Windpower Engineering and Development August 2019 by WTWH Media LLC

THREE KEYS TO CHOOSING GEAR OIL FOR WIND TURBINES //

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The technical resource for wind profitability

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REACHING NEW HEIGHTS PAGE 13

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A GUIDE TO OFFSHORE WIND IN AMERICA

ADVANCED BOLTING TECHNOLOGY

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A FEW THOUGHTS...

slow & steady wins the race? IF THE ABOVE idiom holds true, U.S. offshore wind developers are bound to benefit from their patience and perseverance. After the trial and errors of Cape Wind (remember the proposed wind project off the shores of Cape Cod that hit permitting setbacks? You can read more about the lessons learned on page 21.), and the small victory of the five-turbine Block Island Wind Farm, offshore progress in America has been slow…yet steady. Slow because siting and building in federal waters is a challenging feat. Vineyard Wind can attest to this. The developer of an 800-MW wind project 15 miles south of Martha’s Vineyard is undergoing evaluations by more than 25 federal, state, and local regulatory bodies — and approvals have been no easy feat. Vineyard was recently denied cable-lay permitting by a Massachusetts municipality vote. Separately, the federal Bureau of Ocean Energy Management (BOEM) has delayed issuance of a final environmental impact statement that would support the construction of the planned 84 offshore turbines. However, such project delays may give ports a chance to revamp their infrastructure to accommodate the offshore wind industry. Several ports — such as Massachusetts’ Brayton Point, which is fully re-developing into an offshore wind hub with heavy-lift capacity and grid services — are prepping to compete as part of the offshore wind supply chain. A report from the Business Network of Offshore Wind suggests a collaborative approach is key, where port infrastructure is shared between developers to avoid bottlenecks and

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delays. Unfortunately, one U.S. port is unlikely to accommodate a project’s full requirements (read more on page 25). Despite obstacles, which will soon include the expiring production tax credits, the offshore wind industry is determined and steadily advancing. Vineyard Wind says “it remains viable and continues to move forward.” In addition, more than 20 GW is in the offshore project pipeline, with states continuing to make major commitments to the industry. New York is a leading example with the largest procurement of offshore wind power in U.S. history: 9 GW by 2025 (view other state commitments on page 14). New York also pledged $200 million toward new port developments and recently selected five multi-year projects to advance the responsible development of offshore wind. This includes funding to better understand fish and bird behavior to mitigate potential impacts from wind turbines. Earlier this year, the fishing industry also signed a 10-year agreement with federal regulators (the BOEM, NOAA, and RODA) to collaborate on offshore wind development. What’s more is several U.S. legislatures have introduced the bipartisan Offshore Wind Jobs and Opportunity Act, which would establish federal grants for offshore wind education and training. If passed, the bill would create a federal grant program to assist colleges, state and local governments, unions, and non-profits in the development of programs to prepare workers for sector jobs. Together such efforts, however slow and steady, are bound to pay off. Fingers crossed. WPE

WINDPOWER ENGINEERING & DEVELOPMENT

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

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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© 2019 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, April, August 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

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AUGUST 2019

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MAKE PLANS TO ATTEND TOP-RATED CONFERENCES

Wind Resource & Project Energy Assessment Conference September 10 – 11, 2019 | Renton, WA Wind Energy Finance & Investment Conference October 1 – 2, 2019 | New York, NY Offshore WINDPOWER Conference and Exhibition October 22 – 23, 2019 | Boston, MA Clean Energy Executive Summit November 19 - 21, 2019 | Carlsbad, CA

Wind Project O&M and Safety Conference

February 26 – 27, 2020 | San Diego, CA

Wind Project Siting and Environmental Compliance Conference April 7 - 9, 2020 | Washington, DC

CLEANPOWER 2020

June 1 - 4, 2020 | Denver, CO www.awea.org

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W I N D P OW E R E N G I N E E R I N G & D E V E LO P M E N T / / V O L . 1 1 N O. 3

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40 COVER STORY

D E PA R T M E N T S 01

EDITORIAL Slow and steady wins the race?

SAFETY Best practices for offshore wind transit

WINDWATCH Is your home county suitable for wind energy? A global wind-turbine mapping project, A national standard for renewable electricity, Renewables surpass coal, The energy sector gets its own blockchain, An open invitation to women leaders, How robots may change wind O&M, Wind work around North America

OPERATIONS & MAINTENANCE Three keys for choosing and analyzing gear oil in wind turbines

POLICY Lessons learned from Cape Wind

PROJECTS Catching the next wave… Is California next in line for offshore wind?

LUBRICANTS What’s new in gear oil, filters & analysis

COMPONENTS Why sealing is one component of effective bearing lubrication

WINDPOWER ENGINEERING & DEVELOPMENT

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Cover photo courtesy of Charlie Chesvick, iStock.

offshore wind guide MAPPING THE FUTURE OF OFFSHORE WIND IN AMERICA, INSURING OFFSHORE PROJECTS, A NEW JACKET, EQUIPMENT WORLD

F E AT U R E S WHY COLLABORATION IS CRITICAL FOR OFFSHORE WIND AND PORT SUCCESS Over the next two decades, East Coast states and California expect to develop more than two-dozen offshore wind farms. The interest in an American offshore industry is clear. Next, however, comes the how. Building a supply chain — and, specifically, port infrastructure that supports the unique requirements of offshore wind — is critical to industry advancement. PAGE 25

www.windpowerengineering.com

HOW TO CHOOSE THE RIGHT BEARINGS FOR OFFSHORE WIND TURBINES To maximize offshore capacity, larger, more powerful wind turbines are typically used and require components that can withstand harsh sea-salt conditions. Such high-powered turbines pose a challenge to conventional bearing designs, which means it is critical to understand which bearings can perform reliably if wind developers are to capitalize on offshore opportunities and project ROIs. PAGE 42

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WINDPOWER ENGINEERING & DEVELOPMENT

JONNY ALLEN

CHERISE GAFFNEY

DOUGLAS LUCAS

CHAD MARRIOTT

JONNY ALLEN is a Senior Underwriter and Head of Offshore Renewables with the global insurance company, Travelers, Allen is responsible for Travelers’ offshore wind book of business in the company’s syndicate at Lloyd’s. He also chairs the European Wind Turbine Committee and represents the syndicate at a number of renewable market groups. CHERISE GAFFNEY is a partner in Stoel Rives LLP’s Environment, Land Use, and Natural Resources practice group. She advises clients on federal natural resources law in complex permitting and compliance matters. Gaffney has extensive experience on issues arising under the Endangered Species Act, Marine Mammal Protection Act, Federal Power Act, National Environmental Policy Act, and Administrative Procedure Act. DOUGLAS LUCAS has worked in the bearing industry for 18 years at The Timken Company. For the past 15-plus years, he has supported wind energy in various positions, from an Application Engineer to a Chief Engineer. In his current role as an advanced application technologist, Lucas is responsible for application and new product development that delivers innovative, high-value technology solutions to Timken customers in the global wind markets. Lucas holds bachelor and master’s degree in mechanical engineering from the University of Akron, as well as a professional engineering license in the State of Ohio.

CHAD MARRIOTT, a partner at Stoel Rives LLP, leads the firm’s energy subgroup and serves as counsel to sponsors, owners, and investors in the development, sale, acquisition, and financing of renewable and thermal generation projects in the U.S. Marriott has worked heavily in the wind, solar, and battery energy storage spaces, serving as sponsor’s counsel in the negotiation of about $3 billion in tax equity and separate cash equity investments in 900 MW of renewable projects. Separately, Marriott has led teams advising on the acquisition of historic wind assets for repowering and served as lead counsel on the acquisition of operational and development-stage wind, solar, and battery storage projects in North America. TIM TAYLOR, a partner at Stoel Rives LLP, is one of Sacramento’s best-known environmental and land use lawyers. He helps residential, commercial, and industrial developers achieve compliance with California’s numerous land use and environmental laws — with a particular focus on the California Environmental Quality Act and related litigation. During his more than 25-year career, Taylor has dealt extensively with a wide range of federal environmental laws, including the National Environmental Policy Act, the Clean Water Act, and the Endangered Species Act. He also represents numerous public agency clients on state planning, zoning, development, and environmental law matters.

TIM TAYLOR

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wind watch Is your home county suitable for onsite wind energy? The answer is likely, yes

ONSITE WIND ENERGY can drastically cut a manufacturing facility’s CO2 emissions. This is according to new analysis from One Energy, an industrial power company, which found that more than 1,027 U.S. manufacturing counties are financially viable for onsite wind projects. “Almost a third of the U.S. has high concentrations of wind and manufacturing, making these areas ideal for onsite wind energy projects,” said Jereme Kent, CEO of One Energy. “This presents a tremendous opportunity for companies to reduce their energy costs and their carbon footprint.” The company also found that nearly 30% of all U.S. counties have manufacturing facilities that could benefit from wind — even if the investment tax credit drops to zero next year. What’s more: there are 16 U.S. states with annual electricity-generation CO2 emissions, which would be individually offset by installing wind turbines. One Energy based its analysis on its Wind for Industry program, where customers sign a 20-year agreement that lets them buy energy produced at a fixed rate that’s lower than retail electricity rates. The new market report evaluated three main elements: wind resource, manufacturing concentration, and project

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economics. For a project to be viable, the wind resource must be attractive, the factory must use enough energy, and the area grid pricing must exceed One Energy’s projected rates based on the wind resource. In a typical three-turbine project (1.5-MW each), a single manufacturer can reduce their CO2 emissions by 168,000 metric tons over a 20-year period, which is equivalent to reducing 183 million pounds of burned coal. “Our total addressable market report for onsite wind energy was developed as an internal planning document,” said Kent. “However, given that there is no comparable market information available, we decided it was worth sharing with the public.”

For this study, the wind resource was analyzed county by county across the U.S. and translated into a capacity factor (CF). The CF was then paired with known, three-turbine project costs to determine an estimated 20-year PPA rate. The PPA-rate determination was performed using three different ITC rates: 18%, 12%, and 0%. Download the full report at oneenergy.com/market-analysis.

www.windpowerengineering.com

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A global wind-turbine mapping Project AN AMBITIOUS PROJECT to map the geolocations of every wind turbine in the world is underway. Led by IntelStor, a cloud-based market intelligence company, the researchers have already tracked more than 24,500 offshore and 83,400 onshore wind turbines. IntelStor says it has identified missing wind turbines from published datasets and corrected past inaccuracies in labeling decommissioned turbines. Learn more at intelstor.com

The global wind-turbine mapping project has officially surpassed the 100,000 count.

Introducing a national standard for renewable electricity NEW LEGISLATION was The Renewable Electricity recently introduced by Standard Act would push several U.S. Senators, the country toward reduced dependence on fossil fuels which would more than while incentivizing investments double the supply of in wind and solar energy. renewable energy in the country, from 18% of electricity generation in 2018 to at least 50% by 2035. The Renewable Electricity Standard (RES) Act of 2019 sets a “federal floor-setting standard” that requires retail electricity providers across the country to increase their supply of renewable energy by a percentage of total retail sales each year, starting in 2020. Under the RES, each kilowatt-hour of electric energy generated by a new clean energy source — such as wind or solar power — is entitled to a renewable electricity credit, which would then be turned in for compliance. “Climate change poses an existential threat to our environment, public health, way of life, and security – requiring an immediate and aggressive federal response to achieve significant cuts in carbon emissions, as well as other pollutants that hurt our most vulnerable communities,” said Tom Udall (D-NM), one of the lead Senators pushing for the RES. He added: “As states step up with legislation to increase the use of renewable energy, the entire country needs to follow suit.” The full text of the bill text can be found at tinyurl.com/RESbill.

Renewables surpass coal FOR THE FIRST TIME, renewable energy production surpassed coal-based electricity production in the United States. In fact, coal generation fell to a 47-year low this spring, according to the Energy Information Administration. S&P Global Market Intelligence predicts that 28 GW of U.S. coalfired generation will retire between 2019 and 2023. As a result of these retirements, the demand for thermal coal is expected to fall by more than 150 million tons over the next five years. This is good news for renewables and the environment.

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Source: SierraClub.org

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WIND WATCH The energy sector gets its own blockchain THE WORLD’S FIRST PUBLIC, enterprise-grade blockchain tailored to the energy sector is here. Meet the Energy Web Chain, recently launched by the non-profit Energy Web Foundation (EWF). A blockchain is a digital record of transactions linked in a peer-to-peer network. The Energy Web Chain currently has more than 10 affiliates — including utilities, grid operators, and blockchain developers — hosting validator nodes for the live network. These organizations serve as the chain’s public proof-of-authority (PoA) network design: a publicly accessible, ethereum-

based network with “permissioned” validators. Ethereum is an open-source, global platform for decentralized applications. This PoA-based design offers several benefits to the energy sector, including scalability, energy efficiency (which also equates to low transaction costs for market participants using the network), and increased regulatory compliance. “Never before have we had a globally decentralized, open-source, public network supported by some of the world’s largest corporate entities — let alone in the energy sector,” said Jesse Morris, chief commercial officer with EWF. “These companies rarely collaborate or jointly innovate, and The launch of the Energy Web Chain follows more than two years of development by EWF, which was co-founded by the Rocky Mountain Institute and Grid Singularity, a blockchain technology company. The Energy Web Chain plans to overcome some of the cost, scalability, and power consumption problems typical of conventional blockchains.

now they’re teaming up to support a brand-new digital technology.” EWF is also currently migrating decentralized applications, or dApps, from test networks onto the Energy Web Chain. The dApps focus on three keys for the energy sector: 1.

Expand markets for renewable energy trading 2. Increase the effectiveness of demand response programs 3. Streamline electric vehicle charging “This is a watershed moment for accelerating a low-carbon, customercentric electricity system,” said Morris. “I hope that we will look back on the EW Chain launch as another inflection point in electricity’s evolution, just as we now see wind and solar tumbling down the cost curve, the deployment of smart meters, and other digital infrastructure.” EWF’s next target is to decentralize the chain by Q4 2019, so it fully belongs to and is validated by the energy sector. Learn more at energyweb.org

An open invitation to women leaders WOMEN ONLY ACCOUNT for about 32% of workers in the renewable energy industry and most of those jobs are administration roles. According to a 2019 IRENA report, which examined gender equity in the sector, women’s participation in science, technology, engineering, and mathematics is quite low. To advance the role of women as agents of change in society and promote best practices within the wind industry, the Global Wind Energy Council (GWEC) has teamed up with

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the Global Women’s Network for the Energy Transition (GWNET) to launch the Women in Wind Global Leadership Program. This program is designed to accelerate the careers of women in the wind industry, support pathways to leadership positions, and foster a global network of mentorship knowledge-sharing and empowerment. To get involved or learn more about the program, go to tinyurl.com/WomenInWind

www.windpowerengineering.com

AUGUST 2019

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CASTROL OPTIGEAR SYNTHETIC CT 320

THE LONGEST TRACK RECORD, LONGEST OIL LIFE AND LONGEST GUARANTEE. • Castrol has over 30 years of experience and knowledge in the wind industry. • Our Optigear CT 320 gear oil is running on its 10th year without intervention. • An industry leading guarantee gives you the confidence you’ve chosen the very best. Discover why leading turbine manufacturers and energy companies opt for Castrol Optigear.

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

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8/12/19 3:50 PM

WIND WATCH How robots may change wind O&M ROBOTS MAY SOON change the way routine maintenance is conducted on wind turbines, leading to fewer up-tower climbs for wind technicians. Given the risks and high cost of conventional rope or aerial lift access for turbine O&M, this is promising news for the industry — and particularly for the offshore wind sector, which typically faces harsher winds and riskier conditions at project sites. Autonomous, robotic devices that can reliably scale a wind-turbine tower and crawl on blades offer significantly safer, up-close inspections that rival human counterparts. One benefit to robots is the inspection tools they may carry, including cameras, sensors, and artificial intelligence. For example, in one current research project, Sandia National Laboratories is equipping a crawling robot with a scanner that will search for hidden damages inside wind-turbine blades. The reason? According to mechanical engineer, Joshua Paquette, who’s a part of Sandia’s wind energy program, current blade inspection methods rarely catch damage soon enough to minimize costs or repairs. “In these visual inspections, you only see the surface damage,” explained Paquette. “Often though, by the time you can see a crack on the outside of a blade, the damage is already quite severe. You’re looking at a very expensive repair or you might even have to replace the blade.” Sandia showcases b-roll video footage of its robotic crawler, performing a test inspection on a damaged blade segment at tinyurl.com/SandiaFootage. Routine inspection is critical for keeping

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wind turbines in service and maximizing clean-energy generation, says Paquette. Robowind, an early-stage robotics company, agrees. It recently partnered with professors from California State University to develop robots and robotic tools for windturbine blade maintenance. However, the team believes robotic devices can do more than inspect blades. Robowind is developing devices with the capabilities to inspect, clean, sand, paint, and repair. The latter includes applying blade coatings, leading-edge protection, or installing vortex generators (VGs). VGs are aerodynamic devices sometimes applied on turbine blades to optimize wind generation.

Researchers with Sandia National Labs test crawling robots to detect wind-turbine blade damage with the aim of driving down wind-turbine maintenance costs. (Photo: Randy Montoya; tinyurl.com/SandiaRobots)

www.windpowerengineering.com

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WIND WATCH A two-year UK-funded initiative also began this year to prove offshore wind O&M can be safely and successfully carried out by autonomous vessels, crawling robots, and drones. The MIMRee (Multiplatform Inspection, Maintenance & Repair in Extreme Environments) project is relying on experts in the fields of robotics, artificial intelligence, non-destructive testing, marine and aerial engineering, and others. The MIMRee researchers are employing autonomous vessels to initially scan and map the wind turbines at a project site. Onboard drones will then conduct visual-imaging inspections of the blades and transport crawling robots to the blades to make repairs. The robots may also use an electronic skin (developed by high-tech startup company, Wootzano) to “sense” or “feel” a blade’s surface and collect structure data. The end goal is to develop a holistic digital and robotics system that’s capable of planning, communicating, sharing data, and working together on complex sequences of maintenance tasks. The advanced robotic system is expected to save a typical wind farm about $33 million in O&M over its lifetime. WPE

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The MIMRee wind O&M initiative is using a six-legged crawling repair robot, called the BladeBUG. Watch a video about the research project at tinyurl.com/MIMRee

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Wind work around North America Wind energy is set to overtake hydropower this year, according to the Energy Information Administration. Total wind generating capacity (97.18 GW) is rapidly closing in on that of hydropower (100.33 GW). In fact, a record 39,000 MW of new wind projects are currently under construction or in advanced development. Texas, of course, still leads the way with over 8,500 MW of new wind under construction. This is followed by Wyoming (4,780 MW), New Mexico (2,635 MW), Iowa (2,623 MW), and South Dakota (2,127 MW). The American Wind Energy Association’s First Quarter Market Report indicates that 14 states have over 1,000 MW of wind capacity in the pipeline, and eight states are on track to more than double their installed wind capacity. Now just imagine when the first utility-scale offshore wind projects in the U.S. are added to the mix.

US Wind is tracking wind speeds for its offshore project, planned for 17 miles off the coast of Ocean City. The developer is currently using a meteorological tower to collect raw wind data offshore and validate its mathematical models. The met towers will also monitor the performance of the turbines, once installed. The project is expected to provide 7,000 jobs and represents an in-state investment of nearly $1.5 billion. It’s expected to be operational in 2023.

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Construction starts on first U.S. offshore wind farm in federal waters

Siemens Gamesa lands largest repowering order to date in North America

Dominion Energy has officially begun work on the Coastal Virginia Offshore Wind, the only fully permitted offshore project in U.S. federal waters. The developer is breaking ground to install a half-mile conduit, which will hold cables connecting two 6-MW wind turbines, 27 miles off the coast of Virginia Beach to a substation near Camp Pendleton. The turbines will be unnoticeable from shore once the construction is complete in 2020.

MidAmerican Energy is repowering its 429.3-MW Rolling Hills wind farm in Iowa, with plans to replace the blades, hubs, and nacelles for all of the turbines. Siemens Gamesa will upgrade the units, using 163 of its SG 2.7-129 and 18 of its previously sold SWT-2.3-108 model. The blades will be produced locally in Iowa, and the nacelles and hubs will come from Kansas. The repowering project has an option for 12 additional turbines.

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Wyoming getting more wind power and a new transmission system

Rocky Mountain Power (RMP) kicked off its Energy Vision 2020 initiative, which includes the construction of three new Wyoming wind farms that will provide a total of 1,150 MW. As part of the initiative, RMP also plans to repower its existing wind fleet with longer blades and new technology to boost production. Additionally, it will build a 140-mile, highvoltage transmission line in Wyoming to connect more wind to PacifiCorp’s system.

US Wind moves ahead with Maryland offshore wind project

Hybrid wind, solar & battery storage project to power California county

QTS to power Texas and New Jersey data centers with wind

California power supplier, East Bay Community Energy, approved two PPAs for a combined 157.5 MW from new wind and solar facilities, as well as 30 MWs of battery storage. The project entails repowering a former Altamont Pass wind farm. Twenty-three modern wind turbines will replace 569 100-kW turbines. The project is expected to generate more than 60% of its power for Alameda County during peak hours. Construction of the solar and battery projects will begin in 2021.

An investor in carrier-neutral data centers and services, QTS Realty Trust, is also investing in wind power for its Texas and New Jersey data centers. A 10-year PPA will offset 100% of the consumption from the two data centers. QTS will receive the environmental attributes from Rio Bravo Wind in Starr County, Texas. In addition, an equivalent amount of financial energy was recently purchased from the Radford’s Run Wind Farm in Macon County, Illinois.

www.windpowerengineering.com

Starbucks to power more than 3,000 stores with wind & solar

Starbucks recently invested in a threeproject renewable energy portfolio in the U.S., including one wind and two solar projects. The wind farm includes 50 MW from an ALLETE Clean Energy project in the Southwest Power Pool market, which was acquired from Apex Clean Energy. The PPA portfolio will provide clean power to the electricity grids that serve more than 3,000 U.S. Starbucks stores and communities by 2021, when all three projects come online.

MHI Vestas opens its first office in America

MHI Vestas Offshore Wind celebrated the opening of its first U.S. office this summer. At the Cambridge Innovation Center, in Boston, the new office is aligned with the OEM’s offshore wind advances in the U.S. MHI Vestas was named the preferred supplier for the 800-MW Vineyard Wind Farm off the coast of Massachusetts, the U.S. market’s first commercial-scale offshore wind project. MHI Vestas plans to install its V164-9.5 MW wind turbines in 2021.

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The Block Island Offshore Wind Farm (Deepwater Wind, acquired by Ørsted) Credit: American Wind Energy Association; awea.org

WITH MORE THAN 20 GW OF PLANNED PROJECTS, BUILDING OFFSHORE WIND IN THE U.S. OFFERS ENORMOUS OPPORTUNITIES FOR NEW JOBS, REVITALIZED PORTS, AND SUPPLY CHAIN DEVELOPMENT. IT ALSO MEANS LOW-COST, CLEAN ENERGY FOR MILLIONS OF AMERICANS.

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the offshore wind guide | offshore wind map

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For a current pipeline of offshore wind projects in the United States, visit the Business Network for Offshore Wind at offshorewindus.org (and click on “US Market Overview” in the dropdown menu).

Mapping the future of offshore wind in America THE U.S. has a vast offshore wind energy resource with the power potential of more than 4,000 GW, according to the American Wind Energy Association. This map outlines the states that have already made commitments to offshore wind, mainly on the Eastern seaboard. In the West, California has a goal of 100% clean energy by 2045 and is considering floating offshore wind as one option to meet that goal. One report suggests offshore wind could generate up to 1.5 times as much electricity as California uses in one year. The Bureau of Energy Management anticipates conducting a lease sale of offshore waters in the Pacific in 2020.

WINDPOWER ENGINEERING & DEVELOPMENT

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Map Key: A. Maine – Legislation requiring approval of 12-MW Maine Aqua Ventus floating wind demonstration project B. Massachusetts — 1.6 GW (calls to double this commitment, with bids in 2022 & 2024) C. Rhode Island – Home to America’s first offshore wind project, the 30-MW Block Island Wind Farm, with the 400-MW Revolution Wind project in the permitting stage. D. Connecticut – Supporting up to 2 GW of offshore development E. New York – Targeting 9.0 GW by 2035 (up from 2.4 GW MW by 2030) F. New Jersey – 3.5 GW by 2030 G. Maryland – 358 MW current commitment, with an additional 1.2 GW by 2030 possible H. Virginia – 2 GW by 2028 I. Ohio – pushing for 20.7-MW Icebreaker demonstration project in Lake Erie (first freshwater offshore site)

www.windpowerengineering.com

AUGUST 2019

8/12/19 1:11 PM

the offshore wind guide | q&a

Insuring offshore wind farms A Q & A W I T H S E N I O R U N D E RW R I T E R , J O N N Y A L L E N

ALONG WITH THE environmental benefits of clean energy, the economic value of offshore wind power in America is expected to be notable. An Eastern seaboard state in the U.S. could expect at least $600 million in economic benefits from one offshore wind farm, according to the advocacy group, Environmental Entrepreneurs. For offshore wind projects to deliver in the U.S., however, reliability is key. Yet these wind farms face several risks given the harsh conditions of a marine environment. This means developers must fully understand those risks and properly insure projects to avoid unexpected losses. In the February 2019 Windpower Engineering & Development issue, Jonny Allen, Senior Underwriter and Head of Offshore Wind at global insurance company Travelers, answered questions relating to insurance and offshore wind sites (read the article online at tinyurl.com/OffshoreWindInsurance). Here, Allen shares more of his insight on

the industry, based on his several years of wind experience in Europe. Q. In what ways does the offshore wind industry differ from the onshore sector concerning risk? A. The transportation, installation, project architecture, including wind-turbine foundations and electrical cabling, are far more complex in a marine environment. This means underwriters must consider the combined risks of vessels, heavy lifts, winds, waves, and tight scheduling for offshore projects. However, most of the offshore wind risk is present during the underwater construction phase of a project, known as the subsea work (such as the cabling) — and well before a turbine tower or nacelle leaves the harbor. Insurance requirements for the offshore wind industry must be specific to the project location, layout, suppliers, installers, and operators, and the range of potential coverage is much greater than for onshore wind. The project size

and complexity can also be far more significant, so considerations for both developers and insurers to get the balance of risk and premium correct is even more critical offshore. Nonetheless, offshore and onshore wind projects do have similarities. The wind turbines are typically manufactured by the same suppliers and share similar risks relating to component breakdowns, weather events, and electrical outages, which require sophisticated insurance products. Q. How soon should a wind developer secure an insurance plan for a project? A. Typically, we see engagement with insurers six to 12 months before a project’s financial close for established offshore wind territories. Longer lead times allow underwriters more time and input into decisions that can affect a project’s risk, which could lead to considerable cost savings in the future. Early project tasks, such as surveying the project site or installing Offshore wind projects present unique challenges and risks, which means insurance is critical to protect developers from unexpected losses. It is important to seek the advice of a qualified underwriter with experience in the wind business to mitigate project risks and maximize coverage.

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WINDPOWER ENGINEERING & DEVELOPMENT

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the offshore wind guide | q&a

meteorological masts or light detection and ranging technology (LiDAR), can require liability coverage. The sooner such discussions are had with a broker, the better to maintain a project’s timeline. Q. Are there standard insurance policies available to offshore developers? A. In a broad sense, operational and construction policies have a standard framework but with key clauses that are specific to offshore wind. This may include clauses that cover the different exposures typical of new project territories, such as hurricanes on the East Coast of the U.S. or typhoon risks in Asia. The policies are then tailored to a specific project. Since each offshore wind developer has its own risk appetite, the policies can vary widely. Q. How do federal marine regulations, such as the Jones Act, affect insurance policies for offshore wind? A. Underwriters are often investigating how changing construction methods can increase or decrease risk profiles. In general, more complexity means higher risk, which can impact a project’s profile. The Jones Act is a good example of how decisions made by current project developers may improve risk profiles. These choices, for example, may stimulate American shipbuilders to meet the challenge of providing a fleet of new vessels — which may sustain the offshore wind sector for decades to come. In the near term, however, this will likely require increased transit times from staging areas outside of U.S. waters or the use of feeder barges and jack-up vessels. Both have different but increased risk profiles, which insurers must consider.

Q. Are there certain transportion or port infrastructure risks that developers should consider during the construction phase of a project? A. In Europe, offshore projects often have the benefit of multiple port options, which can drive efficiencies when developing a construction schedule. Risks still exist, however. One example is the spatial requirements at ports to meet the increasing size of wind turbines. Access to secure storage for materials is another consideration when selecting a port. Also, harbors must properly accommodate the vessels required during the construction of a wind farm. Underwriters might question traditional property risks, such as security and exposure to weather events. Typically, pre-commissioning of turbines is now done onshore to decrease hours offshore, and this includes the risk of lifting errors or electrical breakdown increases. As developers begin to share port facilities, the chances of an accident or event impacting several projects increases, which insurers view as an accumulation of exposure. This may lead to the continuation of underwriting such risks. A multi-line insurer with expertise in offshore wind and writing ports and terminals will be highly valuable because of his or her understanding of the changing risk requirements of project developers. Q. Can you share how O&M challenges may affect insurance costs from turbine downtime? A. One current O&M challenge is distance for projects situated far from shore, which requires long transit times, floating accommodation platforms, or possible helicopter transfers. One way to offset these risks is to increase the use of predictive monitoring so that wind-farm maintenance is only performed when essential. This typically means greater upfront costs and developers require a certain confidence that it would be repaid over the lifetime of a project. It is the job of insurers to understand and share what insurance savings these offshore investments may produce over time. WPE Jonny Allen

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www.windpowerengineering.com

AUGUST 2019

8/12/19 1:16 PM

the offshore wind guide | design

A new jacket for offshore wind

THE INDUSTRY STANDARD in lightweight offshore jackets has typically been the x-braced configuration in which diagonal supports intersect between four steel-legged structures. For decades, jackets served to support offshore oil and gas platforms, and now the offshore wind industry is benefitting from and improving the design. Case in point: Structural engineering company, IntelliSIMS (iSIMS), and energy service company, MORRISON, recently teamed up to optimize structural performance and provide significant cost savings for the offshore wind industry. The “iJacket” is the result, an offshore jacket that promises the same support as the x-braced design with additional benefits, according to the developers. “We completely re-arranged the structural framing patterns of the conventional offshore jacket,” explains Justin Bucknell, managing partner with iSIMS. “This means we took the fullface frames and disposed of two of them and re-oriented the other two as intersecting planes through the center of the structure — which hasn’t been done before.” Rather than using the typical fourlegged jacket structure, the patented iJacket uses a three-dimensional

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bracing system that allows for reduced steel. “But without compromising strength or fatigue,” adds Bucknell. According to its developers, the new design offers three key benefits to the offshore wind industry. The iJacket: • Supports the same deck load, drilling derrick, wind turbine, or other payloads as its conventional x-braced counterpart. • Stands up to challenging environmental loading demands such as extreme windstorms, hurricanes, and tough marine conditions. • Uses fewer components than conventional jackets, allowing for automated manufacturing and a streamlined installation process. “Perhaps of most significance for the offshore wind industry is that the iJacket lends itself to lean and rapid manufacturing,” says Bucknell. “By reducing its structural components and adding more efficient fabrication, we've been able to take out 30 to 35% of the steel weight.” This reduction means lower manufacturing, transportation, and installation costs. “As the iJacket

weighs less, it can be installed by a crane or vessel of less capacity than a conventional jacket,” he says. “And once onsite, it can simply be lifted and placed in location.” What’s more is the iJacket is 100% ROV (remotely operated vehicle) accessible, which eliminates the need for divers to carry out risky and costly underwater inspections. “Overall, its lower weight and reduced footprint make transport and offshore assembly quick and economical, allowing for more optimized cargo arrangement and less barge transportation cost,” says Bucknell. “ It’s an important development for the offshore wind industry.” WPE On typical windfarm development, in water depths of 20 meters and above, the iJacket is estimated to deliver a significant reduction in overall foundation costs. Watch a video about how it’s designed at tinyurl.com/iJacket

WINDPOWER ENGINEERING & DEVELOPMENT

8/12/19 1:18 PM

t h e o f f s h o r e w i n d g u i d e | e q u i p m e n t wo r l d

Equipment World for offshore wind Here are a few of the latest developments in equipment and tools for the offshore wind industry.

DIGITAL TOOL FOR CABLE LAYOUT

CORROSION-RESISTANT WASHERS

Ørsted | o r s te d .co m

Nord-Lock Group | nord-lock.com

FICO Xpress Optimization lets users digitally optimize the cable layout of an offshore wind farm that connects the turbines to the substations. A feature of Ørsted’s OptiArray tool, FICO Xpress offers “what if” scenarios, letting engineers map and test different cable layout designs. The new program aims to provide significant cost savings by reducing cable siting time and optimizing decision-making. FICO’s capabilities include scalable highperformance solvers and algorithms, rapid application development, comparative scenario analysis, and reporting capabilities for on-premises and cloud installations.

SINGLE-PASS PLOW FOR OFFSHORE CABLE INSTALLATION Osbit Ltd. | osbit.com

A multi-function pre-play and backfill subsea plow aims to minimize the operational risk and time required to install offshore cables. The PLP240 offers singlepass capability, which enables boulder clearance and pre-trenching up to 1.7m in a single run. The plow is also fully subsea adjustable and features an extensive surveillance suite for accurate and effective trenching. What’s more is the PLP240 is reconfigurable into backfill mode, which uses the same control and surveillance suite to monitor the cable and trench profile. Global Marine Group will use the Osbit-designed PLP240 for construction of an offshore wind farm in Denmark this year.

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www.windpowerengineering.com

Corrosion is a serious concern in the wind industry where turbine components endure harsh conditions such as heat, humidity, and air pollution. Rust and weathering will eventually weaken steel parts and can potentially affect their function, forcing wind operators to increase repairs — which decreases productivity. Nord-Lock Group has raised the corrosion-resistance on all of its steel wedge-locking washers and promises at least 1,000 hours in salt spray tests, ensuring optimum performance over time. According to ISO 12944-6:2018, 1,000 hours in a salt-spray chamber corresponds to at least C4 High or C5 Medium conditions. Products include Nord-Lock Original Washers and X-Series washers with standard and enlarged (SP) outer diameter and Steel Construction (SC) Washers. Nord-Lock corrosionresistant steel washers are ideal to pair with galvanized bolts, an advantage for offshore wind turbines.

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8/12/19 1:27 PM

t h e o f f s h o r e w i n d g u i d e | e q u i p m e n t wo r l d

AN ELECTRIC TORQUE TOOL REDESIGN HYTORC | hytorc.com/lithium-series-ii

HYTORC has redesigned its electric torque tool with expanded functionality, greater durability, and intuitive usability. The result: The LITHIUM SERIES II Electric Torque Tool, which offers strength and portability in industrial bolting jobs. This lightweight, 36-volt, battery-powered tool has a capacity of up to 5000 ft-lbs and is compatible with conventional sockets, including the HYTORC Washer and the HYTORC Nut. The LITHIUM SERIES II Tool was developed with TorcSense Technology, an award-winning method of direct torque measurement and closed-loop control that provides extreme repeatability in bolting performance. This is critical for assets in remote locations, such as offshore wind turbines, which are challenging to access. The LITHIUM SERIES II Tool also contains advanced data acquisition and bolting features that set the standard for quality and accuracy in bolting.

NEW CREW-TRANSFER VESSEL FOR THE U.S. MARKET

UNDERWATER NOISE MITIGATION SYSTEM AdBm Technologies | adbmtech.com/technology

Chartwell Marine | chartwellmarine.com

Chartwell 24 is a new, international crew-transfer vessel (CTV), built using lessons learned from European wind-power projects. The vessel is capable of carrying 24 industrial personnel and up to six crew members. With four engines – and options for hybrid propulsion – Chartwell 24 enables power-sharing and enhanced efficiency, which maximizes vessel reliability and availability. The CTV offers several advanced safety features, including a step-free deck that eliminates trip hazards, as well as walkways with handrails and sliding safety rails. From an operational perspective, skippers benefit from all-round visibility and an uncompromised deck cargo. With the largest CTV foredeck in the market, Chartwell 24 adds to its cargo capacity. It also meets EPA Tier 4 and IMO Tier 3 emissions’ standards.

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AdBm NMS reduces the impact of underwater noise on marine life. Customized, injectionmolded Helmholtz resonators – which are tuned to specific frequencies — are used to capture and mitigate noise from various sources. The system can be installed near the noise source or used to shield a sensitive marine area. It is suitable for use in high currents and has proven reliable in full-scale offshore testing. The Helmholtz resonator blocks are leased on a per-project basis, with technical support and acoustic data collection and analysis also available.

WINDPOWER ENGINEERING & DEVELOPMENT

8/12/19 1:27 PM

t h e o f f s h o r e w i n d g u i d e | e q u i p m e n t wo r l d

MAKING RELIABLE CONNECTIONS WITH ETHERNET-MANAGED SWITCHES Antaira Technologies | ant aira .co m

Industrial networking company, Antaira Technologies, has expanded its infrastructure offering for harsh environments with 18-port gigabit, ethernet-managed PoE+ and non-PoE switches. The new LMP-1802G-SFP and LMX-1802G-SFP series are an ideal choice for campus ring solutions. Campuses have networking rings consisting of hardened and industrial switches for outdoor environments — including offshore wind sites — that require a wide temperature-rated device. That means these weatherproof devices can communicate reliably, sending critical information back to an enterprise switch at a data center. The new series offers two fiber-optic ports that support an open standard ring technology (ERPS). There are many proprietary ring technologies available but using ERPS ensures equipment from different manufacturers can work together in the ring Antaira’s LMP-1802G-SFP series also offers several PoE ports (30 Watts) for highdensity security applications and fiber-optic interfaces for long-range connectivity.

WIND-TURBINE BLADE PITCH SYSTEM

ASSET MANAGEMENT SUITE FOR WIND O&M

Mita-Teknik | mi t a - tek nik .co m

Kongsberg | ko gnif ai .co m /so lu t io n s /si tu at io n - map

The new Mita Pitch System aims to minimize O&M costs, reduce downtime, and improve the productivity of onshore and offshore wind turbines. One way it does so is by applying minimum loads to a turbine’s structure and withstanding machine vibrations. In fact, the system can endure the harsh operating environment of rotating turbine hubs, including operating temperatures ranging from -22 ° to 140° F (-30° to +60° C). A Built-in-Self-Test scheme for on-the-fly evaluation and simple maintenance procedures ensure quick care and commissioning. An integrated condition-monitoring system with smart algorithms collect continuous data, further supports project operations and maintenance planning.

Kongsberg’s Renewables Asset Management (RAM) is a suite of applications for operating and managing onshore and offshore wind farms. These applications integrate data and functions from conventionally separate systems into one unified program, without the need for manual data transfer. An integrated asset management system increases the efficiency of operations and provides a better situational overview of a project and its assets — which also increases operational safety. For example, one feature of RAM is a live overview of a project and its surroundings. This includes real-time data of equipment, workers on location, weather updates, and the status of wind turbines and substations.

WINDPOWER ENGINEERING & DEVELOPMENT

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www.windpowerengineering.com

AUGUST 2019

8/12/19 1:27 PM

POLICY

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

In December 2017, Cape Wind Associates officially announced an end to the development of its proposed offshore wind farm and surrendered its federal lease for 46 square miles in Nantucket Sound — officially putting an end to a 16-year effort to build the controversial project.

lessons learned

from cape wind MICHELLE FROESE | EDITOR

HISTORY CAN OFFER hindsight and wisdom to presentday circumstances. The slow, but sure-moving U.S. offshore wind industry is one example. Although much of the sector is looking to Europe and the UK for experience and lessons learned, we can also look in our own backyard. Case in point: Cape Wind. Remember the controversial project, which after a 16year battle for developmental approval in Nantucket Sound, surrendered its federal lease area at the end of 2017? The proposal had a good run, and its eventual failure was certainly not for lack of effort. Lauren Glickman, who works as a clean energy communications consultant — including with WRISE, the Women of Renewable Industries & Sustainable Energy — recalls directing a grassroots campaign in support of Cape Wind. “Working on a grassroots campaign in support of Cape Wind was a pivotal moment for me,” she shares. “It was an opportunity to work on a solution-oriented campaign for clean energy instead of just fighting against the fossil-fuel industry.”

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However, opponents argued that the project posed a threat to offshore navigation, marine life, birds, and the local economy. After multiple permitting and litigation losses and delays, and state regulatory denials, the project proved impossible. “Cape Wind introduced to me to how critically important communications and community outreach can be in the success or failure of a project. It is not enough to offer a clean energy alternative,” says Glickman. “Stakeholder engagement is also crucial.” The final barriers to the project first came in January 2015, when energy providers Eversource and the National Grid opted out by ending contracts to buy power from the proposed wind turbines. Then, in 2016, matters turned worse when the state Energy Facilities Siting Board declined to extend permits for the project that had originally been issued in 2009. Although, in hindsight, Cape Wind seemed doomed to fail from its early planning stages, it failed to deter offshore wind efforts in the country. America’s first and only, five-

WINDPOWER ENGINEERING & DEVELOPMENT

8/13/19 1:35 PM

POLICY

turbine 30-MW Block Island Wind Farm off the shores of Rhode Island is one small but positive example of the offshore sector’s determination. As the proposal for Cape Wind was losing its battle, Block Island successfully began construction and operation. “Even though Cape Wind may not have become a reality, it paved the way for projects like Block Island Wind and the growing interest in scaling the U.S. offshore wind industry in the Northeast and beyond,” says Glickman. Cape Wind also led to key insights and new approaches to offshore siting. Just ask Hilary Tompkins, a partner with the law firm Hogan Lovells, in Washington, D.C. Before this, she spent nearly eight years as the Solicitor for the U.S. Department of the Interior (DOI), under the Obama administration. The DOI is responsible for the management and conservation of public lands, and natural and wildlife resource programs. Tompkins’ DOI legal team inherited Cape Wind from the Army Corps of Engineers. Although an application for the project had been filed in 2001, it was still going through the Environmental Review Process in 2009. “The project serves as an unfortunate example of government bureaucratic delays, but you have to remember that we were just developing renewable energy regulations at the time,” she shares. “So, there was plenty to learn.” Here are three of those lessons. 1. Location matters “It’s extremely important to set a project in the ‘right’ area with low conflicts,” says Tompkins. For example, one opposition group filed more than 25 appeals to obstruct the construction of Cape Wind. Although the project eventually prevailed in legal appeals, there were other permitting snags. “Siting was a key issue,” she explains. “Ideally, developers should avoid marine transportation areas such as travel routes, where fisheries are significantly active, and where there might be Federal

WINDPOWER ENGINEERING & DEVELOPMENT

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Aviation Administration concerns with air travel. They must also consider sea-life migration pathways and endangered species — and avoid national historical sites.” The National Park Service had also ruled that Nantucket Sound (where Cape Wind was sited) fit eligibility criteria for listing on the National Register of Historic Places because of its significance to two Native American tribes. Fortunately, awareness has led to progress. “After Cape Wind, the Interior got much better at identifying those areas in the Atlantic that are suitable for offshore wind. So, I believe the regime we’re currently operating under is more informed and educated about minimizing the impacts that could lead to conflict and permitting delays,” says Tompkins. Consider the record-breaking auction held by the DOI’s Bureau of Ocean Energy Management (BOEM) in December 2018, which included nearly 390,000 acres offshore Massachusetts. Eleven wind companies participated, with a $405 million winning bid from Equinor, Mayflower Wind Energy (a joint venture between Royal Dutch Shell and EDP Renewables), and Vineyard Wind. The winning bids for the Massachusetts lease areas far exceeded the previous record bid for a single lease area, set by a $42.5 million bid from Equinor (then Statoil) in a 2016 New York lease auction. The government is better managing siting areas and supporting the growth and economic development of the offshore wind industry. “This is an outgrowth of efforts from Cape Wind, which I think is very encouraging and I'm optimistic that this

time, developers are going to have greater success in the offshore industry,” she adds. 2. Avoid litigation One caveat to Tompkins’ last statement is this: “Developers must consider all of the various legal review requirements that come from different directions when siting and constructing wind projects,” she says. “Because you want to avoid litigation at all costs.” Tompkins speaks from experience. Cape Wind faced numerous legal battles, including challenges that its turbines would present hazards to flying aircraft, migrating birds, marine life, and the fishing industry. “It is critical to find ways to streamline the approvals process for a project in a way that will be legally defensible,” she says. This means knowing who to ask for what. “For instance, we got dinged for Cape Wind because we relied on BOEM to address certain environmental impact issues, such as with migratory birds. However, the court told us we were wrong and, instead, should have relied on the Fish and Wildlife Service to attain the correct information.” Tompkins says the DOI has since focused on developing new approaches, including digitalization of data to better streamline the environmental review process. The aim is to obtain and secure reliable information and a faster permitting process. “I think the Interior should also create a universal environmental policy approach for required documentation and work with contractors who already know the

Even though Cape Wind may not have become a reality, it paved the way for projects like Block Island Wind and the growing interest in scaling the offshore wind industry in the Northeast and beyond. www.windpowerengineering.com

AUGUST 2019

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

POLICY

leasing area to further streamline significant environmental review that review process,” she says. at the construction phase of a One example is BOEM’s project as opposed to burdensome draft guidelines for the use of environmental reviews at every a “design envelope” approach stage. in construction and operations “It’s so good to know this plans (COPs) for U.S. offshore process is defensible and was wind projects, which is standard recently upheld by a federal district in some European countries. The court in Washington, D.C., in the design envelope approach lets the Fisheries Survival Fund v. Jewell BOEM analyze the environmental case,” said Tompkins. This case impacts of a proposed project, involved the wind lease that the while reducing or eliminating DOI issued to Statoil Wind US in subsequent environmental offshore New York. and technical reviews, without The Cape Wind farm would have gone here. sacrificing environmental 3. Plan ahead safeguards. “I may sound biased but it’s critical According to the BOEM, this approach would save permitting to have legal counsel, who have worked in the private and public time and “afford developers a degree of flexibility and allow sector, understands your business, and the government approval them to make certain project-design decisions — such as which process,” says Tompkins. “These are examples of processes that turbines to use — at the more commercially advantageous time developers should think about and map out on the front-end of later in the project development process.” their project, so they know what to anticipate down the road.” Nonetheless, Tompkins says it’s imperative to cross all She says there’s a lot to consider with offshore wind, aside “i’s” and dot all “t’s.” Offshore projects require multiple federal from the project itself. For example, port infrastructure, which agency approvals — think the National Historic Preservation Act, must be able to accommodate turbine components and crew Endangered Species Act, NOAA Fisheries reviews, and others transfer. Then, there’s the transmission grid considerations. — and it’s relatively easy to miss a step. “Even after the site “We also need a transmission grid that can receive this assessment is approved, developer’s move into the construction new source of energy from offshore and deliver it efficiently and phase of a project and that’s a much more formidable undertaking cost-effectively onshore. In North Carolina, we’re even seeing when major environmental reviews come into play under NEPA.” the state assess who will have transmission authority over this NEPA, or the National Environmental Policy Act, process sector,” adds Tompkins. “And really, all participating states will occurs when there is a proposal to take a major federal action — need to figure out how domestic energy sources will best include such as an offshore wind project in federal waters. These actions and outsource offshore wind.” are defined at 40 CFR 1508.18 and the environmental review This means offshore developers will need to work with under NEPA can involve three different levels of analysis. (Learn governments and state officials at multiple levels for permitting, more at tinyurl.com/NEPAreview). construction, and transmission. “There's going to be an evolution One benefit from Cape Wind is the framework used by the in our energy delivery system,” says Tompkins. “Getting those DOI for offshore wind permitting, which involves a four-phased who were involved from the early days and development of the leasing process (lease sale, site assessment plan, construction offshore industry, and from inside the government, is an important and operations plan, and decommissioning) that requires more key to long-term success.” WPE

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WINDPOWER ENGINEERING & DEVELOPMENT

8/12/19 1:57 PM

Reason #4,001

IT’S A WIN-WIN. Bats are remarkably important animals with far-reaching ecological and economic impacts. Wind facilities are a critical component of our clean energy future, but pose a significant threat to bats. Thanks to NRG’s pioneering Bat Deterrent System, we can keep bats out of harm’s way so that clean energy generation and bat conservation can co-exist.

There are a million reasons to save bats. What’s yours? nrgsavesbats.com

NRG Systems — Windpower 08-19.indd 24

8/12/19 3:52 PM

MI C H E L L E FR O E SE | E DI T O R

W H Y C O L L A B O R AT I O N I S C R I T I C A L F O R

Offshore wind is finally happening in America. Subsea cable installation has officially begun on the Coastal Virginia Offshore Wind project, 27 miles off the coast of Virginia Beach. Several other offshore developments in the U.S. are also well underway. However, are the ports along the East Coast ready for the industry? AUGUST 2019

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ew York recently announced the largest procurement of offshore wind power in U.S. history: to develop 9.0 GW of projects by 2035. New Jersey has set a goal of 3.5 GW by 2030. Barely a year after Massachusetts pledged to at least 1.6 GW of offshore wind, the Department of Energy Resources released a report recommending the Commonwealth double that commitment for a total of 3.2 GW. Connecticut has signed on for 2.0 GW of offshore wind. And there are others. Over the next two decades, East Coast states and California are expected to develop more than two-dozen offshore wind farms. The interest in building an offshore wind industry in America is clear. Next, however, comes the how. Developing a reliable supply chain — including port infrastructure that supports the unique requirements of offshore wind — is critical to industry advancement. “Timing is everything and congestion could be a major problem over the next decade,” points out Lars Andersen, president of K2 Management’s North

WINDPOWER ENGINEERING & DEVELOPMENT

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P O RTS | W H Y C O L L A B O R AT I O N I S C R I T I C A L FO R O F FS H O R E W I N D A N D P O RT S U C C E S S

American operations. K2 is an experienced owner’s engineer and lender’s technical advisor. “For example, a single port harbor facility will be overburdened if several projects are under construction at the same time. Therefore, developers will likely have to consider multiple facility strategies and secure their options well ahead of time.” Andersen expects (and recommends) a cooperative approach to emerge between wind developers and port owners and operators. His sentiment is shared by a recent report released by the Business Network of Offshore Wind, a non-profit dedicated to establishing an offshore wind supply chain in the U.S. The report states that both U.S. coasts must cooperate on several important fronts — including for transmission grid development and supply chain support — to sustain a successful offshore wind industry for the country. “States such as Massachusetts, New York, New Jersey, and others are working to build an industry to protect the environment, generate jobs, and provide affordable renewable energy,” says Liz Burdock, president and CEO of the Network. “They are competing with other states...and rightly so. But states must also cooperate to minimize public costs, share resources, and globalize what the U.S. has to offer.” Andersen agrees. “As different ports will provide different capabilities, expect to see more public-private partnerships, ad-hoc agreements, and regional pacts moving forward,” he says. “Ultimately, a reliable offshore wind sector in the U.S. will depend on high-quality port infrastructure, and lots of it.”

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Several U.S. East Coast states have set ambitious targets to build offshore wind projects. For the sector to succeed in the U.S., developers will require a reliable workforce and supply chain — including ports, vessels, and component suppliers — to keep up with demands.

Such quality infrastructure must include heavy-lift capacity, adequate laydown for the handling and storage of large components, unimpeded access in and out of the harbor, geographic proximity to the project site, and zero air draft restrictions for wind-turbine construction efforts. “Currently, however, there are no East Coast ports that hit every requirement on the list of proposed projects,” Andersen points out. He provides a couple of examples in Massachusetts: •

•

New Bedford Marine Commerce Terminal received $15.4 million in federal funding to improve the infrastructure and environment of the port, primarily to support offshore wind and the fishing industry. This is great news because New Bedford is capable of handling heavy loads — but the shipping channel is protected by a hurricane barrier with a 150-foot horizontal opening, which may limit wind transport. Brayton Point, a former coal plant in Somerset, is currently re-developing into an offshore wind hub with advanced grid services, heavy-lift capacity, and a substantial area to hold and stage components. However, the ability of specialized jack-up vessels currently required for offshore construction is limited due to the nearby Mt. Hope Bridge’s 135-ft, underheight clearance or air draft restriction.

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PORTS

New Jersey’s Port of Paulsboro presents a similar challenge because of its proximity to a bridge and power lines, which essentially prevents offshore developers from safely or efficiently using it as a hub to transport turbines to sea. “Massachusetts, Rhode Island, Connecticut, New York, New Jersey, Delaware, Maryland, and Virginia are all promoting their state’s port infrastructure as ideal staging options for wind,” says Andersen. “And there are pros and cons with each site, but what’s lacking is a perfect home run.” This makes sense. American ports were never built for offshore wind. In Europe, for example, large installation vessels will enter a port, transport components to the wind site, and stay on site until after installation. In the U.S., access constraints in and out of a harbor will likely impede this approach. So, developers will have to sacrifice an ideal setup for the best available option. Nevertheless, U.S. marshaling ports are already laying “claim.” Offshore developer, Vineyard Wind, has signed a $9 million, 18-month lease at the New Bedford terminal for its 800-MW project. Ørsted and Eversource, which won several BOEM (Bureau of Ocean Energy Management) offshore auctions, signed a 10-year lease at the New London State Pier, and have partnered with the Connecticut Port Authority to develop a $93 million facility there. Other agreements are also in the works. “Project developers are already committing significant resources to secure their preferred port sites,” says Andersen. “There are a lot of moving parts, with states competing for private sector investment and developers competing for ports and installation vessels. With the growing project pipeline, the market for port facilities will be very active throughout the next several years.” And likely for several years post wind-farm construction.

A RENEWABLE ENERGY HUB As U.S. ports work to revitalize or reform their infrastructure along the East Coast to support the developing offshore wind sector, each may offer different benefits (or challenges) depending on location and local marine regulations. The recently announced Anbaric Renewable Energy Center, which will transform Brayton Point Power Station in Massachusetts — a former coal-fired power plant — to a logistics port, manufacturing hub, and support center for the offshore wind industry, serves as one example. “The Renewable Energy Center represents Anbaric’s broader vision for its Massachusetts OceanGrid project: high-capacity transmission infrastructure to maximize the potential of the region’s offshore wind energy resource,” said Edward Krapels, CEO of Anbaric, in a press statement. The company specializes in early-stage development of large-scale electric transmission systems and is working with Commercial Development Company’s Brayton Point LLC. Although a nearby bridge may force height restrictions for wind-turbine towers to and from the port, the Renewable Energy Center marks a significant commitment and investment in the offshore wind industry. The Center will include a 1200-MW highvoltage, direct-current converter with 400 MW of onsite battery storage. What’s more: the Brayton Point Commerce Center is equipped with a 34-ft deep water port capable of berthing large transAtlantic merchant vessels, which were formerly used to import coal. This means the port will also be used for bulk cargo, heavylift cargoes, and building materials for the offshore wind sector. “Developing a landing point for 1200 MW of offshore wind at the site of a former coal plant physically and symbolically represents the transformation from fossil fuels to wind,” added Krapels.

O&M considerations Following a project’s commissioning and operation, O&M teams will also require the use of ports for transportation of personnel and components for turbine repairs and upgrades. “Certainly, the development of ports and port infrastructure is imperative,” Burdock points out. “In addition, other critical issues

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P O RTS | W H Y C O L L A B O R AT I O N I S C R I T I C A L FO R O F FS H O R E W I N D A N D P O RT S U C C E S S

A hurricane gate at the mouth of New Bedford harbor in Massachusetts limits vertical vessel clearance to 150 ft. Last year, the U.S. Department of Transportation awarded a $15.4 million grant to the Port of New Bedford to support its offshore wind staging efforts. (Credit: Mary C. Serreze)

for offshore success include ensuring enough transmission capacity and interconnection points to the electric grid, as well as reliable workforce development for wind-farm construction and maintenance.” An O&M port serves as the transition between an offshore wind farm and land-based activities. “Such a facility needs to be close enough to the offshore project to limit transit time from shore while also providing adequate support for supply chain infrastructure and the efficient movement of workers or wind technicians and supplies,” says Andersen. He suggests developers consider their long-term O&M and site access strategy before selecting a port. Some questions to consider: Will the offshore wind site be accessed using conventional crew-transfer vessels (CTV) or would it be better served by larger service and operations vessel (SOV) – or a combination of the two? SOVs can transport larger quantities of spare parts and tools that CTVs, and typically also serve as a temporary hotel, so the crew can stay overnight if necessary instead of going back and forth to land. “Many potential East Coast O&M base sites in close proximity to the projects have the water depth to support CTV operations but not SOV operations,” he says. How quickly can the port accommodate O&M crew schedules in the event of unexpected maintenance? And are there time or seasonal restrictions? On the East Coast, at least, wind projects would likely adhere to a

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seasonal window for construction and maintenance – typically April through October. The Northeast coast is also heavily developed, he points out. “Most shoreside harbors are popular resort areas that are surrounded by vacation homes and have significant levels of pleasure craft traffic. It can be challenging to permit new commercial uses in these areas and shoreside logistics in the summer months can also be challenging due to seasonal congestion.” What is the port’s storage capabilities for spare turbine components? This is to ensure turbine parts are available on-demand to reduce turbine downtime. Is there a “Plan B”? Making plans based on proposed future improvements at a port facility is

risky, says Andersen. “The sources of funding and the permitting timelines should be carefully evaluated. Developers are always contemplating a ‘Plan B,’ but second options can be tough to find when there are limited alternatives.” “Regardless of the chosen path, siting of an O&M facility requires a long-term, flexible strategy and early engagement with local stakeholders,” says Andersen. This means communication and cooperation skills are critical for offshore success. “Forming respectful partnerships early on will certainly be the key to establishing and maintaining a presence in these top East Coast harbors,” he says. “As the U.S. offshore wind supply chain takes shape, the industry will revitalize the country’s ports and their surrounding areas, which means supporting businesses and the workforce in America,” adds Burdock. “The more we work together, the stronger the offshore wind industry can be.” WPE

Thanks to insight and feedback from about 100 offshore wind experts in the U.S. and overseas, the Business Network for Offshore Wind’s Leadership 100 report recommends steps to ensure offshore success in America. The steps touch on state policies, supply chain efforts, and electrical transmission requirements. Learn more at tinyurl.com/Leadership100 or offshorewindus.org

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PROJECTS

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C H E R I S E GA F F N E Y | T I M TAY LO R | C H A D M A R R I OT T | STO E L R I V E S L L P

catching the next wave is california next in line for offshore wind? OFFSHORE WIND PROJECTS

are extremely capital intensive, so it makes sense that the first wave of development in the U.S. has focused on high-load, transmissionconstrained East Coast regions. New England is one excellent example, where power prices are high enough to support offshore wind. The relatively shallow water depths — which extend beyond state territorial waters and submarine topography off the Atlantic coast — complement existing and well-proven windturbine installation methods. But make no mistake, California is the natural target for the second wave of development. As the world’s fifth-largest economy with a powerhungry population, an extensive

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coastline, and a progressive legislature and governor, California is likely to lead the offshore wind industry on the West Coast. Regulations, permitting, and financial considerations may offer new challenges to offshore wind developers out west.

Regulation & permitting

Attaining approvals for offshore wind projects in California will involve several federal and state agencies that are charged with managing and protecting: • Submerged lands and coastal resources • Protected species • Cultural resources • Water quality

• • •

Existing ocean uses, such as crabbing and fishing Shipping and navigation Recreation and public safety

Developers considering offshore wind projects in California will need to approach the federal and state permitting process strategically. This requires an in-depth consideration and understanding of how potential resource impacts and regulatory approvals and conditions may affect project planning, development, and timing. Wind developers will also need to consider federal and state approvals.

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PROJECTS

Federal approvals State approvals For successful offshore wind development, it will be Several California agencies are likely to be involved in offshore wind important to work closely with several federal agencies. development along the state’s 840-mile coast. The Bureau of Ocean Energy Management (BOEM) has Under the California Coastal Act, the Coastal Commission has jurisdiction over renewable projects that are located on the jurisdiction over the “environmental and human-based resources of the Outer Continental Shelf (OCS), the area three nautical miles California coast and ocean … for use by current and future generations.” from California’s coast. BOEM is responsible for granting (Source: Pub. Resources Code §30001.5) leases, easements, and rights-of-way for renewable energy The Coastal Commission regulates the development within the development activities, including the siting and construction coastal zone (defined as offshore to the state’s jurisdictional boundaries of offshore wind projects on the OCS. It offers a competitive and variable distances inland — sometimes by as much as five miles) leasing program, which includes a lease sale auction. and affected local coastal communities. As with other offshore energy How it works: The winner of the lease submits a site development industries, offshore wind is subject to the Coastal assessment plan for BOEM’s approval, allowing for resource Commission’s authority to determine consistency with the Coastal Act. assessment and technology testing. The leaseholder then The State Lands Commission is responsible for development develops a construction and operations plan for BOEM’s and other operations over submerged public trust lands in the state. approval. Typically, its jurisdiction is accountable for in-water projects, such as In addition, the BOEM has a number of other docks and marinas, but approvals will also be required for onshore responsibilities, including evaluating the proposed cables from offshore wind turbines that cross the shoreline. These project pursuant to the National Environmental Policy Act facilities are subject to discretionary permitting in the form of fixed-term (NEPA), assessing the potential impact of its approvals on leases issued by the Coastal Commission and conditions to protect properties under the National Historic Preservation Act, public access, including coastal access and the natural environment. and consulting with the National Marine Fisheries Service The California Department of Fish & Wildlife administers the (NMFS) and U.S. Fish and Wildlife Service under the California Endangered Species Act (CESA) and will be called upon Endangered Species Act (ESA). to determine whether any part of an offshore wind project affects The latter is important to confirm that the construction threatened or endangered species or their habitat. Proponents are and operation of the project wise to understand the are unlikely to jeopardize intricacies of CESA, listed species or destroy including how it differs or adversely modify critical from the federal ESA, and habitat. whether incidental take Other federal agency permits are required for approvals will also be state-listed species. required, depending on the Finally, local agencies project. Specifically, a U.S. may have a hand in Army Corps of Engineers offshore development approval under section 404 either through focused of the Clean Water Act will planning tools, such as be needed for any dredge Local Coastal Programs, or fill approval, including or other onshore local trenching for offshore cables permitting and approval or wetland fill that may be processes. The 76 coastal associated with onshore California counties and facilities. Authorizations under cities vary widely and the Marine Mammal Protection warrant close individual Act from NMFS may also be scrutiny depending on a necessary. project’s location. Additionally, a U.S. Discretionary actions Coast Guard Private Aid to by public agencies in Navigation Permit will be California that may have a required to ensure compliance significant physical effect with private and uniform aid on the environment are With offshore wind development on the U.S. East Coast well marking requirements and to underway, California is likely next in line for wind energy ensure waterway safety. projects in the Pacific. 30

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PROJECTS

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subject to the California Environmental Quality Act (CEQA). Wind developers must consider the time and cost implications of compliance with this farreaching statute. CEQA mandates public notice and participation and, when relevant, the mitigation or avoidance of potentially significant impacts. With the exception of the Coastal Commission, which is subject to an equivalent CEQA process known as a Certified Regulatory Program, each of the agencies identified must fully comply with CEQA before approving a project.

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Financial considerations

As the wind industry learns best practices for permitting offshore projects, individual companies will develop their own thesis for financing them. With a relatively long timetable for offshore wind in California and a steep learning curve, the financing landscape is likely to change over time. Large balance sheet sponsors are expected to continue to dominate the field, but the overall capital stack may look somewhat different in the next five to 10 years. For example, the production tax credit (PTC) and the investment tax credit (ITC) will have expired — possibly, without renewal. For now, the safe assumption is that California offshore wind will be unable to rely on the same federal tax credits that have accounted for a substantial portion (typically 40 to 50%) of terrestrial wind financing. If they are, it’s unclear whether the credits would represent a comparable percentage of the capital stack. Without the PTC or ITC, the gap fillers will likely be term debt and equity partnerships akin to some of the recently announced joint ventures, such as Engie-EDP and EnBW North AmericaTrident Winds. WPE

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SAFETY

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best practices THE UNITED STATES is fairly new to the offshore wind market and this means the maritime regulations specific to the industry are still undergoing development, according to the American Wind Energy Association. However, work offshore requires extra cautions. Transporting operators, wind technicians, and equipment to offshore wind farms occur with the risks that are inherent to work at sea. Winds are stronger at sea, and waves and currents are rarely simple to navigate. This means the vessel operators and crews must take water and weather conditions into account for each journey. Additionally, traveling by offshore vessel requires particular care and attention because turbines can be hours away from shore and for many workers, it may be their first trip by sea. Safety first

Vessel masters (or captains) must be conscious of wave heights while transferring wind crew to and from a vessel. The danger of wave height is also a concern while a vessel is docking at an

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for offshore wind transit

offshore site and when workers scale the ladder to the deck of a wind rig. “The biggest consideration is the weather forecast,” says Andy Calderbank-Link, head of fleet operations at Seacat Services. The company, a veteran offshore wind support service from the UK, operates vessels that can transport up to 24 industrial personnel to an offshore site. Seacat vessels travel at top speeds of 20 knots (about 23 mph), with trips potentially taking up to three to four hours. “If it’s rising conditions you’ll have to make a decision [to depart or stay] early on. There’s a lot of decision-making going on, hopefully in tandem with the control center — with marine coordinators — to make an informed decision.” Placing rubber lining on the front of transport vessels limits possible impact damage when docking at an offshore wind site. “When we arrive on site, we want to ensure that the design capability of the vessel is as good as it can be to conduct a safe push-on in the weather limits described within the terms of a reasonable day’s work out there,” says Ian Baylis, managing

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SAFETY

director of Seacat Services. It takes skill to safely assess and conduct a vessel’s impact or “push-on” force when approaching an offshore turbine. Too little force means the vessel will remain too far away for safe crew transfer to the wind rig and too much could result in damage to the vessel. The maximum wave height for safe on and off-boarding and transport of a crew is between 1.75 to 2 meters (5.5 to 6.5 ft.). These measurements should be disclosed in a service contract for the vessel operators. However, a vessel master will make the final decision on whether to take a trip or not. “A good vessel master will have to see whether it is right or wrong,” Baylis says about navigating the seas, and each day may bring about a different decision. The master can make a judgment call on weather and water conditions, even if they fail to exceed the maximum measurements disclosed in a service contract. “The vessel master is responsible for the safety of his vessel and all personnel. We have to stand by the decision that the master makes. It’s safety first all the way.”

Strong winds and high tides can make transport to offshore wind turbines a challenge. A vessel master always has the final say on if the seas are safe to navigate. (Image: Seacat Services)

Proper docking

Upon reaching the offshore wind site, the vessel docks in landing tubes on the side of the wind rig. Interlocks between the boat and offshore site ladder are engaged when docking, Baylis explains. He says that it is important to maintain a safety gap of 500 to 650 mm between the vessel and ladder. Essentially, this gap provides a space between the ladder on a wind tower and the edge of the vessel’s bow fender. If the boat detaches from the ladder, the gap serves to protect the wind tech. Additionally, if the vessel is pushed up and down by waves, the worker should remain safe. “The person climbing up can remain still on the ladder and the boat will simply pass behind them,” says Baylis. As with all final decisions on the boat, the vessel master is responsible for giving

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the final go-ahead to transfer personnel. The person ascending to or descending from a wind turbine must use an arresting agent to prevent falls. A self-retracting lifeline and life preserver must be attached to every person on the vessel. “That means if someone did accidentally fall from the ladder, he or she would hang securely, thanks to the fallarrest system,” says Baylis. “Once up the ladder and through the safety gate at the top, then the process starts over again with however many technicians are on the turbine.” Then, the process is reversed on the way down. Vessels should be equipped with devices to measure real-time wind, tide, and sea conditions, and operators should inform local marine coordinators of the trip, keeping a live radio feed for sea traffic updates. Vessel crew must remain seated inside the cabin during the trip unless given consent from the vessel master to enter other areas of the boat during transit. Seacat Services consults resources such as the G+ Global Offshore Wind Health and Safety Organisation (formed by the world's largest offshore wind operators and developers with the aim of offshore safety) and the International Marine Contractors Association (the international trade association for the marine contracting industry) when determining best practices for transporting wind technicians to offshore wind farms. “We’ve had crews that have been in this game from the start, so they’ve built up many, many years of understanding of what is safe, what isn’t safe, what the limits are and what they’re not,” shares CalderbankLink. “I think this will be a challenge in emerging markets because that experience isn’t there. So, it’ll be interesting to see how the U.S., addresses the offshore market. There’s a lot of experience in Europe that needs tapping into.” WPE

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OPERATIONS & MAINTENANCE

Three keys for choosing and analyzing

wind-turbine gear oil

MICHELLE FROESE | EDITOR

Routine gear oil analysis is critical to monitor levels of contamination. Choose an oil that can handle finer filtration (5 to 10-micron filters for full-flow inline applications, and 3-micron filters for fine offline filtration) for increased performance and lower contamination levels.

A WIND TURBINE is only as reliable as the quality of its components, and this is particularly true of a turbine’s main gearbox. The job of the gearbox is to speed slow, high-torque rotation into a much faster rotation for the turbine’s generator. However, the harsh operating conditions that wind turbines endure — including variations in wind speed and direction, vibration, temperature, debris, and moisture — present challenges to even the most advanced gearboxes. One key to minimizing the effects of such conditions and optimizing gearbox health is lubrication, which reduces friction by protecting metal surfaces from corrosion while keeping the gears clean. Given the tough operating conditions and remote location where most wind farms are located, however, choosing the ideal oil formulation has typically been easier said than done.

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Fortunately, lubricant quality and analysis have advanced substantially in recent years, which has led to more reliable formulations and testing. This, in turn, has directly impacted turbine O&M, downtime and saved costs.

The three keys

“For a high-performing gearbox, there are a few key features that all wind-farm owners or operators should look for in a lubricant,” shares Brian Burks, a senior wind-turbine field applications’ engineer with AMSOIL, a manufacturer of industrial lubricants and filters. Here are three qualities to look for in gearbox oil: 1. Performance. The harsh environments wind turbines operate in are unlike other

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industrial equipment, so lubricants must be carefully engineered to perform over time. There are no cutting corners here to save short-term costs. “Choose a high-performance gear oil that provides excellent anti-wear characteristics, superior anti-foam performance, repels water, and maintains its viscosity,” advises Burks.

Brian Burks, a senior wind-turbine field applications’ engineer with AMSOIL, supervises an oil change on top of a Siemens 2.3-MW wind turbine.

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OPERATIONS & MAINTENANCE

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2. Longevity. “Modern, well-engineered gear oils are reaching a decade of continuous use in the field,” he says. “However, such longevity should never come at the cost of added maintenance with continued top-treats of additives to correct a decrease in performance.” Top-treating gearbox oil, by adding depleted additives, is one way that wind maintenance teams have attempted to mitigate lubricant degradation and extend oil life. The concern with top treating is it may introduce new contaminants or affect the formulation of a balanced oil, which could negatively impact gearbox performance. “Wind-turbine gear oil should provide persistent performance and protection over its claimed lifetime,” says Burks. 3. Support. A quality lubricant should be backed by an equally quality supplier. “Wind is a unique industry that requires specific knowledge and skills to solve the problems that it presents. You should be able to lean on your wind-turbine lubricant supplier to support your needs in the field and up-tower at the point of lubrication,” says Burks.

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OPERATIONS & MAINTENANCE

Oil analysis and O&M

No matter how well-balanced a gearbox’s oil formulation, regular O&M is essential to test that lubrication is performing optimally and plan for the necessary oil-drain intervals. “In many other applications, an oil may be condemned due to oxidation, but quality gear oil will fail to oxidize in a turbine gearbox because of the relatively low temperatures the oil encounters,” explains Burks. “So, an operator is more likely to condemn the oil based off of contaminants.” Typical oil contamination paraments to watch out for include: • Viscosity • Total acid number • Water • Iron • Particle counts Burks notes that anti-foam performance may also degrade in some oils over time so if there is more foam than typical in gearbox oil, it may be time for a change. Higher quality gear oil has increased drain intervals from what was three to five years to seven to 10 years or more. According to Burks, the first step for taking an oil sample is to use a “super clean” or “ultra clean” sample bottle. These bottles come sealed and guaranteed to be cleaned of most particles that could throw off a particle count. Next, it’s important to follow a proper oil sample gathering procedure. “To obtain a representative sample it should be taken within 30 minutes of turbine shutdown to make sure particles and contaminants are evenly distributed,” he says. “The sample size is dependent on what tests are being performed but, for most routine analysis, a 4 oz sample is sufficient.” Follow these sample steps: • Take the sample from a sample port between the oil pump and the oil filter — but purge the sample port properly before taking the sample. “A conservative rule of thumb is to pull 4 oz of purge before taking a 4-oz sample,” says Burks. “This ensures the sample port is cleaned of any debris and stagnate oil.” • When the purge is complete, swap in the sample bottle midstream and hold the sample line vertical while taking the sample. (The sample is complete when the sample bottle is approximately 70% full to allow plenty of room for a lab technician to adequately agitate the sample before performing analysis.) • Properly seal and label the sample and immediately ship to your laboratory.

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Conventionally, in the wind industry, a wind turbine’s oil sample was drawn and analyzed every six months or so... however, that’s changing because of better monitoring systems. •

If time is of the essence, pre-source a laboratory that is geographically close to the wind farm.

Conventionally, in the wind industry, a turbine’s oil sample was drawn and analyzed every six months or so (which is much less frequent than other industries with similar critical assets simply because of the remote location and relative inaccessibility of turbine gearboxes.) However, that’s changing because of better monitoring systems. “Most operators now stray away from timebased interval changes and rely on conditionbased monitoring programs. This means they only change gearbox oil when laboratory analysis indicates it is necessary,” says Burks. Advanced condition-based monitoring technology that offers real-time elemental analysis and particle counting can support this process. “These systems are capable of reporting additive levels, particle counts, and iron levels in the oil, and sometimes vibration data. This means wind owners and operators can obtain valuable, real-time data that can also be correlated with other variables, such as wind events or other data drawn from SCADA,” he explains. With routine oil analysis, the result is only a brief snapshot in time that may miss certain indications of wear. “But with continuous condition-monitoring data flowing in, it’s possible to see the bigger picture,” says Burks. “This is particularly helpful for identifying gearbox health problems in addition to monitoring oil health — and should, ultimately, save time, O&M costs, and increase healthy turbine operations.” WPE

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LUBRICANTS Periodic analysis of windturbine gear oil is ideal because even a high-quality product is no guarantee of gearbox health.

what’s new in

gear oil, filters & analysis THE WIND-POWER INDUSTRY is continually improving turbine components and operation for greater uptime and power generation. One key to reliable operation is quality gear oil and filters. Here are a few new products and technologies. A carbon-neutral formulation

Bearing failures account for 70% of gearbox failures, according to one report. One way to manage this problem is with proper lubricant use. Castrol offers the world’s first carbon-neutral gear oil for wind turbines: Optigear. The formulation has been proven to reduce friction, actively resist wear, and extend bearing life by up to 50%. One of several blends, Castrol Optigear Synthetic CT320 is a premium synthetic oil for turbine gears operating under high loads and wide temperature ranges. It offers the lowest water content in the field, based on sample data, and is formulated for easy conversion from other competitive oils to deliver reliable surface protection. Optigear’s advanced “ash-

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less technology” can run reliably in cooler conditions (up to 8° C | 46° F), providing consistent wear protection for up to eight years of oil life. T I N Y U R L . C O M / C A R B O N N E U T R A LO I L

Extended turbine uptime

Wind-turbine gearbox operations and management are demanding. The equipment must withstand extremes of hot or cold climates, water, dust, and fluctuating wind speeds. These severe conditions and varying loads can cause damage to the gearboxes, including micropitting or surface wear. To extend operational uptime and reduce unplanned breakdown, Shell Lubricants has launched a new synthetic gearbox oil for turbines in the U.S. market. Shell Omala S5 Wind offers enhanced protection of bearings and gearboxes, with a 10-year warranty.

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8/13/19 11:57 AM

LUBRICANTS

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The Particle Pal Pro is a portable oilanalysis kit that provides ISO Cleanliness readings of virtually any gear oil.

“These sector-specific applications have particular demands and can carry a high penalty for poor reliability, especially if they are in remote locations,” said Warren Cates, Senior Research Scientist, Shell. “The robust wear and corrosion protection Shell Omala S5 Wind offers can help extend the service life of the gearboxes, while innovative foam control and optimal filterability also help to reduce gear and bearing damage.” TINYURL.COM/OMALAS5

in wind turbines is critical to avoid potentially catastrophic machine failures. An oil analysis assesses the quality of the oil and checks for contaminants. However, conventional methods have proven deficient in many ways. For example, taking a sample for laboratory analysis is time-consuming and inconvenient from the remote location of most wind farms. Laser counters used in particle counting are also less than ideal at recognizing air bubbles and eliminating them from the counts. Particle Pal Pro is a new, tablet-based portable oil-analysis kit that provides wind techs almost immediate insight into the state of turbine gear oil. It recognizes the shape of particle contaminants and categorizes them to offer users a broad count spectrum and root-cause analysis. The kit’s digital-imaging counter (combined with water content and oil condition sensors) helps engineers quickly understand the current health and remaining life of their oils. F I LT E R T E C H N I K . C O.U K / PA R T I C L E - PA L- P R O

Integrated oil monitoring

Shell’s new gearbox lubricant, Omala S5, extends wind-turbine uptime and doubles the industry standard warranty for gear oils.

Better bearing care

AMSOIL offers a new Main Bearing Grease (MBG) and Flushing Oil (MBF). MGB is a unique combination of synthetic PAO base oils, lithium complex thickeners, and carefully chosen additives that help prevent wear, rust, and hardening. It works well in large, slow-speed bearings with high loads. MBF is designed for use with industryapproved industrial equipment flushing procedures expressly requiring low-viscosity oil. Its natural solvency helps break down contaminants, while its low viscosity assists with removing particles. A M S O I LW I N D. C O M

A portable oil-analysis kit

Gearbox oil contamination is inevitable at some point, which is why early detection

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Regular gear oil sampling is standard in the wind industry to ensure cleanliness and optimal gearbox operation. However, two companies are eliminating this timeconsuming process by offering the industry’s first gearbox-integrated, oil-monitoring system. This means an end to periodic oil sampling. Condition-monitoring company, Poseidon Systems, is supplying the oil-monitoring equipment and services for all Gearbox Express re-manufactured gearboxes. The newly integrated system will include Poseidon’s Trident QW3100 oil-quality and water contamination monitor, DM4500 metallic wear debris monitors, and Trident AP2200 data collector and communication device. “It is our belief that metallic debris monitoring provides the earliest, most reliable, and cost-effective gearbox condition-monitoring solution,” Through Poseidon’s said Bruce Neumiller, CEO of Gearbox Express. integrated oil-monitoring Additionally, Poseidon Live will provide online system and online data data analysis and remote monitoring to give wind portal, wind operators can quickly and easily assess operators real-time fault progression monitoring. the health state of their “Online oil quality and debris monitoring offer our Gearbox Express gearboxes. customer’s many benefits, not the least of which is the ability to reduce if not completely eliminate the need to perform periodic oil sampling,” said Mark Redding, president of Poseidon Systems. WPE G E A R B OX E X P R E S S . C O M

WINDPOWER ENGINEERING & DEVELOPMENT

8/12/19 3:39 PM

How to choose the right for offshore wind turbines DOUG LUCAS Wind Energy Engineer T h e T i m ke n C o m p a n y

Wind power in the United States has more than tripled over the past decade and currently provides the largest source of renewable generating capacity in the country. However, other than one five-turbine wind farm off the coast of Rhode Island, U.S. wind generation comes from onshore turbines. But that's about to change.

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nshore wind developers and operators deserve enormous credit for their hard work and dedication. If the U.S. is to fully optimize wind capacity in the country, however, it is time to follow the UK and European markets. And this means pushing the offshore wind sector forward in America. “There’s no end in sight for windturbine growth,” reads the lead of a recent investigation into the growing prevalence of wind power and larger turbines, globally. The report anticipates that the average rating of wind turbines worldwide will reach 2.8 MW by 2022, with significantly higher growth in the offshore market. In Europe, it is projected that the average offshore turbine could be 12 MW by

2024. (Read more at tinyurl.com/TurbineTrends) Investments for offshore wind are typically bigger than onshore but marine projects offer greater generating capacity in the long run. Also, nearly half of the U.S. population lives in coastal areas, which means these regions have extremely high power needs. Offshore projects can leverage strong marine winds to cost-effectively supply electricity to these customers. To maximize offshore capacity, larger, more powerful turbines are typically used with components that can withstand the harsh sea-salt conditions while providing reliable operation. However, such highpowered turbines are a challenge to conventional bearing designs. For this

reason, offshore turbines rely more on direct-drive technology rather than gearboxes. Main-shaft bearings are still used routinely, however — and in just under half of offshore turbines, according to findings from MAKE Consulting. These bearings must endure higher loads, increased deflections, and slower rotational speeds than the ones found in smaller offshore turbines. The lubricants are exposed to salt water, a corrosive element that may cause unwanted tribology conditions and premature bearing surface damage. Ultimately, wind operators and turbine OEMs must understand which bearings perform reliably if they are to fully capitalize on offshore opportunities.

Gearless, direct-drive technology (shown on left) may be the more reliable choice for offshore wind turbines, which must withstand fast wind speeds and harsh conditions. However, nearly half of all offshore turbines still use gearboxes (right) and require highquality bearings that can handle high loads.

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WINDPOWER ENGINEERING & DEVELOPMENT

8/12/19 3:42 PM

BEARINGS | HOW TO CHOOSE THE RIGHT BEARINGS FOR OFFSHORE WIND TURBINES

MAKING THE RIGHT CHOICE Dependable engineering and expertise are critical when selecting bearings capable of the performance required in offshore wind turbines. Here are a few additional tips. •

Reliability of the main shaft requires a bearing that can adequately withstand various loads from ever-changing winds. This feature is particularly critical as wind loads increase, such as in offshore applications.

•

Bearings that offer the highest possible performance potential in a compact design are ideal for reducing the overall component size, weight, and manufacturing costs in wind turbines.

•

Additional options are available to increase reliability and performance. For example, for onshore turbines, advanced diamondlike carbon (DLC) coatings are available that protect against micropitting and other surface damage.

Recently, tapered roller bearings (left) have demonstrated desirable performance in several new wind-turbine applications when compared with conventional, spherical roller (right). Spherical bearings are composed of raceways that are rounded (spherical) on the inside axially. In tapered bearings, which are smaller in size, the rings and the rollers are tapered in the shape of truncated cones to simultaneously support axial and radial loads.

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Maximizing offshore performance The sheer size of offshore wind turbines — which are typically double the capacity of onshore machines — and extreme wind loads mean great demands are placed on a turbine’s gearbox and main-shaft bearings. The potential for costly failures in offshore wind turbines runs high. This means it is vital to choose high-quality components with reliable system designs for efficient operation and minimal downtime. Ideally, a bearing’s geometry, clearances, and load capacity are custom-engineered for the application’s operational conditions and this is particularly important in offshore turbines. An improperly engineered bearing may cause too much pre-load, which may result in high stresses, high bearing temperatures, and a shorter life. Additionally, a bearing with too much clearance may experience excessive deflections, improper roller load sharing, higher stresses, misalignment, and edge loading, premature cage, or sliding damage. There’s a lot that can go wrong. (“Clearance” is the total distance that one bearing ring moves relative to another.) Regardless of the form of damage, however, the result is the same: compromised performance of the turbine. Eventually, the bearing requires repair or replacement, leading to turbine downtime and lost operation. Technical expertise and product quality are necessary to successfully capitalize on the asset’s longevity and potential.

www.windpowerengineering.com

AUGUST 2019

8/12/19 3:43 PM

BEARINGS

A wind turbine’s main shaft requires a reliable bearing for operation. Some bearing designs have been known to fail prematurely resulting in costly maintenance repairs. Advances in bearing designs mean better stability, durability, and performance.

LESSONS FROM THE GROUND UP Industry lessons learned from onshore wind turbines may guide offshore decisions. This also applies to bearing performance.

Offshore component repairs and replacements are also typically more costly than onshore ones. Replacing a damaged bearing in an offshore turbine requires a specialized O&M team with a transport vessel and the necessary equipment to correctly diagnose the problem. Additionally, it’s necessary to disassemble the turbine to repair the damage, which requires a costly offshore crane rental.

Weighing the options Recently, tapered roller bearings have demonstrated desirable performance in a number of new wind-turbine applications when compared to spherical roller bearings, which are the conventional choice in most existing onshore wind applications. In fact, there are several 5-MW+ offshore turbine designs that now employ tapered roller main-shaft bearings. Spherical bearings are composed of barrel-shaped rollers within a rounded (spherical) race, which behaves like a ball and socket joint (much like a hip or shoulder joint). The rollers in tapered roller bearings are shaped like a truncated cone and are fit within races that are angled (or tapered) to simultaneously support axial and radial loads. Tapered bearings can be sized smaller and offer an increased power density compared to spherical ones, reducing the overall cost of energy. An ability to properly carry thrust and radial loads typically means high performance in harsh conditions and unpredictable changes in wind speed and direction. However, it is imperative that the specific demands of the application are considered first. This is because there is no one correct bearing for all applications — and that includes all offshore wind farms. Although there is a decent body of data and research for offshore applications, offshore wind is relatively uncharted territory in the United States. For those wanting to take advantage of such project developments, it requires working with the right suppliers who can offer proven expertise on problem-solving and total system design to tackle the challenges of offshore wind. WPE AUGUST 2019

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High performance from a turbine’s gearbox and main-shaft bearings depends on precisely mounted clearances for a specific turbine’s design and desired power output. Conventional onshore turbines use spherical roller bearings — rolling-element bearings that allow rotation with low friction and are required to operate in clearance, or the distance that one bearing ring moves relative to another. A bearing’s mounted clearance is established after the bearing is fitted onto the shaft and into the housing. Because the spherical bearings must operate in clearance, the blade loads may be transmitted into the gearbox unintentionally because of the radial and higher axial movement within the bearing, resulting in premature gearbox bearing overload. Pre-loaded tapered roller bearings with aptly controlled bearing clearances and ideal bearing designs can significantly minimize radial and axial movement in the bearings and system. Reducing such radial translation is beneficial for the bearing and system performance. However, too much pre-load may increase the risk of excessive pre-load and the potential for thermal runaway. Therefore, precisely mounted clearances are desired to obtain the turbine design life requirements.

WINDPOWER ENGINEERING & DEVELOPMENT

8/12/19 3:42 PM

COMPONENTS

Why sealing is one component of

effective bearing lubrication MICHELLE FROESE | EDITOR

EFFECTIVE SEALING is a critical but, at times, overlooked component of effective bearing lubrication in wind turbines. In many cases, seals are the differentiating factor that impacts overall bearing and system performance. Consider that most wind turbines experience some amount of lubrication leakage. These occurrences are relatively minimal for onshore turbines but can pose an environmental risk for offshore wind turbines. Undetected or excessive leakage can lead to a wide range of costly problems and repairs. Additionally, water ingress can compromise lubricating greases and oils when bearing seals break down or are unsuitable for their intended task. Moisture is a strong contributor to white-etching cracking (cracks within the microstructure of a bearing), which lead to early failure of roller bearings. Bearing seals should be given careful consideration at the windturbine design stage. The market offers a variety of options for meeting the extreme demands of main-shaft turbine bearings, including: • • • • •

Single lip seals: All-purpose seals available in a wide range of sizes that are suitable for most applications. Dual lip seals: Used for difficult sealing applications involving the separation of two fluids or exclusion of foreign materials. Single lip split seals: Engineered for ease of installation on large shafts (requires no costly teardown to replace seal). Bearing isolators: Keeps bearings protected from contaminants and debris in applications where long life is paramount. Protector seals: Used in highly contaminated operating environments to protect bearings on rotating and stationary shafts.

Automatic lubrication of wind-turbine components — made possible with The Timken Company’s Groeneveld Twin — typically means costs savings and less turbine downtime due to repairs. In bearings and gears, the grease spreads out better across surfaces simply because automatic lubrication takes place while the turbine is in operation. There’s also little risk of blown out seals, thanks to the short intervals and small quantities of lubrication. Additionally, it will form a grease collar or film over the surface and around pivot points, which means dirt and moisture are kept out.

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COMPONENTS

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Bearing seals are typically made from special elastomers and PTFE materials. Over time, the cumulative impact of abrasive forces caused by varying loads and speeds, temperature fluctuations, moisture, debris, and lubrication challenges can drastically reduce seal performance in turbines. For these reasons, it is advisable to speak with a bearing expert to determine the optimal sealing arrangement for a given application. A bearing isolator, for example, may employ a labyrinth seal design that uses an intricate pathway to exclude debris and retain lubrication. Essentially, this can eliminate seal torque, resulting in less frictional forces in the bearing. Bearing seals play an integral role in maximizing turbine uptime and productivity. And while proper lubrication remains top of mind for wind-farm operators, more turbine owners are beginning to appreciate how seals can positively impact their bottom line. WPE

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