Windpower Engineering and Development 2022 Renewable Energy Handbook December 2021 by WTWH Media LLC

The technical resource for wind profitability

DECEMBER 2O21

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2022 RENEWABLE ENERGY HANDBOOK

12/17/21 12:33 PM

Welcome to the 2022

Renewable Energy

Handbook

Welcome to the 2022 Renewable Energy Handbook. We’re wrapping up another stellar installation year for renewable energy in the United States. And as busy as everyone has been, we’re sure a few standout stories missed your eyes this year. Don’t worry, this handbook reviews what has been trending in both the solar and wind industries in our sister publications Solar Power World and Windpower Engineering & Development. In addition to installation tips, service guides and O&M best practices, the 2022 Renewable Energy Handbook offers our editors' picks for the top solar products released in the last year as well as the top wind projects recently brought online. It appears that the U.S. legislative branch will be closing out 2021 with votes on some major bills, so be sure to check our two websites for the absolute latest on how the solar and wind industries will shake out in 2022. We’re crossing our ﬁngers for extended ITCs, PTCs and new manufacturing credits!

2022 RENEWABLE ENERGY HANDBOOK

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WINDPOWER ENGINEERING & DEVELOPMENT does not pass judgment on subjects of controversy nor enter into disputes with or between any individuals or organizations. WINDPOWER ENGINEERING & DEVELOPMENT is also an independent forum for the expression of opinions relevant to industry issues. Letters to the editor and by-lined articles express the views of the author and not necessarily of the publisher or publication. Every effort is made to provide accurate information. However, the publisher assumes no responsibility for accuracy of submitted advertising and editorial information. Non-commissioned articles and news releases cannot be acknowledged. Unsolicited materials cannot be returned nor will this organization assume responsibility for their care. WINDPOWER ENGINEERING & DEVELOPMENT does not endorse any products, programs, or services of advertisers or editorial contributors. Copyright© 2021 by WTWH Media, LLC. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, or by recording, or by any information storage or retrieval systems, without written permission from the publisher. SUBSCRIPTION RATES: Free and controlled circulation to qualified subscribers. Non-qualified persons may subscribe at the following rates: U.S. and possessions, 1 year: $125; 2 years: $200; 3 years $275; Canadian and foreign, 1 year: $195; only U.S. funds are accepted. Single copies $15. Subscriptions are prepaid by check or money orders only. SUBSCRIBER SERVICES: To order a subscription or change your address, please email: please visit our web site at www.windpowerengineering.com WINDPOWER ENGINEERING & DEVELOPMENT (ISSN 2163-0593) is published four times per year in February, May, September and a special issue in December by WTWH Media, LLC, 1111 Superior Avenue, Suite 2600, Cleveland, OH 44114. Periodicals postage paid at Cleveland, OH and additional mailing offices. POSTMASTER: Send address changes to: Windpower Engineering & Development, 1111 Superior Avenue, Suite 2600, Cleveland, OH 44114

WINDPOWER ENGINEERING & DEVELOPMENT // 2022 RENEWABLE ENERGY HANDBOOK

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WHAT’S S INSIDE THE 2022 RENEWABLE ENERGY HANDBOOK

An Introduction to the Renewable Energy Handbook ...........................................................................2

SOLAR POWER

WINDPOWER

Solar Market Overview ........................................ 8

Wind Market Overview ...................................... 53

2021 Top Solar Products .................................... 10

Major Wind Projects of 2021 ............................. 54

2021 Solar Power Leadership Winners ............. 15

2021 Windpower Leadership Winners .............. 57

EV Charging ........................................................ 16

Bolts ................................................................... 58

Installation .......................................................... 20

Gearboxes .......................................................... 64

Inverters ............................................................. 24

Offshore Development ....................................... 68

Mounting ............................................................ 30

Safety ................................................................. 72

NEC 2020 ........................................................... 34 Operations & Maintenance ............................... 38 Energy Storage .................................................. 42 Project Reliability ............................................... 46 Cables & Wires .................................................. 48

2022 RENEWABLE ENERGY HANDBOOK

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SOLAR MARKET OVERVIEW

Solar industry pushes forward as supply chain, tariff issues loom Federal

policy played a crucial role for the solar industry in the battle against climate change in 2021, although continued pandemic supply chain issues loomed in the background. The centerpiece of federal solar policy is the Build Back Better Act, which is expected to be voted on by the end of 2021. The $555 billion allocated to the clean energy sector in the bill would fund 10-year extensions of the section 48 and section 25D investment tax credits, direct pay for the commercial ITC, refundability for the residential ITC and a standalone storage ITC. “The Build Back Better framework contains the most ambitious and transformational clean energy policies we’ve ever seen from Congress," said Abigail Ross Hopper, president and CEO of SEIA, in a statement. Wood Mackenzie calculated the ITC extension could power a 44% boost in solar deployment, although it wouldn’t drive enough growth to achieve President Joe Biden’s goal of 80% carbon-free electricity by 2030. “An extension would allow the already strong residential solar market to continue to grow. The direct pay provisions of the proposed extension will be a major win for small and medium nonresidential projects (<1 MW) thanks to the

SOLAR POWER WORLD // 2022 RENEWABLE ENERGY HANDBOOK

challenges of securing tax equity,” said Bryan White, WoodMac solar researcher. The Build Back Better bill would also create new credits for domestic solar manufacturing — a necessity for avoiding solar tariff battles in the future. Since the United States currently depends on China for its solar supply chain, much of 2021 was spent anxiously waiting to see how tariffs and duties would affect the cost of solar. At the end of the year, the International Trade Commission recommended extending Section 201 protections on crystalline modules that increased import prices the past few years. In a separate high-stakes module case, the Dept. of Commerce rejected in November 2021 the request by the American Solar Manufacturers Against Chinese Circumvention to impose additional tariffs on Chinese solar panel companies allegedly circumventing antidumping and countervailing (AD/ CV) duties by manufacturing portions of their products in three Southeast Asian countries. Solar prices rose in all markets in 2021 because of tariff- and pandemicrelated supply chain problems. The prices increased quarter-over-quarter and yearover-year in every market segment for the ﬁrst time since WoodMac began modeling system price data in 2014. “The solar industry continues to demonstrate strong quarterly growth,

and demand is high across every segment,” said Michelle Davis, principal analyst at Wood Mackenzie, in a press release. “But the industry is now bumping up against multiple challenges, from elevated equipment prices to complex interconnection processes. Addressing these challenges will be critical to expanding the industry’s growth and meeting clean energy targets.” A Rystad Energy analysis found that more than half of global utility solar projects planned in 2022 are threatened by these supply chain issues. Bloated costs on manufacturing materials and shipping could threaten 50 GW of projects. “The current bottlenecks are not expected to be relieved within the next 12 months, meaning developers and offtakers will have to decide whether to reduce their margins, delay projects or increase offtake prices to get projects to ﬁnancial close,” said David Dixon, senior renewables analyst at Rystad Energy, in a statement. Although plenty of challenges are ahead for the solar + storage industry, there’s also exciting new opportunities to bring manufacturing stateside and give new groups of people access to solar power through community solar and new direct pay tax credits. SPW

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TOP PRODUCTS

Solar Power World editors pick the top products of 2021 While

not completely back to “before COVID” times, this past year has felt like a return to normal solar installation activity. Projects are still going ahead, now with extra focus on product improvements that lend toward more remote accessibility and less downtime. There’s also more attention being paid to energy storage for power independence, accelerating a market already on the edge of mainstream acceptance. There were a lot of new product announcements made quietly in 2021, for lack of the fanfare often associated with

launching new products at tradeshows and conferences. Solar Power World editors kept track of everything and picked our favorite new products for the U.S. market from the past year. We are excited and eager to see products inperson at tradeshows in 2022, so here’s a collection of what we’ll be quick to check out. These are just a few of our favorites, so be sure to visit our website for an even more extensive list of the top products of 2021.

Ground-mounted solar goes low-profile AS S E E N I N A E R O CO M PAC T ' S CO M PAC TG R O U N D

Ground-mounted solar arrays have traditionally used a racking structure that elevates solar modules several feet or higher from the ground. It’s a tried-and-tested method for installing solar, but for a number of reasons — like zoning regulations, material costs or even neighbors who disapprove of seeing solar — customers might decide they’d prefer racking with a lower profile. If the roof is out of the question, there are smaller solar racking options for the ground that are similar to those found on flat rooftop systems. Austrian solar structure manufacturer Aerocompact developed CompactGround, a lowprofile racking solution. At its highest, CompactGround has a 40-cm gap between the panel and the ground. That condensed footprint and lower profile also brings the benefit of reduced wind exposure. In the midst of supply chain issues for the industry, Aerocompact is offering a racking solution with lower shipping and material costs. The company claims up to 1 MW of CompactGround racking can fit in a single truckload.

SOLAR POWER WORLD // 2022 RENEWABLE ENERGY HANDBOOK

The system can be installed in south-facing or eastwest orientation. It’s secured to the ground using either ballast blocks or ground screws and doesn’t require heavy machinery for installation. CompactGround’s ﬂexible footing allows it to adapt to uneven ground surfaces. Aerocompact designed CompactGround to be quickly deployed, using only three primary components that make it ideal for temporary installation scenarios. It works for kilowatt-sized and larger-scale buildouts, promising higher output in the same footprint of a traditional solar ground-mount project.

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TOP PRODUCTS

Microinverter advancements allow solar to provide daytime backup without battery AS S E E N I N E N P H AS E ’ S I Q 8

Solar customers often think installing a rooftop system alone is enough to provide backup power if the grid goes down. Usually, that's not true without a battery paired to the system. But thanks to a microinverter breakthrough, solar projects without batteries can in fact provide backup power if the grid goes down — in the daytime, at least. "For the ﬁrst time you're able to use all the solar that you're making, which, frankly, is what most people think solar power does already," said Robert Pierce, senior director of product communications and content at Enphase. Enphase's hotly anticipated IQ8 microinverter began shipping in December 2020. The inverter uses chip technology to island homes during daytime outages, though they must be paired with an Enphase System Controller to execute that function. Customers can choose to add storage later on to keep the home's electricity backed up even when the sun isn't shining. The Enphase Energy System with IQ8 comes in four

different conﬁgurations — Solar Only, Sunlight Backup with no battery, Home Essentials Backup with a small battery and Full Energy Independence with a large battery. Pierce said this buildingblock aspect helps to make storage available to more people, no matter their backup power needs and budget. “Until IQ8, it was challenging to properly manage customer expectations of battery design and sizing limitations and to explain different options," said Aimee Carpenter, CEO of installation companies Solterra Solar and Good Energy Solar, in a press release. "Enabling a customer to start with any size Enphase battery and grow over time is going to make battery backup with solar a possibility for many more of our customers."

TOP PRODUCTS

Centralized string inverter solutions increase uptime for utility-scale projects

Early detection methods reduce lithium battery thermal runaway risk

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Utility-scale solar installers in the past have had to choose between two very different inverter architectures — either the monolithic central inverter or the dispersed string inverter. Now, they have the best of both worlds with centralized string inverter skids. Fimer is focusing all its utility-scale resources on the soon-to-be-released modular PVS-260/PVS-300 inverter skid for centralized projects. The units are made of many string inverters but are pre-assembled and tested in the factory then craned onto the site like a central inverter. The company said these flexible units make storage integration simple as well. “With the utility sector predicted to grow significantly over the next few years, we wanted to offer a solution that maximizes ROI on both conventional system architectures and all other emerging system arrangements including storage, while maintaining the essential values of modularity,” said Maren Schmidt, managing director of Fimer’s utility line of business, in a press release. String inverters are often preferable to centrals due to their modular nature and serviceability. If one goes down, the project is only missing a small portion of power production rather than a large chunk. Plus, it’s much easier to service or swap out small string inverters than large centrals, which require trained engineers to repair. Marco Trova, Fimer’s senior global product manager, said this string inverter focus will allow Fimer to be more agile when adapting to new project voltages and technologies too. No longer will the manufacturer need to keep outdated parts in stock to service large central units — instead, they can update the string inverter as needed and send entire units out relatively easily when technology shifts. The company expects its first U.S. installation to take place in Q3 of 2022.

SOLARPOWERWORLDONLINE.COM

The chances of a lithium battery going into thermal runaway — an increase in operating temperature that can lead to short-circuiting and fires — is very rare, especially when energy storage systems are rated at and installed to UL and NFPA standards. But accidents do occasionally happen, and the best way to prevent a battery-related fire is to detect thermal runaway before things get out of hand. The difficult part is actually recognizing thermal runaway before it happens. Traditional fire detection and suppression systems (smoke detectors, sprinklers) need the presence of smoke to spur into action, but smoke in a lithium battery installation means thermal runaway has already started. Just before smoke appears though, a lithium battery will begin releasing gas as it deteriorates. Detecting that off-gas, and differentiating it from dust, smoke and other airborne particles, is paramount in a battery safety device, especially when trying to avoid false alarms and downtime at larger energy storage sites. The Siemens FDA241 aspirating smoke detector can handle all of that and more by using blue and red wavelengths to detect off-gas particles produced in early stages of battery failure and overheating. The dual wavelengths allow the device to distinguish dust, steam, smoke and off-gas particles, signaling the device to react accordingly to the problem. For sites with high airborne dust concentrations, the FDA241 uses air filters and a "purge function" to blowback dust particles and keep the unit clean and focused on offgas detection. Thermal runaway may be rare, but it's better to be safe than sorry.

SOLAR POWER WORLD // 2022 RENEWABLE ENERGY HANDBOOK

TOP PRODUCTS

Big watts hit residential roofs AS S E E N I N S O L A R I A ' S P OW E R X T 43 0 R - P L

Watt-ratings on solar panels are quickly going up, thanks to technology advancements and improved manufacturing. Modules have been exceeding 400 W in utility-scale applications for a while now, mostly due to bigger wafers, bigger panel sizes and bonus bifacial gains. Unfortunately, modules used in residential rooftop projects can’t take advantage of those three advancements if the market wants to stick to products that can be installed by one person on a steep roof. But some module manufacturers are finding a different way to boost power. Solaria hasn't turned to larger wafers for its new PowerXT 430R-PL line of modules. Instead, Solaria continues to perfect the shingling method of module production, overlaying fifth-cut cells into horizontal strips for maximum power output. The shingled cells and conductive adhesive in lieu of busbars allow for PowerXT modules to fit more unobstructed silicon inside their frames, boosting power and efficiency. PowerXT 430R-PL comes in at 430 W and 20.4% efficiency, in a slightly larger-than-traditional 60-cell panel footprint. Other companies, either through shingling or a similar process called tiling, have also recently released modules exceeding 400 W for the DG market, including JinkoSolar (415 W), LG (405 W) and REC (405 W). More powerful modules that can still be carried up a ladder and mounted to a roof by one person is a win for both the installation company and customer. The company completes higher-rated projects with fewer installers on the roof, and customers get more bang for their buck.

Solar panel cleaning reaches new heights AS S E E N I N S U N B R U S H ' S S U N B R U S H M O B I L L I F T

If a solar panel is installed outside (and when isn’t it), it will undoubtedly accumulate debris. Anything from dust to bird droppings can cover a solar module and lead to less output and an unsatisﬁed system owner. The task of cleaning solar modules is approachable at ground-level, but washing the dust away on a roof or carport is a whole different challenge. When a hose or rainwater isn't enough to keep solar panels in hard-to-reach places clean, there's SunBrush's Mobil Lift. The German solar PV cleaning system provider entered the U.S. market in early 2021, bringing a range of rotating brush accessories built speciﬁcally for solar panel cleaning. These brushes mount to common machinery found on construction sites.

SOLAR POWER WORLD // 2022 RENEWABLE ENERGY HANDBOOK

The Lift model mounts to the underside of the platform on a hydraulic bucket truck or a crane with a human-platform. The person piloting the platform also has control of Lift's rotating brush and can telescopically guide the cleaner along panel rows installed at height with just a joystick. Brushes have a built-in water sprayer and can clear dust, pollution buildup, snow, moss and algae blooms from solar panel surfaces. They come standard with the company’s patented “WashTronic” ﬂoat system that is paired with a warning system to ensure proper pressure on the panels. With Lift, brushes come in 14-in. diameters and lengths from 6 to 10 ft.

SOLARPOWERWORLDONLINE.COM

Congratulations!

2021

LEADERSHIP IN

SOLAR ENERGY Celebrating the companies and individuals leading the solar PV industry. Solar Power World announces the winners of our Leadership in Solar program. Nominees were released in our January issue, and our user community voted on which companies they felt best exemplify solar leadership. Congratulations to the winners!

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SOLAR POWER WORLD // 2022 RENEWABLE ENERGY HANDBOOK

EV CHARGING

Will EV charging stations become the next must-have accessory? BY T E R A N C E J . H A R P E R , M . S | AS S I S TA N T E N G I N E E R I N G M A N AG E R | I L L U M I N E - I

Over

the next 10 years, electric vehicles (EVs) are expected to increase their share of the automobile market signiﬁcantly. According to a report from Deloitte, the “global EV forecast is for a compound annual growth rate of 29% over the next 10 years [with] total EV sales growing from 2.5 million in 2020 to 11.2 million in 2025 and reaching 31.1 million by 2030.” With such exponential growth expected in the EV market, the question of how to keep all those vehicles charged without relying on fossil-fuel produced electricity is emerging as a central concern for homeowners and businesses

SOLAR POWER WORLD // 2022 RENEWABLE ENERGY HANDBOOK

across the country. As more residential and commercial buildings decide to add EV chargers to their properties, many of them are choosing to marry their EV charging stations with solar installations. The synergy is obvious. EVs are designed to lower the transportation sector’s carbon emissions, while solar installations are designed to reduce the carbon footprint of electricity production. Most importantly, the two technologies are easy to integrate, making them costeffective for projects where saving money is at a premium. In this article, we will discuss the current state of the EV charger market,

how to choose the type of electrical panel necessary to support EV charger networks, and why engaging an engineering ﬁrm early in the process is essential to getting the job done right. The current state of the market is strong (and growing) As more consumers gain access to EVs, the push for increased charger accessibility is coming from the EV owners themselves. In particular, luxury apartment tenants are demanding that their buildings add EV chargers to their garages.

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EV CHARGING

Charge Point

As a result, apartment landlords (particularly ones for luxury apartments) are retrofitting their older parking structures — or building new parking garages — with upward of 10 or more chargers, an increase that indicates significant changes are occurring (specifically, Illumine-i has seen luxury apartment owners in Arizona, in particular, take heed of this burgeoning trend). Recent reporting suggests that the Biden Administration has proposed $174 billion to support EVs and the necessary charging network, including up to 500,000 new EV chargers. The spending would be made through grants and tax incentives, which could lead cities to start mandating EV chargers in their buildings (though we have not seen any specific moves in that direction yet). Single-phase vs. three-phase design Adding EV chargers is an enormous, positive step forward as the U.S.

SOLAR POWER WORLD // 2022 RENEWABLE ENERGY HANDBOOK

vehicle fleet transitions away from internal combustion engines. As more homeowners consider adding chargers to their properties, however, it’s essential to take the capacity of the property’s electrical panels into account. That’s why we recommend only doing one to two EV chargers at most residences because these chargers can be considerable extra loads on single-phase electrical panels. A competent design engineer will do the appropriate load calculations to make sure there is no overloading of the residential circuits. For commercial applications, the EV charger load becomes too large for a single-phase panel to handle, the engineer might recommend the inclusion of a multiphase unit into the overall building design. When installing single-phase chargers for commercial type installations, threephase electrical panels should be used. This results in a smaller overall panel rating, which means cost savings for the

overall project. In addition, depending on the on-site voltage, a three-phase panel will eliminate the need for a step-down transformer. For example, EV chargers have an input of 208/240 VAC 60Hz single phase. For 10 EV chargers requiring around 32 A of current, a 240-V, single-phase panels will produce a higher total proposed load than if a 208-V three-phase panel was used. In most cases, commercial garages have electrical systems at 208-V threephase panels or 480-V three-phase panels, requiring a step-down transformer to 208 V at one of the voltage inputs for the EV chargers. With this electrical setup at the 208-V three-phase current, still requiring 32 A of current produces a total proposed load that allows a smaller-sized electrical panel. Such construction saves money on the overall project without cutting the current output to the EV chargers. In three-phase

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EV CHARGING

panels, the EV chargers should be balanced across the three phases, and load calculations should be included for all panels upstream to the main panel that are affected. Typically, we see homeowners ask for EV chargers in the residential market as complements to the solar projects because it is easier to bundle the two, either as a solar + storage or a solar + EV charger project. Though we see many EV chargers being added to garages and parking lots, we believe eventually you will see an uptick in special sections of apartment building parking lots where residents can park their EVs. Why an engineering firm is a must Particularly in retrofit situations (whether they’re residential or commercial buildings), an experienced engineering firm is a must. Building owners should partner with firms that can provide

site-load and arc-fault calculations along with permit-ready plans for construction. They should also choose companies that can design systems with any EV charger in the market to not be locked into one company’s technology. They should also ﬁnd ﬁrms that can speed turnaround times to speed project approval, which will help keep the budget on projects lower. Finally, the company should have the relevant experience — commercial or residential — to the project at hand. EVs are expected to become the vehicle of choice over the next decade as prices continue to decrease. With that spread, the number of EV chargers will have to grow exponentially and keep pace with demand. As you plan your parking lot or garage, you have to ask yourself — will your project be ready for the EV revolution? SPW

INSTALLATION

A guide to bidding for, procuring and performing federal solar contracts BY C H R I S TO P H E R H O R TO N | PA R T N E R | S M I T H , C U R R I E & H A N CO C K L L P

The

federal government is the largest energy purchaser in the United States, with an annual electricity bill for the fiscal year 2019 of almost $4 billion. As a result, President Joe Biden’s administration is aggressively pursuing 100% clean energy and netzero emissions by 2050. In fiscal year 2020, federal agencies invested over $842 million in energy efficiency and renewable energy improvements. It is expected that this number will continue to grow as federal agencies seek to improve energy systems and infrastructures for federal buildings. The increased focus on construction and improvements

related to renewable energy provides solar contractors with a great opportunity to grow their business through federal contracting. Doing business with the federal government, however, is very different from contracting in the commercial and residential sectors. An overview of government construction contracting The federal government procures construction services and materials through multiple agencies. All procurement notices for federal contracts over $25,000 are posted on the newlylaunched System for Award Management

(SAM) website. Contractors can use this new website to register for business with the federal government, search for contracting opportunities and manage and monitor the procurement process. The type of information contained within the site includes pre-solicitation notices, solicitation notices, award notices and sole source notices. To be eligible to compete for government contracts, it is necessary for the solar contractor to obtain a data universal numbering system (DUNS) and then register with SAM. Solar vendors who want to sell to the government should be familiar with the General Services Administration

A 5-MW solar system at Fort Campbell in Kentucky installed in 2017 accounts for 10% of the base’s energy needs.

SOLAR POWER WORLD // 2022 RENEWABLE ENERGY HANDBOOK

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(GSA), which is a self-supporting federal body that assists the government in obtaining products and services. The GSA also oversees its schedules, which are itemized lists of vendors who provide commercial goods and services. GSA will only work with companies that have been in business for at least two years and have a balance sheet of sales greater than $75,000 each of the last two years. Solar contractors can also pursue federal government work through subcontracting opportunities. Most government construction contracts, including subcontracts, reflect policies contained in statutes and in the Federal Acquisition Regulation (FAR). Besides containing standard contract clauses, the FAR also sets forth extensive guidance to federal agencies and contractors on procurement, contracting methods, contracting requirements and contract management. Small business and minority business opportunities Congress has enacted statutory goals for procurement that includes awarding no less than 23% of prime contracts to small businesses. Additionally, Congress authorized each agency to establish annual goals relating to procurement goals for small businesses and minority businesses. For individual agencies, these goals apply to both prime contracts and a general contractor’s buyout of subcontracts. The Small Business Administration (SBA) administers and supervises various small business programs, including “Small Disadvantaged Business,” “Women-Owned Small Business Federal Contracting Program” and “8(a) Business Development Program” (minority owned business). To pursue small business opportunities, solar contractors must be certified through the SBA. As an example,

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to certify as a “Small Disadvantaged Business,” the contractor must be owned and controlled by one or more disadvantaged persons and the contractor must be “small,” which is based upon a calculation by the SBA. Solicitation and procurement of federal contracts The procurement process begins when a federal agency identifies a need for construction services, such as solar energy. A contracting officer is then assigned to manage the solicitation and procurement process. The contracting officer will identify the kind of procurement method used. Once the procurement method is chosen, a request for proposals is drafted and publicly issued at the SAM website. The request for proposals instructs solar contractors on how to submit proposals, explains what criteria will be used to evaluate proposals and establishes a time frame for receiving proposals and selecting contracting awardees. The request for proposal will also identify the project delivery method, which can include design-bid-build contracts, design-build contracts and construction management contracts. Solar contractors should also be aware that federal contracts can be

further categorized by the type of delivery — indefinite delivery contracts, definite quantity contracts, requirement contracts and single-task order contracts — and type of price — fixed-price contracts, cost-reimbursement contracts and incentive-type contracts. When submitting a proposal, a solar contractor must make certain certifications to the federal government, including certifications that the contractor is responsible, registered with SAM and not debarred, suspended or proposed for debarment. The government expects of its contractors the highest integrity and ethics. Any false statements in proposals, or at other times during the contracting process, can lead to criminal prosecution. During the evaluation period, the government may review qualifications, experience, methodology, the timeline for providing services and the anticipated cost. This evaluation process can take months and it is not uncommon for contractors to have to submit multiple revised proposals until one is finally accepted and negotiated. Upon an award, the solar contractor is bound to execute the contract and begin performance. If another contractor that supplied a proposal thinks that it had the best value proposal, the contractor can question the

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INSTALLATION

government’s evaluation process. The upset contractor could file a bid protest with the Government Accountability Office (GAO) or with the U.S. Court of Federal Claims. This process can significantly delay the performance date. If a bid is rejected, it is essential to contact the contracting officer and ask questions about why the proposal was rejected. Contract performance and management Performance and payment bonds are required before any contract of more than $100,000 is awarded, pursuant to what is known as the Miller Act. These bonds represent a promise by the solar contractor that the surety will pay or perform on the part of the solar contractor if the solar contractor fails to do so. Since liens cannot be placed on federal projects, solar contractors and/or their suppliers and materialmen must look to a Miller Act payment bond for relief. The Miller Act has strict notice requirements with which federal contractors must comply. Failure to provide bonds can lead to termination for default by the federal government. During performance, solar contractors must be familiar with their contractual obligations and rights. Most of these obligations and rights arise from FAR, including the handling of payments, differing site conditions, contract changes, delays, suspensions and acceleration. For example, FAR includes a standard construction contract changes clause that permits a contracting officer to authorize changes within the general scope of the contract. If any change issued by the contracting officer causes an increase or decrease in the contractor’s cost of or time required for performance, the contractor must assert its right to an adjustment within 30 days. This is done by notifying the contracting officer of the change and describing the general nature and amount of the adjustment. Solar contractors must also be familiar with the Contract Disputes Act (CDA). The CDA provides a framework for asserting and handling post-award claims by either the government or a contractor, including breach of contract claims, claims for time or interpretation issues regarding a specification and claims arising out of an implied-in-fact contract between the federal government and a contractor. All disputes under the CDA must be submitted to either the U.S Court of Federal Claims or to an administrative board of contract appeals. SPW

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INVERTERS

The future of cybersecurity: How renewable power plant controls protect inverters from hacks and attacks BY TO M K U S T E R | C E O | M E R I T S I A N D M E R I T CO N T R O L S

The

world is changing rapidly as renewable energy penetration increases. Declining renewable energy costs mean it could be feasible to power the United States on 90% clean electricity by 2035, according to a study by UC Berkeley and GridLab. Rapid adoption of non-carbon fuel sources is a trend that seems likely to continue for the foreseeable future. At the same time, the world is becoming less secure. Cybersecurity threats to operational technology and inverters that are increasingly internetconnected to help run the electric grid are escalating. Atlas VPN reports that cyber crime totals $1.5 trillion in revenue annually — that’s three-times the annual

revenue of Walmart. In short, cyber crime is a lucrative career for hackers. When it comes to utility-scale solar plants, Internet-enabled smart inverters are especially at risk because they communicate with the grid to perform management functions. There’s potential for hackers to tap into these inverter communications, throwing the grid voltage out of control, which could lead to brownouts or blackouts. The potential for damage is especially alarming when compounded with the increasing frequency of natural disasters. Research labs and inverter manufacturers are taking steps to ramp up cybersecurity within the inverter itself. However, the ﬂow of information

SOLAR POWER WORLD // 2022 RENEWABLE ENERGY HANDBOOK

on the grid is really complex. There are market and load management systems that communicate with balancing authorities connected to utilities. These systems tap into project supervisory control and data acquisition (SCADA) systems and, ﬁnally, the power plant controller (PPC). This leaves a lot of links within the chain vulnerable to cybersecurity risk. Is there a solution to mitigate risk effectively? One approach is to introduce cybersecurity protection at the renewable power plant control level. Alleviating breach risk within solar plant communications helps protect the inverter and, therefore, the solar plant and grid as a whole.

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Protecting the inverter First, it helps to understand some basic solar plant operations and architecture. Power plant controls consist of software and hardware, including a PPC and SCADA system. Site operators use a PPC to control plant behavior like production levels, revenue, compliance and grid stability. The PPC communicates with the plant’s SCADA system and field devices like inverters over a power plant network using industry-standard communication protocols like Modbus, TCP or DNP3. The SCADA system serves as a security gateway that allows or restricts the flow of information between the plant and inverter networks. The hardware and software associated with the plant control and SCADA systems are housed within an enclosure in a substation outside of the solar plant. They connect to the inverter and other field devices through a network of fiber-optic cables. Attacks can occur anywhere along the plant architecture. Hackers can embed malicious malware onto the inverter’s communication board, plug into the port of the enclosure that hosts the fiber-optic cables or infiltrate the plant control network.

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Come Visit us at Intersolar! Such events can jeopardize the plant’s reliability by tripping a circuit breaker at the point of interconnection or curtailing inverters to disrupt power generation, rapidly affecting the project’s power output. Even more damage could be done by controlling the inverter’s reactive power injection or absorption, leading to grid voltage spikes or drops. So what’s to be done? As inverter manufacturers work to strengthen security directly within the inverter’s communication board, added protection along the power plant control system creates further safeguards. For example, an intrusion alarm can signal operators through the SCADA system if the door to the fiber optic network enclosure has been opened. Operators can also include a list of authorized users to restrict access to plant controls according to IP addresses. It’s even possible to define what type of device is allowed to exchange information in a network port and instruct the system to block anything else. As an added measure of protection, Merit Controls also recommends security methods more specific to inverters, such as separating each device’s IP network so that one inverter can’t “talk” directly to another. All communication must occur through the secure SCADA system, which filters traffic. A plant control system also continuously monitors inverter configurations — manufacturer programs for how to regulate frequency, voltage ridethrough and more on a specific site. Hackers could potentially change these values and jeopardize the plant’s reliability, but the right renewable plant control systems will alert operators immediately if a change is detected.

Another recommendation is to use ring communication protocols for fault redundancy. Ring protocols dictate how field devices like inverters are connected to communicate — in this case, in a ring rather than in a linear configuration. This means if one inverter is down for maintenance, the rest of the network will still be able to talk, hence avoiding the whole system disconnecting due to a single point of failure. We recommend using standard naming conventions and communication protocols (media redundancy protocol [MRP] for ring topology; OPC UA, Modbus or DNP3 protocols for the SCADA system filtering, IEC 61131-3 for vendorindependent programming language, etc.) because proprietary or thirdparty protocols can introduce more risk. Standards widely accepted by the industry make it easier to audit the plant and troubleshoot issues to ensure long-term project success. Future-proofing against attacks As cybersecurity threats continue to proliferate, security officials are adjusting existing cybersecurity programs. For example, the North American Electric Reliability Corporation (NERC) recently partnered with the Dept. of Energy on two pilot projects within the organization’s Cybersecurity Risk Information Sharing Program (CRISP) to capture data from SCADA and industrial control systems. NERC plans to use this data to help monitor for hacking and strengthen grid security. Also, NERC’s Electricity Information Sharing and Analysis Center (E-ISAC) is working to guard against malicious activity on utilities’ business networks. The pilots help advance how CRISP collects and shares information, and should help identify threats to

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INVERTERS

utilities’ industrial control systems by capturing “raw and/or refined operational technology data” and comparing it with data that utilities send to them. On behalf of our clients, Merit Controls monitors daily ICS-CERT alerts from the Cybersecurity & Infrastructure Security Agency to stay updated on new vulnerabilities and attacks. We recommend project stakeholders do the same. Making sure the SCADA and PPC firmware is always up to date is important too. In addition, we have teamed up with inverter manufacturer Sungrow to provide turnkey technology solutions to address cybersecurity concerns. We see the greatest inverter and overall system security benefits coming from such partnerships. It’s hard to say what the next cyberattack on power generation systems will look like, or where it will come from. What we do know is that taking security measures now will ensure the best possible protection for inverters and other important solar plant components. At Merit Controls, safeguarding the components that power our grid is not only our ethos, it is also our responsibility as a vendor in this industry. A smart cybersecurity framework will protect solar and other distributed energy resources, ensuring the security of our critical infrastructure and enabling the advancement of a cleaner, secure and more resilient grid. SPW

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EPCs

and developers need to move away from pitching solar carports primarily as a means of delivering kilowatt-hours. It is time to look at ﬁnancing with carports differently; the solar production acts as a means of funding physical infrastructure. It is a different mindset — focusing on the value of structural amenity and its beneﬁts to business owners and their patrons, with the energy savings being the revenue stream that pays off the structure’s mortgage. This approach involves breaking away from how solar is traditionally marketed, which focuses heavily on the economics of, “this is how much you will save by going solar.” While effective for rooftop and ground-mount solar, this methodology falls short when selling

SOLAR POWER WORLD // 2022 RENEWABLE ENERGY HANDBOOK

carports as it fails to adequately capture the full value of the product. For a rooftop or ground-mount system, oftentimes the goal is to minimize the spatial impact of the system. Customers tend to prefer a solar system that is not obstructive and out of sight, if possible. Solar carports differ fundamentally in that they are an enhancement of the space they occupy alongside the energy they produce. Solar developers and EPCs need to account for the unique beneﬁts solar carports offer and market them accordingly. Shade and weather protection Some of the beneﬁts of a solar carport are easy to identify. In addition to providing shade, these structures also function as a shelter from inconvenient, or even costly, weather events. People

are always relieved to have covered parking during rain or snow, but they are even more thankful during a hailstorm. For some businesses, such as auto dealerships, installing a canopy system can lead to a direct economic payback, with many insurance companies offering more attractive premiums and lower deductibles if vehicle inventory is housed under covered parking. These benefits are primary factors driving the sale of standard carport systems and these benefits need to be factored in when communicating with customers. Enhanced built environment Moreover, there is inherent value in the carport as an architectural fixture that enhances the business’s built environment, which offers benefits

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not only for patrons but also employees. When we talked with Armen Zadoorian, senior engineer at AVX, a leading international electronics manufacturing company that completed a nearly 1-MW Quest Renewables carport in 2019, he outlined the numerous benefits the system has on the work environment. “People brag when they get a spot to park underneath the canopies,” he told us, going on to say that employees have started opting to spend their lunch breaks in the now shaded grassy area or sitting in their shaded cars under the canopy. In the case of the system at AVX, the customer not only achieved its corporate goals to produce solar energy, but it in effect expanded the livable space of its work environment. Aesthetics and public image Aesthetics and public image must also play a central role when making a pitch for solar carports. Sustainability has become an inherent value in today’s society, driving an increasing number of major corporations, such as Amazon, Apple and Delta, to make ambitious public pledges to strive toward 100% sustainability and net-zero carbon emission. A well-designed carport can

be a powerful, attention-grabbing structure, and businesses can reap the benefits of such an investment in the form of increased positive publicity. This can serve to enhance a business’s public image, communicating that it is forward-thinking and cognizant of its impact on the environment. A solar carport can draw the respect of other like-minded members of the community, functioning as an open invitation to potential patrons to share in that mission. Conclusion Whether it be a solar rooftop, ground-mount or carport, each solar system type has its own unique set of advantages and disadvantages which should not be measured against each other using a standard metric. As we recognize that solar carports are distinct from rooftop and ground-mount systems, we must also acknowledge that customers are not uniform in their interests. Doing so will not only allow for a more holistic view of the solar industry’s target customer base but will also encourage the solar industry to expand that market and reach new customer types. If we want to market solar carports — or any solar system for that matter — more successfully, we must look beyond what can be quantified in spreadsheets. SPW

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NEC 2020

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Updates to NEC 2020 that solar installers need to know BY E D G A R L I M | M A N AG I N G D I R E C TO R | U G E N G I N E E R I N G

of August 2021, 13 states have already adopted NEC 2020 and 11 states are undergoing the process of adoption. For the solar industry, these updates to the electrical code will impact project engineering, improve safety and ensure that regulations keep up with the pace of technological advancements. There are several key takeaways that every installer should know to minimize safety hazards and avoid code violations. States that have already adopted NEC 2020 include Colorado, Minnesota, Massachusetts and Maine. California, Connecticut, North Carolina, Rhode Island and a few others have started the process and should be adopting it in the coming months. That means changes could already be effective in your state, and if not, they’ll be happening soon.

SOLAR POWER WORLD // 2022 RENEWABLE ENERGY HANDBOOK

Conductors, conduits and OCPDs The ﬁrst revision to explore is within Article 690.8. It was rearranged for clarity and 690.8(A)(2) was added to introduce language that provides an alternative to the maximum circuit current calculation. Previously, the only method for calculating the maximum current of a string was through the multiplication of the maximum output of the PV module by 1.25 for irradiance correction. Now, we can base it off the rated input current of the conversion equipment, typically an inverter. This alternative method is more permissible and could result in smaller conductor sizes, sometimes by up to two standard sizes. In light of the upward trend for raw material prices, this could result in substantial savings in both copper conductors and conduit costs.

The next notable change is within Article 690.9(A). It now contains clearer language and leaves less room for interpretation regarding overcurrent protection of PV systems. Per 690.9(A)(3), installers now have the option of locating the Overcurrent Protection Device (OCPD) at either the supply end or the load end of the circuit in certain scenarios. Module-level rapid shutdown updates There were some modiﬁcations related to rapid shutdown within Article 690.12. The requirements for conductors outside the array boundary (1 ft from the array in all directions) hasn’t changed, but the code now allows the use of PV hazard control systems that are certiﬁed to the UL 3741 standard for conductors inside the array, such as the upcoming P1101 optimizer

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from SolarEdge. Installers will still have the option of using solutions that reduce the voltage within the array to 80 volts within 30 seconds or totally isolating the system with no exposed wiring methods. The labeling requirements for rapid shutdownequipped systems were modified within Article 690.56(C). The label verbiage for array-level rapid shutdown was removed since all rooftop PV systems complying with NEC 2020 will now require deenergization at the module-level. Regarding the location of the labels, it must be affixed to each piece of service equipment. However, it should be noted that the definition of service equipment is not limited to just service disconnects, so installers might need to affix it to other AC equipment depending on local AHJ interpretation.

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Disconnect safety There was language added to Article 690.13 requiring accessible disconnects to be equipped with a lock system or other solutions requiring a tool to open the enclosure. This is to mitigate risks associated with unintentional contact of live components by unqualified persons. Section E of the article lists all the types of disconnect switches that this requirement extends to, including remote-controlled switches that are operable locally. Wire management The next notable change is within Article 690.31. It now contains a table for correction factors going up to an ambient temperature of 120°C, up from 80°C previously. This applies to situations where conductors with higher temperature ratings are used, such as 125°C-rated XLPE cables. Revisions were made in section 690.31(B) that now allow for Class 1 circuits to be placed in the same raceways as DC circuits. The section was also modified to include the requirement of a marking scheme for the polarity of PV system conductors. When conductors are not color-coded, they have to be labeled “+,” “POSITIVE,” or “POS” for the positive conductor and “-,” “NEGATIVE,” or “NEG” for the negative conductor. Properly labeled and color-coded conductors can help reduce the time required to troubleshoot ground faults during commissioning and O&M of systems. It can also help prevent crossed polarity during installation, which could be hazardous to installers.

SOLAR POWER WORLD // 2022 RENEWABLE ENERGY HANDBOOK

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NEC 2020

The maximum distance between supports for a singleconductor is now 24 in. which was previously 12 in. This will help increase labor efficiency when performing O&M on PV systems as the previous maximum support distance made it challenging to remove PV modules. 690.31(C) now covers the use of multiconductor jacketed cables (commonly referred to as MC Cables) and proper installation methods for both rooftop and ground-mount applications. Matching connectors Intermateability of cable connectors used for the connection and splicing of PV conductors is now addressed within Article 690.33. Mismatched connectors have been shown to increase the likelihood of electrical arcs, which is one of the top causes of PV thermal events. It is not uncommon to see a pairing between Staubli MC4 (Multi-Contact 4mm) connectors that come pre-installed on many module-level power electronics, and “MC4 Compatible” connectors that come standard with certain PV module manufacturers. Mismatched connectors have also been observed at string wiring and DC homerun splices when installers do not procure connectors of the same make and model that come with the specific PV module.

Connectors from different manufacturers might have differing tolerances during the manufacturing process, which could result in water ingress, hot spots and potentially thermal events in worst-case scenarios. This code revision now shines light on this issue and should help to minimize the occurrence of mismatched connectors by requiring a 100% match. Article 705 There are notable changes related to the interconnection of PV systems within Article 705, including clearer language around supply-side connections and disconnecting means. Section 705.13 was added to address the use of power control systems (PCS), which could enable larger system sizes where export is limited by the utility. It is prudent for developers and EPCs to work with engineering firms that are familiar with the latest electrical code and commercially available solutions to ensure their systems are engineered for safety and reliability. In addition, properly engineered systems take both constructability and O&M into consideration. SPW

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O&M

Thinking of launching an O&M division? Here are five factors to consider. BY E R I C D O M E S C I K | CO - F O U N D E R A N D P R E S I D E N T | R E N E W V I A E N E R G Y

Even

in the midst of the COVID-19 crisis, the U.S. solar industry has shown impressive growth, with no signs of slowing down. The industry added a record 19.2 GW of new capacity during 2020 — a 43% increase from 2019. The report also projected that by the end of the decade, the U.S. solar market would quadruple from current levels. This projected growth has numerous implications for solar developers across the country, including what will likely be an unprecedented demand for operations and maintenance (O&M) services. Solar developers often contemplate how and when to expand their offerings to include O&M. In making this important decision, there are a number of factors to consider, ranging from the size of your client base to the availability and skillset of your employees, among other areas.

SOLAR POWER WORLD // 2022 RENEWABLE ENERGY HANDBOOK

For Renewvia, we carefully explored expanding our solar development business to include O&M, prior to launching our maintenance division last year. We are fortunate to have built our EPC business around a client base that believes in the value of incorporating solar into their long-term business plans, with many installing solar at multiple facilities. With this in mind, we have always tried to offer maintenance and warranty replacement services beyond our standard one-year workmanship guarantee, as a way to provide additional value, gain referrals and earn potential new business. However, as our client portfolio grew, we found ourselves in need of hiring full-time employees to focus solely on monitoring and maintaining existing sites. We also began to hear from clients a desire to formalize long-term services. We were

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O&M

extremely pleased to receive the welcoming and supportive responses from our clients on moving forward with O&M services for a fee. According to Stuart Sherrill, president of SteelFab, Renewvia’s first O&M client, “We were looking to assure our investment in solar energy output is achieving its fullest potential. Having a professional relationship with an O&M provider like Renewvia has allowed us to focus on our core business of fabricating structural steel while providing peace of mind that we are fully utilizing and cashing in on our significant clean energy investment.” Others communicated the need to ensure their solar investment was fully optimized. Marsh Butler, president of the Butler Automotive Group, shared, “We see solar as a definitive investment in our future as a company, and expanding our relationship to include O&M has enabled us to optimize that investment, which benefits both our business and the environment.” Key considerations when forming an O&M division When determining the right time to form an O&M division, there are several factors that should be considered. These include: 1. Ensure critical mass to justify the investment. Renewvia ultimately chose to establish an O&M business when the client base was in place and there was a clear pathway for growth. It became evident that the demand for O&M was on the rise with current clients and clients where we act as a third-party O&M provider. There are a number of upfront costs, so without understanding the client landscape, it can be a risky decision. 2. Hire a specialized and dedicated workforce. Providing first-rate O&M service requires a workforce with a highly specialized skillset that includes an understanding of data acquisition systems, performance monitoring and reporting, preventative maintenance planning, corrective maintenance execution and all aspects of solar PV. For an O&M operation to function at its best,

SOLAR POWER WORLD // 2022 RENEWABLE ENERGY HANDBOOK

O&M A SteelFab site, with O&M now managed by Renewvia.

these team members must be dedicated, experienced and able to react quickly to multiple clients with varying issues and opportunities. 3. Invest in the right internal systems. O&M providers are only as good as their systems (and the people who operate them), which should offer actionable data that reflect the real-world performance of clients’ solar portfolios. Not only should systems include data acquisition, performance monitoring and diagnostics, but they should also provide real-time comparisons to actual performance on financial, operational and historical levels. Solar developers and EPC firms alike “Let us help you minimize risk, save time, and expedite your renewables project with our one-stop-shop land solution.” Shawn Fields President

need to determine whether to outsource or develop their own proprietary performance monitoring systems and, more importantly, commit to them. Each of these choices has both cost and quality implications, and clients like consistency in both the outputs they receive and the commitment level and service that is provided. 4. Deliver a customized O&M offering. O&M is not a one-size-fits-all approach. It should include offerings that work for companies and solar systems of all sizes, from robust preventative and corrective maintenance to the ability to inspect and fix equipment at specified intervals. At Renewvia, our systems range from 20 kW to 1.5 MW across multiple states and vary from rooftop installations to carports to ground-mounts. The customization of our O&M plans consider all these factors prior to finalizing with our clients. 5. Take a customer service-oriented approach. As an O&M provider, it is critical to establish trust with clients, as you will likely spend a great deal of time on their sites. At Renewvia, we make the highest levels of customer service our imperative. These are values that are exhibited by our employees and required when we choose to use subcontractors for our work. We know that no matter how good the technology, relationships matter. According to John Thornburg, Renewvia’s O&M manager, “We always keep customer service at the forefront. This means really listening to our clients to understand their unique needs and then customizing solutions that work for them for the longterm.” There is no question that the market opportunity is exciting and growing, but launching an O&M division must be done at the right time. Taking these key factors into consideration ahead of making the investment will enable solar developers to realize the full potential of O&M now and in the future. SPW

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ENERGY STORAGE

A Borrego solar + storage project in Hubbardston, New York. Greg M. Cooper/Borrego

Timing is important, but it’s not everything: Considerations on when to add energy storage to your solar project BY C H A R L E Y W E S C H L E R A N D M I K E CO N WAY | B O R R E G O E N E R G Y

The

U.S. energy storage industry is booming, with annual commercial- and utility-scale deployments reaching gigawatt-level run rates. Although it is still relatively nascent, the industry is mature enough that the big questions around storage system design, battery chemistries and topology are well-understood by a handful of sophisticated engineering, procurement and construction (EPC) ﬁrms and energy storage integrators. Those companies have gained the experience and expertise and have the relationships

SOLAR POWER WORLD // 2022 RENEWABLE ENERGY HANDBOOK

with developers, independent power producers (IPPs), utilities and permitting authorities to successfully navigate the complex and still murky waters of storage integration and installation. However, solar + storage is a distinct type of system integration, not just a simple add-on of storage to PV and different than stand-alone storage, a process that requires an experienced EPC and developer. The ideal scenario would ﬁnd the storage components designed-in from the beginning of the project, but there are many reasons to

consider adding storage to a solar project at various times during development, construction and even once the plant is operational. Storage optionality (the ability to add storage) can help the marketability of the project to utilities increasingly looking for the grid stability and reliability beneﬁts that storage offers. Utilities prefer storage-paired solar facilities: for a modest increase in levelized cost of energy (LCOE), they receive beneﬁts such as the ability to shift energy to times more consistent with peak load and to utilize ancillary services.

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STORAGE

Storage attachment rates are climbing, indicating that the wider energy industry is recognizing the increasing value of storage and capitalizing on new opportunities. This article looks at the key considerations for adding energy storage and how the timing of the decision of when to add storage impacts the project. There are three scenarios for adding storage to a solar project: designing-in storage from project conception, adding storage once solar development is already under way, and retroﬁtting an existing operating PV system with storage. Scenario one: Design storage inclusion from the beginning Ideally, storage is designed into the solar array from the beginning of project conception. By planning for storage from the early stages, a project owner can optimize for the most beneﬁcial commercial use-case for the battery and best meet an offtaker’s needs. This approach makes it less likely for a restudy or utility delay, permitting and planning approvals won’t need to be revisited, and the site can be optimized with storage in mind instead of as an afterthought.

Initial considerations for this plan include land space, interconnection limit, system size and potential revenue streams. For example, in some markets the enhanced solar production that comes with a high DC-to-AC ratio is rewarded. In these markets, it is ideal to make decisions on storage and solar sizes early in order to avoid development rework that could occur should a developer want to increase the DC-to-AC ratio with the addition of batteries later. In markets experiencing interconnection constraints, DCcoupled energy storage may help mitigate otherwise expensive system upgrade costs by driving down the AC net injection of the combined system. This market model has been used extensively in both Massachusetts and New York, where years of distributed solar activity have reserved the vast majority of available hosting capacity on the systems. Scenario two: Add storage once project is underway The second scenario for adding storage is adapting as you go; that is, layering in storage after the initial interconnection and permitting applications have been submitted. It’s less

ENERGY STORAGE

A Borrego solar + storage installation in Assonet, Massachusetts. Greg M. Cooper/Borrego

disruptive to the project and continues the momentum that the project is already carrying through permitting, lease agreements and the like. If there is an incentive, adding storage at this stage will help secure the highest incentive. Adding storage around EPC project award has distinct advantages. Depending on the configuration that was approved in interconnection, there may be an opportunity to jump ahead of the line (depending on the program) or start a study in parallel while getting town approvals for a relatively small footprint

SOLAR POWER WORLD // 2022 RENEWABLE ENERGY HANDBOOK

adder (at least on most distributed generation sites). By doing so, remobilization and restudy costs can be mitigated or potentially avoided. The storage can be considered as a part of site optimization and provide midstage value engineering that may otherwise be lost. This should occur ideally before the offtake origination effort and definitely before the offtake agreement is finalized. It’s a reasonable approach to introduce additional revenue streams at this juncture but not as practical later in the process.

Adding DC-coupled storage is a potential avenue for introducing storage to an in-flight project without changing fault current contribution and the anti-islanding/ effective grounding methodologies on the inverter, which could lead to a restudy. Oftentimes, public policy drivers can influence developers to add energy storage to in-process PV applications when a new energy storage program is introduced within an existing PV market. As an example, both Massachusetts and New York introduced energy storage incentives as part of their PV programs between 2017 and 2018. In both cases, developers in those markets already had mature PV portfolios and naturally reacted by requesting to add energy storage to those active interconnection applications. The overwhelming demand for application modifications resulted in both jurisdictions adopting statewide guidelines for adding energy storage to in-flight PV applications. If the plan calls for adding storage once site improvement has begun, it should likely be treated as a separate project, given the long permitting, study and procurement lead times. At this juncture, stakeholders may provide additional space on the project site and make general design decisions to support any future add-ons without affecting the construction timeline.

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ENERGY STORAGE

Scenario three: Adding storage to an operating PV plant The final scenario would be to integrate the storage system with an operating PV power plant. Adding storage after the fact differs from designing a storage-only project and has some unique challenges. But there are certain cases where it makes sense to retrofit PV with storage, such as upcoming capacity RFPs, tariff-based program updates, utility preference and the like. A key challenge can arise when the original terms of a power purchase agreement do not consider storage. Primary questions include whether the solar facility needs to be augmented to better support storage integration, higher DC-to-AC ratio and other factors. Another factor is interconnection logistics. If the system is AC-coupled, will it need a new interconnection entirely? If it’s DC-coupled, will this require any changes in interconnection? The answers to both these questions may vary, depending on the interconnection entities. In terms of design and optimization, it’s prudent to identify if there are opportunities to expand or repower the existing power plant. Incentives can play a key role in the decision-making as well, since retrofitted solar + storage plants are eligible for the federal investment tax credit (ITC). Timing isn’t everything Ideally, integrating energy storage with a solar PV system should be considered from the beginning of a project, but adding storage at any stage in development and construction is possible. As storage costs decrease, retrofits have become an increasingly attractive way to maximize the financial returns for a project. The key to success for any solar + storage project is working with an experienced EPC team that can guide the site owner to the best possible outcome. SPW SOLAR POWER WORLD // 2022 RENEWABLE ENERGY HANDBOOK

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PROJECT RELIABILITY

Wireless networks hold the key to protecting utility solar projects BY G I A N S C H E L L I N G | R E N E WA B L E S B U S I N E S S D E V E L O P M E N T M A N AG E R | H I TAC H I E N E R G Y

Developers

across the country are building large-scale solar projects at an incredible pace, helping the industry do its part to move the world toward a more sustainable future. But the auction-driven push to lower the levelized cost of energy (LCOE) combined with changing weather patterns are forcing energy companies to rethink how they optimize overall yield, further decrease LCOE and keep PV plants online in harsher environmental conditions. Unfortunately, large solar plants are becoming increasingly vulnerable to extreme weather from climate change: storms, temperatures and precipitation continue to grow unpredictably.

This puts arrays at risk of decreased output or being knocked ofﬂine completely, creating penalty payments for unplanned outages or reduced production as well as costly maintenance and repairs. Communications systems give operators visibility into onsite weather conditions and enable remote-automated or manual equipment control. Massive data from deployed sensors like anemometers, irradiation sensors and the arrays themselves allows operators to predict extreme conditions and take action to keep systems up and running remotely from a central operations center. Still, building large communication networks capable of handling the explosion of monitoring and performance data is

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PROJECT RELIABILITY

a complex and expensive undertaking. This is particularly true for brownfield applications, since these plants typically already have power cables (including fiber optic communication infrastructure) laid and connected to existing equipment during the installation phase. It would be costly to upgrade and scale for additional sensors such as weather measurement devices. Wireless communication networks for existing projects Wireless communication networks can provide cost-effective, scalable and reliable connectivity for solar projects. In fact, deployed wireless project examples showed up to 75% cost reduction when expanding existing wired communication networks in installed PV plants with wireless vs. more wired communication infrastructure. But we cannot just put a wireless device on an inverter and call it a day. Power companies need to rethink how they design, plan, build, update and scale communication networks in a costefficient, manageable way. Here are three things to consider when building out solar wireless communications networks: 1. Consider a private network: Public utilities are seeing an increase in cyberattacks that seek to disrupt economies or hold systems and data ransom in exchange for a large payout — the larger a power generation asset is, the more important its yield’s impact has on an overall region, hence the more attractive it is for cyberattacks. For monitoring of mission-critical machine-to-machine applications, it is important to consider a private and dedicated wireless communications solution that allows for more stringent control and security of the network. These private solutions can be

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deployed anywhere around the world for dedicated, multi-application use and are therefore more reliable and secure with end-to-end protection built in. In fact, new regulations from governments and pressure from lenders insist on following security standards such as NERC CIP in the United States — protocols that may be prohibitive of public infrastructure. 2. Insist on plug-and-play scalability: When a developer expands an existing solar project, it’s critical for them to be able to scale wireless communications networks along with it. Every time a new array, inverter, prognostic, weather instrument or other sensor is added, it needs to be connected, configured, tested and integrated into the grid. Operators would benefit from a solution that automates much of the provisioning process, enabling them to plug-andplay new devices without significant human interaction. 3. Implement self-healing technology: A self-forming, self-optimizing and selfhealing meshed architecture renders wireless communications less prone to outages. Imagine that a large storm takes out the connection to an anemometer. Typically, in the case of wired communication infrastructure, a

technician would have to go out into the field and either repair or replace the equipment. Conversely, a mesh would automatically reconfigure the network to close the service gap. Operators could then work in the background from the remote control center to get the sensor back up and running without causing a disruption of service. Eliminating the need to send a technician into the field while avoiding outages reduces operational costs and extends the lifetime of the asset. Wireless is the future Extreme weather and other environmental concerns are putting large-scale solar projects at risk. Power companies must protect their solar assets through remote asset monitoring, but the explosion in data is overwhelming existing communication networks and forcing companies to rethink wired infrastructure for specific applications. Wireless communication networks have the ability to scale connectivity, extend the lifetime of assets and save power companies significant OPEX costs over the lifetime of the solar project. It’s just a matter of choosing the right wireless solution for your solar plant needs. SPW

SOLAR POWER WORLD // 2022 RENEWABLE ENERGY HANDBOOK

CABLES & WIRES

Prefabricated wire wipes out related schedule risks BY J O E PA R Z YC H | E B O S W I R E P R O D U C T M A N AG E R | T E R R AS M A R T

The

pandemic has caused unpredictable material costs and shortages. Add the constant challenge of balancing risks and returns and it's an increasingly complex climate for solar EPCs and developers. The numbers aren’t great. Currently, 90% of all power and energy infrastructure projects are either overbudget or delayed, according to a study by FMI Consulting. Analysts from the International Journal of Innovation, Management and Technology say construction projects overall typically

SOLAR POWER WORLD // 2022 RENEWABLE ENERGY HANDBOOK

exceed budget by at least 16% — often far more. Utility-scale PV construction is no different: Every minute and every cent counts. So how do EPCs ensure solid project efficiencies and returns? By making sure to address every detail proactively throughout the project lifecycle. Take a neglected eBOS component: wiring. Cutting corners in the wiring supply chain risks unforeseen delays and cost overruns in a project’s final phases that can damage overall profitability.

Optimized electrical and wiring layouts, streamlined product deliveries and dependable partners are key to avoiding downstream challenges. Key considerations for wiring success Consider prefabricated wire over bulk options. While bulk wiring may seem less expensive initially, prefabricated solutions that are custom-built to meet a project’s unique layout will result in faster integration in the ﬁeld. Bulk, off-the-shelf wires require more time to manually crimp, cut and install

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CABLES & WIRES

on site, adding labor and equipment costs. Using bulk wiring can also lead to inconsistent tolerances and inefficient material use and waste — and that’s if all goes well. Wire connection incompatibility in a project’s final stage can impact tight, end-of-project timelines and budgets when there is no slack left in the schedule. Lastly, wire fabricated in the field can’t provide the consistency and long-term reliability that is critically important to asset owners and operators. By comparison, prefabricated wiring can offset risks and yield the following advantages: • Wire systems are assembled with precise wiring gauge, harness length and combiner box combinations. • In-house assembly means superior quality control for better reliability and performance. • Controlled manufacturing compresses lead times and results in faster delivery. • Customized solutions simplify on-site execution and compress installation schedules. • Efficient plug-and-play connections are packaged for accurate installation in the field. The final result is a high-quality wire solution that is custom-manufactured to each project’s unique cost and schedule requirements. What to look for in an eBOS partner Developing custom wire solutions requires solar experience. Make sure to select a wiring provider that understands other PV components and has a global perspective on the project’s lifecycle. Most bulk wiring providers don’t. An experienced partner familiar with project complexities both upstream and downstream can anticipate installation issues. Look for a wire provider that can value-engineer custom solutions based on unique project factors like topography, racking height and number of modules. A wire provider should be familiar with O&M practices and able to design a wiring strategy that supports the project’s long-term maintenance. There are added benefits to working with eBOS partners that integrate wiring with other electrical components. When combined with a turnkey eBOS and mounting offering and in-house assembly, project pitfalls can be avoided, creating a smooth and coordinated process throughout execution.

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SOLAR POWER WORLD // 2022 RENEWABLE ENERGY HANDBOOK

CABLES & WIRES

Project success story When cranberry farmers in southern Massachusetts decided to go solar, they were not fully aware of the complexities involved in putting in an agrivoltaics system. Their hybrid system combined 9 MW of solar with 36 MWh of storage and was to be installed over a producing, 150-year-old cranberry wetland (bog). Installing a system over fragile cranberry vines demands extreme caution, requiring precise placement of panels and wiring. The array had to be high enough to not interfere with the crops below and to allow for farming activities such as harvesting to take place seamlessly. That meant designing the system with some unique features: • Modules had to be mounted on 25- to 40-ft-long wooden, moistureresistant utility poles driven 15 to 30 ft into the ground to elevate the trackers 10 ft above the bog. At this height, significantly more wire was required than for a standard ground-mount system. • Keeping the cranberry bogs fully functioning and undisrupted was key; the wiring solution needed to minimize installation activities. • Wires had to be delivered within a tight six-week timeline rather than the usual eight- to 12-week lead times.

wiring in place alongside the racking and module installations. The added benefit of using a prefabricated wiring solution ensured speedy installation. About 1,300 source circuit conductors were cut to length and labeled in the factory. The wires were terminated with MC4 connectors installed on the panel end for fast connection with the combiners, and the bundles were shipped on spools to the site. Bespoke design and execution yields success Leveraging turnkey BOS experience and in-house assembly allowed the wiring partner to bring unique value to this complex installation, delivering thoughtful coordination and simplicity onsite. The customized, end-to-end wiring solution delivered a quick plug-and-play execution, including:

•

• •

•

Accommodating the atypical height over the bog with consistent and accurate cut lengths. Streamlining wiring integration with combiner boxes. Coordinating with other components to shave weeks off the typical timeline for a project of this size and complexity. Ensuring speedy product delivery and wiring so that construction did not delay harvest.

The outcome points to the benefits of selecting a wiring partner with upfront problem solving skills and expert estimators who can design custom solutions. Finding a flexible vendor with a view of the entire process — from design and supply chain to manufacturing — delivers high-quality planning and solutions to mitigate project risks. SPW

Collaborating with the developer and the EPC, the wire partner designed and delivered a customized solution to ensure the project’s success. Wiring was combined with other BOS components to create a turnkey solution. The system took into account the project’s unique height, placement, human activities and project turnaround times. And instead of waiting for the racking to be completed before installing the wiring, the partner put the

SOLAR POWER WORLD // 2022 RENEWABLE ENERGY HANDBOOK

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WIND MARKET OVERVIEW

The United States has finally entered the offshore wind boom No

disrespect to land-based wind projects – they still contribute over 10% of the country’s U.S. electrical capacity and (along with utility-scale solar) made up more than 90% of new U.S. generation additions in the ﬁrst half of 2021. But it’s ﬁnally time for offshore wind to shine. The Biden Administration in March announced a goal to deploy 30 GW of offshore wind in the United States by 2030, a target that will also create tens of thousands of union jobs and provide more than $12 billion in annual capital investment in projects on both U.S. coasts. The U.S. offshore market was already starting to advance, but direct support from the presidential administration encourages actual progress. In order to meet the ambitious goal by the end of the decade, the Bureau of Ocean Energy Management (BOEM) has to advance new lease sales and review operation plans much more quickly. Ports need to be upgraded to accommodate offshore development and new factories need to be constructed close to shores. And probably most important, more Jones Act-compliant wind turbine installation

vessels (WTIVs) – the platforms with large decks and legs that lift out of the water, along with a crane to position offshore turbines – need to hit waters. These are all items the United States is currently working on. If everything proceeds positively, industry research groups are still predicting the United States to fall short of Biden’s goals. The Global Wind Energy Council (GWEC) predicts the country to hit 28.4 GW by 2030, while IHS Markit is even less optimistic, predicting only 21 GW. This isn’t just a U.S. problem – IHS says that new infrastructure has to be rapidly developed to meet future technological advancements, or else the global market will stall out. For example, current WTIVs are unable to install turbines exceeding 15 MW – while companies like GE and Siemens Gamesa continue to push the limits with their offshore turbine prototypes. Adjacent industries must catch up to the wind market’s appetite for innovation. In the meantime, the country is marching forward. BOEM will begin offering West Coast lease sales in early 2022, with over 95% of the proposed lease sale area located 30 miles off

WINDPOWER ENGINEERING & DEVELOPMENT // 2022 RENEWABLE ENERGY HANDBOOK

the California Coast. New lease areas off North Carolina and New York will also open soon, and the department is exploring the wind potential in the Gulf of Mexico. New Jersey is building an offshore monopile foundation manufacturing facility and New York has established a site to build support structures for offshore towers. Dominion Energy has a Jones Act-qualified WTIV that it has agreed to loan to Ørsted for use on an offshore site near Rhode Island while also using it for its own project near Virginia. The United States can still meet Biden’s offshore goals through industry cooperation. There are many markets to model – the leading European market has its own lofty goal of 60 GW of offshore wind by 2030 and 300 GW by 2050. Governments across the world are setting more ambitious goals, the cost to install offshore turbines is coming down and new foundation types (floating wind) allow for projects in deeper waters with windier weather. The U.S. offshore wind market is finally making real progress. Expect more new project announcements and adjacent industry players entering the market in 2022 and beyond. WPE

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MAJOR U.S. WIND PROJECTS

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182-MW Maryneal Windpower Project powers on in Texas

Nolan County, Texas Duke Energy Sustainable Solutions brought the 182-MW Maryneal Windpower Project to commercial operation in July. The Texas project is supplying cellular service provider Sprint with 173.3 MW of wind power through a 12-year virtual PPA, reducing the company’s carbon footprint by 9%. Wanzek Construction built the project made of 38 4.8-MW Nordex USA turbines, and the project created approximately 200 jobs during peak construction.

WINDPOWER ENGINEERING & DEVELOPMENT // 2022 RENEWABLE ENERGY HANDBOOK

2021 was a year of preparations for incoming offshore wind development in the United States, with industry players gearing up to realize the untapped energy potential just off the U.S. shoreline. Submarine transmission lines are being laid; ports are being established to manufacture and deploy offshore turbines; industry-related services are being established stateside and international resources in offshore development are being tapped; and curriculum is being developed to train technicians for an industry that is estimated to create 25,000 entry-level jobs alone. In addition to all of that, the U.S. onshore wind industry remains a consistent source of energy diversiﬁcation, putting up hundreds of megawatts in many different states, with a heavy focus on the South and Midwest. This next year is bound to see more concrete developments in offshore wind, complementing federal policy fast-tracking renewable energy deployment and putting the United States on a clearer path toward a carbon-neutral grid.

RWE Renewables enters Ohio wind market with 250-MW project

Logan & Hardin counties, Ohio RWE Renewables completed its ﬁrst wind power project in Ohio, a 250-MW wind farm located across two Northwest counties. The Scioto Ridge Wind Farm is composed of 75 Siemens Gamesa turbines and has the capacity to power 60,000 homes. Despite its history of industrial manufacturing, wind provides less than 2% of Ohio’s total electricity generation. Scioto Ridge will generate $75 million in payments over the next 25 years that will be given to local governments, school districts and landowners.

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MAJOR U.S. WIND PROJECTS

209-MW Reloj de Sol wind farm comes online in Texas

Zapata County, Texas EDP Renewables completed a 209-MW wind farm in Texas last May. The Reloj de Sol Wind Farm joined the company’s four operating wind facilities in the state. The project created 101 full-time positions during construction and 10 permanent jobs for operating and maintaining the wind farm. Reloj de Sol is expected to pay $36 million over its operating lifetime to local governments and landowners.

Colorado utility is sole offtaker on 104-MW wind farm

Seibert, Colorado Colorado residents in K.C. Electric Association’s service area are enjoying power produced by a recently completed 104-MW wind project. EDP Renewables constructed the Crossing Trails Wind Farm across Kit Carson and Cheyenne counties using 20 Vestas V1850 4.3MW and ﬁve Vestas V136 3.6-MW wind turbines. Some components used on the turbines were manufactured in-state. Crossing Trails created more than 100 jobs and will employ six full-time team members to operate the wind farm.

Invenergy completes 486-MW segment of three-part Oklahoma wind farm project Woods County, Oklahoma Invenergy constructed the Sundance and Maverick Wind Energy Centers in North Central Oklahoma, the former 199MW and latter 287-MW wind farms in a larger portfolio of projects in the region. Interstate utility American Electric Power commissioned a 1,485-MW project portfolio called North Central Energy Facilities to provide its customers with clean energy. The third and ﬁnal facility, Traverse (999 MW), is expected to come online by early 2022. The total portfolio of projects represents a $2 billion investment in the region.

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Duke Energy Renewables builds its largest wind farm

Kay County, Oklahoma Duke Energy Renewables completed the largest wind power project in its ﬂeet, a 350-MW facility built in Kay County, Oklahoma. Frontier Windpower II is an expansion of Frontier I, together generating 550 MW of wind energy. AT&T and Ball Corporation both have 15-year PPAs on Frontier I, totaling 321 MW. The project is made of 74 4.8-MW Nordex Group wind turbines and at peak construction employed about 250 people. Amshore Renewable Energy developed the project and Wanzek Construction was the construction contractor.

200-MW East Raymond wind farm supports Austin utility

Willacy and Cameron counties, Texas East Raymond wind facility, a 200-MW onshore wind farm spanning Willacy and Cameron counties in Texas, started commercial operation in January 2021. East Raymond is powered by 91 Vestas V120 and V110 2.2-MW turbines that generate power for more than 60,000 households in the region. RWE Renewables developed the wind farm and Austin Energy signed a PPA on the project back in August 2019, offsetting more than 60% of the utility’s customer energy needs.

Construction completed on 302-MW Indiana Crossroads Wind Farm

White County, Indiana EDP Renewables North America developed a 302-MW wind facility in Indiana that will deliver clean energy to customers in Northern Indiana Public Service Company’s (NIPSCO) service territory. The Indiana Crossroads Wind Farm comprises 72 V150 4.5-MW Vestas turbines that were constructed by White Construction, a subsidiary of IEA. The project originated through a NIPSCO program that found clean energy developments were lower-cost options for its customers.

Developers upgrade and repower California wind farm

Livermore, California East Bay Community Energy (EBCE) and Greenbacker Renewable Energy repowered a wind project in California in July. The Scott Haggerty Wind Energy Center was formerly made of 569 100-kW wind turbines that were replaced by just 23 new turbines, bringing the facility to 57.5 MW. The wind farm is supporting EBCE’s Renewable 100 program, joining a mix of wind and solar projects serving about 100,000 customers.

Avangrid Renewables builds 154.8-MW wind farm on South Dakota farmland

Deuel County, South Dakota Avangrid Renewables completed construction of the 154.8-MW Tatanka Ridge Wind Farm in South Dakota in January 2021. The wind farm’s 56 turbines were constructed on 18,000 acres of corn and soybean farms and cattle ranches leased from over 100 landowners. Regional electric cooperative Dairyland Power Cooperative signed a 51.6-MW PPA on Tatanka Ridge that will power approximately 16,000 homes in its operating territory.

WINDPOWER ENGINEERING & DEVELOPMENT // 2022 RENEWABLE ENERGY HANDBOOK

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BOLTING

Maintaining a successful wind industry with efficient maintenance tools BY R A D TO R Q U E S Y S T E M S

Despite

some major disruptions due to the ongoing COVID-19 pandemic, the global wind industry is still having record-breaking years. According to the Global Wind Energy Council, 2020 saw a 53% year-on-year increase of new capacity installed, with no hint of slowing down. Thanks to the clean energy output and smaller footprint, wind farms are a growing business. With more wind turbines being built globally, the need to keep these assets operating safely and as efﬁciently as possible is increasing. By ensuring the turbines are operated and maintained consistently, the initial investment can be preserved, unscheduled stoppages and downtime can be avoided and the environmental impact of replacing the turbines sooner can be reduced.

susceptible to unpredictable weather patterns. Operations crews are always working within a tight, compact schedule to accomplish their required maintenance tasks. Some days can be too windy to have cranes working to lift materials, so the job is shut down. When the window occurs and the weather calms, it’s important that crews can efﬁciently tackle as much as they can within a short time frame.

Unpredictable environments Working on a wind farm is unlike any other environment. A wind turbine is constantly exposed to the elements and experiences all types of weather — heat, cold, rain and, of course, wind. Dirt can build up and cause issues for both the turbine and those tasked with operating and maintaining it. Not surprisingly, one of the most signiﬁcant challenges faced by managing a wind farm is the height — everything needs to be carried up several ﬂights, and the weight of tools and required components can be a big factor in maintenance. Added to these challenges is that the need to work in the landscape that is often

Ongoing maintenance Wind turbines generally require preventative maintenance checkups a few times a year that must be performed by specialized technicians. With more than 25,000 bolts on an average wind turbine, one of the most important routine maintenance activities is to perform a torque check on the bolts used on all parts of the turbine. Torque is an indirect indicator of fastener tension and boltedjoint clamp load. Bolts are checked on the towers, in the cell, the generator, and the power generator. Even the blades are bolted on, so it’s important they are checked regularly.

WINDPOWER ENGINEERING & DEVELOPMENT // 2022 RENEWABLE ENERGY HANDBOOK

It’s essential that the bolts carry a precise bolt load and are within the variation speciﬁed by the original equipment manufacturer. When bolts are checked, it’s to ensure they are tight — but not too tight. If they are too loose, malfunctions or even catastrophic disasters can occur. If they are too tight, they can be stretched to the point where they can no longer carry a clamp load and will need to be replaced. With so many bolts, the extreme environments, and the height of the wind turbine, this is a job that needs to be done efﬁciently while meeting exacting standards.

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Right tools for the job Given the demands of the speciﬁc requirements of the wind industry, it’s important that the right tools are used for the job. Precision torque wrench tools, like the E-RAD BLU series from RAD Torque Systems, are the choice of wind turbine manufacturers, wind power construction and maintenance contractors, as well as utilities around the world for their heavy-duty bolting requirements. “The wind industry overall and the maintenance and operation of wind farms can be a pretty rough environment,” said Kevin Campbell, master distributor of the RAD Torque product line in the Western U.S., with Dynamic Bolting. “Working in that climate so high off the ground can be very demanding and there can be strict requirements for the tools needed to get the job done. “The E-RAD BLU series precision torque wrench tools are accurate, compact and fast,” Campbell continued. “And most importantly, they’re lightweight — precisely what’s needed for this tough environment.” Unique tools for a unique workplace After more than two decades of building extreme duty torque wrenches for heavy duty applications, RAD Torque Systems understands the unique challenges of the wind energy industry. Used by companies like General Electric,

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BOLTING

Vestas, Siemens, Goldwind and Iberdrola, RAD tools have been relied on to build and maintain wind power facilities around the world. These years of experience have allowed RAD to design specific tools to make technician jobs easier while ensuring they meet the exacting maintenance requirements. Durable, high-speed and lightweight, the E-RAD BLU saves labor time, lowers project downtime and maintains wind towers faster, all while handling the 5,000 ft-lbs. and even up to 10,000 ft-lbs. needed for tower bolts. Torque ranges for the E-RAD BLU are 100 to 11,000 ft-lbs. (135 to 15,000 Nm), far exceeding what’s needed for regular maintenance. Providing a high degree of accuracy (+/- 3% on target) for high torque assembly applications, the E-RAD torque wrench has a patented and advanced electronic pistol grip to reduce bolting time up to 300% as compared to conventional hydraulic wrenches. The E-RAD uses advanced technology to ensure a high degree of accuracy and data collection. Allowing multiple models of wrenches to be used in combination with one controller, the E-RAD has Bluetooth connectivity with RAD Smart Socket for transducer verified joint calibration, highly advanced data logging and tool management features, and a military grade single cable and connector system. In some wind turbine towers, technicians have to flange sections from the inside. Other turbines have unique curvatures that do not allow for the use of straight tools. RAD’s offset gearboxes and 90° tools allow an E-RAD to fit inside the diameter and curvature of a turbine’s shell, which means no job is out of reach, even on more challenging turbine designs. The E-RAD is extremely light in comparison to its hydraulic competitor and does not require a heavy pump. That means it’s easier to transport up to and use on

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work platforms. But that doesn’t mean it compromises on torque strength. It can take up to 120 bolts and up to 11,000 ft-lbs. to connect a large diameter flange. The E-RAD is a continuous rotation tool and can complete a task like this in a much shorter time than a hydraulic wrench. Safety first The most important consideration when performing any kind of maintenance work is safety. While there are instances where access

can be an issue, technicians can fall back to a hydraulic wrench. But in all other applications, the E-RAD clearly outshines. “When using a hydraulic wrench, you need two people communicating: tool handler and pump operator,” Campbell said. “You need to rely on that communication which can be difficult and is prone to human error. And there can be other issues, like the weight of the pump while you’re trying to bring it up the turbine, the potential to spill fluid, which can

WINDPOWER ENGINEERING & DEVELOPMENT // 2022 RENEWABLE ENERGY HANDBOOK

cause a slipping hazard…these are all problems the E-RAD solves. “Every opportunity that it’s possible to fit a RAD style tool into an application, it’s the tool of choice,” Campbell continued. “The first time a technician picks up an E-RAD, they are impressed. It’s quiet, it’s accurate. The tool provides the confirmation of the work performed and the accuracy of the work performed. Hands down, it’s just the best torquing device I’ve ever worked with.” WPE

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GEARBOXES

Oil debris monitoring saves time when it comes to wind turbine gearbox maintenance BY J O R DA N F R E E D | D I R E C TO R O F CO R P O R AT E M A R K E T I N G & P R O D U C T S T R AT E G Y | G AS TO P S

There

is an abundance of literature dating back over the past 20-plus years about the challenge of premature gearbox failures, and the cost impact they have on wind turbine operation. While the principals of prognostics and health management (PHM) are well established, and the objective of replacing unplanned failure events with scheduled maintenance based on early indication of degradation has not changed, the wind industry and sensor technology continue to evolve in ways that steadily increase the value proposition. With global acceptance of the need to shift our energy dependence to renewables, the demand for wind energy is driving the development of much larger turbines and a significant increase in offshore wind farms. The primary cost avoidance targets associated with PHM, or condition based maintenance (CBM) are tied to business interruptions, inspection and repair costs, along with downtime penalties. The larger the turbine, the more difficult to reach, the higher the cost and complexity associated with inspection and maintenance. Secondary or catastrophic failure events that cannot be addressed on-site are even more concerning with taller, harder to reach and heavier components. Further, with greater dependency on wind as a primary energy source, the cost

of downtime penalties is also likely to continue increasing. Wind turbine heights and rotor diameters have easily doubled since the early 2000s as the industry pushes the boundaries of production per turbine. With the emergence of offshore wind as a major source of energy, size will continue to increase the maintenance

WINDPOWER ENGINEERING & DEVELOPMENT // 2022 RENEWABLE ENERGY HANDBOOK

challenge. In 2019, General Electric installed the Haliade-X turbine prototype in the Port of Rotterdam. The wind turbine stands 260 m (853 ft) tall and has a rotor diameter of 220 m (721 ft). Vestas plans to install the V236-15MW offshore prototype at Østerild National test centre for large wind turbines in Western Jutland, Denmark, in the second

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GEARBOXES

half of 2022. The wind turbine is 280 m (918 ft) tall with a predicted production output of 80 GWh a year, enough to power nearly 20,000 households. The criticality of keeping the massive wind turbines of the future running and being able to efficiently maintain them based on condition will only increase in importance. While wind turbine, gearbox and bearing manufacturers strive to design more reliable assets, the common phenomenon limiting useful life continues to be surface fatigue resulting from repeated stresses under bearing rolling contact or gear meshing contact. Excessive loads, misalignment, material flaws, manufacturing defects, mishandling, contaminants in the oil, high oil temperatures and corrosion are some of the potential contributors to localized damage that begin to degrade the bearing or gear. In other words, the reality is that even with more reliable bearings and gearboxes, there will always be a probability of failure over time supporting the value proposition of moving from reactive to proactive, condition-based and ultimately to predictive maintenance. That desired future state of truly predictive maintenance is well articulated in the principal of “Maintenance 4.0” that is the application of “Industry 4.0” technologies (industrial analytics, automation, robotics, etc.) to operations and maintenance (O&M) activities. The business objective is to radically improve equipment availability while lowering O&M costs through digitalization. While much attention is paid to the advances in artificial intelligence as means to turn data into valuable insights, the often unspoken challenge is that insights are only as good as the data. In the case of wind turbines, that data comes from sensors used to monitor the health of

the bearings and gearboxes. Progressing toward predictive maintenance requires the ability to not just identify damage, but to determine damage severity and calculate time to failure or remaining useful life (RUL). This is where oil debris monitoring differentiates itself from other types of sensors, as quantifying the wear debris from a damaged component is a direct representation of the damage of the monitored component. For wind turbine gearboxes, oil debris monitoring (ODM) technology provides an early indication of bearing spall and gear pitting damage and quantifies the severity of damage progression towards failure. Online oil debris monitoring provides the most reliable and timely indication of bearing degradation because: • Bearing failures on rotating machines tend to occur as events and could be missed by means of only periodic inspections or data sampling observations. • As large wear particles are being detected by the oil debris monitoring sensor, there is a low probability of false indication from benign smaller wear debris particles. • Residual or wear-in debris can be differentiated from the actual damage debris because the accumulated particle counts recorded due to the former tend to decrease while those due to the latter tend to increase.

WINDPOWER ENGINEERING & DEVELOPMENT // 2022 RENEWABLE ENERGY HANDBOOK

While ODM technology itself is a proven technology used in asset management across multiple industries, truly understanding the physics of failure to be able to develop the algorithms necessary to accurately predict RUL requires years of study. Ottawa, Canadabased Gastops first started conducting surface fatigue tests on bearings to understand the progression of failure in 1992, bringing ODM to the wind market in the early 2000s. The company is now a world leader in critical equipment condition monitoring, having installed over 20,000 oil debris monitoring sensors on active wind turbines with a proven history of detecting early signs of damage in advance of failures, maximizing availability while minimizing downtime and maintenance costs. Realizing the goals of PHM, the technology is used to monitor drivetrain health, by detecting the initiation of damage and monitoring its progression, which enables maintenance events to be scheduled proactively, preventing costly unplanned downtime during critical operating periods. The ability to determine the remaining useful life of an asset is critically important as it provides the necessary information for operators to optimize the operational lives of their gearbox and main bearing. The company’s flagship product, MetalSCAN, is an online

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GEARBOXES

advanced oil debris sensing technology which is plumbed into the return oil line from the gearbox or main bearing. Any debris generated within the gearbox passes through its core and is quantified in terms of size, frequency and the type of metal, whether it is ferrous or nonferrous material. This information is collected and compared against predefined warning and alarm limits, developed using customized algorithms based on the geometry of the gearbox. When debris passes through the sensor, MetalSCAN translates the information it gathers into the RUL of the gearbox or main bearing. This allows the operator to understand the current health, adjust operational parameters and plan maintenance activities, preventing the requirement for shutdown during critical operation periods. While ODM provides an ideal data source to provide the valuable insights required to support predictive analytics,

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realizing the vision, and leveraging the potential of Maintenance 4.0 will require a variety of data sources in multiple locations to improve the accuracy of modeling, allowing operators to pinpoint failures throughout the system. Many wind turbine manufacturers already combine vibration sensors and ODM into the overall condition monitoring systems they provide. As technology advances to enable the transition from conditionbased maintenance to truly predictive maintenance, real-time equipment intelligence will be required. Systems that combine the information from next generation real-time sensors that monitor data on multiple factors such as oil debris, oil condition, vibration, temperature and pressure will be used to develop advanced analytics and digital twins. Connectivity to enable large-scale industrial internet of things deployments with the assurance of data security and network reliability will

be key factors in enabling wind farm operators of the future to realize the vision of Maintenance 4.0. Paramount to success in this evolution remains the intersection of machine intelligence with human ingenuity. The expertise that comes with decades of research into the physics of failure by a company like Gastops combined with a commitment to innovation and drive to realize the vision of real-time prognostics will lead to a future of optimized O&M costs in the wind industry. Today’s ODM technology is already providing the benefits of PHM envisioned 20 years ago. The rapidly increasing demand for wind energy is driving the creation of massive wind turbines that are being located offshore. There is a clear requirement to evolve condition monitoring systems to provide operators with PHM capability enabling the future of predictive maintenance. WPE

WINDPOWER ENGINEERING & DEVELOPMENT // 2022 RENEWABLE ENERGY HANDBOOK

OFFSHORE DEVELOPMENT

The complicated U.S. regulations for offshore wind vessels BY M AT T T R E M B L AY | S E N I O R V I C E P R E S I D E N T , G L O BA L O F F S H O R E | A B S

The

next three years could be a deﬁning period for the U.S. offshore wind sector. It represents a growth area of the maritime industry at both a domestic and international level. Globally, developers have announced projects totaling at least 200 GW of new capacity since the beginning of 2020, according to a report by RCG, which indicates that the active project portfolio for offshore wind developers now stands at 500 GW. After a period of relatively slow progress, the U.S. government under the Biden Administration has refocused efforts to promote renewable energy development with a goal of 25 GW of generating capacity installed by 2030, and to review more than a dozen lease area construction and operations plans (COPs) by 2025. The growth potential of the U.S. market is

further supported with the findings of a recent ABS poll, where nearly 90% of respondents believe offshore wind will play a significant role in sustainable U.S. energy strategy. To support this ambitious activity, the White House announced in March 2021 that grant and funding resource opportunities related to offshore wind have been designated by the U.S. Dept. of Transportation Maritime Administration as well as the U.S. Dept. of Energy Loan Programs Office. Getting to grips with the supply chain Momentum is building, and stakeholders are accelerating their plans for engagement into the United States. While the U.S. market waits for its first Jones Act-compliant turbine installation vessel, it needs to keep a watch on Europe, where the supply

WINDPOWER ENGINEERING & DEVELOPMENT // 2022 RENEWABLE ENERGY HANDBOOK

chain may also face vessel constraints. It is a critical time across the U.S. supply chain in which U.S. developers will need to rely on European suppliers that are already in high demand to begin to meet U.S. offshore wind plans. Meeting the 2030 target will catalyze signiﬁcant supply chain beneﬁts, including new port upgrade investments totaling more than $500 million; one to two new U.S. factories for each major windfarm component including wind turbine nacelles, blades, towers, foundations, and subsea cables; additional cumulative demand of more than seven million tons of steel — equivalent to four years of output for a typical U.S. steel mill; and the construction of four to six specialized turbine installation vessels in U.S. shipyards, each representing an investment between $250 and $500 million.

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Construction and commission of a U.S.-flagged vessel is essential but concerns are being raised by offshore wind developers if they will face higher costs. A U.S. vessel is unlikely to be built without the confidence that the vessel is used to full capacity and in most cases a vessel is likely to need 500 MW to 800 MW of annual capacity installation for at least five years in order to balance the books.

Constructed with elements via Adobe Stock

Is compliance a necessary hurdle in the expansion of the U.S. market? Compared to the European offshore wind vessel market, the U.S. market is different. First, there is the Merchant Marine (Jones) Act of 1920, which is a U.S. trade law that defines how maritime commerce is regulated. Specific restrictions limit the transfer of cargo between U.S. ports to vessels that are registered and built in only the United States. Ownership of these vessels must be by majority U.S. incorporated entities with U.S. citizen representation. Onboard vessel crews may use only United States Coast Guard (USCG) credentialed mariners and a majority of U.S. citizens. In 2016, the commissioning of a U.S. offshore project - Deepwater Wind's 30-MW Block Island wind farm - located near the Rhode Island coast illustrates the challenge which current U.S. operators face. With a lack of U.S. vessels, developers contracted a vessel from Europe, but the Jones Act meant that the vessel was prohibited from entering U.S. shores to collect and transport wind turbines, towers and blades. To overcome this issue, smaller U.S.-flagged liftboats were used that delivered wind turbine equipment out to the site, where it was transferred to the European jack-up vessel, which inevitably increased the cost and complexity of the project.

WINDPOWER ENGINEERING & DEVELOPMENT // 2022 RENEWABLE ENERGY HANDBOOK

While the U.S. Customs and Border Protection agency (CBP) holds ultimate responsibility for making rulings on whether a specific trade activity is subject to the Jones Act, the USCG determines whether a vessel is U.S.built and therefore eligible for Jones Act trade. USCG has determined that "U.S.-built" can be achieved if all major components of a vessel's hull and superstructure are fabricated in the United States and the vessel is assembled entirely in the United States. Companies outside of the United States that form the supply chain, including component manufacturers for engines, propellers and certain hull elements are not included. Construction of a vessel to U.S. standards and certification by USCG may be achieved outside of the United States for international trade but it is not eligible for Jones Act designation unless specifically permitted via a formal waiver process. Presently, waivers are rare and typically granted for national defense or emergency justifications. A 12-point guide More dedicated vessels are essential for the future success of the US offshore wind market, and a global supply chain can help the U.S. offshore wind market to flourish. In a fresh look at the here-and-now situation, a detailed assessment and awareness of the compliance and safety requirements of a vessel and its crew are provided in a new industry report released by ABS, which highlights: 1. 2.

How does the Jones Act impact offshore wind support vessels? What are the central elements of U.S. regulations for vessel design, construction and operation? Which departments are responsible for maritime safety?

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OFFSHORE DEVELOPMENT

4. Can vessel designs previously approved by other Flag authorities in accordance with IMO and with International Standards be considered? 5. How are wind turbine technicians, offshore workers and crews viewed in U.S. regulation? 6. What are minimal safe manning requirements? 7. What are the primary distinguishing crew licensing elements for U.S. registered vessels? 8. Are there unique U.S. requirements for vessel stability? 9. What are the certification and registration requirements for a vessel in U.S. operations? 10. How are U.S. regulations applied for diesel engines in small workboats? 11. What are the implications for crew transfer vessels? 12. What are the requirements for crew berthing conditions and onboard design considerations?

Composite Windblade Repair Training

Is a change of mindset on the horizon? There is no question: Change must happen. As the industry begins to expand and country decarbonization targets need to be met, construction and maintenance of offshore wind projects calls for a combination of expertise that is comparatively new to the U.S. market and requires a variety of specialist support tonnage. A dedicated U.S.-flagged installation vessel will be efficient and cost-effective by loading all components at a U.S. port on one vessel. To use a foreign, non-Jones Act installation vessel, components from a U.S. port must be transported by a U.S. built feeder vessel. Other wind support vessels such as a Service Operation Vessel (SOV), floating heavy-lift vessel, and Crew Transfer Vessel (CTV) operating in U.S. offshore wind farms are also required to comply with the U.S. regulations. However, what is clear is that members of the maritime world and the offshore wind industry at large need to increase their dialogue and collaborative efforts, and fast, to drive forward the required development of the U.S. offshore wind market to reach the Biden Administration's offshore wind targets. But action is needed now — not tomorrow. WPE

R-5: Composite Windblade Repair For those responsible for performing structural repairs to composite wind blades, this course covers fundamentals necessary to understanding aerodynamic skin, core, and trailing edge repairs. R-15: Advanced Windblade Repair A follow-on to our Composite Wind Blade Repair course, this course is for those directly involved in providing high performance repairs to large area damage, spars, and tips.

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SAFETY

An inside look at how safety standards are created for the wind industry BY W E S L E Y W I T T , C H A I R ; A N D K R I S T Y A B E L , V I C E C H A I R | G WO N O R T H A M E R I C A CO M M I T T E E

The

amount of standardized safety training continues to increase year-over-year across North America in the wind industry because companies gain productivity and a more flexible workforce, while workers are more easily hired and valuable to their employers. In 2020, the number of Global Wind Organisation (GWO) training modules completed grew by 30% compared to the previous year and exceeded 10,000 courses in North America. More and more technicians are trained in basic safety training (BST) that includes first aid, manual handling, fire awareness and working at heights.

Additionally, growth is seen in basic technical training (BTT) and advanced rescue training (ART). BTT covers safe working activities in relation to the mechanical, electrical and hydraulic components of a wind turbine, while ART enables technicians to perform up-tower rescue in the nacelle, tower, hub, spinner and inside the blade using industrystandard rescue equipment. Comparing 2019 to 2020, completed BTT courses grew by 24% across North America, while the number of ART courses completed rose by an amazing 600% — illustrating how the standard created by GWO members met an industry need for up-tower rescue.

WINDPOWER ENGINEERING & DEVELOPMENT // 2022 RENEWABLE ENERGY HANDBOOK

Technicians with certifications in all three GWO standards (BST, BTT and ART) can save employers approximately three weeks of entry level training, allowing them to perform safely and effectively on wind turbines. An additional benefit of GWO standard training for employers is that certificates for completed courses are uploaded to WINDA, the global wind industry training records database. Employers can use the database to verify certifications of employees and contractors who have finished GWOcertified training courses, essentially making the hiring and onboarding more efficient and effective.

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SAFETY

An inside look at development of training standards GWO standards are created by the industry, for the industry. The membership of globally leading OEMs and owner-operators use a dynamic list of known risks and hazards faced by wind turbine technicians to inform their development of training standards. There are currently 25 top hazards and risks grouped into GWO’s current list. There are risks on the list, like diving and helicopter transfer, for example, that GWO members know there is already an established training standard available and there is no need to re-invent the wheel. Since this list was last published, working with lifts/ elevators has also been developed into a new GWO training standard — the GWO Basic Lift User course. The beginning for development of a standard is analysis of data, including injury records, risk statistics and existing training programs already in use by wind turbine manufacturers and owner-operators, which are the GWO membership. Specifically a standard for control of hazardous energy (COHE) was released in October 2021. The COHE standard addresses several electrical challenges for employers, which are working on energized systems working in high voltage. The team developing the COHE standard begin with a problem-solving statement that specifies the training standard is intended to mitigate safety risks of hazardous energies for technicians in the wind industry and reduce the need for company-specific COHE trainings while ensuring efficient resource allocation and stakeholder collaboration.

We have observed that the GWO current training standards aren’t fully reflecting the risk environment faced by technicians in the wind industry in terms of hazardous energies, which is a central part of the value proposition for GWO, like creating risk-based training that reflects the risk environment in the wind industry. The process for development of the COHE training standard includes three areas of focus: • Analysis of members’ needs and requirements to create the COHE standard. • Design of a minimum viable product standard based on identified needs. • Develop and test of the training standard to increase technicians’ knowledge of hazardous energies, their characteristics and how to recognize them.

WINDPOWER ENGINEERING & DEVELOPMENT // 2022 RENEWABLE ENERGY HANDBOOK

This training will increase technicians’ skills to measure for the presence of hazardous energy and to isolate the sources of hazardous energy. This is a complex area, governed by a wide range of regulatory systems depending on where you are based. For example, working with electricity in Europe is a protected profession requiring several years in education after high school. In other countries, simply calling oneself an electrician can be enough to qualify. Nevertheless, the COHE standard will do what GWO training standards always do — look at the risks and hazards speciﬁc to a wind turbine environment and provide training that helps workers avoid injury in that place of work.

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SAFETY

reflect a changing risk landscape using feedback from GWO members, training providers and certification bodies. This year, updates were made to basic technical training with a more specific equipment list, Rigger Signal Person with simplified instructions resulting in a savings of two hours for the course and Blade Repair where further emphasis was added to the craftsmanship skills in grinding materials to perform repairs.

The standard will be built on a foundation of learning objectives that the GWO instructors must achieve with their students in the speciﬁed time. Each learning objective incorporates lesson elements where instructors teach students using a taxonomy guide supporting learning in three domains: knowledge, skills and ability. Within those three domains, the lessons will either be at the basic level, intermediate or advanced. With COHE still under development, the lessons and learning objectives remain under wraps until the training is piloted by a select group of training providers. For the industry, by the industry Standards for the wind industry are developed by working groups, which

WINDPOWERENGINEERING.COM

consist of subject matter experts from GWO member companies. This is key because standards are created and developed by specialists who understand the various roles of wind technicians, turbine components and technologies, risks, hazards, local regulations and challenges. The working groups also ensure that each standard complies with regional and national legislation. Next, the COHE training standard is approved by the GWO training committee. The training committee is made of leaders also from member companies who specialize in health, safety and environment, learning and development and operations. In addition to creating and developing training standards, existing GWO courses are reviewed and updated through a constant review cycle to

Inside North America The GWO North America committee was formed in 2019 to align standards with any regulatory requirements or practices prevalent or in development in the region. Working groups are also underway in North America to create and tailor standards for the region. One working group is now assessing challenges and opportunities for GWO standardized training in North America for onshore and offshore wind. The intent is to ensure that GWO standards continue to meet the regulatory environment of North America, make training more efﬁcient and reduce retraining. Stakeholders collaborating in North America include Avangrid Renewables, ENERCON Canada, GE Onshore Wind – Renewables, RWE Renewables, Siemens Gamesa Renewable Energy and Vestas Wind Systems. Across the North America region, standardized safety and technical training offers advantages for companies and the workforce to make renewable energy a reality for both onshore and offshore wind turbine industry. WPE

WINDPOWER ENGINEERING & DEVELOPMENT // 2022 RENEWABLE ENERGY HANDBOOK

Statement of Ownership, Management, and Circulation (Requester Publications Only) 1. Publication Title

2. Publication Number

Windpower Engineering & Development 4. Issue Frequency

Four times a year: February; May; September; December

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0 0 4 -_ 2 3 5 5. Number of Issues Published Annually

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WTWH Media, LLC 1111 Superior Ave., Suite 2600, Cleveland, OH 44114

ABARIS Training .................................71

9. Full Names and Complete Mailing Addresses of Publisher, Editor, and Managing Editor (Do not leave blank) Publisher (Name and complete mailing address)

Courtney Seel; WTWH Media, LLC 1111 Superior Ave. Suite 2600, Cleveland, OH 44114 Editor (Name and complete mailing address)

Kelly Pickerel; WTWH Media, LLC 1111 Superior Ave., Suite 2600, Cleveland, OH 44114 Managing Editor (Name and complete mailing address)

Billy Ludt; WTWH Media, LLC 1111 Superior Ave., Suite 2600, Cleveland, OH 44114 10. Owner notpublication leave blank. If the publication is owned bythe a corporation, give theofname and address of the corporation followed by the Owner(Do (If the is owned by a corporation, give name and address the corporation immediately followedimmediately by the names and addresses of all stockholders owning holding 1 percent or or more of the amount of stock. not owned corporation, give names and addresses the names and addresses of allorstockholders owning holding 1 total percent or more of theIftotal amountbyofastock. If not owned by a corporation, giveofthe individual If owned a partnership or other unincorporated ﬁrm, give its name and address as give well as those of each individual owner. If theof names andowners. addresses of theby individual owners. If owned by a partnership or other unincorporated firm, its name and address as well as those publication is published nonproﬁt organization, name and address): give its name and address.) each individual owner. If by theapublication is publishedgive by aits nonprofit organization, Complete Mailing Address Full Name

WTWH Media, LLC

1111 Superior Ave., Suite 2600, Cleveland, OH 44114

Scott McCafferty

1111 Superior Ave., Suite 2600, Cleveland, OH 44114

Mike Emich

1111 Superior Ave., Suite 2600, Cleveland, OH 44114

Marshall Matheson

1111 Superior Ave., Suite 2600, Cleveland, OH 44114

11. Known Bondholders, Mortgagees, and Other Security Holders Owning or Holding 1 Percent or More of Total Amount of Bonds, Mortgages, or Other Securities. If none, check box None

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Full Name

AD INDEX

Complete Mailing Address

Mosaic ................................................11

Allied Moulded Products ...................26

Norbar Torque Tools ..........................53

AZTEC Bolting ......................... cover, 61

Nucor ..................................................17

Baja Carports ......................................33

Panasonic ......................................... IBC

Bright Oak ..........................................23

QuickBOLT ...........................................7

ALA Industries ....................................56

Nine Fasteners ...................................39

Altech Corporation ..............................3

NTC Wind ...........................................60

Bailey Specialty Cranes .......................21

OMCO Solar .......................................27

Blattner Co .........................................35

Has Not Changed During Preceding 12 Months Has Changed During Preceding 12 Months (Publisher must submit explanation of change with this statement)

N/A

PS Form 3526-R, September 2007 (Page 1 of 3 (Instructions Page 3)) PSN: 7530-09-000-8855 PRIVACY NOTICE: See our privacy policy on www.usps.com PS Form 3526-R, July 2014 [ page 1 of 4 (see instructions page 4) ] PSN: 7530-09-000-8855 PRIVACY NOTICE: See our privacy policy on www.usps.com

13. Publication Title

Windpower Engineering & Development

15. Extent and Nature of Circulation

Rooftech .............................................45

Continental Control Systems .............37

Snake Tray ..........................................32

DEPCOM ...........................................41

Sungrow .............................................00

Gastops ..............................................65

Vaisala .................................................63

Intellirent ............................................25

WHC Solar .........................................51

Chint .....................................................5

Shoals Technologies Group ............... BC

DCE Solar ...........................................31

SolarPod .............................................37

September 2021

Average No. Copies Each No. Copies of Single Issue Published Issue During Preceding Nearest to Filing Date 12 Months

Outside County Paid/Requested Mail Subscriptions stated on PS Form 3541. (Include direct written request from recipient, telemarketing and Internet re(1) quest s from recipient, paid subscriptions including nominal rate subscriptions, employer requests, advertiser’s proof copies, and exchange copies.)

6,136

3,271

3,623

Average No. Copies Each No. Copies of Single Issue Published Issue During Preceding Nearest to Filing Date 12 Months

Outside County Paid/Requested Mail Subscriptions stated on PS Form 3541. c. Total Paid and/or Requested Circulation of 15b (2), (3),telemarketing and (4)) (Include direct written (Sum request from(1), recipient, and Internet re(1) quest s from recipient, paid subscriptions including nominal rate subscriptions, employer requests, advertiser’s proof copies, and exchange copies.) Outside County Nonrequested Copies Stated on PS Form 3541 (include b. Legitimate Sample copies, Requests Over 3 years old, Requests induced by a Paid and/or (1) In-County Paid/Requested Mail Subscriptions stated on PS Form 3541. Premium, Bulk Sales and Requests including Association Requests, Requested (Include direct written recipient,Lists, telemarketing Internet reNames obtained from request Businessfrom Directories, and otherand sources) Distribution (2) quests from recipient, paid subscriptions including nominal rate subscriptions, (By Mail employer requests, advertiser’s proof copies, and exchange copies.) and d. NonreIn-County Nonrequested Copies Stated on PS Form 3541 (include Outside quested copies, Dealers Requests Over 3 years old, Requests induced by a Sales Through and Carriers, Street Vendors, Counter (2) Sample the Mail) Distribution (3) Premium, Sales Requests including Association Requests, Sales, andBulk Other Paidand or Requested Distribution Outside USPS® (By Mail Names obtained from Business Directories, Lists, and other sources) and (4) Requested Copies Distributed by Other Mail Classes Through the USPS Outside (e.g. First-Class Mail®) the Mail) Nonrequested Copies Distributed Through the USPS by Other Classes of (3) Mail (e.g. First-Class Mail, Nonrequestor Copies mailed in excess of 10% c. Total Paid and/or Requested Circulation (Sum of 15b (1), (2), (3), and (4)) Limit mailed at Standard Mail® or Package Services Rates) Nonrequested Distributed Outside the on MailPS (Include Pickup Stands, Outside CountyCopies Nonrequested Copies Stated Form 3541 (include (4) Shows, Showrooms and Other Sources) Sample copies, Requests Over 3 years old, Requests induced by a (1) Trade Premium, Bulk Sales and Requests including Association Requests, Names obtained from Business Directories, Lists, and other sources) Total Nonrequested Distribution (Sum of 15d (1), (2), (3) and (4))

d. Nonref. In-County Nonrequested Copies Stated on PS Form 3541 (include Total Distribution (Sum of 15c and e) quested (2) Sample copies, Requests Over 3 years old, Requests induced by a Distribution Premium, Bulk Sales and Requests including Association Requests, g. (By Copies (See Instructions to Publishers #4, (page #3))and other sources) Mail not Distributed Names obtained from Business Directories, Lists, and Outside h. the Total (Sum of 15f and g) Mail) Nonrequested Copies Distributed Through the USPS by Other Classes of (3) Mail (e.g. First-Class Mail, Nonrequestor Copies mailed in excess of 10% Requested Limit mailed atCirculation Standard Mail® or Package Services Rates) i. Percent Paid and/or (15c divided by f times 100) Nonrequested Copies Distributed Outside the Mail (Include Pickup Stands, (4) Trade Shows, Showrooms and Other Sources) 16. Publication of Statement of Ownership for a Requester Publication is required and will be printed in the issue of this publication. e. Total Nonrequested Distribution (Sum of 15d (1), (2), (3) and (4)) 17. Signature and Title of Editor, Publisher, Business Manager, or Owner f.

6,597

14. Issue Date for Circulation Data Below

a. Total Number of Copies (Net press run) (4) Requested Copies Distributed by Other Mail Classes Through the USPS (e.g. First-Class Mail®)

terrasmart .............................................9

HELUKABEL USA .........................29, 69

Western Land Services .......................40

ITH Bolting .........................................59

Yotta Energy .......................................19

14. Issue Date for Circulation Data Below

a. Total Number of Copies (Net press run)

b. Legitimate Paid and/or 13. Publication Title In-County Paid/Requested Mail Subscriptions stated on PS Form 3541. Requested (Include direct written request from recipient, telemarketing and Internet reDistribution (2) quests from recipient, paid subscriptions including nominal rate subscriptions, (By Mail employer requests, advertiser’s proof copies, and exchange copies.) 15.and Extent and Nature of Circulation Outside Sales Through Dealers and Carriers, Street Vendors, Counter the Mail) (3) Sales, and Other Paid or Requested Distribution Outside USPS®

PV Labels Inc. ................................... IFC

CAB Solar ...........................................43

Fireaway Inc. .......................................73 12. Tax Status (For completion by nonprofit organizations authorized to mail at nonprofit rates) (Check one) The purpose, function, and nonprofit status of this organization and the exempt status for federal income tax purposes:

KENSINGTON ELECTRICS, INC ........12

AceClamp ...........................................28

3,271

3,623

3,221

2,366

136

3,318

2,502

6,589

6,125

6,597

6,136

50%

59.2%

Date

Total Distribution (Sum of 15c and e)

g. Copies not Distributed (See Instructions to Publishers #4, (page #3)) I certify that all information furnished on this form is true and complete. I understand that anyone who furnishes false or misleading information on this form or who omits material or information requested on the form may be subject to criminal sanctions (including fines and imprisonment) and/or civil h. Total (including (Sum of 15f and g) sanctions civil penalties).

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

EVP Marshall Matheson

Managing Director Scott McCafferty 310.279.3844 smccafferty@wtwhmedia.com @SMMcCafferty

Publisher

805.895.3609 mmatheson@wtwhmedia.com @mmatheson

Courtney Nagle cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel

SALES Jami Brownlee 224.760.1055 jbrownlee@wtwhmedia.com

Jim Powers 312.925.7793 jpowers@wtwhmedia.com @jpowers_media

Ashley Burk 737.615.8452 aburk@wtwhmedia.com

PS Form 3526-R, September 2007 (Page 2 of 3) i. Percent Paid and/or Requested Circulation (15c divided by foftimes 100) X I certify that 50% all my distributed copies (electronic and print) are legitimate requests or paid copies.

17. 16. Publication of Statement of Ownership for a Requester Publication is required and will be printed in the issue of this publication. 17. Signature and Title of Editor, Publisher, Business Manager, or Owner 18.

Pat Curran, Senior Digital Media Manager

December 2021 Date

10/2021

I certify that all information furnished on this form is true and complete. I understand that anyone who furnishes false or misleading information on this form or who omits material or information requested on the form may be subject to criminal sanctions (including fines and imprisonment) and/or civil sanctions (including civil penalties).

PS Form Form3526-R, 3526-R, September July 2014 2007 (page(Page 2 of 2 4)of 3)

WINDPOWER ENGINEERING & DEVELOPMENT // 2022 RENEWABLE ENERGY HANDBOOK

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sales@shoals.com

Windpower Engineering and Development 2022 Renewable Energy Handbook December 2021

Articles inside

Major Wind Projects of 2021

Safety

Cables & Wires

Bolts

Project Reliability

Energy Storage

EV Charging

Solar Market Overview

2021 Top Solar Products

Mounting

NEC 2020

Installation

Operations & Maintenance