaiting a flight at Amsterdam’s Schiphol International Airport, I read an article about The Netherlands commitment to clean energy — particularly at its airports.

January 2018 marked a commitment by the country’s major airports (including Schiphol) to fully switch to wind power for electricity.

According to the Royal Schiphol Group, which manages many of The Netherland hubs, local wind farms began supplying the company’s air terminals with a total of 200 gigawatt-hours of clean energy.

What’s more: new wind turbines are planned for operation in 2020 to ensure an adequate power supply and the country’s train network also runs entirely on wind, a milestone reached one year earlier than originally planned. Impressive, right?

Now imagine if North American airports routinely relied on renewable energy. A study by the National Academy of Sciences on the subject found that airports could benefit from onsite renewable sources by gaining greater control over their electrical infrastructure. For example, this means airport operations could function independently of global energy markets (a major plus for the travel industry considering airlines’ profits typically hinge on fuel prices;

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read more at tinyurl.com/CleanAirports).

Renewables may also serve as a source of backup power (which could have served Atlanta travelers), and particularly projects with hybrid battery storage.

Certainly, a number of U.S. airports have installed solar panels (think Honolulu, Denver, Indianapolis, Tampa, and Tucson International has a unique “solar amphitheater” above its parking lots). In 2008, the Massachusetts Port Authority installed 20 wind turbines on the roof of Logan Airport’s offices, which use energy from wind along the waterfront. We can do better.

If Fortune 500 brands and a host of other non-utility entities, including cities and universities, can buy a record amount of U.S. wind power in 2018 (according to the American Wind Energy Association’s latest Market Report), then airports and transportation companies in the country are wise to follow suit. Energy comprises a large portion of operating costs at airports and wind offers low, stable prices that are an incentive to buyers. In fact, the cost of wind has fallen by 69% since 2009, falling another 7% in 2018, according to investment firm Lazard.

America is currently looking to the UK and Europe for lessons learn in offshore wind (see the article on page 26). Perhaps it should also look to The Netherlands for inspiration relating to renewables and travel and transportation.

Speaking of clean-energy leaders, check out the companies our readers voted for as the frontrunners in wind leadership on page 36. Kudos to those wind and renewable workers and advocates diligently working toward a cleaner, more sustainable world. WPE

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EDI TOR

MICHELLE FROESE W I N D P OW E R E N G I N E E RI N G & D E V E LO P M E N T MF R OE S E@W T W H M E D I A .COM | @F O R E N E WA B L E S

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ALLEN

CENTERA

JOHNNY ALLEN is a Senior Underwriter and Head of Offshore Renewables with global insurance company, Travelers. Allen is responsible for Travelers’ offshore wind book of business in the company’s syndicate at Lloyd’s. He also chairs the European Wind Turbine Committee and represents the syndicate at a number of renewable market groups.

KIMBERLEE CENTERA is the CEO and founder of TerraPro Solutions, a developer of renewable energy projects. Centera is a risk-management expert for the development and financing of large-scale generator energy projects, with a track record of delivering results on complex, high-value projects. She began her career in renewables over 25 years ago. Today, Centera oversees an exceptional team of professionals who provide turnkey project development solutions for renewable energy utilities.

GEORGE FINLEY is the America Manager of Mining and Wind products with Morgan Advanced Materials. He is also a part of the company’s Global Wind team, collaborating with all of the various regions in the world that Morgan is involved with. He has traveled the globe during the past 36 years, solving problems in many industries. Finley’s background is mechanical with a focus on metallurgy. Since joining Morgan in 2004, his expertise is with carbon brushes, commutators, slip-rings holders, and springs. He continues his efforts to improve electrical performance and reduce costs of operating motors and generators.

FINLEY

wind talk

Podcasts interview the industry’s biggest newsmakers and allow them to tell their stories.

Visit iTunes or SoundCloud to subscribe, or listen directly from archives at windpowerengineering.com

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Resources I N T E R A C T I V E

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FEBRUARY 2019

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FEATURES

EDITORIAL The case for clearner airports

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WINDWATCH What’s new, Meet the enhanced GWO training standards, Wind work around North America

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INVESTMENTS Insuring offshore wind farms...what developers need to know

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COMPONENTS Taking the grind out of ground rings

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cover story

Repowering can add up to 20 years to the life of a wind turbine.

SAFETY A wind tech’s guide to dropped-object prevention LEADERSHIP IN WIND ENERGY To keep wind-power flowing successfully, we at Windpower Engineering & Development know it is important to recognize the leaders that push the industry forward. Learn about the accomplishments of the exceptional engineers and companies in the country that are busy building a strong and reliable wind-powered future in America.

www.windpowerengineering.com

Six factors to consider before repowering a wind site

As more wind farms reach end-of-life, decommissioning is no longer the only viable option. Repowering is a valuable alternative for certain aging wind sites. However, it is a big job and there are many policy, permitting, and cost factors to consider first. | PA G E 2 0

Working together for offshore wind success

Europe and the UK are decades ahead in offshore wind development — and the United States is benefitting. Thanks to collaborative efforts with organizations overseas, the U.S. is gaining key insights and critical partnerships to better meet offshore training and supply chain demands for a successful industry. | PA G E 2 6

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A global forum for offshore wind WELCOME the World Forum Offshore Wind (WFO), a newly founded not-for-profit association exclusively dedicated to fostering the global growth of offshore wind.

According to the WFO, it will work with governments around the world to discuss and advance the key political parameters required to deploy offshore wind energy. This includes encouraging politicians to take action and introduce legislation that permits offshore wind farms.

The organization was founded by nine international companies, which together, represent the offshore wind value chain. The Business Network for Offshore Wind, which represents over 200 member businesses in the United States, has joined the WFO. “Offshore wind has taken off in so many countries during the past two years, especially in the U.S. New markets are opening, and our success will depend largely upon global coordination and growth of the offshore wind value chain,� said Liz Burdock, president and co-founder of the Business Network.

Learn more at wfo-global.org

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WIND WATCH 100 for 100% renewables SKEPTICS SAID it was impossible.

“We heard every version of ‘no,’ ‘can’t,’ ‘won’t,’ and ‘shouldn’t.’ We were laughed out of rooms,” shared Sierra Club’s Jodie Van Horn in an article called, 100 Cities Agree: 100% Clean Energy For All. (Read the full article at tinyurl.com/100CitiesCommit) Van Horn says it’s been three years since Ready For 100 launched, a Sierra Club initiative that pushes for the United States to commit to 100% renewable energy.

The campaign is well underway, recently reaching a milestone: 100 cities and towns across America have officially committed to transitioning to 100% clean energy.

Cincinnati, Ohio is credited as the 100th city to join the ranks of communities ready to fully commit to renewable power.

“One in seven Americans — 48.7 million people, total — now live in a place committed to 100% clean, renewable energy,” writes Van Horn. That’s impressive and the Sierra Club and its members deserve full credit for the efforts as we work toward a country that’s powered by clean energy.

A full list of the cities that have committed to clean energy can be viewed at sierraclub.org/ready-for-100/commitments

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Putting training first

LAST FALL, the New York State Energy Research & Development (NYSERDA) released its “2018 New York Clean Energy Industry Report,” which found that over 151,000 workers were employed in the clean energy sector in the state. More than 5,600 jobs were added just in the last year and more are expected.

In fact, the state announced $27.5 million in new funding for workforce development and training initiatives to help prepare New Yorkers for the clean energy industry’s growing job opportunities.

With the growth of renewables — new data from the Federal Energy Regulatory Commission suggests renewable capacity could be quadruple that of fossil fuels by 2021 — education and training are essential.

For example, in Georgia, Fort Benning Career Skills launched a new course last year to help

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transition soldiers and veterans to jobs in wind power and other renewable industries. (Side note: According to the American Wind Energy Association, veterans find jobs in the wind industry at a rate of 72% higher than the average U.S. market.)

With several U.S. offshore wind projects in the pipeline, the University of Delaware launched the first offshore wind skills training program in the country: the Offshore Wind Skills Academy.

According to the University, the Academy will focus on the skills necessary to build a domestic industry such as permitting, environmental assessments, and local suppliers and vessels.

In addition, a trio of Massachusetts-based institutions for higher education signed to Connect4Wind, with an aim of sharing resources and collaborating on the development of curriculum and programs centered on the offshore wind energy sector in the U.S. (Read more about this initiative in the article on page 26).

The U.S. Business Network for Offshore Wind has a host of training events available at offshorewindus.org/training.

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WIND WATCH How many wind turbines would it take to power the world?

RESEARCHERS ESTIMATE that wind farms have the potential to produce up to 40 times the electricity the world consumes, but these projects currently provide only about 4% of the world’s electricity. However, improved infrastructure and higher voltage cables have drastically reduced the cost of wind power. It is predicted that by 2040, a third of global power will come from renewables such as wind and solar energy.

A new infographic by RS Components, entitled, “How Many Wind Farms are Needed to Power the World's Major Cities?” shows just how many wind turbines are needed to power the top 25 global cities today. Tokyo takes the top

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spot, with a total of 10,310 offshore turbines required, while Milan has the lowest amount at 238.

To work out the number of turbines needed, each city’s annual energy consumption was divided by the amount of power the example turbine (the same one each time) can generate in a year. Data was compiled from the International Energy Agency (iea.org) and the European Wind Energy Association (ewea.org).

Readers can go to tinyurl.com/WindPowersWorld, use the “sort-by” functions, and find your city (or the nearest one to it) to learn how many offshore turbines it would take to power your region.

WINDPOWER ENGINEERING & DEVELOPMENT

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WIND WATCH Meet the enhanced GWO training standards EVERY CONSTRUCTION SITE presents certain risks or hazards and this is particularly true of wind sites. Wind farms pose a safety challenge to techs and engineers because of the chance of falls and dropped objects. The harsh conditions typical at wind sites only heighten these concerns.

Strong wind gusts or frigid temperatures can quickly and unexpectedly threaten a site’s level of safety.

To mitigate such hazards, Global Wind Organisation (GWO) has been working diligently to promote and increase safety standards in the wind industry. GWO is a non-profit, member-based organization established by wind-turbine manufacturers and owners. Members collaborate by sharing evidence and risk information and, according to the GWO, this helps the industry “identify work activities where the creation

of standardized training can enhance safety for technicians and deliver various productivity benefits.”

A worldwide network of certified training providers is essential to delivering GWO standard training. At the start of 2019, there were nearly 300 training sites in 37 countries.

Just last year, 68 new sites opened, including three new training facilities in the United States and one in Canada.

An additional six U.S. training sites are expected to gain certification over the next 18 months as the country’s supply chain gears up for offshore wind on the Eastern Seaboard.

GWO recently released its 2019 work plan that includes several enhanced “task specific” training standards.

“Our work plan in 2019 is agreed upon by 16 leading global companies that are the world’s largest employers

GWO members developed the Basic Safety Training Standard in 2012 and today more than 70,000 people, including over 1,000 Americans, have received the training. The organization’s new Blade Repair Standard is scheduled for release in April of this year.

Learn more at globalwindsafety.org

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WIND WATCH in wind energy,” said Eloy Jauregui, Chairman of GWO and Safety Director of Acciona Energia. There will be a mixture of projects reaching completion — like the Blade Repair Standard.”

Jauregui refers to the wind industry’s first global training standard for blade repair technicians, set for release on April 1, 2019. The GWO Blade Repair Standard Working Group is currently pilot testing the training, which aims to align the training programs of different manufacturers and deliver a standard benchmark of skills for blade inspection and repair technicians.

Another priority for GWO is aligning its standards with other similar training programs in the industry. For example, it has already completed this process against entry-level wind technician trainings from its members such as Vestas Service D and Siemens Level 1-4. Thanks to a short ‘gap training’ session, techs who’ve earned one of those manufacturers’ training can receive a GWO Basic Technical Training standard certificate, which is recognized by all 16 members of the organization.

“All GWO training can be merited against similar training by using gap analyses,” explains Jakob Lau Holst, CEO of GWO. “This identifies how similar the training is and if there are any gaps where the existing training needs to be 'topped up.’ On the other hand, a training course could deliver all the learning objectives of a GWO standard already and the technician deserves a GWO certificate.”

The important thing, explains GWO, is that standards are about comparing apples with apples.

“We are speaking with organizations across the United States, such as labor unions and other training bodies who already deliver courses,” says Lau. “If their training can be compared to a GWO

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standard and the differences ironed out, it will benefit everyone because we all recognize the same thing.”

The final piece of the puzzle at GWO is the way certificates are awarded and stored. Certified training providers upload them to WINDA, the wind industry database. WINDA then helps employers verify the status of GWO-certified training providers and the training status of delegates who have attended GWO training courses.

Information about WINDA is available at globalwindsafety/winda.

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Wind work around North America There’s good news for 2019. According to a new report from the U.S. Energy Information Administration, new electric generating capacity will primarily come from wind, solar, and natural gas. What’s more is that nearly half of the utility-scale capacity additions will consist of wind power (at 46%). Currently, about 10.9 GW of wind capacity is scheduled to come online in 2019 though most will start operations closer to December. Three states will take the majority of the credit and be home to more than half of the year’s planned wind capacity additions. Congrats, Texas, Iowa, and Illinois.

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Connecticut’s Public Utilities Regulatory Authority officially approved Ørsted’s longterm power-purchase agreement with two local utilities (Eversource and United Illuminating) for the 200-MW Revolution Wind offshore project.

Oceanographic and geophysical survey work began in 2018. Offshore installation work for the project will begin in 2022 with operations expected in 2023.

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Invenergy has begun commercial operations of MidAmerican Energy’s utility-has scale battery storage system in Knoxville, Iowa. The project aims to enhance the reliability of renewables by storing energy produced when wind speeds or sun exposure are high. The lithium-iron phosphate battery project can provide four megawatt-hours of storage capacity, supplying one megawatt of power for up to four hours.

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Texas gets Enel’s largest U.S. wind farm

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Enel has begun construction on the near 450-MW High Lonesome wind farm in Upton and Crockett Counties in Texas. The project is financed through the company’s own resources and should enter operation by the end of 2019. It will generate about 1.7 TWh annually, avoiding the emission of over 1.1 million tons of CO2 per year.

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New York sets major offshore wind goal As part of a Green New Deal, New York Governor Andrew M. Cuomo proposed an ambitious mandate of 100% carbon-free electricity in New York by 2040 — the most aggressive goal of its kind in the U.S. Cuomo set a goal of quadrupling the state’s offshore wind target to 9,000 MW by 2035, up from 2,400 MW by 2030.

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MidAmerican’s battery storage system goes online

Shell to repower California wind farms

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Shell Energy North America and Coachella Hills Wind recently signed a long-term PPA to procure up to 100 MW of wind energy from the Coachella Hills Wind project developed by Terra-Gen. The contract is to repower the existing Coachella Flats and Painted Hills wind projects with an expected online date of December 1, 2020

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Alberta getting more wind power EDF Renewables signed a 20-year Renewable Electricity Support Agreement with the Alberta Electricity System Operator for the 201.6-MW Cypress Wind project. The contract represents a partnership between EDF and the Blood Tribe, a Canadian Native Tribe. Cypress Wind should create more than 250 jobs at peak construction with full operations starting in 2021.

www.windpowerengineering.com

Boston home to new MHI Vestas headquarters MHI Vestas Offshore Wind has picked Boston for its new U.S. headquarters. One of the company’s first goals at its new location is to progress its plans for the 800-MW Vineyard Wind project. Vineyard Wind will feature Vestas’ V164-9.5 MW turbines and is scheduled for installation in 2021. It will be the first large-scale offshore wind farm in the United States.

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New offshore wind tax credit in Jersey New Jersey companies making a capital investment in offshore wind facilities within the seven southern counties of New Jersey can now apply for tax credits through the state’s Offshore Wind Tax Credit Program. The new program is a financial tool to spur private investment and employment growth in major offshore wind industry projects by providing reimbursement for eligible capital in the state.

FEBRUARY 2019

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INVESTMENTS

Offshore wind projects provide unique challenges for developers relating to environmental and siting regulations, offshore transportation and worker safety, weather conditions, and wind-farm uptime.

It is important to seek the advice of a qualified underwriter to mitigate project and insurance risks.

A Q&A WITH SENIOR UNDERWRITER, JONNY ALLEN

Insuring offshore wind farms:

What developers need to know

OFFSHORE WIND is quickly gaining momentum in the United States. The last year brought a wealth of new news stories related to offshore auctions and state commitments to developing wind farms, particularly in the Atlantic. Although the focus has been on siting and environmental permitting, one critical aspect of new wind project development is insurance.

Offshore wind turbines are at greater risk of component failure and downtime compared to landbased turbines because of the stronger winds, higher moisture, and harsher conditions at sea. There are also risks to wind technicians and workers requiring vessel trips to and from a project site, which presents additional challenges — such as the taller towers

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typical of offshore wind turbines and less stable platforms when moving from vessel to turbine.

To answer questions related to insurance and offshore wind, we spoke with Jonny Allen, Senior Underwriter and Head of Offshore Wind at Travelers, a global insurance company. Here Allen shares his insight on the industry based on his years of wind experience in Europe.

Q. What considerations should project developers give to insurance for offshore wind projects?

A. Each offshore wind project brings unique challenges and complexities based on several factors including size, scope, location, and type of stakeholder. We learned early on that the offshore wind claim process is different from that of onshore wind, particularly given the marine element.

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W I N D P O W E R E N G I N E E R I N G .COM

When something goes wrong, there can be several potential root causes and pinpointing which one caused the loss can be difficult. For this reason, it is critical to have a solid insurance policy in place.

This is partially why the role of an underwriter is so important.

Underwriters understand the industry, claim process, and coverage options, and can work with customers to make sure their specific issues and needs are addressed while helping to mitigate risk.

Q. As interest in offshore wind grows in the U.S., what are some of the biggest challenges you foresee?

A. Some of the biggest challenges we see relate to factors like scaling technology, construction methods, geography, climate and weather, natural disasters, regulations, and conservation policies.

Some of the more significant challenges include: • Wind events: Parts of the U.S. experience hurricanes, a weather-related scenario the industry has yet to face.

As such, there is a lack of modeling to pull from or consensus on data because these geographic areas are newcomers to offshore wind. No one fully understands how wind turbines can stand up to those heavy winds in the U.S. Will a typhoon-class turbine work in hurricanes, or will further design changes be necessary? While the wind season is relatively defined in the U.S. and a developer could plan to install turbines outside of that timeframe, what happens if a project is delayed?

• Local content: In the U.S., many questions remain for the industry. For example, will future offshore wind projects have workarounds, such as using non-U.S. vessels to perform installations and U.S. vessels to ship items to the site? Will the country build its own specific vessels or be granted waivers to the Jones Act? How will the inland transit of large items be handled? Finding a balance between cost-effectiveness and stimulating the economy is important.

• Contractor experience: Experience is an extremely important factor when selecting a contractor but finding one can be challenging in an emerging territory. While Europe has contractors that are specific to offshore wind, it did not begin this way. The U.S. will have to decide carefully on an approach: work with smaller contractors with specific offerings or established energy operators that are adapting their existing offerings for offshore wind installations?

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INVESTMENTS

Q. How might local supply-chain requirements for offshore wind projects impact insurance risk?

A. While the demand for minimum local content supports development, it’s important for offshore developers to balance cost-effective procurement with project risks. We have seen claims as a result of inadequate supply chain factors such as poorquality materials, inexperienced subcontracting, and incorrect transport and storage.

Underwriters would rather charge less to support a project if risk management through quality supply and contracting can be demonstrated at all levels. Underwriters can help with this by communicating what this can look like well before the project breaks ground.

Q: What’s driving the increase in turbine size and how does it impact insurance?

A. Today, we’re seeing wind turbines six to nine megawatts in size, some of which have a wingspan the size of the London Eye. In the next five years, capacity will more than double to 15 to 20 megawatts, with tower sizes that exceed 250 meters. Larger rotors harvest greater wind energy and can reach stronger, steadier winds at higher altitudes.

Bigger turbines can produce greater outputs and maximize ROIs. Additionally, such projects can use fewer turbines, which can result in shortened, cost-effective installation timeframes.

However, the growing size of turbines is leading to engineering challenges and new insurance considerations, including larger limits and additional exposure. For example, taller towers and bigger blades are more difficult to transport and install, requiring specialized vessels and crew.

For some offshore projects, this can also mean engineering plans that are costly, projectspecific, and dependent on a single piece of equipment (such as a specialized vessel or crane).

If lost or damaged, this can cause major delays.

Moreover, insurance companies have little data to project how these turbines will stand up to major windstorm events.

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INVESTMENTS

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Q. Are there lessons that can be learned from the windfarm installations in Europe?

A. Absolutely. The U.S. wind industry can benefit from understanding how Europe has dealt with technological challenges, offshore turbine installations, cable and power transmission issues, and costs.

Consider a German model, for example, which clusters multiple project sites and uses a separate company to provide the transmission networks for the wind farms back to the main electric grid. This encourages competitive bidding for wind projects and reduces risk by removing the requirement for each developer to build long and costly grid connections for each project.

Interestingly, many of the problems encountered in the industry’s early days are still prevalent 10 years later. Given the inherent complexities of offshore conditions and the composition of the seabed this makes sense. It also means the lessons that have been learned to date are vital as the industry continues to grow and develop.

Q. Any final tips for choosing an insurance plan?

A: Choose an insurer with experienced offshore wind underwriters who have spent time in the field, going on to vessels and up turbines, speaking with people involved in the projects and getting to know the assets they’re insuring. Underwriters that truly understand the business of wind energy can help developers find the right balance of coverage based on their specific needs. WPE

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COMPONENTS

W I N D P O W E R E N G I N E E R I N G .COM

ta k i n g t h e g r i n d o u t o f

ground rings WHILE THE PROMISE OF OFFSHORE WIND is grabbing many headlines of late, it is onshore wind that is currently producing the majority of the renewable electrical energy in the United States.

For the most part, onshore wind turbines are set at capacities of two to three-megawatts, meaning component reliability is key to production.

Given the harsh conditions in which turbines operate, this is typically easier said than done. Therefore, it is important to ensure all turbine components are subject to regular operations and maintenance checks — including for small devices, such as ground rings and brushes.

Understanding ground rings One operational challenge onshore wind operators face is the phenomenon

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of ground-ring grooving. Wind-turbine ground rings help divert powerful shaft currents, which may reach 60 amps/1,200 volts or even higher. Their core function is to prevent damage to bearings and other equipment.

Ground rings work by transferring current through the use of brushes, which are typically held in contact with the ring with a constant force spring.

This means that as long as there is contact, the current will be diverted effectively. The brush is an electrical conductor that works with slip rings and brush holders, protecting vital components from parasitic currents and static electricity.

Worn or low-quality brushes can wear on a slip ring, causing it to degrade prematurely or force early component replacement.

GEORGE FINLEY WIND SEGMENT MANAGER ELECTRICAL CARBON BUSINESS MORGAN ADVANCED MATERIALS

In addition, wear and tear may result in misaligned shafts and components — which also cause wear on components. For example, brushes may become misaligned and lose contact with the vibrating slip ring.

Unfortunately, it takes little movement for this to occur and even a variation of one or two degrees can impact proper function. If this happens, the air gap between the ring and brush causes a high inductance of the circuit and arcing electrical currents will slowly erode the metal. This leads to grooves in the slip ring and, occasionally, may affect the bearings, too.

As the metal erodes and grooves deepen, it creates a growing gap between the ring and holder, causing greater instability between the slip ring and brush. This effect has several

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COMPONENTS

names and is referred to as footprinting, ghosting, or photo imaging.

The WTG1 brush box holder form Morgan Advanced Materials are manufactured from aerospace -grade materials. The radial mounted brush holders eliminate friction chatter that occurs when brushes are placed in a stubbing or leading orientation. Constant force springs deliver equal and proper brush pressures for a low wear differential from brush to brush.

An arcing risk Arcing has the potential to cause far more damage than reduced ground ring effectiveness. When metal erodes, the result is a sandpaper-like surface with fine dust particles layering the brushes. This dust contains conductive material (carbon and copper), which may cause a current to flow between phases or phase to ground. This may lead to a destructive flashover or, even worse, an electrical explosion. The result: catastrophic damage to the wind turbine.

Damage to the turbine components must then be assessed and repaired.

For example, the slip ring may require

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COMPONENTS

W I N D P O W E R E N G I N E E R I N G .COM

A FEW IDEAS WHEN REPLACING GROUND RINGS It’s rarely possible to replace ground rings up-tower. Typically, the entire slip ring assembly in a wind turbine requires removal to access the ground ring. And slip ring assemblies are extremely heavy, often in excess of 200 lbs (75 kg). Proper lifting equipment and at least two technicians are necessary.

Clear safety precautions are a must to avoid worker injury and equipment damage.

Ensure techs are properly trained and employ well-fitted, quality fall-protection gear. This is a given but never risk personnel safety to save costs.

re-machining in-situ or offsite repair.

Failing that, replacement is necessary at the cost of up to $5,000 per ring.

If new bearings are needed, expect a cost of between $5,000 and $10,000 each. What’s more: when brushes lose contact with the ground ring, costly damage to electrical equipment and circuit boards is likely. And a single day of downtime represents an estimated $1,500 in lost revenue.

To reduce the likelihood of such a destructive event from occurring, wind operators typically use a brush holder that accommodates two brushes — covering some 40° (1/9th) of the ring.

The idea is that if one brush loses contact, the other works as a failsafe.

However, in practice, this creates a ‘bouncing’ effect between the two sideby-side brushes — called friction chatter — and causes both to lose contact simultaneously. In addition, brush holders come as fixed and unmodified devices and are generally placed a fair distance from the ring, which does little to fix the problem.

g

An adjustable idea A new idea to reduce slip ring and brush wear uses a fully adjustable drop-in replacement ground brush holder system. Instead of two brushes,

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To prevent slip-ring damage, consider using a durable rubber mat as a protective surface for the ring. For example, the mat can be used to protect the new ring in the lift bag while transporting it up-tower. It can also be used during the transitions from the yaw deck to the nacelle, and again as the ring is moved within the nacelle and into position on the generator shaft.

After the slip ring and holders are removed, take the time to thoroughly clean the slipring compartment. Removing all brush dust and grease is the best way to prevent early contamination in the new slip rings and brushes.

this new invention deploys four within the same mounting space. This means upgrading is straightforward and simply involves unbolting and removing the old brush holders, and bolting in the new one.

These brushes are durable and manufactured from aerospace-grade copper graphite material. The material is specially treated to withstand low and high humidity environments, and forms a low friction film or patina on the slip ring. The low-friction film reduces friction chatter (the ‘bouncing’ of the brushes) and dusting, and extends the brush life. Additionally, the proprietary treatment is not a sticky resin so, if dust occurs, it is unlikely to collect or stick, making brushes easier to clean.

The carbon holders are also fully adjustable to increase the distance between brushes and improve stability and contact.

This gap provides up to three times the coverage of the typical OEM design in a turbine.

Other features include quick disconnect brush terminals for

An example of a damaged ground ring with grooving caused by arcing between the ground ring and the brush face.

simple maintenance or replacement.

The unit cost of this new brush holder is also significantly lower than for a replacement ring or bearing, and particularly when turbine downtime is considered for component repairs.

Reliability is critical in wind applications that must withstand harsh conditions. A word to the wise: consider wind-turbine components carefully, even the small ones, and mitigate the risk of wear whenever possible. WPE

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Met towers, meteorological measurement tools used for wind siting, typically require siting permits that can take months to obtain.

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Kimberlee Centera

C E O & Fo u n d e r | Te r ra P ro S o l u t i o n s

factors TO CO N S I D E R B E F O R E

repowering A WIND SITE

At one time, wind developers planned for decommissioning at the end of a wind farm’s lifecycle. However, the availability of more efficient components and turbines means that trend is changing. Repowering is now an important option for some aging wind sites, but it is a process,

C

and there are many policy, permitting, and cost factors to consider first.

alifornia’s Governor recently signed SB100 into effect, declaring 100% renewables by 2045. Coupled with SB700, which extends incentives for state energy storage systems, the world’s fifth largest economy has made a clear and strong commitment to sustainability and clean energy. But what does the new legislation mean for those working in the wind industry,

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and particularly in California where land is scarce and property values are sky high?

Some suggest that existing sites containing legacy renewable projects, such as the wind farms in the Altamont Pass in Northern California, Tehachapi Pass in Kern County, and the Palm Springs Basin of Riverside County, may prove key to meeting the state’s cleanenergy targets. Smart developers

and utilities seeking to capitalize on existing wind regimes, and proven revenue streams are likely to re-energize existing projects.

This means that repowering outdated wind farms may become the new “green” in California.

What is repowering exactly?

Essentially, repowering updates an aging wind project. This

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SIX FACTORS TO CONSIDER BEFORE REPOWERING A WIND SITE

RECOMMENDATIONS FOR REPOWERING Prior to committing to repowering an older wind site, consider this checklist.

•

Identify local and regional zoning and permitting requirements for a wind project, including restrictions on property, public rightof-way, as well as visual and safety setbacks.

•

Assess and determine which new turbine technology will conform to the proposed site.

•

Model the legacy operating wind data.

•

Confer with the Department of Defense.

•

Submit the turbine coordinates to the Federal Aviation Administration.

•

Undertake “Phase I Environmental Site Assessment.”

•

Evaluate the feasibility of operating the project through the remaining Power Purchase Agreement (PPA) term and compare the results to repowering the current wind turbines.

•

Review real-estate agreements to determine suitability for repower and economic impact of regeneration or extension.

•

Identify new potential off-takers and negotiate a new PPA.

•

Model the feasibility and suitability of hybrid technologies.

may mean replacing several windturbine components and turbines, or the full fleet of turbines and towers at a site. Additionally, repowering may modernize interconnection infrastructure, construct or redesign new roads, or add more turbines to the project.

Typically, the aim is a wind farm with a greater and more efficient generating capacity than before.

Using California as a model, there are many considerations that may impact the development of a repowered site.

Here are six important factors to assess or contemplate prior to moving forward with a repower project.

1. Changes in national or local laws and jurisdictions Projects developed in the late ’80s and early ’90s are now subject to changes in laws and regulations affecting local and regional jurisdictions. Previously, certain jurisdictions permitted projects in parts, under separate departments.

For example, a developer may have consulted with several different authorities at the federal, county, or city level for permitting of safety setbacks affecting turbine height approval.

However, this required simultaneous consultation with different entities and meant that a developer must then synthesize these conditions into the site plan for the Conditional Use Permit (CUP). A CUP grants use of land in a particular area for permitted construction.

Fortunately, some entities have since formed coalitions to streamline the compliance process. Riverside County is one example where the Bureau of Land Management, City of Palm Springs, and County of Riverside developed a comprehensive process for defining and subscribing to visual and safety setbacks. When evaluating the value in repowering a wind project, careful review of current requirements and restrictions in local jurisdictions are imperative to ensure the new plans are lawful. Legal changes can also affect the timeline and costs for a repowering project, particularly if a developer is hoping to take advantage of incentives, such as the Production Tax Credit (which expires in 2020).

A map of California’s Altamont Pass, Tehachapi Pass, and Palm Springs Area, where legacy wind projects are likely to attract repowering efforts.

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2. New wind-turbine technology Turbine technology has dramatically improved over the past 20 years.

The result: the average capacity factor (a measure of power-plant productivity) for wind turbines installed before 1998 was about 22% and today it’s at nearly 35%, according to the Office of Energy Efficiency and Renewable Energy.

In addition, wind energy costs have decreased from a little over 55 cents (current dollars) per kilowatthour (kWh) in 1980 to an average that is under three cents per kWh in the United States today. Lower costs and increased efficiency are providing developers with important incentives for monetizing repowered projects.

3. Contract structure of real property agreements A detailed review of the project’s original site control documents is another important step to identify limiting or restricting factors that may affect a repowering project. For example, an existing contract may exclude property that is pertinent to new turbine additions or contain prohibitions on road restructuring.

In addition, any lease term in California that exceeds 35 years is considered a “beneficial transfer of real property,” according to the local assessor, which may result in hefty additional real property taxes and assessments. Typically, wind lease agreements require the developer incur the cost of assessments relating to new installations or site improvements.

So this cost must be quantified and accounted for over the term of a project in the repower project financial model.

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TO REPOWER OR GREENFIELD? A greenfield is a new wind project on land that’s previously undeveloped and without a permit. One of the first steps of a greenfield development is an assessment of the local permitting agencies to determine the likelihood of a new wind project.

This process should include a thorough review of the requirements to determine restrictions that may impede new project plans, such as permitting risks (think: safety, visual, or viewshed setbacks). Timing is also a critical factor for the start of project construction and delivery of power to a utility off-taker. Early assessments of potential schedule delays or unexpected costs are critical to project success.

Another early make-or-break factor of a new wind project is local community support. For example, the first meteorological tower at a project near San Diego County, California, took 12 months to permit and install at nearly $1 million. A met tower is a wind measurement device used to determine project siting and turbine placement.

In this case, the met tower required an administrative permit necessitating an extensive public relations push, including community presentations and a vote by the county board of supervisors.

One advantage of a repower project is that it’s typically safe or “de-risked” from community and jurisdictional concerns because the wind farm already exists. Therefore, legacy operating and existing wind data can mitigate many of the principal challenges facing developers on a repowered development project.

4. Environmental and permitting considerations Depending on the location and ownership of the project property, a series of agencies including federal, state, county, water authorities, Bureau of Indian Affairs, may have the right to exercise jurisdiction over the project.

For example, the California Natural Resources Agency is one of many agencies that oversee and enforce environmental and permitting regulations throughout California.

Turbine size may also affect the permitting regimes. Larger wind turbines, for instance, use more space and may require additional compliance steps and approvals.

The Federal Aviation Administration (FAA) maintains jurisdiction over the location of wind-turbine locations and improvements.

It is important to prepare a pre-submittal of the proposed turbine locations to the FAA for clearance prior to (or concurrently with) permitting and environmental review of the project. Similarly, the Department of Defense (DOD) imposes jurisdictional

Repowering essentially updates an aging wind project.

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SIX FACTORS TO CONSIDER BEFORE REPOWERING A WIND SITE

requirements over wind projects so a preliminary discussion with the local DOD office is recommended as a gating item in the initial review of the wind project and turbine locations.

According to a 2017 Energy Information Administration report, repowering can increase wind turbine fleet output by 25% and add up to 20 years to the life of the turbine.

5. Power purchase agreements or PPAs Wind projects are typically developed with 15 to 20year PPA terms. Repower projects are often facing the end of their initial PPAs — the document that states the underlying revenue stream and financial security for the project. For this reason, careful consideration and implementation of a viable strategy are necessary for operating the wind project through the expiration of its PPA term. Additionally, redevelopment of the wind farm, which may require a new design of the project and decommissioning of the existing wind turbines, means new negotiations or agreements.

To properly evaluate the economic impact of early decommissioning of the wind turbines or running the turbines through the entirety of the PPA term, feasibility modeling is highly recommended.

Together with the expiring PPA, consideration must be given to the negotiation of a PPA with the existing off-taker or a new one.

Many alternatives are available for PPA’s today that were previously unavailable, including hedge arrangements and corporate PPA’s with off-takers such as Facebook, Starbuck’s, Google, and General Motors.

6. Integration of hybrid technologies Hybrid renewable projects are now an option for many developers. Pairing wind with solar or battery storage may enhance and improve the economics and reliability of such projects while providing greater energy generation efficiency.

Although battery storage is still in its infancy, it can reduce concerns relating to the variability of wind power — storing energy when winds are strong and providing power to balance the grid when winds are low.

Storage is likely to become a key consideration for developers looking to maximize revenues and generation flexibility when repowering wind farms. WPE

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Michelle Froese | Editor

Working together for

offshore

wind success

One way the U.S. offshore wind industry can optimize project developments and better ensure ROIs is to learn from the experience of others — and that’s precisely what those spearheading the offshore sector in the country are doing. Europe and the UK are decades ahead in offshore wind, so the United States is seeking advice, lessons learned, and success stories from overseas to better ensure a smooth start. What’s clear so far: education and collaboration are the keys.

T

he Humber, UK is quickly becoming the benchmark location for offshore wind. A large tidal estuary on the east coast of Northern England, the Humber offers a significant hub for wind development and marine experience that essentially spans the full lifecycle of an offshore wind farm. And while the region is serving the United Kingdom and Europe quite well, those working in the industry are more than willing to share their lessons learned and expertise.

“It’s the envy of the world,” shared Ray Thompson, Head of Business Development with Siemens Gamesa, at an Offshore Wind Connections conference in Hull last year. Ports on the Humber include the Port of Hull, Grimsby, and Immingham. “Ten years ago if you wanted to see how the wind

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The U.S. Department of Energy estimates some 43,000-plus new jobs will come from the offshore wind market by 2030.

According to one report, the UK installed over 50% of all European offshore wind capacity brought online last year. The country is now extending its reach and offering offshore wind support to the United States.

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industry worked you went to Bremerhaven in Germany. Now everybody wants to come to Hull to see how it’s done.”

Indeed, the region has paved the way for Ørsted’s Hornsea Project One (the world’s first offshore wind farm to exceed 1 GW) and Project Two, and others such as the 860-MW Triton Knoll that began construction in 2018. In fact, Ørsted currently employs some 350 workers at its rapidly expanding East Coast Hub in Grimsby.

Siemens UK also invested heavily in its windturbine production facility at the Alexandra Dock in Hull, which is proving invaluable.

A 2017 report released by trade organization, RenewableUK, found that UK-based companies provided nearly 50% of the total content of British offshore wind farms and that the country was exporting turbine-related components to countries such as China, India, Taiwan, and the United States.

However, organizations such as Team Humber Marine Alliance (THMA) are ensuring more than just components are sourced from the UK. “To maximize the huge potential of offshore wind, globally, it takes great collaboration,” says Mark O'Reilly, CEO and Chairman of THMA. The Alliance is a collaborative UK-based membership organization that works to support, educate, and facilitate work within the marine, maritime, and offshore wind sectors.

“Our aim is to bring together governments, industry, academia, and training to ensure proper accreditations and effective supply chains for a successful offshore industry across the world,” adds O'Reilly. In fact, THMA organized the Offshore Wind Connections conference in Hull and was part of a delegation that took part in the New Bedford Offshore Wind Symposium in late 2018 — with a focus on a UK and U.S. collaboration. Those delegates also visited New York and New Jersey to answer questions and offer guidance to local wind leaders, including government.

“There is enormous interest from organizations and at the state level in the United States about how the Humber and other offshore wind hubs in the UK have overcome offshore challenges, such as environmental, educational, and supply chain ones,” says O’Reilly.

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WORKING TOGETHER FOR OFFSHORE WIND SUCCESS

Building a skilled workforce The U.S. Department of Energy estimates some 43,000plus new jobs will come from the offshore wind market by 2030. This is good news for the economy and job force, however, adequate training is essential — and particularly in the U.S., which only has one five-turbine offshore wind farm to date.

“Like any new industry, it’s a blessing but there are challenges,” suggests O’Reilly. “The offshore wind industry is a tough one given the stringent environmental and manufacturing standards, and the harsh marine conditions. Typically, at least for wind techs, it’s not a 9-to-5 gig either.”

However, there is diversity in the sector, which opens the market up to many fields, he adds. “For The U.S. could tap into a vast offshore wind energy resource and better steward its marine environment by galvanizing large -scale research and example, when Siemens UK opened its blade fostering public-private partnerships, according to a report by POWERmanufacturing plant in Hull, nearly 800 production US. The study is the result of a two-year initiative convened by the operatives were needed for work and can you believe Massachusetts Research Partnership in Offshore Wind — a partnership of several academic and research institutions.

22,000 people applied?” These are very different jobs than those of vessel operators, but just as critical to the Liz Burdock agrees. She is the cooffshore supply chain. “Regardless of the task, education and adequate training founder and executive director of the with a focus on the unique demands of the offshore wind sector are keys to Business Network for Offshore Wind success.” (the Network), a national non-profit To this end, three Massachusetts-based institutions for higher education organization dedicated to building (Bristol Community College, Massachusetts Maritime Academy, and the University the U.S. offshore wind supply chain. of Massachusetts Dartmouth) signed up for Connect4Wind in 2018, with the aim “We’re likely going to see a stack-up of of sharing resources and collaborating on the development of curriculum and multiple offshore wind projects ready programs centered on the for construction around 2021, and my offshore wind energy sector concern is that we won’t have adequate in the United States. supply-chain capacity or enough “For Bristol Community businesses to ensure these projects get College, this is one of several built in an efficient and timely manner.” partnerships that further Burdock visited Europe late last year solidifies our commitment to to meet with and recruit businesses offshore wind training and to support U.S. offshore wind efforts. the creation of jobs,” a release The Network has already established about the Connect4Wind a close connection with THMA. “We stated. Bristol is currently certainly don’t want a displacement of local U.S. businesses and I want to stress that,” she adds. “But partnerships are big, particularly when experienced The Massachusetts Clean Energy Center recently published an European or UK companies can assessment of the jobs and support and collaborate with our own economic impacts associated with the development of 1,600 MW in local businesses to ensure projects are Massachusetts. That study estimates built to meet capacities, deadlines, and that over the next decade, offshore wind projects will create nearly 3,000 budgets.” jobs and generate economic impacts between $1.4 billion and $2.1 billion.

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the only facility to offer an associate’s degree program in offshore wind in the U.S. “It also ensures that the region’s higher education institutions will be able to support the offshore wind industry with highly skilled workers, innovative training programs, and the shared use of specialized facilities well into the future.”

The University of Delaware also recently launched one of the first offshore wind skills training program in the country, with introductory classes beginning in 2019. According to the University, the new Offshore Wind Skills Academy will focus on the skills necessary to build a domestic industry such as permitting, environmental assessments, and local suppliers and vessels.

“The northeast states in the U.S. have committed to 10,000 megawatts of offshore wind to be built in the next 10 years,” said Willett Kempton, a new director of the Offshore Wind Skills Academy, in a recent press statement.

“That is the equivalent of building an entire nuclear power complex each year for the next 10 years.”

Meeting this demand will undoubtedly require significant effort

by American companies interested in entering the offshore market and global offshore wind companies learning about operating in the U.S. “Establishing a new industry takes drive, initiative, and the people to push it forward and support it,” says O’Reilly.

“Given our time in the U.S. with the Alliance, I’ve seen that in the country already. I think the U.S. will do well.”

Drawing from experience One reason O’Reilly predicts a successful offshore wind market is its openness to support. “It's all about collaboration,” he says. “The Alliance encourages partnerships and joint

WINDPOWER ENGINEERING & DEVELOPMENT

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WORKING TOGETHER FOR OFFSHORE WIND SUCCESS

ventures because often times that’s how a sector overcomes challenges and advances.”

He points to the strict offshore and environmental rules in the UK as one example. “Authorities such as the Marine Management Organization have been willing to support offshore wind developers so they can better understand and meet permitting laws.”

The United States is following similar footsteps. Last year, the U.S. Department of Energy awarded the New York State Energy Research and Development Authority (NYSERDA) $18.5 million over four years to establish a public-private consortium tasked with developing cost-effective, efficient methods for offshore wind installation, supply chain challenges, and O&M. The consortium already launched its first roadmap aimed at accelerating the deployment of offshore projects.

“The key is finding companies with complementary services and getting them to work together to foster opportunities that may have been lost without that relationship,” says O’Reilly. “It's a bit like matchmaking, connecting individuals and organizations, and then seeing what comes from it.”

A new report from the Partnership for Offshore Wind Energy Research (POWER-US) also finds that collaboration is one step to advancing the offshore industry in the U.S. The study says that the country could tap into a vast offshore wind energy resource and better steward its marine environment by focusing on large-scale research and fostering public-private partnerships. It notes that public investment in research and strong connections between academia and industry are what helped advance

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offshore wind energy in Europe.

Additionally, it describes how large-scale public support and the convening of complementary expertise were critical to the success of other large-scale U.S. scientific and engineering initiatives, such as earthquake simulation, oceanography, and materials manufacturing.

According to the report: “The emphasis on ‘convergence’ highlights the importance of a collaborative approach, bringing together expertise from a wide range of disciplines, including engineering, atmospheric science, logistics, economics, environmental science, and local communities and the marine industry, including fisheries.”

“Working with the fishing industry is another example of collaboration,” says O’Reilly. “I believe the U.S. is currently in talks with the fishing industry to ensure minimal impact and reinforce the opportunities to work together.”

Indeed, offshore wind developer, Deepwater Wind (acquired by Ørsted in November 2018) adopted a firstof-its-kind procedure to prevent impacts to commercial fishing gear

from offshore wind energy activities.

The procedure was developed with the commercial fishing industry and accounts for feedback from Atlantic coast fishermen.

Deepwater Wind determined that keeping fishermen informed is the key to preventing damage to fishing gear, and has included a process for gear loss and damage claims.

The Responsible Offshore Development Alliance has also partnered with Ørsted with the goal of improving communications between the commercial fishing industry and offshore wind developers. It offers an unprecedented opportunity for those who fish commercially to provide direct input to the wind industry on matters of interest to their business.

A core component of the partnership will be the creation of a joint industry task force to explore improved approaches to fair project siting, design, and operations.

“It’s really common sense,” shares O’Reilly. “Proper communication, collaboration, and education are bound to lead to a more successful outcome — and, in this case, industry.” WPE

Deepwater Wind was the first American wind developer to adopt procedures to prevent impacts to fishing gear. The offshore wind company was acquired by Ørsted in late 2018.

www.windpowerengineering.com

FEBRUARY 2019

2/10/19 8:10 PM

Harness the Power of Advanced Composite Repair in Your Hands 5-Day Courses

Abaris Training is the world leader in advanced composite training. We have trained more than 25,000 students since our inception in 1983, across a number of industries ranging from aerospace to automotive to marine to wind energy and more. Our goal is to teach the latest technology to our students in a friendly yet professional atmosphere. Currently we offer over 22 different courses covering many disciplines surrounding engineering, manufacturing, repair, and NDI of advanced composite structures.

All courses are taught by highly motivated instructors, all of which have vast experience and knowledge of composites and are acknowledged for being the top in their respective fields. In addition to training at Abaris facilities, Abaris can bring the training to you. Our Direct Services division specializes in organizing either off-the-shelf, or custom courses at customer facilities, worldwide.

www.abaris.com | +1.775.827.6568

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SAFETY

B I L LY L U D T | A S S I S T A N T E D I T O R | W T W H M E D I A

A wind tech’s guide to

dropped-object

prevention Learning the “Three T’s”

WIND-TURBINE TECHNICIANS face the challenging task of climbing a couple hundred feet or more uptower and safely transporting the tools required for working atop their towering workplace. This is typically done with proper tethering to ensure tools are securely fastened to a tech’s body while climbing and working at height.

Dropping objects from atop a 250-foot turbine tower carries plenty of risks. The greatest hazard is an injury to workers on the ground. A corner of the manufacturing industry has developed fall-protection products to keep tools secured, however, there has been a lack of enforceable standards for drop prevention while laborers work at heights.

Fortunately, last year brought new standards for dropped-object prevention. Although these regulations

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are voluntary, they represent a step forward in the safety industry. To ensure tools and gear travel securely up and down wind-turbine towers, there are also three simple rules — known as the “Three T’s” — that wind techs can follow to avoid dropped objects while working up-tower.

The standards In July 2018, the International Safety Equipment Association enacted the American National Standard for Dropped Object Prevention Solutions (ANSI/ISEA 121-1208), which, for the first time, created standards for manufacturing and testing equipment meant for drop prevention. The new standard is a step forward in the safety industry, but a voluntary one.

“It takes tool tethering from duct tape and rope, which most [workers]

www.windpowerengineering.com

are using out there, to engineered solutions that are that are safer to use,” says Nate Bohmbach, product director at Ergodyne, a developer of safety gear for construction and industrial workers. Until now, there has been little guidance for workers on what constitutes a proper tethering system.

Bohmbach points out that without a set standard, there is nothing to differentiate duct tape and string from a properly rated tool lanyard and attachment point. “The new standard formalizes tethering as a best practice,” he adds.

ANSI/ISEA 121-2018 also establishes minimum design, performance, testing, and labeling requirements for dropprevention products.

Ergodyne backed the new safety standard with international manufacturing company 3M. Bohmbach

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says it provides a rule sheet for the manufacturers designing dropprevention products and the workers using the gear.

“Now that we’ve led the way to develop this standard, our full attention is on helping workers understand what it means and how it can help them,” says Bohmbach.

To this end, Ergodyne employees have authored “The Three T’s of dropped objects prevention.” The three T’s stand for trapped, tethered, and topped. They are modeled after the ABC’s of fall protection.

• Anchorage: Attaching a lifeline to a secure point.

• Body support: Wearing a body belt or harness.

• Connecting device: The device, often a lanyard, which connects body support to an anchor point.

“It’s not just dropped-object prevention, Bohmbach says. “It’s safely managing your equipment to and from the work site and while at heights, and dropped objects is a huge part of that.”

The three T’s

By Ergodyne’s definition, trapping means to secure a tool with a retrofitted attachment point meant for tethering it to an anchor. This can be done with sleeves, slips for screwdrivers, brackets and wraps, or other attachments installed with tape and string.

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SAFETY

In July 2018, the International Safety Equipment Association enacted the American National Standard for Dropped Object Prevention Solutions, which, for the first time, created standards for manufacturing and testing equipment meant for drop prevention.

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SAFETY

Fatalities caused by falls from elevation continue to be a leading cause of death for construction employees across industrial sectors, according to the Occupational Safety and Health Administration (OSHA) in the U.S. Consider hosting a Safety Stand-Down at your company, a voluntary event for employers to talk directly to their workers about safety. OSHA’s National Safety Stand-Down raises fall hazard awareness across the country in an effort to stop fall fatalities and injuries. In 2019, it takes place from May 6 to 10.

Learn more at osha.gov/StopFallsStandDown

Tethering tools with a lanyard keep them secured to an anchor using a carabiner. Ergodyne carries lanyards that come in different lengths, including a coiled model that stretches.

Equipment can also be carried up a wind turbine using a topped bucket, bag, or pouch. Ergodyne’s topped products have tethering points and covers to keep contents from spilling out if inverted.

Although dropped objects and fall risks are two different hazards, one can lead to the other. “The obvious drop risk is an object striking somebody below. That’s why you prevent dropped objects,” he explains. “But we also teach in our training that this protects workers at height as well. A dropped object can lead to somebody trying to overexert and grab something that they've dropped, and it can throw them off balance and lead to a fall.”

Bohmbach compares this reaction to catching a pen that’s rolling off a desk. Now imagine accidentally losing grip on a cell phone or wrench when atop a wind turbine.

A similar reaction could result in an injury or a fatality.

Technicians typically carry hand tools, power tools, and monitoring devices, such as iPads, up turbines. Each of these items should be fastened to a technician or held inside a topped container. Any loose object is at risk of dangerously falling to the ground or inside the turbine and causing equipment damage.

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Typically, the objects that fall during work done while at height are not tools but items such as smartphones, tables, or keys. These objects should be stowed safely away in pouches that zip close and attach to carabiners through a steel ring.

www.windpowerengineering.com

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SAFETY

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“Anything that will help a climber keep his hands free and those tools tethered — basically our whole line could apply to wind power,” shares Al Buczkowski, marketing communications manager at Ergodyne. The company field tests products for about a month before bringing them to market. The drop-prevention gear is given to a trusted technician and used on a work site.

“It's really just listening to that end-user.

They’re the ones that know the problems and it's having a direct line with them,” Bohmbach adds. “Techs are gear junkies. They know what's good and what's bad; they know what's going to work and what's not going to work; and they love actually getting their hands on new stuff and trying it out and that's with any of our products, not just dropped object stuff.” WPE

Power and hand tools should be secured by attaching a carabiner to a connection point on the tool.

The lanyard is then anchored on a worker’s person or another stable point at the worksite. Look for protection products that are thirdparty tested in harsh conditions.

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201tr9oduction in

THE YEAR AHEAD promises new growth and exciting challenges for the wind industry. Over 20,000 MW of new wind capacity was already well under construction near the end of 2018, with another 17,000 MW in advanced development. According to the American Wind Energy Association’s (AWEA) Market Report, seven states were close to doubling wind, bringing the total capacity of wind in the United States to more than 90,500 MW. What’s more is the low cost of wind. In a recent study from research firm, Lazard, wind is now the cheapest source of new power generation in many U.S. markets — and that’s regardless of incentives. Wind is, for the first time, also becoming costcompetitive with existing conventional power plants.

Lower costs are leading to increased demand and new, more efficient turbine components and towers. For example, 2018 saw the first orders for 4-MW land-based wind turbines from turbine manufacturers such as Senvion and Vestas. GE also promises the first prototype of its Haliade-X offshore wind turbine in 2019, featuring the world’s first 12-MW capacity. Flip through the pages of this issue and you’ll get a sense of

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ergy n E d in W in ip h rs e d a Le

the innovation that permeates the wind industry.

The U.S. offshore industry has also fully launched with more offshore wind farms to begin construction in the coming years. In fact, The U.S. Department of Energy predicts about 22,000 MW of offshore wind is possible by 2020 and states such as Massachusetts (1,600 MW by 2027), New York (2,400 MW by 2030), New Jersey (3,500 MW by 2030), and others have already set lofty offshore wind goals.

And because U.S. waters are deeper than the North Sea, expect to see a few floating wind turbines. California has already proposed a 100 to 150-MW floating offshore wind farm more than 20 miles off the coast of Eureka.

To keep wind-generated power flowing, we at Windpower Engineering & Development know it is important to recognize the leaders that push the industry forward. Here, you’ll see the accomplishments of fellow engineers and companies in a range of categories. Kudos to the winners!

Your vote for one of more of the companies also listed on the following pages will be recorded on our website until the end of 2019.

2018 WINNERS: bearings Aurora Bearing Company

ELECTRICAL / ELECTRONIC RAD Torque Systems (100%)

FASTENING / JOINING Aztec Bolting Services, Inc. (100%)

HARDWARE / COMPONENTS Dexmet Corporation (100%)

Operations & Maintenance Castrol (81%)

windpowerengineering.com/leadership Select the company you think has provided leadership in the wind industry.

www.windpowerengineering.com

2/13/19 5:50 PM

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LEADERSHIP IN WIND ENERGY

2019

Abaris Training Resources, Inc. is recognized as the leading provider of advanced composite training for wind blade manufacturers, repair technicians, and engineers worldwide. Abaris has over 35 years of experience teaching composite structural repair techniques and methodologies to the aerospace industry and over the past decade, transferred that knowledge to those now serving the wind energy industry.

Abaris Training Resources, Inc. 5401 Longley Ln, Ste 49 Reno, NV 89511 775.827.6568 Training@abaris.com

Abaris Training is the world leader in advanced composite training. We have trained more than 25,000 students since our inception in 1983, across a number of industries ranging from aerospace to automotive to marine to wind energy and more. Our goal is to teach the latest technology to our students in a friendly yet professional atmosphere. Currently we offer over 22 different courses covering many disciplines surrounding engineering, manufacturing, repair, and NDI of advanced composite structures. Classes are available in four different facilities: Reno, NV; Plainview, NY; SĂŁo JosĂŠ dos Campos, SP, Brazil; and at the KVE facility in Maastricht, The Netherlands. All courses are taught by highly motivated instructors, all of which have vast experience and knowledge of composites and are acknowledged for being the top in their respective fields. In addition to training at Abaris facilities, Abaris can host entire groups at our facility or bring the training to you. Our Direct Services division specializes in organizing either off-the-shelf, or custom courses to our customers, worldwide.

www.abaris.com

windpowerengineering.com/leadership Voting for this company will identify it as a leader in the wind power industry.

FEBRUARY 2019

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WINDPOWER ENGINEERING & DEVELOPMENT

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ADVERTISEMENT

LEADERSHIP IN WIND ENERGY Aurora Bearing Company was founded in 1971 and manufactures the world’s most complete range of rod end and

2019

Aurora Bearing Co’s new LCOM Spherical Bearings outperform “LS” bearings

spherical bearings. Configurations range from 2-piece economy commercial and molded race construction through 3-piece precision designs. Aurora also produces a full line of military spec rod ends, spherical bearings, and journal bushings.

Custom designed rod ends, spherical bearings, and linkages are a specialty.

For more information, contact: 630-859-2030 Fax: 630-859-0971 aurorabearing.com

Aurora Bearing Company 901 Aucutt Rd. Montgomery, IL 60538 Ph: 630-859-2030 Fax: 630-859-0971 aurorabearing.com

Like all Aurora Bearing spherical bearings, the LCOM series features a one piece steel raceway, swaged around the ball for a smooth, precise, close tolerance fit, along with the benefit of the strength and vibration resistance of steel. In addition, this series is optionally available with Aurora’s proprietary AT series PTFE liner, for a zero clearance, self lubricating fit.

Aurora LCOM Spherical Bearings were designed to offer a higher level of performance with dimensional interchangeability for the “LS” spherical bearing category; a market segment which has remained largely unchanged since the 1950s. “LS” bearings are characterized by being of 3 or 4 piece construction, with an inner ball, an outer ring, and a one or two piece brass, bronze, or copper alloy race between.

Since the early 1950’s users of these bearings, which are also marketed with a “FLBG”, “RS”, or “VBC” prefix, have had to accept their low strength and poor vibration resistance due to the low strength race material. Aurora’s LCOM bearings incorporate superior materials and manufacturing processes to overcome the performance deficiencies associated with “LS” bearings.

COMM-M Bearings are stronger choice for DIN ISO 12240-1 applications

windpowerengineering.com/leadership Voting for this company will identify it as a leader in the wind power industry.

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Metric spherical plain bearings built to DIN ISO 12240-1 (formerly DIN 648) schedule K often are made with inner races or rings made of brass, bronze or copper. For many low demand applications these bearings have proven to give satisfactory service. However, in applications with high loads or high vibration levels or both, the bearings can quickly develop excess clearance due to a deformation of the relatively soft race material.

www.windpowerengineering.com

This weakness is addressed in the Aurora Bearing Company’s COM-M series spherical bearings. Like all Aurora inch dimension spherical bearings, these metric bearings all feature a 1 piece steel raceway, cold formed around a chrome plated, alloy steel ball for strength, precision, and structural integrity.

Aurora COM-M series bearings are available in sizes from 3mm to 30mm., and follow the dimensions of DIN 648 schedule K. Bearings are optionally available with Aurora’s self lubricating AT series ptfe liner, for a smooth, zero clearance fit that is self lubricating and maintenance free.

Maintenance free & corrosion resistant rod ends from Aurora

The Aurora CM/CW-ET series rod ends offer a combination of features unique in the rod end industry. Instead of the low strength steels typically found in stainless rod ends, the ET series features bodies made from heat treated 17-4PH material. Not only do they offer excellent corrosion resistance compared to conventional rod ends, they provide greater load capacity, strength, and durability as well. The ET series comes standard with Aurora’s exclusive AT2100 PTFE liner. This, combined with a heat treated 440C stainless ball, gives a durable, zero clearance, self lubricating, maintenance free bearing interface to go with the benefits of the heat treated body. Their two piece design allows exploiting these high performance features to be exploited at an economical price. The Aurora ET series bearings can be used to enhance the performance of equipment in wash down, marine, and other environments that require extra corrosion resistance.

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2019

ADVERTISEMENT

LEADERSHIP IN WIND ENERGY AZTEC BOLTING SERVICES, INC. has been a leading provider of bolting tools to the wind energy industry for over 30 years.

Aztec Bolting utilizes the latest products from Enerpac to Skidmore for all your torque and tension requirements. We offer the finest tools available for sale or rent, including hydraulic tools that can yield up to 80,000 ft./lbs. Aztec Bolting also provides calibration services and repairs through our ISO 17025 accredited mobile fleet and calibration facility at the company headquarters in League City, TX. Working alone, or on site with your labor force, Aztec is committed to delivering the right solution, to meet your timing and budgetary requirements. Aztec Bolting Services, based in League City, TX, has expanded our service area with new offices in Port Arthur, TX, and continues to provide a state-of-the-art mobile fleet division with additional office locations in Midland, Corpus Christi and Sweetwater, TX, and Oklahoma City, OK.

Aztec Bolting Services 520 Dallas Street League City, TX 77573

Since 1987, Aztec Bolting Services has been providing innovative equipment and superior technology. As a distributor of Enerpac Bolting and Tensioning Products, Skidmore-Wilhelm, Stahlwille, and Norbar hand torque wrenches, electronics and torque multipliers, we are prepared to assist our customers in achieving their Wind Power Construction and Maintenance goals.

As a premier distributor of Enerpac products, Aztec Bolting is proud to introduce the new Enerpac Wind Power Generation Bolt Tensioners.

Designed by a highly experienced group of tensioning professionals, who specialize in creating customized solutions for unique applications, the new Enerpac tensioners offer high precision with low maintenance.

“Aztec’s mission is to provide quality products and services to meet every torque and tension need with the utmost care, quality and service.”

If your project requires critical fastening applications whether in high performance or tight spaces, the new line of Enerpac PGT, FTR, and FTE Series Tensioners offer universal solutions with precision and speed.

Our professionals can be on-site anytime, anywhere with our ISO 17025 Accredited Mobile Calibration Fleet. Our Mobile Units can provide more versatile services than ever before from Controlled Bolting Training to on-site calibrations of your products.

1308 South Midkiff Road, #305 Midland, TX 79701 802 Navigation Boulevard #106 Corpus Christi, TX 78408 1113 Lamar Street Sweetwater, TX 79556 3620 HWY 69 N Nederland, TX 77627 800.233.8675 www.aztecbolting.com

windpowerengineering.com/leadership Voting for this company will identify it as a leader in the wind power industry.

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Enerpac S-Series Aztec’s hydraulic torque wrench systems are foundational in wind turbine applications. The Enerpac S-Series Hydraulic Torque Wrench is the fundamental square-drive torque wrench. It is incredibly versatile with a light and sleek design, which delivers up to 25,140 Ft/lbs of torque. The S-Series also features a 360 degree swivel manifold and durable rigid steel design.

Enerpac W-Series Another example of a quality wrench is the Enerpac W-Series Steel Hexagon Torque Wrench. The W-Series sets the standard in versatility, reliability, and durability. The innovative design sports a pinless construction with a quick release drive and auto crank engagement. This hexagon torque wrench has a 360 degree swivel manifold and you won’t need tools for changing hexagon heads.

And because Aztec Bolting is an authorized national distributor of Enerpac products, you can count on a lifetime warranty.

Aztec Bolting and Enerpac products are guaranteed.

WINDPOWER ENGINEERING & DEVELOPMENT

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LEADERSHIP IN WIND ENERGY Castrol, one of the world’s leading lubricant brands, has a proud heritage of innovation and fuelling the dreams of pioneers. Our passion for performance, combined with a philosophy of working in partnership with manufacturers, has enabled Castrol to develop lubricants and greases that have been at the heart of numerous technological feats on land, air, sea and space for over 100 years.

2019

Leading lubricant supplier

Castrol is part of the BP group and serves customers and consumers in the automotive, marine, industrial and energy production sectors. Our branded products are recognized globally for innovation and high performance through our commitment to premium quality and cutting-edge technology. To find out more about Castrol please visit www.castrol.com.

With over 30 years’ experience in the industry, we know how challenging the wind energy business is today.

Castrol 150 W Warrenville Rd Naperville, IL 60563 www.Castrol.com/windenergy

Our parent company BP owns and operates over 2000 megawatts of wind energy, giving us unique insight into your operations, both as a supplier and an operator We understand that our customers need to maximize uptime and minimize operation and maintenance costs. We can share with you the many ways a lubricant can impact this performance. We recognize owners have specific criteria for their gearbox oils based on turbine OEM, change-over procedure, environment and O&M strategies. To meet these differing demands, Castrol is the only lubricant supplier that offers FIT FOR PURPOSE Technology solutions. We can work with you to determine the solution that will meet your performance needs and financial objectives.

This includes our unique proprietary technology that can extend oil changes well beyond any other competitor – all while delivering exceptional wear protection.

We bring expert support to help you maximize the output of your assets, and reduce the cost of each kilowatt of energy produced. This includes every area of turbine mechanics from gearboxes, to main bearings to hydraulic systems. Using our condition based monitoring expertise, we can provide vital insights into the health of your gearboxes and support predictive maintenance techniques all while housing your fluid analysis data in one location, available any time you need it.

windpowerengineering.com/leadership Voting for this company will identify it as a leader in the wind power industry.

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www.windpowerengineering.com

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LEADERSHIP IN WIND ENERGY Dexmet Corporation manufactures precision expanded metal foils and polymers for applications in aerospace, power generation, filtration and automotive industries. Dexmet was founded in 1948 and is based in Wallingford, Connecticut. For over 60 years Dexmet has been at the forefront of expanding technology and has redefined the standards for micro mesh materials providing the greatest range of products and capabilities for foil gauge metals and thin polymer films. Dexmet manufactures thin, light-weight precision expanded Copper and Aluminum from .001” thick and widths reaching over 48” that can meet specific weight, conductivity and open area requirements required by aerospace or wind generation applications.

Precision MicroGrid® materials from Dexmet are the industry standard for expanded materials used in lightning strike protection, on carbon fiber structures with OEM aircraft manufacturers as well as EMI/RFI, and ESD protection for sensitive internal instrumentation.

The Dexmet Quality System is ISO AS9100:D and ISO 9001:2015 certified.

Dexmet Wallingford, CT 203-294-4440 dexmet.com

windpowerengineering.com/leadership Voting for this company will identify it as a leader in the wind power industry.

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As the power output requirements increase for wind turbines, wind generator manufacturers are moving towards larger blades to rotate these larger turbines at lower wind speeds. As the wind blades increase to over 45 meters in length, blade construction is moving away from the more traditional all fiberglass construction to utilize more carbon fiber. The carbon fiber provides a substantial weight savings and increased strength to combat the extreme stress loads exerted on the blades during operation. Carbon fiber, however, is conductive and more prone to be struck by lightning. Without proper protection, they are susceptible to severe damage and catastrophic failure.

For two decades Dexmet has been working with aircraft designers developing precision expanded MicroGrid foils for lightning strike protection on carbon fiber composite aircraft and its components. Benefiting from the development work done in the aircraft industry, Wind Blade Manufacturers are now realizing the importance of having the proper lightning strike protection for larger carbon fiber blades.

As with Aerospace applications, weight is always critical so Dexmet provides different conductive materials to minimize the weight based on the different strike zones. As with all rotary blades, lighting is more prone to hit the leading edge and the outer blade surfaces towards the tips where the highest amount of static energy is generated.

For these locations, the heavier, more conductive materials are utilized. As you move towards the root of the blade, a lighter weight material can be incorporated to reduce weight and cost. The variability with Dexmet’s expanding process provides the capability of producing a custom material based on desired weight, conductivity, or open area to meet exact application requirements.

2019

Dexmet MicroGrid® Proven Lightning Strike Protection • Proven Technology for Lightning Strike Protection • Highly Conductive Patterns Matched to Specific Requirements • Open Area Design for Easy Dry or Wet Layup without Delaminating • Easily Repairable for Low Maintenance Costs and Minimal Downtime MicroGrid® Materials For Hybrid-Carbon Fiber Wind Turbine Blades Dexmet MicroGrid materials are thin, open area products applied to a layer on the top of the structural carbon fiber spar/web or other systems that utilize carbon such as de-icing solutions that consume carbon heating mats on the leading edge. Dexmet materials can achieve the critical conductivity, sometimes in conjunction with the carbon components, to dissipate 20-25 years’ worth of lightning strikes. Dexmet expanded copper and aluminum MicroGrid meshes are essential at extending the life of hybrid carbon fiber composite blades.

Dexmet LSP material are used in conjunction with the other parts of the entire lightning strike protection system for a wind turbine blade.

Dexmet mesh can provide connections between receptor(s) and anchor blocks/root through which high voltage current pass to ground connections.

To learn more about the benefits of Dexmet materials, witness its lightning protection performance or understand how it can reduce your maintenance costs and down time, contact us at products@dexmet.com or visit our web site and let us show you how to incorporate the innovative MicroGrid® materials into your composite designs and start recognizing the benefits today.

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LEADERSHIP IN WIND ENERGY World-class image quality, overnight

The Hawkeye® Pro V2 Video Borescope is a fully portable, articulating, video borescope manufactured

by Gradient Lens Corporation (http://www.gradientlens. com/V2). “We know portability, image quality, and costefficiency are the most important factors for wind power inspection & maintenance teams” said Dr. Doug Kindred, Gradient Lens’ President and Chief Scientist. “Our V-Series Videoscopes deliver on all three”.

delivery, and prices one-half to one-third that of comparable borescopes. . . that’s the innovative Hawkeye® Precision Borescopes manufactured by Gradient Lens Corporation. We sell more industrial borescopes than any other manufacturer.

The wide 70º FOV allows more of the inspection area to be visible to the user. The “deep” DOF allow sharp-focus of objects as close as 15 mm, up to infinity. With the optional Close-Focus Tip users can attain sharp focus of objects from 4 mm – 22 mm.

Our Hawkeye V2 Videoscopes are fully portable and offer 4-way articulation.

However, any Hawkeye Rigid or Flexible, Borescopes can be attached to our Luxxor Video Camera allowing high-quality inspection images to be displayed on portable video monitors, or, laptop and desktop computers. Those images can be saved, documented and e-mailed. We carry over 80 models of rigid, flexible, and video borescopes, and video microscopes.

All are in stock and ready for overnight

2019

The Hawkeye V2 is brighter, has higher resolution, and has more durable construction than most other portable videoscopes on the market today. It is available in diameters of 4 and 6 mm, offers 4-way articulation, is priced starting at $8995, and is made in the USA. Optional Close-Focus, and 90º Prism, adaptors are available that work seamlessly with the V2 when the subject matter is close to, or to the side of, the borescope tip. Hawkeye Video Borescopes deliver the same image quality, portability, and articulation of scopes costing three times as much.

Fully portable, Hawkeye V2 Video Borescopes have flexible, durable, tungsten sheathing, and come complete with video monitor and light source, all in one easy-to-use device. Video and still image capture is quick and easy, and images are stored on SD Memory Cards.They are available in lengths of 1.5, 3.0, and 6.0 meters. Custom lengths are available upon request.

delivery. www.gradientlens.com

Gradient Lens Corporation 207 Tremont Street Rochester, New York 14608 Phone: 585-235-2620 800-536-0790 Fax: 585-235-6645 info@gradientlens.com

windpowerengineering.com/leadership Voting for this company will identify it as a leader in the wind power industry.

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LEADERSHIP IN WIND ENERGY

2019

HELUKABEL: The Worry-Free Cable Experience HELUKABEL USA, based near Chicago IL, is a global manufacturer and supplier of cables, wires and cable accessories. Our extensive product line includes flexible and continuous-flex control cables, data/ network/BUS cables, VFD/servo cables, torsion cables for wind turbines, singleconductors, and multi-norm cables with domestic and international electrical approvals.

HELUKABEL combines excellent cable quality, innovation and technical expertise with a vast product portfolio and smooth logistics operations. We call that the worryfree cable experience!

New automation technology means new cable challenges. With almost 40 years in the cable business, we have designed our products to provide an uninterrupted flow of power and data to today’s automated manufacturing systems, regardless of working conditions.

Our cable engineering expertise allows us to meet and exceed customer expectations as industry technology becomes more advanced.

We continuously provide new cable solutions for our customers, which allows them to maintain their position at the forefront of the market.

HELUKABEL cables have long service lives, and have been tested to multi-million flexing cycles. This makes the automated manufacturing process leaner by reducing downtime and increasing productivity. We also develop and manufacture complete cabling protection systems for robotics applications.

Combining a product portfolio of over 33,000+ line items with worldwide logistics operations allows us to deliver the cable products you need, when you need them. With a fully automated logistics center in Germany, and a large warehouse near Chicago IL, we are able to serve the North American market on a just-in-time basis. Truly making HELUKABEL your one-stop shop cabling solution provider.

HELUKABEL, USA T: (847) 930-5118 sales@helukabel.com www.helukabel.com

windpowerengineering.com/leadership Voting for this company will identify it as a leader in the wind power industry.

FEBRUARY 2019

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LEADERSHIP IN WIND ENERGY

2019

HYDAC was founded in 1963 as a company producing hydraulic accumulators and filters. Today, we are internationally active with 9000+ employees, 30+ manufacturing locations and 500 trade and service partners throughout the globe.

Our fluid engineering solutions are defined by the scope and complexity of our customers’ requirements.

Our products range from individually designed components in the fields of fluid engineering, hydraulics and electronics right up to complete systems for specific functions.

All components and systems are conceived and designed in-house. Experienced industrial and product specialists develop innovative products and efficient solutions for high-quality, cost-effective production. Our

With a strong nationwide presence and over 50,000 system installations, HYDAC stands out as a leader in the Wind market. Our dedicated Wind field sales and service team is supported by a network of experienced engineers to meet any and all challenges, from new designs and solutions to upgrades and retrofits. Multiple USA-based manufacturing facilities provide our customers the flexibility to meet immediate needs and the ease to develop and implement solutions.

HYDAC’s broad knowledge base and product offering includes lube, generator, and converter cooling systems, as well as HPUs and HR flex cable management systems. HYDAC offers numerous upgrades to improve filtration efficiency, increase element life, optimize heat removal, reduce energy use and improve high voltage management. These upgrades include in-line and off-line filtration options, complete filter replacements, system component upgrade/

production facilities share one common goal; quality. We take pride in both our products and solutions.

With HYDAC’s innovative engineering team, complete lube systems can be re-designed, replaced or modified for repowering and high cycling or to accommodate new IE3 motor requirements. Filtration upgrades are available to remove varnish permanently, via off-line filtration or during maintenance with up tower fine filtration skids. Tank optimization analysis services are available to ensure that tank design is optimized, with baffles and sufficient air separation.

Experience, dedication, and innovative design solutions are the HYDAC way.

HYDAC 2260 City Line Road Bethlehem, PA 18017 www.hydac-na.com

replacement including heat exchanger and accumulator replacement/rebuild kits, and an exchange program for all Wind Turbines. Add-on filter assemblies, designed specifically for the Wind market, improve ISO Codes and protect heat exchangers. All designs and offerings take into consideration limited tower hatch space. windpowerengineering.com/leadership Voting for this company will identify it as a leader in the wind power industry.

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2019

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LEADERSHIP IN WIND ENERGY Established in the late 1800s, Megger has been the premier provider of electric test equipment and measuring instruments for electrical power applications. The trademark was first registered in May 1903 and is guarded by the company.

Although we’re best known for our world famous range of insulation testers, Megger provides a full service solution to meet your electrical test and measurement needs. Manufacturing insulation testers is where Megger started; the Megger brand name is so well known today that maintenance professionals often incorrectly use it as a verb when they refer to doing an insulation test on wiring. This famous name dates back to 1889, when the first portable insulation tester was introduced with the MEGGER brand name on it.

Megger 866-254-0962 megger.com

At Megger, we understand that keeping the power on is essential for the success of our customer’s business. That is why we are dedicated to creating, designing and manufacturing safe, reliable, easy-touse portable test equipment backed by worldleading support and expertise.

We can assist your acceptance, commissioning and maintenance testing for predictive, diagnostic or routine purposes. By working closely with electrical utilities, standards bodies and technical institutions, we contribute to the dependability and advancement of the electrical supply industry.

We focus our expertise in developing innovative testing solutions that are world class in safety, performance, reliability and easy to use. Megger is committed to providing our customers with measurement results and insight to make informed decisions about their assets, increasing uptime and safety.

windpowerengineering.com/leadership Voting for this company will identify it as a leader in the wind power industry.

FEBRUARY 2019

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LEADERSHIP IN WIND ENERGY In 1942 the “North Bar Tool Company” (as Norbar was then known), became the first company in Britain to commercially manufacture a torque wrench. The initial demand was driven by the need for the gasket-less cylinder head of the Rolls Royce Merlin engine to be accurately tightened. Bill Brodey and his partner Ernest Thornitt obtained a license from Britain’s war-time Government to begin manufacture of torque wrenches and Norbar was born. Since then, Norbar has continued to invest in the very latest design, manufacturing and quality control technology to achieve the highest level of innovation and precision in the field of torque control equipment.

2019

Norbar EvoTorque2 – A radical change comes to electric torque multipliers!

Norbar Torque Tools introduces EvoTorque2, where we have brought together durability, low cost-of-ownership, Norbar quality and accuracy, and all the features you need, and rolled them into one, price-competitive tool.

EvoTorque2 is easy to program, presents a small and lightweight package, stores thousands of readings, and can be serviced in the field. There are too many features and advantages to list in a few short lines of text, so the best way to measure the advantages and value of EvoTorque2 is to try it yourself. Stack us up against the competition – you’re going to be amazed!

Norbar Calibration Fixtures – Accuracy and durability brought to the field!

Norbar Torque Tools knows how critical it is to have and prove the calibration and accuracy of your torque tools. We have been providing calibration equipment to the Wind industry around the world. We can package and configure equipment to suit all your needs, and our modular design allows your equipment to grow and change as your needs grow and change.

Whether you need fixtures to calibrate hydraulic wrenches, or joint-simulators to calibrate your non-impacting torque tools, or just a way to calibrate or verify torque wrenches, Norbar has the equipment and expertise to cover all your needs!

Norbar HandTorque Multipliers – Big range and a small size, with a Certificate of Calibration!

Norbar Torque Tools, Inc. 36400 Biltmore Place Willoughby, OH 44094 Phone: 866.667.2272 Fax: 440.953.9336 Email: info@norbar.us www.norbar.us

Norbar Torque Tools Compact Series Torque Multipliers are designed to deliver high torque ranges, in user-friendly gear ratios, packaged in a small and lightweight package. Because size and weight considerations are critical to your business, Norbar has developed a line of torque multipliers that make life in the tower easier by providing a powerful 27:1 gear ratio – an operator input of 100 lb-ft generates 2700 lb-ft of torqueing power!

When it comes to real convenience, Norbar has designed the Compact Series Torque Multipliers to accept the same torque reactions as you will use on your EvoTorque2 tool, saving you even more time and money down the road.

All Compact Series Torque Multipliers include a Certificate of Calibration, and are delivered in a high density plastic carrying case.

windpowerengineering.com/leadership Voting for this company will identify it as a leader in the wind power industry.

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LEADERSHIP IN WIND ENERGY

2019

Rotor Clip is a global leader in the manufacture of tapered, constant section and spiral retaining rings meeting Inch, DIN, ANSI Metric and JIS standards. This includes the manual and automatic tools needed to install/remove every ring we sell.

Rotor Clip also manufactures wave spring rings as well as self-compensating hose clamps, all produced in a lean environment dedicated to eliminating waste and ensuring quality through IATF 16949, ISO 9001 & ISO 14001 registration, and AS9100C certification.

Bearing Retention & Preload Solutions through Engineering Expertise.

Rotor Clip TruWaveÂŽ single-turn wave springs are suited for applications that include connectors, fluid power seals, noise and vibration attenuation, and bearing preload.

The design of standard single turn wave springs with gap typically used for preloading components features sharp corners at the cut off area of the spring ends. These sharp corners can scratch the surface of the bearing as well as the mating parts when the wave form shows a steep incline depending on the load specification.

As with all of our wave spring designs, there is no charge for tooling on custom designs with this end feature.

Feel free to contact our technical sales staff (tech@ rotorclip.com) to find out if your design can benefit from our new single-turn wave spring design.

Maybe you have questions about another of our retaining ring, wave spring or hose clamp products.

Our technical sales engineers are here to help you find the right solution for your application. www.rotorclip.com

Rotor Clip’s patented single-turn wave spring design solves this problem by flattening the ends of the spring so that they will not create excessive wear that can damage the application.

This new design also offers the potential for cost and weight savings in applications where design engineers would typically choose a multi-turn wave spring with shim ends to prevent wear on mating components. However, multi-turn wave springs with shim ends require more material in their production, which adds to both cost and weight.

windpowerengineering.com/leadership Voting for this company will identify it as a leader in the wind power industry.

FEBRUARY 2019

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Abaris Training ................................................................................. 31 Aurora Bearing Company .............................................................16 AWEA................................................................................................ IBC Aztec Bolting...................................................................... cover, IFC Castrol................................................................................................. 13 Dexmet Corporation.........................................................................11 Gradient Lens Corporation .........................................................29 HELUKABEL USA ...........................................................................36 HYDAC Technology Corporation ...............................................25 Megger ............................................................................................. BC Norbar Torque Tool .......................................................................... 5 Offshore Technology Conference ..............................................18

SALES

L E A DE R SH IP IN W IN D EN ERGY

WINDPOWER ENGINEERING & DEVELOPMENT Abaris Training ................................................................................ 37 Aurora Bearing Company ............................................................38 Aztec Bolting....................................................................................39 Castrol................................................................................................40 Dexmet Corporation........................................................................ 41 Gradient Lens Corporation .........................................................42 HELUKABEL USA ........................................................................... 43 HYDAC Technology Corporation ............................................... 44 Megger ..............................................................................................45 Norbar Torque Tool ........................................................................46 Rotor Clip .......................................................................................... 47

LEADERSHIP TEAM

Jami Brownlee 224.760.1055 jbrownlee@wtwhmedia.com Ashley Burk 737.615.8452 aburk@wtwhmedia.com Neel Gleason 312.882.9867 ngleason@wtwhmedia.com @wtwh_ngleason

Michelle Flando 440.381.9110 mflando@wtwhmedia.com @mflando Tamara Phillips 216.386.0953 tphillips@wtwhmedia.com Jim Powers 312.925.7793

VP of Sales Mike Emich 508.446.1823 memich@wtwhmedia.com @wtwh_memich

EVP Marshall Matheson 805.895.3609 mmatheson@wtwhmedia.com @mmatheson

Managing Director Scott McCafferty 310.279.3844

Publisher Courtney Nagle cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel

smccafferty@wtwhmedia.com @SMMcCafferty

jpowers@wtwhmedia.com @jpowers_media

CONNECT WITH US! NEW

CHECK US OUT ON ISSUU!

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FEBRUARY 2019

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2018 was a historic year as wind power surpassed 90,000 MW installed and the AWEA WINDPOWER Conference grew 10% making it the largest show in 5 years. The wind industry’s powerful growth is poised to continue in 2019, with more than 37,700 MW of wind capacity under construction or in advanced development.

WINDPOWER is where the industry comes together to plan for the future and keep this success story growing. This May, the biggest wind energy conference in the Western Hemisphere will head to the energy capital of world, where leaders from the wind industry and across energy sectors will gather to take the next steps forward to powering the future, together!

REGISTER NOW! www.windpowerexpo.org

ar as wind power surpassed 90,000 MW installed and ER Conference grew 10% making it the largest show ndustry’s powerful growth is poised to continue in 37,700 MW of wind capacity under construction or pment.

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EVERYONE NEEDS

PROTECTION...

…Especially from lightning.

The Megger DLRO10HD and DLRO10HDX offer reliable testing to make sure you’re protected in the event of a lightning strike.

When a strike occurs, current flows to ground through the lightning protection system. The system’s resistance to ground should be measured regularly to ensure that the protection will work when needed. For these measurements a low resistance ohmmeter, like the DLRO10HD and DLRO10HDX, should be used.

Megger also makes a test lead set specifically designed for testing wind turbines.

They are long enough to assess the continuity of lightning protection conductors in wind turbine blades and are ideally suited for use with the DLRO10HD.

Features of the wind turbine lightning protection test lead set include: n

Available in 3 different lengths to 328 ft

n

Suitable for use on site or in the manufacturing plant

n

10A rated

n

The lead set offers reversible terminations. One termination is a duplex handspike, while the other is a heavy-duty Kelvin clip Cat. No. 1000-809

Look to Megger for lightning and asset protection.

For your FREE copy of Megger’s Guide to Low Resistance Testing, Visit us.megger.com/getbook Reference Code: DLRO10_Lightning_AUG

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