Windpower Engineering & Development August 2018

THINK ULTRACAPACITORS TO REDUCE O&M COSTS /

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August 2018

The technical resource for wind profitability

NEW

NATIONAL STANDARDS

How wind power is impacting American farmers

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WINDWATCH:

Wind Technician PPE Petzl work at height solutions are designed to be lightweight, durable, and easy to use while maintaining the highest quality standard for at-height professionals. From the line of VOLT harnesses, to the standard setting VERTEX helmets, and the innovative shock absorbing ABSORBICA lanyards, Petzl’s ANSI compliant solutions deliver the perfect balance of comfort and reliability. www.petzl.com

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THINK ULTRACAPACITORS TO REDUCE O&M COSTS /

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The technical resource for wind profitability

NEW

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How wind power is impacting American farmers

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WINDWATCH:

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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HERE’S WHAT I THINK

Editor Windpower Engineering & Development mfroese@wtwhmedia.com

Wind worth harvesting

A

big sign propped up at the entrance of my local farmers’ market read: If you ate today, thank a farmer. My dad grew up on a farm in the Canadian prairies, so this is wise advice to me. He’s shared plenty of stories about farming life, and the hard work and dedication that goes into it. He loved harvesting crops with my grandfather but there were years their efforts yielded little reward.

However, if my granddad had the option to own or lease a wind turbine on his property, the years of low crop production may have been less troublesome for the family (my grandparents had five kids to feed). Wind energy offers farmers a unique opportunity to save on electricity costs and earn additional revenue. In fact, it is now possible for many farmers to lease a wind turbine for zero money down while benefiting from its production of lowcost renewable energy (see page 10 of this issue).

What’s more is research shows that wind turbines may have a positive effect on crops. A multiyear study, led by Iowa State University, examined the effects of turbulence (produced by moving turbine blades) and found a measurable impact on several key variables that affect the growing conditions for crops. For example, the researchers found that changes in air pressure from turbineinduced turbulence may enrich the carbon dioxide content in the air surrounding crops — which could, in turn, help crops grow more efficiently. In addition, the turbulence suppresses the formation of dew and dries the crops, which may combat harmful molds and fungi.

Currently, American farmers are facing extremely low agricultural commodity prices despite rising production costs. According to a recent blog post from the American Wind Energy Association (AWEA), the total value of the U.S. corn, soybean,

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and wheat crops dropped 10% or roughly $13 billion in June of this year alone. Soybean prices have fallen around 18%, heading to their lowest point in nearly a decade. As AWEA points out, “volatile commodity prices affect a farmer’s bottom line, putting them at risk for significant debt or even bankruptcy.”

Unlike my dad and granddad, however, many of today’s farmers can choose wind power to secure a source of dependable revenue. These statistics from the American Farm Bureau Federation provide a snapshot of why farm work is essential to the economy and our communities.

• • • •

• •

One farm feeds 165 people annually in the United States and abroad About 99% of American farms are operated by families Agriculture is the largest employer in the United States, providing jobs to 23 million Americans Farmers and ranchers receive only 15 cents out of every dollar spent on food at and away from home. (The rest goes to wages and materials for production). In 1980, farmers and ranchers received 31 cents.

There are over two million farms in America Women make up 30% of the total number of U.S. farm operators

Last year, farmers were paid an estimated $267 million to lease land for wind development. With support from local communities, government, and the wind industry let’s ensure farmers receive the support they need to succeed. After all, I’ve heard life is better on a farm.

To the ranchers and farmers who work hard every day, and to those who make my weekend farmers’ market visits possible, a special thank you. W

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JOSHUA HITT is senior product line manager at Maxwell Technologies, a manufacturer of ultracapacitor energy storage solutions for pitch control with over 67,000 wind-turbine installations worldwide. Learn more at maxwell.com/wind MIKE KAHN, chief marketing officer of AEE Aviation Technology, Inc. has more than 25 years of experience in the consumer electronics industry. Kahn leads global marketing and operations for AEE’s Americas and European Divisions. A former executive at Sony, he has a long and proven track record of success in developing new businesses and increasing sales while leading large corporate business units and tech companies, such as Sony Electronics and Yuneec International.

ALISTAIR MARSDEN is a sales & marketing director at renewable energy consultancy, Dulas. The company offers a variety of services, including wind monitoring, data analysis, feasibility, repowering, extension advice, and more. Marsden is responsible for working with Dulas’ global clients to provide them with the resources needed across the lifecycle of their clean-energy projects.

JOHN SALENTINE is the co-founder and VP of Hammerhead Industries. The company manufacturers Gear Keeper tool tethering systems — unique personal safety tethering equipment, which includes retractable tethers and lanyards for tools, gear, and instruments.

Covered by numerous patents, Gear Keeper tethers are precision-made systems that keep tools and instruments safe, secure, and close at hand. With more than 3,000 configuration options and millions of systems in use, Gear Keeper tethers are found worldwide in a range of applications, including wind power.

SIMON SEARLE is an applications engineer with Megger, who works out of the company’s Dover office in the UK. NICOLE STEMPAK is a Cleveland-based journalist who has worked for trade and consumer publications. She has produced audio, video, and written content for community publications, business executives, and healthcare professionals.

LELAND TESCHLER is the executive editor of the Design World network of websites, online resources, and print publications. Teschler worked at Penton Media for 37 years, starting in 1977 as a Staff Editor for Machine Design, and worked his way up to Chief Editor of the publication in 2006. Prior to that, he had been a communications engineer for the federal government. Teschler holds a B. S. in Engineering and a B. S. in Electrical Engineering from the University of Michigan, and an MBA from Cleveland State University.

Coverage areas include power electronics, solar power electronics, test & measurement, Internet of Things, motion control and controllers, solidstate lighting, energy efficiency, and industrial electronics.

CRAIG WALKER is a freelance writer, originally from Pretoria, South Africa but who calls the U.S home now. Walker’s favorite hobby is windsurfing on Lake Erie, Ohio. He holds a B.S. in Aerospace Studies from Embry Riddle Aeronautical University and an MBA.

WALKER

TESCHLER

STEMPAK

SEARLE

SALENTINE

MARSDEN

KAHN

HITT

CO NT R I BUTORS

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

E D I T O R I A L

It’s hard to believe that there’s more to this already hefty handbook, but it’s true! Don’t forget to check out our interactive components on

S T A F F

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EDITORIAL

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WINDPOWER ENGINEERING & DEVELOPMENT

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AUGUST 2018 • vol 10 no 4

CONTENTS

D E PA R T M E N T S 01

Editorial: Wind worth harvesting

30 Safety: Evaluating arc flash hazards in wind turbines

06

Windwatch: Ohio speaks out about Icebreaker

33 Lightning: The importance of testing lightning-

Wind, New wind consortium working to cut offshore construction noise, Wind’s impact on American farmers, and Wind work around North America

protection systems

36 Drones: Tips for choosing the right drone to inspect wind-turbine blades

14

Finance: What is “fintech” and why it’s a key investment tool for wind-farm owners

39 Operations and maintenance: Reducing pitch-

18

Reliability: How to choose the best wind-monitoring

46 Turbine of the month: The hurricane-proof Hitachi

27

Bolting: Three ideas for safer, more efficient bolting jobs

device for project financing

control O&M costs with ultracapacitors

HTW5.2-127

F E AT U R E S

22 New national standards aim to prevent dropped objects

A small one to two-pound wrench might not seem like much of a safety hazard, but an accidental drop from atop of a wind tower could result in life-threatening injury. A new national standard aims to reduce dropped objects at work sites, including wind farms.

W I N D WAT C H

10 ON THE COVER

How wind is benefiting American farmers

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Much of the nation’s lands are ripe And ready to harvest a different kind of cash crop: wind power.

42 How the wind industry is working to reduce cable failures

Despite the critical role cables perform at offshore wind farms, the devices are often an afterthought during project planning and wind-farm development. In fact, studies show that up to 80% of insurance claims in the offshore wind industry are from cable failures.

So the wind industry is collaborating to find out why and change cable reliability.

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oin us in the nation’s capital for a timely educational program, recent advances in offshore technology, as well as top-notch networking with those leading the offshore segment into the 2020s.

PROGRAM CHAIRS

Thomas Brostrøm President North America, ørsted

Stephanie McClellan Director, Special Initiative on Offshore Wind, University of Delaware

KEYNOTE SPEAKER

The Honorable Terje Søviknes Minister of Petroleum and Energy, Norway

Register at awea.org/offshore

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OHIOSPEAKS SPEAKSUP UPABOUT ABOUT OHIO ICEBREAKERWIND WIND ICEBREAKER B Y: C R A I G W A L K E R

A PUBLIC HEARING on Lake Erie Energy Development Corporation’s (LEEDCo) Icebreaker Wind project was held in July at Cleveland City Hall Council Chambers before the Ohio Power Siting Board (OPSB). Icebreaker Wind is the first proposed freshwater wind farm in North America, about 8 to 10 miles off the coast of Cleveland, Ohio.

“The six-turbine Lake Erie project will put Cleveland on the international map as a progressive, forward-thinking city that is advancing clean energy,” Steve Luttner, a representative for LEEDCo, said during the hearing. LEEDCo is a not-for-profit organization spearheading Icebreaker Wind and dedicated to building offshore wind in the Great Lakes Region. “Our global environment — including birds and other wildlife — is often under siege from pollution and other climate-related pressures. Clean energy can help alleviate these considerable issues.”

Nearly 200 people attended the hearing, including project stakeholders, marine organizations, wildlife advocates, Ohio residents, and other interested parties. It gave people a chance to speak up before the project’s adjudicatory hearing on September 24, 2018.

One concern opponents of the project have is the possible impact on birds and bats. The Renewable Director of the Audubon Society, a not-for-profit environmental organization dedicated to conservation, Garry George, shared his concern at the hearing: “The Audubon Society supports wind energy in general — if properly sited and provided there is adequate onsite data collection to inform risk and avoidance and minimization of mortality of the millions of migratory songbirds that migrate across Lake Erie twice a year.”

“Icebreaker Wind has undergone many years of thorough review from 14 local, state and federal agencies,” Luttner pointed out. “LEEDCo has participated in more than 400 public sessions to discuss Icebreaker Wind. We are taking numerous steps to limit any negative impact to birds and bats.”

The Ohio Environmental Protection Agency recently issued a Section 401 water-quality certificate of approval for Icebreaker Wind, confirming the project complies with federal standards relating to water pollution.

LEEDCo is working on the remaining approvals required for the project to begin construction.

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W I N D W A T C H

The Icebreaker Wind project is a proposed 20.7-MW demonstration wind farm in Lake Erie that would consist of six, 3.45-MW turbines.

Icebreaker Wind will interconnect with the Cleveland Public Power transmission system at the Lake Road 138-kV substation.

The interconnection study process is complete, and rights are secured to participate in the PJM market.

OPSB recently published its Report of Investigation, after a near 18-month review of the proposed project. The report recommends approval of Icebreaker Wind and finds the project “serves the public interest” and would pose “minimal adverse environmental impact.”

“I urge the people of this area and the Ohio Power Siting Board to approve this project not only for the water we drink, the air we breathe, but the jobs created that will let workers provide for their families,” Carl Scheutzow of Medina, OH, said at the hearing. He is a self-described fisherman, boater, and solar consultant.

LEEDCo has stated that Icebreaker Wind would create over 500 jobs in Northeast Ohio during construction, and provide $168 million to the local economy over the project’s 25-year life. It ensures local labor and manufacturing will be used when possible.

According to LEEDCo’s website, Icebreaker Wind would provide three key benefits.

Ohio resident, Carl Scheutzow, voiced his support for the Icebreaker Wind project to the Ohio Power Siting Board at the public hearing in July.

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1. Offer a scalable source of renewable energy in Lake Erie 2. Create jobs and economic prosperity in the region 3. Help clean our air and water resources If final certification is granted in September, the project is expected to start construction in 2021.

To download the OPSB report, visit tinyurl.com/IcebreakerWind.

For further information on the Icebreaker project, please go to leedco.org. W

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W I N D W A T C H

New consortium working to cut offshore wind costs & construction noise ONE IMPORTANT WAY marine mammals navigate, forage, and communicate is through sounds. Unexpected or atypical sounds — such as underwater noise from offshore construction activity — is a concern for many wind developers and environmentalists. In our June 2018 issue, the article A quieter way to construct offshore turbine foundations discussed a method for pile driving that replaces the use of loud and disruptive hydraulic hammers (go to tinyurl. com/QuieterWay for a refresher).

A new wind consortium is currently working on another way to reduce underwater construction noise while cutting offshore wind installation costs.

Siemens Gamesa and Universal Foundation, both part of the consortium, are working on an industrialized suction-bucked design. Suction buckets have been used in the oil and gas industry for years, and more recently in offshore wind to anchor tower foundations. (Ørsted, formerly DONG Energy, installed the world's first offshore wind-turbine foundation using suction-bucket technology in 2014.)

The process involves lowering an inverted bucket into the seabed floor and then pumping water out of the bucket to create a negative or vacuum-like pressure. As a result of the pressure, the tower foundation gradually sinks into the seabed floor — without the need for loud or disruptive drilling.

“This project is interesting in many ways,” said Søren Andreas Nielsen, Head of R&D, Universal Foundation, in a recent press statement. “We all share the view that suction technology provides some obvious

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The new “Mono Bucket” combines the key benefits of a gravity-based foundation, a monopile, and a suction bucket.

The suction-bucket installation method eliminates the need for pile driving and noise mitigation measures.

installation advantages, both in terms of environmental impact and costs.”

The benefits of a suction-bucket design include little to zero seabed prep, a noise-free installation process (that’s also quicker than conventional methods, such as pile driving), and easier decommissioning. The ultimate goal of the consortium is to decrease foundation construction and installation cost by 40%.

The partnership between Siemens Gamesa and Universal Foundation builds on an earlier project the companies worked on to develop an 8×8-meter suction-bucket prototype. The second part of this work will see the prototype used in an offshore trial. According to the companies, the new concept merges the noise-free installation advantages windpowerengineering.com

of suction buckets with industrialized fabrication methods that use coil steel instead of conventional plate steel.

“By applying this innovative fabrication method to suction-bucket technology in offshore wind, the steel plate thickness can be reduced to below 20mm, compared to today’s typical thickness of 30 or 40mm for this type of foundation,” said Finn Daugaard Madsen, Project Manager with Siemens Gamesa. “This means the use of lower cost steel with higher supply availability.”

The aim is to develop an industrialscale suction bucket that’s commercially ready for new offshore wind farms.

“During part two of the project, we are eager to prove the installation integrity and reliability of the system,” added Daugaard Madsen. W WINDPOWER ENGINEERING & DEVELOPMENT

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W I N D W A T C H Did you know that more than 99% of operating wind-power capacity is located in rural areas? Learn more about wind power and its benefits by downloading this AWEA report: tinyurl.com/WindBringsJobs

B Y: N I C O L E S T E M P A K

How wind energy is impacting American farmers MUCH OF THE NATION’S rich fertile lands are ripe for harvesting a different cash crop: wind. Wind is an inexhaustible resource that offers farmers a reliable revenue stream that requires no tilling and is unaffected by droughts, floods or insects.

Wind is spurring economic development in rural America and offering farmers financial security.

“Leasing land to wind power helps keep our family farm in the black,” says Tim Hemphill, a lifelong hog, corn, and soybean farmer from Milford, Iowa. Hemphill leased part of his farmland for a wind project that has helped increase and diversify his sources of income.

Hemphill is not alone. Wind projects yielded more than $245 million in annual landowner lease payments to farmers and ranchers in 2016 alone, according to the U.S. Wind Industry annual market update. That number is expected to grow an additional $1.2 billion in the next couple of years.

Wind energy generation also saves about 226 gallons of water for every American each year, finds the American Wind Energy Association. This provides a major benefit for rural livelihoods that depend on the significant use of freshwater to raise livestock or grow crops.

Wind energy is clearly helping farmers maintain their lands and preserve them for future generations. According to a recent survey, Michigan landowners with wind turbines on their property: • • • •

Invest twice as much in their farms through home improvements, field drainage, and irrigation and farm equipment than landowners in townships without wind farms.

Bought more farmland in the last five years than other landowners.

Are more likely to believe their land will be farmed in the future than other landowners.

Are more likely to have a succession plan in place for their farm than other landowners.

At a community level, wind projects can be the largest source of county tax revenue. In most states, wind projects help pay property, sales, and income taxes that support public infrastructure.

Navigant Consulting anticipates new wind projects will provide a cumulative $8 billion in tax revenues between 2017 Wind energy is a drought-resistant cash crop that farmers and ranchers rely on to make a living and keep their land in the family. Throughout 2016, U.S. wind projects paid at least $245 million in lease payments to landowners. The local taxes they pay help rural communities afford infrastructure, such as roads, and essential personnel, such as teachers. According to 2016 statistics, landowners in seven states received annual land lease payments in excess of $10 million, led by Texas. (Source: AWEA)

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W I N D W A T C H

In most states, wind projects help pay property taxes that support public infrastructure.

A LEASE ON WIND For over a year, distributed wind energy developer United Wind has offered its WindLease program through the Farmer’s Business Network (FBN), which is the largest independent farmer-to-farmer network in the United States.

WindLease lets FBN members lease a small wind system for no money down to stabilize electricity costs over the long term and save on utility bills. United Wind handles turbine construction and O&M with zero upfront costs. Farmers simply pay a fixed monthly rate for their electricity needs.

“FBN members operate complex businesses. They are always looking at ways to improve their bottom line and ensure the sustainability of their farm,” said United Wind CEO Russell Tencer in a press statement. “Our WindLease provides a turnkey solution to meet those objectives while turning wind into a source of economic gain.”

and 2020. That money is improving the quality of life for farmers, their families, and community.

Wind energy provides farmers with a fixed priced, zero-emission energy source. Farmers can work the land while protecting themselves, their land, and the nation’s food supply.

“For farmers, wind energy is a crop to harvest with no expense or risk,” says Keith Iseler, a retired Michigan dairy farmer. “There’s no need to plow, plant, harvest, haul, or store. No expenses for land, tillage, fertilizer, fuel, herbicides, and pesticides. And no machinery costs." W WINDPOWER ENGINEERING & DEVELOPMENT

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R E S E A R C H

ESA changes could benefit wind developers ON JULY 25, 2018, the U.S. Fish and Wildlife Service (USFWS) and the National Marine Fisheries Service (collectively, the “Services”) released proposed revisions to the Endangered Species Act (ESA). The regulations aim to improve the efficiency and effectiveness of the ESA and, according to Stoel Rives law firm, should assist wind developers.

The ESA mandates all federal departments and agencies to conserve federally listed species.

Section 7 of the Act outlines specific procedures for interagency cooperation and conservation of the listed species.

“In the context of the wind industry, these proposed regulations should assist wind developers to the extent that the proposed project requires federal permits or is developed on public lands and requires a Section 7 consultation,” shares Cherise Gaffney, a partner in Stoel Rives’ Environment, Land Use, and Natural Resources practice. Specifically, the proposal seeks an expedited Section 7 consultation process for projects that have predictable and minimal adverse effects on listed species or critical habitat and provides clearer guidelines for the initiation of formal consultation.

“Additionally, the USFWS' proposal to remove the blanket rule that automatically extends the ESA's ‘take’ prohibition to threatened species under its management has the potential to provide regulatory certainty for certain activities, including wind development,” adds Gaffney. She gives the example, the USFWS' northern long-eared bat 4(d) rule. “This rule tailors protections to areas where bats may be affected by white-nose syndrome during sensitive life stages, thus focusing on specific threats to the species. It permits other activities that do not harm the species to continue.”

For a complete summary of the Services proposed rules, visit tinyurl.com/ESA-regulations W

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The proposed ESA rules should improve regulatory efficiency and environmental stewardship. Project developers will want to review the proposed species listing and critical habitat changes carefully, however. This is particularly true for projects in areas where a species may be a candidate or proposed for listing.

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Wind work around North America Wind is hitting new records in America, according to AWEA’s second-quarter report.

The U.S. wind industry installed 626 MW this past quarter, bringing year-to-date installations to 1,032 MW. The new projects mean American wind capacity surpassed 90,000 MW nationally, extending wind’s lead as the largest source of renewable energy capacity in the United States. AWEA attributes the strong demand to the low cost of wind power, which is attracting utilities and major corporations such as AT&T and Walmart. In fact, corporate customers accounted for 56% of newly contracted wind capacity in the second quarter, with utilities committing to the remainder. (To view AWEA’s quarterly report, go to awea.org/2q2018).

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Vestas received an order to repower two Washington wind farms: the Marengo Wind and Marengo II Wind, commissioned in 2007 and 2008, respectively. The order is for 216 MW of Vestas’ V100-2.0 MW turbine components, excluding towers. Repowering will begin in the second quarter of 2019 and is expected to reduce operating costs and increase the wind farms’ annual energy production.

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Offshore wind coming to Atlantic City

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Ørsted is moving forward with its Ocean Wind project, planned for about 10 miles off the coast of Atlantic City, NJ. The company recently deployed AXYS’ FLiDAR WindSentinel, a floating LiDAR device that measures wind and wave conditions. The buoy will determine the ideal locations for wind turbines. The New Jersey lease is 160,480 acres, with the potential for 1,000 MW of offshore wind.

2

PacifiCorp’s Energy Vision 2020 approved

PacifiCorp gained final state approvals for its Energy Vision 2020 plan. The initiative includes three new wind projects in Wyoming, for a total capacity of 1,150 MW, and a new 140-mile high-voltage transmission line. The company also plans to repower 900 MW of its existing wind in Wyoming and Washington, upgrading turbine blades and components to boost power output by more than 25%.

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AT&T commits to wind & education

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Wind Catcher gets the ax

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More solar & wind planned for Virginia

Ohio public hearing set for Republic Wind

The Ohio Power Siting Board will hold a public hearing for Apex Clean Energy‘s proposed 200-MW Republic Wind Farm.

The Ohio project would consist of up to 58 wind turbines, across about 24,000 acres of leased private land in parts of Seneca and Sandusky counties. The hearing is on October 2, 2018, at 6pm in Green Springs, Ohio. View details at tinyurl.com/ RepublicWind

New projects added to Iowa’s Wind XI

MidAmerican Energy has selected Mortenson to build two wind farms in Iowa, as part of its 2,000-MW Wind XI project. Together, the new Arbor Hill and Ivester wind farms will provide 341 MW, and are Mortenson’s 16th and 17th wind projects built in the state for MidAmerican. The Wind XI project will include 1,000 wind turbines and is scheduled for completion in December 2019.

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Vestas to repower Washington wind farms

AT&T is expanding its renewable energy program with NextEra Energy Resources, with plans for 300 MW of power from two new wind projects in Wilbarger and Hardeman Counties, Texas. This adds to its earlier investment in wind facilities in Texas and Oklahoma. AT&T also committed $50,000 to develop the AT&T Wind Energy Scholarship fund at Texas State Technical College.

The $4.5 billion Wind Catcher Energy Connection was a proposed 2,000-MW wind and 350-mile transmission line project that would have delivered low-cost, clean energy to American Electric Power’s (AEP) customers in Louisiana, Arkansas, Texas, and Oklahoma.

However, AEP has nixed the Wind Catcher plans after Texas’ Public Utility Commission denied approval of the project.

Dominion Energy Virginia aims to develop 3 GW of new solar and wind by 2022, as part of its Grid Transformation & Security Act. The plans seek State Corporation Commission’s approval for Dominion’s proposed Coastal Virginia Offshore Wind Farm, a 12-MW MidAtlantic project. A two-turbine test project is currently underway with offshore wind developer, Ørsted.

WINDPOWER ENGINEERING & DEVELOPMENT

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8/14/18 11:13 AM

FI NA NC E Michelle Froese Editor

Why “fintech” is a key investment tool for wind owners

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igitalization affects nearly all stages of a wind farm’s lifecycle. Software simulations and analytics are helping wind planners and owners maximize turbine placement and project developments.

Smart sensors and IoT-connected monitoring software mean wind turbines can often selfdiagnose or predict component failures before they happen. It makes sense for wind owners to leverage a similar digital platform to optimize financial costs, gains, and long-term project plans. Enter the world of “fintech,” or financial technology.

“Fintech is simply the application of modern technology to any sort of financial process or project, including renewables such as wind and solar energy,” explains Benjamin Cohen, the Founder and CEO of T-REX, an enterprise solutions provider for renewable energy project finance. “The end goal is to manage risk, improve capital costs, and maximize those important returns on investment.”

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A cash flow report of a wind energy portfolio. By eliminating manual processes and automating workflow, a quality fintech platform can offer wind developers and project owners speed, efficiency, and security across all of their financial investments.

Much like a wind turbine’s predictive monitoring software, a quality fintech platform collects, manages, and analyzes data, providing users with suggestions to optimize their project. “However, in this case, the aim is to optimize a project’s financial health rather than its asset health.”

According to Cohen, there are two reasons this is important in the current renewables’ market. The first is operating capacity.

“It is virtually impossible for humans to match the speed and performance of a fintech program by using conventional financial models or programs.”

He says T-REX’s QA backend software runs over 2,000 automated checks on calculations in the platform. One benefit of such scrutiny: “A wind operator could ensure a project’s revenue-driven O&M costs are adjusted for every power purchase agreement nuance in an hourly PPA contract.” Given

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AUGUST 2018

8/14/18 11:25 AM

WINNING THE BATTLE

AGAINST BEARING WEAR Bearing failures are the most important issue in wind turbine gearbox maintenance, accounting for 70% of gearbox failures*. Castrol® Optigear® Synthetic CT 320 retains half the water PPM on average than our nearest competitor using similar types of chemistry**. By choosing Castrol Optigear you can increase your bearing life by 50% and win the bearing life battle.

If you want to get the lowest water content in the field opt for Castrol Optigear Synthetic CT 320.

For more information go to castrol.com/windenergy or call 1-877-461-1600

WATER vs. BEARING LIFE

(R.E. Cantley Formula, Timken Corp: Circa 1977) 2.5

Relative Bearing Life

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1.5

70 ppm avg. (Castrol CT 320 in-service data) 92 ppm avg. (nearest competitor published data)

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198 ppm (nearest competitor in-service data) 0.5

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*WEU Operations and Maintenance Report 2016. **Based on sample data available to Castrol.

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FINANCE

T-REX's software-as-a-service platform supplants spreadsheet-based workflow and allows collaboration. This means users can invite colleagues or counterparties to share data and collaborate on projects, while assigning a level of seniority based on a recipient’s role.

that wind PPAs are dynamic contracts, financial models should account for variability such as fluctuating O&M costs.

Here’s a simple example: “A wind developer projects an annual revenue of $100 for a PPA with a set O&M cost of $5. If year one of the contract generated only $90, O&M costs should be adjusted to commensurate with the revenue — so to $4.50.” Cohen says a fintech platform’s “analytical engine” must be built for such PPA nuances to provide precise risk and financial analysis.

The second reason relates to the nature of renewable energy. Fintech is particularly helpful to investors and owners of wind projects, which may produce variable returns depending on energy demands and winds. “Given the variable nature of renewables, typical project finance tools are unable to provide the analytical precision required to properly assess and price related financing risk,” says Cohen. “As a result, many high-potential projects fail to receive adequate funding.”

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The problem is typically one of data management. “Many of our clients already have a wealth of data, but are unable to fully sort through or leverage their datasets to make the wisest investment proposals or financial decisions,” says Cohen. Proposing a project at a low to medium-speed wind site, for example, may seem too risky to investors without a solid financial model that demonstrates viable returns.

With a quality platform, however, fintech users can incorporate and analyze information from many different datasets. “In wind, jurisdiction matters.

So a wind project in New York will typically present different challenges relating to siting, permitting, logistics, O&M, ROI, and so on than a project in Texas. Ideally, each project requires a different investment strategy, which accounts for every one of those parameters from a financial standpoint,” says Cohen.

“There are also considerations with the production tax credits winding down, and potential tax equity implications depending on where

components were purchased. Then, there are insurance cost considerations, and operations and maintenance budgets.” These are different data points but they are all relevant and critical to a project, explains Cohen.

“There are typically many areas of fragmentation across an entire workflow, but fintech can analyze each one and streamline the assessment process.”

The goal of investing in fintech is to optimize the capital structure of an asset or portfolio and gain better financial returns. To do so, wind owners must start with a financial platform built for the industry. Here are three questions to ask before choosing one.

1. Is it secure?

Unfortunately, all digital systems are at risk from cyber hackers. However, there are ways to mitigate risks.

“Global investment banks and other big regulated entities, such as utilities, are finding that data living on the cloud is more secure than on their own servers or in an Excel model — which can be downloaded and shared without

www.windpowerengineering.com

AUGUST 2018

8/14/18 11:29 AM

FINANCE

FINTECH MEETS BIG DATA T-REX recently partnered with Veracity, an open industry platform for digital innovation and collaboration by DNV GL.

restriction,” says Cohen. “As a result, our technology lives on Amazon Web Services, which is an outsourced cloud-based software.”

In the current digital era, it is important to verify the security measures of any financial program applied to wind assets. One way to do so is to ask about security audits.

“For example, a SOC-2 technology audit is completed by Ernst and Young on our security and software development protocols at least once a year,” he adds.

2. Is it collaborative?

Several parties involved in a wind project may be in different locations. So it is important to find a method to securely pass data or contracts back and forth without time lapses.

“A software-as-a-service, or SaaS, collaboration platform offers many advantages over conventional spreadsheet-based workflow,” says Cohen. SaaS is a method of software delivery that lets users access cloudbased applications or data from any device connected to the internet.

“One essential feature for renewable investments is the ability to quickly and seamlessly share project details with other parties in a transaction. This means standardizing data and eliminating the need for multiple spreadsheets or Excel models,” he says. SaaS lets users do just that. It also ensures the most recent document is accessible to each party at all times, so if changes are made they are not lost in the shuffle.

“Accurate, attainable data and clear communication are critical to successful partnerships and investments.”

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The companies will combine T-REX’s fintech platform with Veracity’s big data to quickly and accurately model, structure, and analyze potential renewable-energy transactions. In addition, the combined data platform will enable valuation reports and collaborate with counterparties, while providing actionable market intelligence.

Learn more at tinyurl.com/T-RexPlatform

Cohen recommends a cloud-based platform that lets users collaborate efficiently and more securely at each stage of the investment lifecycle.

“Just make sure the fintech platform you choose has a built-in controls, such as the ability to permission participants based on their role in a deal,” he says.

3. Is it bankable?

Reliability is one key to a quality fintech platform. However, it must also have the capacity to handle complex dataset calculations and simulate outcomes based on numerous inputs.

“Wind developers and financiers rely on multiple variables to make wise, bankable decisions. So analytical precision is key to risk mitigation,” says Cohen. “That means fintech must accurately account for multiple nuances — whether it is the variability of wind, unexpected O&M costs, or the fine print on a PPA — the more detailed an analysis the better.”

When choosing a financial platform, ask about its ability to manage inputs, analyze data, and perform checks and balances. “An efficient, reliable, and comprehensive fintech platform is a bankable one,” says Cohen. W

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8/16/18 9:48 AM

RE L I ABI L ITY Alistair Marsden Commercial Director Dulas

Choosing the ideal wind-monitoring device for a potential new wind site is critical to project development and success.

A deviation in wind-speed data of just 5% from predicted performance, for example, can impact project returns by 5 to 15% — and, ultimately, risk project financing or investment returns.

How to choose the best wind-monitoring device for project financing

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or years, meteorological (met) masts served as the wind-resource measurement instrument of choice for the wind-power industry. These free-standing towers come in different heights and hold the meteorological devices needed to measure important variables — such as temperature, and wind speed and direction — when siting wind farms. However, the introduction of SoDAR (sonic detection and ranging) and LiDAR (light detection and ranging) have given wind developers options.

Granted SoDAR, which uses sound to measure atmospheric conditions, has been used to assess wind conditions for several years and is typically deployed in addition to conventional anemometry. LiDAR is a comparatively newer option in the wind industry that applies light to measure atmospheric characteristics. There are many advantages to both of these remote-sensing devices, including fast and highly accurate data capture. However, these instruments come with a price point that may deter some developers.

So the question is: what device to choose?

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Data collection Accurate wind data is critical for effective siting of new wind turbines and securing project financing — which is the backbone of a new wind farm. Failure to fully assess the merits of each measurement device (a met mast or remote sensing), or effectively deploy the selected technology, can lead to serious financial repercussions. In fact, data quality can make or break a project’s development.

Prior to selecting a measurement device, it is important to consider site-specific factors, such as: • • • •

Landowner issues Site conditions, including weather and accessibility Onsite obstacles, such as complex terrain, trees, or pre-existing infrastructure Data requirements for financing and permitting, such as measurement location and heights

A bankable wind measurement campaign includes a high degree of quality data and thorough documentation, proper selection of measurement locations, and a reliable measurement instrument.

www.windpowerengineering.com

AUGUST 2018

8/15/18 9:24 AM

RELIABILITY

Most investors also require a minimum of one year of onsite wind data. Inaccurate or insufficient site information is one way to risk bankability.

Therefore, it is important to choose a windresource measurement device wisely.

Met masts Remote-sensing units are becoming increasingly competitive. However, met masts retain a key advantage as the industry standard for data collection and assessing project bankability. Met masts have been the go-to measurement device since the early days of wind siting, and are well-recognized by financiers.

A strong second-hand market means these instruments provide a cost-effective choice, particularly compared to SoDAR or LiDAR devices.

Previously owned or refurbished met masts may be passed on to new developers or reused repeatedly.

However, these instruments have limitations and upfront cost is a poor deciding factor of successful siting (or financing).

Met masts typically require siting permits, which can take months to obtain. Their maximum height (about 160m or 525 ft.) and lack of versatility may present planning and operational challenges in the field. This is particularly true as developers choose taller towers to take advantage of stronger winds.

Met masts’ measurement instruments (such as its cup anemometer used to measure wind speed) are also susceptible to mechanical failure and lightning strikes.

Historically, met masts fitted with data loggers, wind anemometers, and other measurement devices, have been used to gain valuable wind data for siting and financing.

Remote-sensing devices, such as LiDAR and SoDAR, are providing wind developers with new choices for their windmeasurement campaigns.

A strong second-hand market means these devices provide a cost-effective choice, particularly compared to SoDAR or LiDAR devices.

It is important to assess these risks, and consider the site conditions and location, before banking on met masts.

Remote-sensing devices One compelling argument for choosing SoDAR or LiDAR units is the range of data captured compared to met masts.

By emitting a laser beam or sound pulses and measuring the return signals, LiDAR and SoDAR units AUGUST 2018

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RELIABILITY

This ZephIR 300 wind LiDAR is capable of measuring wind speeds and additional characteristics from as low as 10m (32 ft.) to as high as 200m (656 ft.).

provide information on numerous wind characteristics, such as wind speed, shear, and direction — and up to heights of 200m (656 ft.). These devices can also measure wind across the full sweep of a rotor blade, providing more bankable data.

What’s more is these remote sensors offer flexibility.

They can be ground-based or mounted, and are easily transported at and between sites. But they will cost and can range up to more than double in price than a met mast. In addition, there is reluctance among some lenders to rely on remote-sensing data for project financing, but this is expected to change as the technology gains greater adoption and acceptance within the industry.

The right choice One key to choosing the ideal method of data collection for a project is careful site evaluation. No two regions are alike, so assessing the physical and logistical features of a site is required. For example, complex terrain such as that found in mountainous or forested regions is more likely to affect the reliability of A new report, Enhanced Data and Enhanced Returns: Getting the best from wind monitoring technology, explains how wind investors and developers can maximize their financial returns through successful deployment of wind-monitoring technologies during project development. It is available for download at tinyurl.com/ WindMonitoring

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remote-sensing data. Similarly, a boggy or overly firm ground can present challenges to erecting and installing met masts.

Local policies or restrictions may also vary between regions and countries, such as the ability to deploy a met mast above a certain height. In addition to practical considerations, there are financial ones. For example, it is important to ask: would an extensive range of data outweigh the upfront costs of investing in remote-sensing technologies? Or: are we dealing with an investor who has a track record of investing in data from met masts?

For some projects, co-location is the ideal choice, which means using remote sensing and a met mast. If time or data quality is a concern, the two instruments may provide quick access to a wider range of information at multiple locations (or wind sites). Co-location may also offer increased bankability because the data obtained from both devices can be compared and validated. While cost restrictions may apply, co-location is typically the most sensible and successful option for a reliable resource assessment.

There are many factors to consider when siting a new wind farm and securing financing. Developers will often seek advice from a consultancy that’s experienced in site assessments and wind measurement campaigns. Ultimately, developers and investors who consider a range of factors, rather than just what device was used for wind measurement, may derive the best value from these campaigns.

As a new report entitled, Enhanced Data and Enhanced Returns: Getting the best from wind monitoring technology, states: “The choice between met masts and remote sensing units is not a zero-sum game — both have a role to play in an integrated approach to wind resource assessment that factors the technology, site conditions and project timeline and resource budgets into the decision-making process.” W

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AUGUST 2018

8/14/18 11:36 AM

Wind Technician PPE Petzl work at height solutions are designed to be lightweight, durable, and easy to use while maintaining the highest quality standard for at-height professionals. From the line of VOLT harnesses, to the standard setting VERTEX helmets, and the innovative shock absorbing ABSORBICA lanyards, Petzl’s ANSI compliant solutions deliver the perfect balance of comfort and reliability. www.petzl.com

Petzl America — Windpower 08-18.indd 21

8/14/18 3:34 PM

One ANSI/ISEA 121-2018 requirement is that dropped object prevention (DOP) products go through “dynamic drop testing” before considered fit for use. This form of testing involves dropping a secured object of known weight multiple times.

The only way to pass the test is if the DOP device, such as a tether securing a tool, successfully prevents each drop.

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www.windpowerengineering.com

AUGUST 2018

8/14/18 1:32 PM

l a n o i t na s d r a d n sta A LOOK AT NEW

T N E V E R P O T D E N G I DES

DROPPED OBJECTS

WIND TECHS CLIMB great heights to perform maintenance tasks uptower. According to the American Wind Energy Association, during work at heights, “all tools and parts must be secured to an employee’s body with a lanyard.” This is sound advice, but how does one confirm that a tethering system used is safe? Also, what about the safekeeping of objects such as water bottles, hard hats, cell phones, or tablets?

One accidentally dropped cell phone off an 80 ft. turbine tower, for example, could severely injure workers on the ground. Although cell phone holsters and safe storage pouches exist for workers at height, unfortunately, there’s been a lack of standards to guide tool manufacturers and engineers on the proper safety criteria of tethering products — until now.

Over the past two years, several safety equipment manufacturers (including Hammerhead Industries) have worked with the International Safety Equipment Association (ISEA) to develop a standard for products designed to prevent dropped objects. The ANSI/ISEA 121-2018 is a significant first step in reducing dropped tool incidents.

The standard ANSI/ISEA 121 Dropped Object standard was officially released in early July 2018. The new guidelines set muchneeded minimum design, performance, and labeling requirements for devices that reduce dropped object incidents in industrial and occupational settings.

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JOHN SALENTINE HAMMERHEAD INDUSTRIES, INC.

A small one to two-pound wrench might not seem like much of a safety hazard, but an accidental drop from atop of a wind tower could result in life-threatening injury. A new national standard aims to reduce dropped objects at work sites, such as wind farms.

The standard provides design, testing, and performance criteria to guide manufacturers and workers in the production and selection of safe tethering and lanyard systems.

windpowerengineering.com

WINDPOWER ENGINEERING & DEVELOPMENT

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A LOOK AT NEW

national DESIGNED TODPRROEVPPENEDT O BJECTS standards

Gear Keeper TL1-3044 Fixed End Tool Tether AL Double Action Locking Carabiner with captive eye 15 lbs / 6.8 kg 48” / 122 cm An ANSI/ISEA – 121 compliant tether, which has been fully tested as outlined by the new standard, and is labeled in accordance with ANSI’s labeling requirements.

The standard focuses on preventative measures, actively used by workers to mitigate risks of dropped objects or tools. Four main categories of products are referenced in the guidelines: 1. Tool tether: A length of material with at least one connector on each end, which connects a tool to an anchor.

2. Attachment point: A device, such as a buckle or D-ring, that connects to a tool so it can safely attach a tether.

3. Anchor point: The point on a person or structure used to attach a tool tether.

4. Anti-drop storage: Stationary storage, such as holsters or pouches, which hold or tether to gear to prevent drops. Also, portable containers, such as tool or lift bags, used to securely hold or transport tools or other equipment.

Tool tether regulations ANSI/ISEA 121 compliant tethering systems list many devices (e.g. tool attachments, lanyards, carabiners, and anchor points) that work safely together, including equipment from different ANSI/ISEA 121 compliant manufacturers. It does not yet tell when or how to correctly tether such tools. However, a few recommendations are included in the appendix.

The ISEA is also continuing to work with manufacturers and end users (such as wind techs) to develop additional online resources, including tips on effectively applying the standard to work-at-heights programs and policies.

According to new the guidelines, a tool tether’s length and weight of the object it carries are two critical elements of safe tethering. The ANSI/ISEA standard takes both into

W EI GH T & L E N G T H C O M PAT I BI L I T Y E XA M PL E

Tool Tether 10 lbs / 4 ft. length

Anchor Point 15 lbs / 4 ft. length

Tool Attachment 5 lbs / 4 ft. length

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www.windpowerengineering.com

A tool tether’s length and the weight it can safely carry are keys to safe tethering. The tether’s rating must meet a tool’s weight, while keeping within the limit of the anchor point. Gear Keeper has created a short video with additional information tinyurl. com/SafeToolTethering

AUGUST 2018

8/14/18 1:32 PM

N AT I VE T O O L T E T H E R P O I N T S

Anchor Points or Hang Holes When tethering tools and other small objects that have built-in attachment points or hang holes, ANSI/ISEA recommends users contact the tool manufacturer to ensure the native attachment point is compliant with the new tool-attachment testing requirements.

consideration and lets users safely couple components that meet the length and weight ratings. Here’s a summary of the guidelines for tool tethers: • • •

•

ANSI/ISEA 121-2018 is a significant first step in reducing dropped tool incidents.

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The rated tool attachment must be greater than or equal to the weight of the tool it carries.

The tether and anchor weight limit must be equal to or greater than the weight allowance of the tool attachment.

The tool attachment and anchor point must have a maximum lanyard length for which the weight was tested (this means that if the tool attachment or anchor point has a specific weight that was tested for a 4-inch tether, it’s unsafe to use a 6-inch tether).

Tethers also now have a maximum length.

Sound complicated? Consider this example: you have a 5-lb tool and a 4-ft. tether with a 10-lb weight limit. You also have an anchor point with a 15-lb weight limit. In this case, the tool is approved for safe tethering.

Why? The 5-lb tool weighs less than the tether’s 10-lb weight rating, so the two are compatible. In addition, the tether meets the anchor point’s maximum 15-lb rating. In this example, the tether’s weight is the maximum weight acceptable for safe tethering and key to meeting the standard. The tether’s rating meets the weight of the tool while keeping within the limit of the anchor point.

However, what if a worker has a tether with a higher weight rating than the anchor point’s rating? According to the guidelines, it is safe if the maximum weight rating of the entire system (tool, tether, and anchor point) is the lowest weight rating. This means windpowerengineering.com

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national DESIGNED TODPRROEVPPENEDT O BJECTS Offshore standards A LOOK AT NEW

pairing a 15-lb tool tether with a 10-lb anchor point is safe — if the tool attached has a maximum weight of 10 lbs.

Product labels ANSI/ISEA 121 requires safety equipment manufacturers to provide instructions on how to use tethers, attachments, anchors, and containers on product labels. Here’s what is required: • • • • • •

The product manufacturer’s name, trademark or other means of identification.

The device’s identification number, date of manufacturing, and/or serial number. This information allows for product tracking.

The device’s rating capacity, identified by weight.

The tether length (for tool tethers only).

The maximum tether length (for anchor points, attachments and, if applicable, containers).

The ANSI standard number. (Ex. ANSI/ISEA 121-201x).

Keeping workers safe at job sites should be everyone’s responsibility, including manufacturers and wind owners and operators. For more information or to purchase a copy of the ANSI/ISEA 121 standard (it costs $30), contact the ISEA: http://tinyurl.com/DroppedObjectPrevention W

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STOP THE DROP ANSI/ISEA 121-2018, American National Standard for Dropped Object Prevention Solutions establishes minimum design, performance, and labeling requirements to prevent dropped-objects incidences at work sites.

The International Safety Equipment Association (ISEA), in conjunction with industry stakeholders, has developed this standard to establish design, testing, and performance criteria for active systems. The standard is a first-of-its-kind to address equipment used to tether and/or contain hand tools, components, structure and other objects from falling from at-heights applications.

What the standard covers. ANSI/ISEA 121-2018 requires manufacturers to provide instructions on how to use tethers, attachments, anchors, and containers. However, it is ultimately the responsibility of safety professionals and end users to evaluate their work environment to ensure workers at heights and on the ground are safe from falls and dropped objects. For example, wearing multiple tethers adds weight. If excessive or unevenly distributed, the tethers increase the risk of a worker losing his or her balance and falling. The devices may also get stuck on ladders or tangled in machinery. It is important to use fall protection and dropped-object products with extreme care.

What the standard does not cover. The current standard does not address passive preventative solutions such as netting, barricades or toe boards. It also fails to address protective solutions for dropped objects that minimize damage from falling objects including head protection, foot protection, and eye protection. Hoisting and lifting requirements for material handling are covered separately, in other applicable standards.

www.windpowerengineering.com

AUGUST 2018

8/14/18 5:00 PM

B O LT ING C r a i g Wa l k e r Contributor

Three ideas for safer, more efficient bolting jobs

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f you’ve ever pinched your finger when bolting items together, you know the feeling’s unpleasant. I had a painful pinch reattaching the rear wheel of my son’s bicycle after repairing the flat. I can only imagine injury from pinching a finger when bolting the tower of a wind turbine together. Lucky for me, the only damage was a small blood blister but wind technicians and manufacturers face a greater risk of serious injury. In fact, hand injuries from misuse of tools are the number one cause of injury for wind techs.

When a tech assembles or repairs parts of a wind turbine, he or she typically uses powerful hand tools that are heavy and harmful if used incorrectly. Hydraulic powertorque wrenches have pinched off fingers because of improper use. Bolts can easily be over torqued and broken if the settings are incorrect, potentially causing harm.

While it’s important to follow a tool’s safety instructions, claims may be misleading. A manufacturer may use the term “ergonomic” or “ergonomically designed” without fully verifying the claim.

What’s more is that wind farms are typically in remote locations, nowhere near hospitals or emergency care. This means medical attention, if needed, may be hours away. So the best course of action is prevention: know your tools, assess the risks, and apply proper safety procedures — then double-check settings and positions for good measure.

To prevent hazards associated with the use of power tools, the Occupational Safety and Health Administration in the U.S. says all power tools must be fitted with guards and safety switches. Safety gear, such as goggles and gloves, must also be worn to protect against hazards. Visit osha.gov and type “tools” in the search bar for more tips.

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B O LT I N G

Bolting accessory developer, Hands Free Bolting, says its BackUp Nut improves tool operator safety and may prevent injuries caused by dropped objects. The device holds bolting tools in place during operation to allow hands-free operation. It also works with a range of tools, regardless of brand. The company offers more tips for safer bolting at tinyurl.com/HandsFreeBolting

Here are three tips that, if applied, may make bolting tasks safer and more efficient.

1. Choose one to get it done If a job requires multiple tools, such as bolt tensioners, as well as torque and impact wrenches, consider a minimalist approach. This reduces the chance of mistakes when swapping one tool for another. For example, depending on the task, one electric tool may replace several pneumatically powered ones.

Although pneumatic tools may offer a better power-to-weight ratio, demand for electric tools is increasing because of improvements in capability and accuracy (meaning the precision with which the tool delivers torque).

For example, Norbar says its EvoTorque 2 electric-torque multiplier delivers torque to within 3% of its setting. It is also extremely compact, which is a benefit to those working in the confines of a nacelle.

Electrically powered tools can be corded or battery powered. The battery powered ones are typically

safer (no cords to trip on) and easier to use (with a simple on & off switch). New models may also offer considerably longer run times, thanks to advances in lithium-ion batteries. One other plus of going electric: no pump or hoses.

Of course, it is important to choose the ideal tool for the job whether it’s a pneumatic or an electric device. However, if it is possible to limit the number of tools brought uptower, this may be the safer choice.

2. Keep it in the family To increase efficiency and safety, consider selecting tools from one manufacturer. Companies develop products with a unique approach to ergonomics, control systems, and safety lockouts. User interfaces on digitally controlled tools also vary by brand, so it’s advisable to stick with one manufacturer when possible. It’s alltoo-easy to miscalculate torque values or mistake degrees of rotation when using similar tools but from different manufacturers. Familiarity with one brand may reduce such errors.

Fortunately, advances in manufacturing mean tools are becoming smarter. For example, bolting HYTORC’s LION Gun is a precision bolting system with built-in data recording. Users can simply set the desired torque output on the tool’s display, and pull the trigger to get precise, repeatable torque without excessive noise or vibration.

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manufacturer HYTORC says its LION Gun precision bolting system offers built-in data recording. This means users can track and log completed bolting jobs for later reference.

In addition, Norbar’s EvoTorque 2 “memorizes” multiple targets, readings, and user IDs, which increases tool (and user) accuracy and accountability. Take advantage of such built-in features to increase tool safety.

3. Look, no hands Techs that use hydraulic torque systems typically work as a two-person team.

One technician operates the hydraulic pump control switch, while the other person correctly positions the hydraulic tool for the job.

To do so safely and effectively, both techs must communicate clearly, which is often a challenge in noisy or confined workspaces. However, as Hands Free Bolting company points out, if a pump is accidentally operated at the wrong time, it may result in the tool operator having fingers or hands trapped between the tool and reaction point. To

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B O LT I N G

Norbar says its EvoTorque 2 accurately applies electronic torque over a range of joints. It uses “intelligent joint sensing technology,” which continually measures the joint during tightening and, if necessary, employs dynamic braking to avoid torque over-shoot from motor inertia. In addition, if the supply voltage is outside its rated tolerance, the tool will not start.

prevent such incidents, the company has designed safe bolting accessories that are compatible with all major brands.

For example, it offers a Back-Up Nut for these two-person jobs, which lets one technician step away from the torque wrench after it’s positioned onto the bolt.

This allows safe, hands-free operation of the pump and reduces the risk of a dropped object. Hands Free Bolting also offers a Safety Valve that fits between the hydraulic power pack and hydraulic torque tool. If the trigger is released, hydraulic power is automatically cut so the tool operator can re-locate the tool without concern of accidental tool activation.

The danger of power tools is evident in the thousands of emergency room visits they account for each year. Many of those visits are caused by misuse of tools or failure to uphold safety standards. Always follow the manufacturer's instructions, inspect and maintain tools before use, wear personal protective gear, and know your work environment. W

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S AF ETY L e e Te s c h l e r Executive Editor

Evaluating arc flash hazards in wind turbines It can be tough to get arc flash labeling right on wind farms.

E

lectrical safety instructor Redwood Kardon tells this story about arc flash problems on wind farms: “Five years ago, when I would go out to a facility, they would say, ‘Oh, we're going to start (arc flash analysis),’ or, ‘We've hired an engineer.’ They didn't have arc flash labels in place. Now, most facilities have arc flash labeling but the workers don't know what the labels are for, and they aren’t trained in how to interpret them.”

An inability to understand an arc flash label can be a potentially lethal shortcoming. Viewing a few of the numerous YouTube videos of actual arc flash events generally gives viewers a healthy respect for these mishaps.

An arc flash, of course, is the conductive plasma that can arise because of a short between high-voltage and high-current conductors such as bus bars. The massive energy discharge vaporizes the copper conductors and causes an explosive volumetric increase that comprises the arc blast. The fiery explosion can destroy everything close by, creating deadly shrapnel.

One of the primary defenses against arc flash injuries takes the form of warning labels. The National Electrical Code dictates that warning labels are displayed anywhere there is an arc flash hazard. The warning label must spell out the flash protection boundary, the incident energy level, and the kind of personal protective equipment (PPE) needed for safely working in the area.

An example of an arc flash study comes from Brainfiller Inc. Engineers would focus on the highest incident energies and make sure they are below the arc rating used for the equipment in question.

Brainfiller Inc. www.brainfiller.com

ARC FLASH CALCULATION STUDY RESULTS BRAINFILLER INDUSTRIES Bus Name

Voltage (kV)

Equipment Type

Arc Gap (mm)

Bolted Fault (kA)

Est. Arc Fault (kA)

Arcing TIme (sec)

Est. Arc Flash Boundary (ft)

Working DIstance (miles)

Incident Energy (cal/cm2)

PPE Level

MAIN SWGR

0.48

Switchgear

32

37.734

19.034

0.167

6.65

24

7.0

#2

PANEL 1A

0.48

Panel

25

27.368

15.497

0.050

2.13

18

2.7

#1

MCC-1

0.48

MCC

25

21.117

12.418

0.100

2.81

18

4.2

#2

PANEL 2

0.48

Panel

25

21.164

12.442

0.033

1.44

18

1.4

#1

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SAFETY

But labels offer little protection if workers fail to understand them. “People get confused about the protection boundaries mentioned in the labels,” says Kardon, who also founded an arc flash teaching company called the Code Check Institute.

Arc flash labels are one of the end results to come out of a formal arc flash hazard analysis. In a hazard analysis, data is collected about the physical arrangement of the facility's power distribution system. The data includes the arrangement of components on a one-line drawing. (A oneline drawing gets its name from the fact that it is a schematic representing the three phases of a three-phase system with a single line.) Also included are the lengths and cross-sectional area of all cables.

With the data collected, next comes a short-circuit analysis followed by a coordination study. A short-circuit analysis establishes the right interrupt ratings on protective switchgear. It is meant to head off the possibility of an electrical fault exceeding the interrupt rating of the device that is supposed to stop it. A coordination study ensures faults are interrupted by the protective device nearest to them. It also helps avoid nuisance trip-outs from transformer inrush or motor starting procedures.

Data from these studies get fed into equations described by either NFPA 70E-2000 or IEEE Standard 1584. These equations will produce the flash protection boundary distances and determine the incident energy and thus the PPE for personnel in the vicinity.

Wind-farm operators who conduct arc flash studies often do so at the direction of OSHA. “Some states administer their own program. But OSHA says that you must have a workplace free from recognized hazards,” says Jim Phillips, a P.E. who specializes in electrical power systems and founded an electrical training company called Brainfiller Inc. “OSHA references what's called an industry consensus standard. The one that is used most widely is a standard called NFPA 70E. It is 70E that calls for an arc flash study.”

Several factors complicate the procedures surrounding arc flash analysis. One of the more fundamental issues is the question of who is qualified to do the analysis.

“That’s controversial,” says Phillips, who also chairs the committee updating the IEEE 1584 standard for performing arc flash hazard calculations. “When we wrote the first draft of the IEEE 1584 standard, we included wording to the effect that only a licensed P.E. could perform the study. But we were practically tossed out of the room by people who weren’t P.E.s. So we had to backpedal a bit.

The standard now states the analysis must be performed by somebody who is trained and knowledgeable, but it has to be done either by or under the direction of a licensed P.E. Of course, people who are not P.E.s just ignore that.”

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There are different levels of personal protective equipment (PPE) prescribed for use during electrical work depending on the expected arc energies. This technician is working on a transformer in a nacelle.

(Image: Code Check Institute – www.codecheck.com)

An example of a one-line drawing used in an arc flash study of a wind turbine.

(Image: Code Check Institute)

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Consequently, the quality of arc flash studies can vary. “I have been contacted by many people asking about how to perform these studies,” says Phillips. “The questions they often ask are so fundamental, it makes you think they have no business doing one. Technically, there is no hard and fast guidance on who can perform arc flash studies, but individual state engineering licensing boards should probably call the shots.”

The end result of an arc flash analysis is a set of warning labels designed to both caution workers about arc flash dangers and provide guidance about how close workers with specified levels of protective clothing can approach. One problem is that arc flash labels can be confusing to the untrained eye.

“They’re labels with a lot of details,” says Phillips. “The label will spell out something called an arc flash boundary. I don’t want to call that boundary a safe distance, but it is a safer distance for unprotected people to stay behind. The label also designates the kind of protection to wear, and it can do so in different ways.

It can use either the calculated incident energy, which is basically the severity of the arc flash, or it can use what's called a category scheme, which dictates

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certain levels of protection. Basically, the label is for the worker to look at and recognize, ‘Oh, unprotected people should stay back X distance. And if I'm doing the work, I have to wear X type of PPE.’" New arc flash calculations A further complication for those in the process of setting arc flash limits is that the calculations used in the IEEE 1584 arc flash standard are about to change.

Expectations are that revisions to IEEE 1584 will be out by the end of the year.

“I often get asked what changed. The easier question is, What didn't change?

The title is still the same. Everything else has changed, top to bottom,” Phillips. For example, the equations are completely different. There's the first round of calculations and then there's a whole series of adjustments for your specific voltage. It's a really complex calculation.”

However, the software normally used for running arc flash calculations will be updated as soon as the new standard emerges. “Each of the major software companies have representatives on the committee,” says Phillips. “As we’ve been developing the equations, they have been getting geared up. They're just waiting for somebody to say, ‘Go,’ and all the new software will be out.”

The aftermath of an arc flash event in a switchgear enclosure of a wind turbine.

(Image: Code Check Institute)

One change that is likely to impact wind farms is a move to have the standard cover a wider range of enclosure sizes. The original 1584 spec only mentioned two enclosure sizes. “The new standard covers a lot more choices for enclosure sizes and adjustments for enclosure sizes,” says Phillips.

Also changing is something called the 85% rule. “The 85% rule is going away,” says Phillips. This rule pertained to calculations of arcing short-circuit current and under what circumstances estimates of its intensity could be relaxed somewhat for calculations of fault clearing time. Also gone from the revised standard are provisions for 125 kV-A transformers.

“The thought was if you're down to 208 V and have a limited short circuit current, the arc would be less likely to sustain and be substantial. We found in the lab that this is not quite the case so that rule is being changed dramatically,” says Phillips.

Those are the highlights of the new standard. There are other aspects of it that may yet change before its release at the end of the year. W

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LIGHTNING Simon Searle Applications Engineer Megger

Photo: iStock

The importance of testing wind-turbine lightning protection

O

ne of the most significant hazards wind turbines face is damage from lightning strikes. Damage claims caused by strikes are one of the top payouts from insurance companies. A recent German study found that up to 80% of insurance claims relating to turbine downtime were from lightning-related damage. In fact, lightning accounted for nearly 85% of one commercial wind farm’s downtime in the United States — costing the owner an extra $250,000 in the project’s first year of operation.

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Another large wind farm in the North Sea, near the German island of Helgoland, suffered such large losses because of lightning strikes that its operation was no longer cost-effective.

Lightning faults are unlike typical electrical faults and cause a greater loss in wind-turbine availability and production. The number of failures due to lightning strikes is known to increase with tower height, and a number of studies indicate that rotating wind turbines may be more susceptible to lightning strikes than stationary structures.

windpowerengineering.com

Given that turbine heights are expected to increase and the industry is growing, the number of turbine failures is likely to rise as well.

Lightning damage to turbines is often attributed to inadequate strike protection, incorrect or insufficient bonding and earthing (grounding), and insufficient transient protection. In addition to a direct strike to a blade, high-energy over-current and over-voltage transients induced by direct and indirect lightning strikes can cause significant damage when these massive structures are left unprotected.

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A wind tech, suited up in fallprotection gear, safely rappels down to a turbine blade to test the asset’s lightning-protection system during an onsite O&M visit.

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Proper protection & testing One way to reduce the likelihood of strike damage is to build lightning protection directly into wind turbines. This form of protection follows a low-resistance path to ground and travels from a turbine blade’s tip to the base of its tower. In the event of a lightning strike, current flows through the protection system and directly to ground, avoiding sensitive equipment in the machine.

It is critical the protection system stays online at all times, and works immediately when required. To do so, the resistance of the path to ground should be measured at regular intervals, ensuring it meets the limits specified by the turbine’s manufacturer (typically, the path is limited to 15 to 30 mΩ, but this depends on a turbine’s size).

For such a test, it is best to use a lowresistance ohmmeter. The most important device

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to test is the conductor inside the blade. This measurement is taken between the blade’s tip and root. A current of one ampere or more is recommended for the test.

However simply checking the continuity, which verifies the flow of an electrical current, is insufficient. This is because the conductor may undergo a significant amount of strain and fracture as the blade flexes in the wind.

If the fractured conductor is touching at the breakpoint during a continuity test, it may still pass the test.

The problem with blades The length of wind-turbine blades is a challenge when testing built-in lightning protection because low-resistance continuity test leads are typically extremely short. Adequate testing requires extra-long leads that are often up to 100m. In addition, these long leads must

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LIGHTNING

maintain a low enough resistance to ensure that accurate measurement is possible.

To achieve this, an understanding of the test instrument design is important. For example, some instruments have a compensation factor, which allows for power loss in standard test leads. When using long test leads, however, the compensation for power loss is insufficient and the test range of the instrument reduced.

How it works: When the resistance of the test leads is increased, the total value of “R” in the equation below will also increase.

P=I2R R = (resistance of load) + (resistance of test leads) P = output power of the test instrument I = output current of the test instrument

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Since the maximum power output (P) of the test equipment is unchangeable, the rise in test lead resistance will cause the maximum current (I) to diminish.

However, this principle may be used to an advantage. If the load is inductive, it may help if more power is supplied to charge the load. By reducing the length of the test leads, “R” will diminish.

In this situation, it is “P” that will increase slightly, as there is a little more power in the instrument than specified on the data sheet. This is intended to compensate for the losses of a few meters of test leads, but if the test leads are kept extremely short, then the extra power is available for the load instead. W

windpowerengineering.com

The wind-turbine lightning protection test lead set from Megger is available in a 328 ft. (100m) length, and is suitable for use on site or in the manufacturing plant.

The lead set is 10A rated and consists of two test leads.

The first cable is 16 ft. (5m) and the second is 328 ft.

(100m). The lead set offers reversible terminations.

One termination is a duplex handspike, and the other is a heavy-duty Kelvin clip.

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8/15/18 11:24 AM

DR O NE S Mike Kahn Chief Marketing Officer A E E A v i a t i o n Te c h n o l o g y, I n c .

Drone inspections of turbine towers and blades can save a wind-farm owner time, cost, and safety risks over rope-based inspections. However, it is important to choose a drone (or UAS inspection service) wisely. High-definition images are key to accurate turbine blade inspections, but first ensure safety measures are followed during flight.

How to choose the right drone to inspect your wind turbines

A

t the end of 2017, nearly 345,000 wind turbines were operational in the world.

What this means is more than 1,035,000 turbine blades are subject to wear, requiring regular inspections and care throughout their lifespan. Advanced drones, or unmanned aerial vehicles (UAVs), are transforming the wind O&M industry.

Drone inspections of turbine towers and blades can save a wind-farm owner time, cost, and safety risks over conventional, rope-based inspections. In fact, Navigant Research predicts the global wind-turbine inspection drone market to grow to $6 billion by 2024. There’s just one catch, and that’s cost.

The commercial choice The sticker price of a quality commercial drone can put a serious dent in the pocketbook. Windfarm owners and operators, for example, are spending up to $25,000 on one drone. Although quality automated turbine-blade inspection companies exist, there are project owners that prefer a DIY (do-it-yourself) approach. This is particularly true for owners of multiple wind sites.

The idea of buying one drone to service several sites sounds like smart budgeting.

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However, saving upfront O&M expenses may prove more costly down the road. Whether buying a UAV or outsourcing drone services for blade inspections, quality is critical for safe, accurate, and reliable results. So choose wisely.

Consumer drones are a fraction of the cost of commercial ones and may entice some windfarm owners. Unfortunately, consumer UAVs are unsafe to fly at wind farms. These devices lack a reliable ground station (the remote control system) and ability to operate safely or effectively in high winds. Consumer drones also lack the camera quality for high-resolution imaging and a software platform for data collection and analysis.

Drone operators must use extreme caution, and particularly near transmission lines and power plants (that includes wind farms). The Federal Aviation Administration or FAA’s (Part 107) commercial drone certification program is required and, unfortunately, has resulted in a number of amateur drone pilots providing wind inspection services. The concern is there are no additional regulatory qualifications required for wind sites above the FAA’s basic test.

Great skill and experience are necessary to pilot a drone near wind turbines. High winds, dust, and electromagnetic interference make smooth

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DRONES

drone piloting a challenge. An unexpected gust of wind could lead to a damaged blade or tower from a drone crashing into it (or even worse, crashing into people on site). A nick of a blade from a drone hovering too closely could also result in repair costs greater than the inspection.

A must-have checklist Increasingly, commercial drones are becoming autonomous, using algorithms to find the quickest and safest routes during blade inspections. Such capabilities will cost, however, and particularly when paired with other high-end drone features. These features may include extended UAV flight times to maximize the inspection time at a wind site (which is typically at a remote location), megapixel cameras with optical-zoom capacity for detailed imaging of possible blade damage, and a highdefinition video display.

So how should a wind owner cost-effectively choose a UAV or drone service, without compromising onsite safety or reliability of the inspection?

Here’s a checklist.

•

•

•

Safety. Flying in windy conditions and near turbine towers and blades present serious risks and visual obstructions. Drone pilots must adhere to numerous safety regulations associated with flight operation near structures. Know the rules and limitations of your drone.

A steady hover. Stability is a basic and necessary requirement of a drone conducting blade inspections. A UAV must find the set target, align its camera lens, and stabilize in flight for as long as necessary to return crisp and clear data and imagery.

This requires strong flight capabilities and a steady hover, even in high winds and harsh conditions.

Weatherproofing. High winds are a given at most wind sites, which means dust or debris is likely. Water from rain or snow is also a concern at some sites.

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With a 40-minute flight time, AEE’s Mach 4 UAV stays on target up to 10 minutes longer than other commercial drones and is equipped to handle winds up to 40 miles per hour. The Mach 4’s conformal coating IPX 55 rating also protects it against most weather conditions.

•

Consider a drone with a camera lens coating that protects it against foreign elements.

A stable, high-res camera. A quality blade inspection must provide as detailed a report as possible, including a slight nick in a blade or beginning stages of leading-edge erosion. A high-resolution camera with zoom imaging is non-negotiable for accurate and detailed data capture of turbine blades. For example, the Mach 4 commercial drone has advanced 4K optics with a 10:1 payload, which means the images it captures can be magnified by 10. Its 1080p live video downlink also lets maintenance teams view targets and footage in real time.

In addition, it is important to ensure a drone’s camera is stable and multi-directional. The flight direction and aim point of a camera may differ during inspections, and particularly in high winds. A camera with an encased

Drone operators must use extreme caution, and particularly near transmission lines and power plants (that includes wind farms). windpowerengineering.com

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•

•

• A steady hand is critical when piloting a drone near wind turbines. Mach 4’s control Y-12 ground station (hand controller) is equipped with 1.4 gigahertz for flight control, offering a stable control experience.

control system and a 360° panoramic view should ensure image capture, regardless of a drone’s direction.

Video capability. Drones with highdefinition video sensors can capture additional footage, or provide a live-stream feed during inspections. Video is also ideal for aerial surveys when mapping or siting wind projects.

Other features, such as a transmission system from bird to downlink, can provide rocksteady video when needed at the critical point of documenting the inspection.

Flight time. Most commercial drones last for 20 to 30 minutes before requiring a charge.

Very few can last longer, however, flight times vary so it is important to do your research.

Experience. A full-featured, commercial drone is excellent for most turbine blade inspections. Without a highly experienced pilot or user, however, it can cause more harm and damage than good. Put safety first. W

VISIT THE NEW

energystoragenetworks.com

WPE EnergyStorage HALF.indd 1

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Joshua Hitt Senior Product Line Manager M a x w e l l Te c h n o l o g i e s

OP ERATIONS & MAIN TENA NCE

Reducing O&M costs with ultracapacitors in emergency pitch-control systems

W

hile wind-farm operators work to optimize turbine performance and uptime, it’s inevitable that certain components will demand greater O&M attention. One aspect of turbine maintenance that typically causes multiple downtime hours per month is battery-based emergency pitch-control systems. Pitch control is an important turbine component used to operate and control the angle of blades to maximize wind generation. It also protects turbine blades from damage during excessive wind speeds or a grid power loss.

This critical device is vital to successful turbine operation and fitted with energy storage backup power. However, site managers are too-often hit with unexpected maintenance costs relating to battery problems in pitch-control systems.

These include degraded performance in cold and hot weather conditions, battery voltage faults, and up-tower climbs to replace failed battery systems.

How can site managers slash costly and time-consuming maintenance of the pitch system’s backup power?

Ultracapacitors are a reliable energy storage option that has resolved many of the typical pain points with battery-based systems.

Chemistry uncovered Ultracapacitors, also called supercapacitors, are high-powered energy storage devices that store charge electrostatically. In contrast, lead-acid batteries operate electrochemically, with inherent disadvantages due to the nature of their chemical process. As a result, ultracapacitors offer much greater efficiency and reliability in emergency pitch controls and require no scheduled maintenance for 10 years or longer. This contributes to greater turbine uptime.

For remote turbines in frigid, winter conditions or hot, summer temperatures, ultracapacitors’ electrostatic design makes for a wise choice. Here’s why: cold temperatures slow the rate of batteries’ chemical reactions, resulting in high internal resistance and inefficient charge acceptance. For Maxwell Technologies’ ultracapacitor retrofit modules replace existing batteries for reliable and fail-safe pitch system performance.

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OPERATIONS & MAINTENANCE

Replacing end-of-life or failed battery parts for emergency pitch-control backup systems in wind turbines is a time-consuming and costly process. It requires wind techs to climb up towers, and turbines to lose generating time.

Ultracapacitor energy storage systems can eliminate scheduled pitch battery maintenance visits and significantly improve pitch system reliability.

example, a battery that provides 100% capacity at 80° F (27° C) will typically deliver only 50% capacity at 0° F (–18° C).

What’s more, each charge and discharge cycle requires electrochemical changes in the battery, causing the battery to lose capacity over time. Frigid conditions can render the battery ineffective. Extreme conditions may completely degrade battery performance, requiring operators to install multiple replacements.

Typically, pitch systems are fitted with environmental conditioning (heaters and fans) to keep batteries within their operating temperature range. However, wind farms still commonly experience premature battery failures from temperature extremes.

The problem with pitch faults Batteries are often the source of pitch faults as reported

by SCADA systems, a turbine’s data-collection system.

Battery voltage faults, one of several types of pitch faults, are specific to the turbine’s emergency pitch backup system. Voltage faults may occur during a battery load test, during battery charger failure, or when cold weather affects system performance and the battery fails to charge.

If the fault is unable to be repaired remotely, at least two wind technicians must climb up-tower to perform diagnostic inspections. Climbs are costly, complex, and offer an inherent safety risk. Repairs also result in turbine downtime and lost revenue.

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Ultracapacitor retrofits One way to overcome the limitations of lead-acid batteries in pitchcontrol systems is to replace the devices with ultracapacitor retrofit systems. Ultracapacitor storage modules provide a reliable and simplified emergency pitch-control backup system.

Ultracapacitor retrofits perform the same function as the battery system, with additional advantages.

• Ultracapacitors can withstand a pitch system’s load with minor voltage drop, compared to battery systems. After ultracapacitors are installed in a turbine’s pitch-control system and fully charged, subsequent recharges occur in a few minutes. This is unlike batteries, which may take about 20 to 30 minutes to recharge. In addition, ultracapacitors provide quick, high power even after long stretches of non-use. This is a performance advantage over batteries, which often fail after stretches of idle time.

• Ultracapacitors are available as “form-fit-functional” replacements for battery pitch systems, requiring zero modifications to the turbine hardware. Current ultracapacitor-based retrofit systems include an integrated charger and communication interface. This means the retrofit system can install in a timely manner. The ultracapacitor system check, voltage, and temperature are automatically reported to the turbine

Ultracapacitors, also called supercapacitors, are highpowered energy storage devices that store charge electrostatically.

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OPERATIONS & MAINTENANCE

•

SCADA system in the same way the original battery system reports data, allowing for seamless plug-and-play functionality.

The ultracapacitor-based system significantly reduces system failure rates, pitch system downtime, and unscheduled O&M costs.

Ultracapacitor-based energy storage reduces time spent maintaining and troubleshooting battery-based systems. Ultracapacitors require no scheduled maintenance over long periods of time and have much higher reliability, which means greater turbine uptime and project returns.

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To remain competitive with other power generation sources, wind operators must ensure that turbines operate at maximum capacity. While batteries are optimal for long-term energy storage applications, the fast, high-power requirement of the pitch control function is best served with ultracapacitor energy storage.

Ultracapacitors improve chronic maintenance issues associated with battery-based systems and contribute to streamlined operations. W

windpowerengineering.com

Battery-related pitch faults for turbine emergency pitch-control systems happen more than you might think. When consumer-owned electric cooperative, Iowa Lakes Electric Cooperative (ILEC), experienced problems with turbines at its wind farm, it switched to ultracapacitorbased energy storage. To learn how ILEC made significant operational improvements by replacing the original battery systems in its turbines with Maxwell Technologies’ ultracapacitorbased energy storage retrofit solution, download the report here: www.maxwell.com/wind

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Cable performance is critical for the successful delivery of energy generated by wind turbines to a transmission grid. However, cable faults and failures are too often the cause of lost generating power or downtime at offshore wind farms.

Research finds that nearly 80% of insurance claims in the offshore wind industry are linked to cable failures.

Despite the criti cal role cables perform at offshore wind far ms, the devices are often an afterth ought during project planning and wind-farm development.

MICHELLE FROESE, EDITOR

OFFSHORE CABLES must safely and reliably endure harsh marine conditions, and typically over long distances to deliver power onshore.

Unlike onshore wind-farm installations, offshore cabling routes are also more difficult to access, let alone install or repair cable effectively. In fact, simply locating a fault can sometimes pose a challenge. Repairs may also take weeks or months, and depend on weather and the availability of equipment and vessels.

So the wind industry is working to reduce O&M and cable failures. Independent energy advisory and certification body, DNV GL, has partnered with offshore researchers and experts such as Deltares, ECN, BREM, and others, in a joint industry project or JIP: “Cables lifetime monitoring.” The aim of this study, according to DNV GL, is to reduce the chance of power cable failures in offshore wind farms.

“By preventing a significant number of cable failures caused by damage during manufacturing, installation, and operation, we are convinced that our study will allow us to significantly reduce the levelized cost of electricity of offshore wind,” explained Jan-Joost Schouten, a project manager with Deltares, in a press statement.

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The JIP says between mid-2018 and 2020, it will extract and analyze important lessons about the major causes of power-cable failures from previous and current cable-monitoring research. For example, earlier analysis by DNV GL showed that cable failure is partly attributed to manufacturing, design, and installation errors. In addition, morphodynamic processes — changes to the seabed floor from sand waves, for example — can expose subsea cables, increasing their risk of damage.

Key lessons from the study will be compiled into a guidebook with tips for improved design, manufacturing, installation, and operation of submarine cable systems.

What’s new in cables While the JIP begins its research, manufacturers are also working to improve marine cables for offshore wind farms. Here are a couple of new ideas.

damage. NjordGuard has a smooth outer surface to reduce drag and snagging risks.

Most notably, the system improves safety because it installs (and can be removed and reused) without the use of divers or underwater remoteoperating vehicles. A tapered pull-and-clamp lets the cable protection be pulled into a monopile entry or J-tube foundation safely and securely.

In addition, the system requires minimal assembly. According to Trelleborg, NjordGuard’s external dual-stiffener coating is factory cast directly onto the connector and its internal stiffener can come pre-assembled. Only its external tail needs to be attached with Trelleborg's proprietary connection system, which can be done on a cable-lay vessel or pre-installed for later use.

Power cables typically account for only 5 to 10% of the total investment costs of offshore wind farms. However, according to energy advisory DNV GL, the components are the top reason for project downtime. Cable inspections and repairs are also costly maritime operations. DNV GL and partners are collaborating to study and, ultimately, reduce cable failure levels and O&M costs through a joint industry project. Learn more at tinyurl.com/OffshoreCables

Cable protection Trelleborg’s Njordguard is an integrated protection system for offshore wind-farm cables in windturbine generators and substation platforms. Its API 17L-certified Uraduct material is highly abrasion-resistant and can travel over the seabed floor without Last year, cable manufacturer Nexans and IoT company, ffly4u, pioneered a new tracking and management service that lets customers know the exact location of their cable drums. The smart service also lets project operators know how much cable is left on a reel.

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NjordGuard has undergone large-scale wet testing and underwater installation testing with monopole and J-tube.

Watch footage at https://tinyurl.com/NjordGuard

TRACKING DRUMS

Cable length When cable is sent to a new wind site, it typically arrives in lengths ideal for efficient delivery but shorter than required for offshore projects. One idea to reduce offshore wind costs is to lengthen cables. For example, Nexans’ underground single-core 33-kV cables (500 sq.mm) now come in lengths exceeding 3 km — an industry first.

The aim of long-length cable is to reduce the number of required joints or splices. Where one length of cable ends, a joint with point-topoint circuits is needed to connect to the next cable, potentially increasing the likelihood of errors or faults. By using long-length cable, wind-farm owners can lower their overall project costs because there are fewer components to install and maintain over time.

The production of long-length cable may seem like a simple, cost-effective idea. And from a production standpoint it is, but transport and installation tell a slightly different story. Typical drums or reels that hold electrical cable for transport are not large enough for 3-km lengths.

So cable manufacturer Nexans designed special drums large and strong enough for long-length cable loads. Each new drum can bear a cable load of 15 tons.

An innovative installation method was also developed so long-length cable could be laid together with the fiberoptic (to provide data communication between generators) and earthing (or grounding) cables. This means one cable layer must be wide enough to accommodate three drums and hold their weight. The one-step cable installation process saves time and costs by laying and joining cable sections at the same time, while the long-length cable eliminates the number of necessary joints. W

To some extent, cable drums are the unsung workhorse of the cable industry. Typically, they provide years of service, storing cables until needed, and transporting cables from a factory or warehouse to a project site. After the cable is used and drum emptied, it is returned to the cable factory to begin another cycle.

The process is simple but if a drum or two goes missing, their replacement costs add up. For example, a distribution service operator, such as France’s Enedis, has spent several million Euros in one year renting cable drums. There are significant costs to purchasing new ones to replace those that are Trelleborg’s NjordGuard is an lost, stolen, or damaged. integrated protection system A cable manufacturing for offshore wind-power cables company could save a pretty penny in turbine generators and offshore substation platforms if it could avoid losing its cable that fits both monopile and drums. Thanks to the industrial J-tube applications. Trelleborg internet of things (IoT) this is says the extendable system requires minimal assembly and now possible. It works this way: can be manufactured to meet A small, wireless sensor, a few any diameter cable. centimeters long, is hidden from view and embedded within a wooden drum, where it tracks the reel location and the type and quantity of cable it holds.

Through IoT, the sensor connects wirelessly to a cloud-based management system that provides real-time information on the drum’s location and its status at a project site. In a nutshell, the system provides data on how much cable has been delivered and deployed at a site and sends a message to the manufacturer when the drum is empty and ready for retrieval.

This intel lets site operators plan operations more effectively because they can follow a drum’s location, track the type and quantity of cable on each drum, manage changes in cable requirements for a project, and minimize cable transport and cable scraps. It also lets cable manufacturers reduce the amount of time that empty drums are left on site waiting for pickup, saving on costs and working capital.

What’s more, the tracking system helps eliminate the risk of cable theft because it raises an alarm when a drum is moved outside a pre-set perimeter or during non-operational times, such as at night. Overall, cost savings of up to 20% are expected for medium-voltage drums with wireless sensors.

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T U R BI NE OF T HE M ON TH C r a i g Wa l k e r Contributor

Turbine of the month: The hurricane-friendly Hitachi HTW5.2-127

T

he U.S. wind industry is working hard to develop more offshore wind sites. New York set plans for procuring about 800 MW of offshore wind — by next year.

Massachusetts recently moved to double its offshore wind commitment to 3200 MW. In June, the Department of Energy announced an $18.5 million offshore wind R&D consortium.

The lure of stronger winds and greater power generation offshore is appealing to developers. However, siting, construction, and operation in marine environments pose unique challenges. One concern that’s seldom discussed is the risk of turbine damage and downtime from hurricanes.

Offshore turbines must be built to sustain harsh conditions and power down for safety in severe storms. However, these machines are typically no match for hurricane-speed winds, which may wreak havoc on offshore wind farms. So manufacturer Hitachi decided to do something about it. Meet the HTW5.2-127 hurricane-resistant wind turbine.

Hitachi’s HTW5.2-127 (or slightly longer-bladed, HTW5.2-136) is a downwind, three-bladed wind turbine with a rating of 5.2 MW. It is Class

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Hitachi’s HTW5.2-127 was built for reliable performance in regions subject to high wind turbulence, lightning storms, and cyclones. Hitachi’s built-in SCADA system enables 24-hour remote monitoring, data acquisition, and O&M alarm and operator notifications. The turbines will “dispatch” wind technicians from the nearest base if required for maintenance. (Image: Hitachi)

T certified for extreme wind speeds of about 127 mph, which is equivalent to a Class 3 hurricane (50 to 58 m/s) on the SaffirSimpson Scale.

Every part of this wind turbine was developed with a goal of strength and durability. For example, the turbine’s steel monopole tower structure includes partitions that protect the electrical system against humidity and airborne salt. The enclosure provides a safe, dry and non-corrosive environment inside the tower.

Here are a few other key features of this turbine, which Hitachi says is engineered with “technologies acclimatized to a tropical cyclone.”

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TURBINE OF THE MONTH

The electric equipment design inside the tower of Hitachi’s HTW5.2-127. Download a brochure about the HTW5.2-127 wind turbine at tinyurl.com/HitachiHTW

A downwind rotor The HTW5.2-127 dons a downwind rotor-blade configuration. This means that when winds are strong, the turbine’s blades flex away from the nacelle, reducing the likelihood of a tower strike. In addition, sensors are installed on the front leading edge of blades to measure precise wind speed and direction.

The yaw and pitch are also modulated to a right angle for maximum wind production.

Lightning protection Hitachi’s hurricane-friendly turbine is equipped with lightning protection that’s deemed safe for an electric charge of up to 600C, which is above IEC’s Class I standard (the International Electrotechnical Commission’s highest rating). The turbine’s major components are rated to withstand 95% of lightning strikes. For additional protection against induced lightning, its electrical and control panels are also equipped with additional surge protection to safeguard against induced lightning.

FRT verification Hitachi wind turbines comply with fault ride through or FRT. This requirement indicates that turbine generators will maintain synchronous operation regardless of nearby electrical events (such as lightning strikes). FRT strengthens overall power system transient stability and prevents system-wide disturbances, such as cascading failures and even blackouts. Essentially, FRT verification ensures that wind turbines will stay online in short periods of voltage dips.

Passive cooling A radiator is located at the front of the nacelle to increase turbine cooling. Hitachi says it lets the radiator exchange the heat of the cooling water from the generator and gearbox efficiently, with fresh air caught in the upper stream (at the front of nacelle).

Outside cooling air is exhausted at the sides and below the nacelle, but it never enters the nacelle. A salt filter is also located directly behind the radiator to protect wind-turbine components. W

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