Windpower Engineering & Development - FEBRUARY 2018 by WTWH Media LLC

HOW ARTIFICIAL INTELLIGENCE WILL IMPROVE O&M /

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HERE’S WHAT I THINK

Editorial Director | Windpower Engineering & Development | pdvorak@wtwhmedia.com

How EVs will drive the wind industry and vice versa

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he automobile, long the symbol of go-anywhere freedom, not long ago became an object of scorn because of its high consumption of fossil fuel. Is it possible to redeem vehicles from such disrepute by substituting electric drives for internal combustion engines? Yes, it is. The great thing about this transformation from gas and diesel to electric is that renewable energy – ideally from wind-generated power –makes every nation a master of its own fate by eliminating dependence on hostile foreign nations for fuel. While the evolution from fossil fuel to electric is just getting started, a recent announcement suggests that the transformation will come more quickly than anticipated. The event was Elon Musk’s unveiling of an over-the-road, longdistance heavy hauling truck — one that would usher in a new kind of 18-wheeler. You may think Musk is as much a showman as a technician and visionary, and you are probably right, but he demands attention and rarely disappoints in public appearances. You can watch his truck’s introduction on YouTube. As it drove on stage, the crowd gasped in awe because of its size and distinct appearance. The specs for the rig were equally impressive. The tractor will pull an 80,000-lb rig, the legal max for tractor and loaded trailer. It will also be capable of, for reasons unknown, 0 to 60 mph in five seconds (presumably without the trailer) and when driven in the real world, a 500-mile range. The size of the battery was not mentioned but a blog estimated it as 1,200-kWh. That is 12 times the size of the battery in a Tesla Model S sedan. A more scientific calculation is available at https://battery.real.engineering. The spreadsheet’s author lets readers plug in figures to find the battery weight and a kilowatt-hour rating. The point is that with today’s electric technology, the truck looks like a viable

option to a diesel-powered rig. Trucking companies that see the rig as a way to cut costs will drive demand for more electric power, and (I have to say it) more wind-generated power. Transport firms will make operating large-battery EVs more than a trendy feel-good exercise. Tesla is not alone. Other electric trucks with less flamboyant marketers include the Thor Class 8, Cummins Aeos Class 7, and Nikola Motors’ hydrogen-fuel cell vehicle. The Nikola is a more interesting variation because its hydrogen will be generated by electrolysis using wind-generated power. It also has other advantages, such as a greater range and shorter refill times. Presumably, it will take only a few minutes for a hydrogen refill instead of an hour or more to recharge an electric truck. Shortly after the Tesla truck debut, a truck mechanic on YouTube suggested that the writing was on the wall for him. It was clear he thought his job and career will soon be over. The mechanic’s despair, however, is a little premature. All the vehicles mentioned will require assembly, maintenance, and drivers. One rule of thumb applied to automation also applies to disruptive technology: For every job eliminated, two more are created elsewhere. What’s more, the transportation transformation from fossil fuel to electricity will require at least 20 years. The budding EV industry will need more power, and getting it from a home-grown wind industry seems a no-brainer. Like the wind industry, the electric-vehicle industry is brand new and can only get bigger and better. W

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SHARMA

SCHMID

PRADA

JUNKERS

GUPTA

GREATREX

GIFFORD

ELKINS

BUDNY

CO NT R I BUTORS

ROB BUDNY, co-founder and VP of Reliability Engineering at Ensemble Energy, is a mechanical engineer with 20 years of industry experience. He previously led the Mechanical Engineering department of a large wind turbine OEM. Budny’s areas of expertise include gear and bearing failure modes and reliability improvement. He has lead failure analysis projects on many wind turbine components. He teaches the three-day long AGMA Gearbox Failure Analysis course and holds a BSME from the University of Maryland, Baltimore County. WARWICK ELKINS, Senior Engineer, Project Development, DNV GL, has been working as a project development analyst in DNV GL for 10 years, delivering wind and solar energy assessments in Europe, Scandinavia, Australia, Africa, and India. As an experienced WindFarmer user, he has recently joined the WindFarmer: Analyst team to lead the business development of the software. Mr. Elkins is responsible for WindFarmer: Analyst marketing, sales, and training initiatives. LORNE GIFFORD is a Civil & Structural Engineer with Brookes Bell Group, a multidisciplinary consultancy to the maritime, offshore and energy, and industrial sectors. Gifford has 30 years offshore and subsea engineering experience, including the development of wind farms and HVDC power interconnectors, as well as investigation, expert witness, and remediation of marine and cable casualties. He has an honors degree, and he is Chartered and a Registered Subsea Engineer. GRANT GREATREX has over 30 years of experience in strategy consultancy and corporate finance with leading global firms and 12 years acting as an expert witness. He has specialized in the areas of renewable energy and clean technology in the European, Latin American, MEA, and SEA markets. His clients range from venture capital, private equity and infrastructure funds to project promoters, IPPs, utilities, as well as technology, equipment and service providers active in a range of renewables technologies and markets. The main areas of Greatrex’s consulting work include: Strategy, Mergers & Acquisitions, Project financing, Transaction advisory, and acting as an Expert Witness in national and international litigations, and arbitrations in these sectors.

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DR. SANDEEP GUPTA is the founder and CEO of Ensemble Energy, a predictive analytics company in Palo Alto, California. The company combines wind-turbine engineering expertise with the latest data-science methods to reduce costs and increase production. Dr. Gupta has worked in wind energy for 13 years, focusing on wind-turbine performance, optimization, and load reduction. He previously led the Loads Engineering department of a large wind turbine OEM. He holds a PhD in Aerospace Engineering from the University of Maryland, College Park. JASON JUNKERS, CEO of HYTORC, oversees operations at the headquarters in New Jersey and affiliates across the U.S., and overseas. Through continuous innovation and process improvement and an overall dedication to customer satisfaction, he vows to keep HYTORC a leader in the industrial bolting industry. GORKA PRADA is the first CEO of NEM Solutions USA Inc. He is managing the company’s newly opened North American branch. Previously, he was Chief Revenue Officer for the company in San Sebastain, Spain. Prada has earned an Executive MBA from the Deusto Business School at the Universidad de Deusto. PHILIPP SCHMID followed business studies focusing on marketing and industrial management. He also researched strategic marketing in China for his PhD studies. He also holds a Bachelor in Engineering. Before joining SKF, he worked as Client Service Executive and Junior Research Consultant for GfK in China and Germany. As of 2008, Schmid joined SKF and worked as project manager, market analyst, and marketing manager in the Renewable and Energy industries. Besides working for SKF, Schmid is also teaching industrial marketing at Baden-Wuerttemberg Cooperative State University. JATIN SHARMA, Head of Business Development at GCube Insurance, has specialized in underwriting offshore wind, wave, and tidal projects since he joined the company in 2010. He is the author of several GCube reports exploring global trends in wind-turbine downtime events, including “Down to he Wire, Gone With the Wind” and, most recently, “Risky Business.” Prior to joining GCube, Sharma was Divisional Director at Willis, responsible for risk consultancy, contract risk management, account management and the procurement of all classes of insurance for onshore and offshore renewable energy projects on behalf of leading power and utility companies in Europe. He started his career as an intern specializing in the Production Tax Credit at the United States Congress and holds an MSc in Climate Change Management from the University of London.

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FEBRUARY 2018 • vol 10 no 1 www.windpowerengineering.com

CONTENTS

D E PA R T M E N T S 01

Editorial: EVs will be good for the wind industry

Windwatch: Artificial intelligence in the wind

Bolting: Ergonomics are the real hazard of some

23 26

industry, A different blade, Storing power in magnetic fields, Standards for offshore work, and more

bolting tools

Bearings: Large offshore wind turbines are

challenging bearing designs

Insurance: Minimizing threats to onshore wind

projects & portfolios

29 Software: Analytic software brings more certainty to predicted wind farm outputs

32 O&M: Take care of lubricants to take care of the turbine 35 Condition monitoring: Lots of data is dross. Actionable information is gold

38 Fluids and filters: Smarter sensors let a gearbox tell how it’s doing

63 Ad Index 64 Downwind: Hear no turbine, see no turbine

F E AT U R E S

40 Offshore wind industry needs a new

paradigm for managing dispute claims

Should construction companies in the wind industry design components to an accepted specification or “fit for purpose”? A landmark ruling by the UK Supreme Court has shifted the legal landscape surrounding offshore wind farm design and construction, which presents the industry with a new paradigm in dispute claims.

ON THE COVER

44 How artificial intelligence will improve O&M

While proper lubrication is fundamental to wind-turbine component reliability, implementing the right lubrication strategy helps deliver long-term results.

Artificial intelligence is being applied to most every industry in efforts to improve operations and trim costs. Here’s how early efforts are already benefitting the wind industry.

Photo courtesy of ExxonMobil

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2018

L E A DE R SH I P I N W IN D E N E R G Y

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Stanford's Ocean One is a hybrid between a humanoid robot and an underwater remotely operated vehicle. Photo: Frederic Osada and Teddy Seguin, DRASSM, Stanford

IT’S NOT HARD TO SEE THE PROMISE in the headline already. Just look at what drones have done for the wind industry in the last couple years. In autonomous mode, a few can complete a blade inspection in about eight minutes, according to one developer. Damage and repair reports with photos are available shortly after that. And there is more to come, says DNV GL, in a recent paper on the topic. The research and forecasting firm says AI, or artificial intelligence, will increasingly automate operations over the next several years in ways that cut O&M costs and improve production. The consulting firm’s paper, “Making Renewables Smarter: The benefits, risks, and future of artificial intelligence in solar and wind,” suggests where AI, such as machine learning, will come into play in the renewables industry. The wind industry is an ideal application for AI because most turbines are outfitted with many sensors that generate mountains of data, and the industry requires complex decisions. Although the algorithms were developed decades ago, the recent advent of inexpensive cloud computing makes AI practical today. The few wind industry areas ripe for AI include condition monitoring, robotics, inspections, certifications, and supply-chain optimization. The article How artificial intelligence will improve O&M in this issue shows one application of AI that is well underway. Drones or flying robots have been the tip of the AI spear. The report suggests watching for robots that crawl, swim, and sail to perform remote offshore inspections and with eventual benefits of troubleshooting and maintenance of difficult jobs. While the drones are good, a crawling robot might be better. Such a device could travel up and down and close to the surface of a blade, carrying microwave and ultrasonic transmitters and receivers to penetrate into the blade and pinpoint faults in its structure. Once an inspection robot is developed, the repair robot is probably close behind. Helical Robots, for one, have shown such potential for its tower-climbing unit.

AI TO GIVE OPERATIONS AND MAINTENANCE A BIG BOOST IN COMING YEARS

FEBRUARY 2018

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AI has been creeping into wind-farm operations in several ways over the last few years. As a result, most advances supported by artificial intelligence have been in resource forecasting, control, and predictive maintenance.

With regard to improving the supply chain, the authors of the paper foresee the delivery of wind components by self-driving trucks and even the automation of some construction. The latter is not so farfetched. One solution to the automation of wind-farm construction was suggested by a UK firm in its Self-Erecting Nacelle System, SENSE. (tinyurl.com/sense-wpe). “We expect the installation of more sensors, the increase in easier-to-use machine learning tools, and the continuous expansion of data monitoring, processing and analytics capabilities

Wall crawling is a first step to an AI blade tech. Abigaille, a wall-crawling robot, was developed by Canada’s Simon Fraser University School of Engineering Science/ MENRVA. The sixlegged climbing robot is sufficiently dexterous and able to transition from vertical to horizontal surfaces. It clings to surfaces using a gecko-inspired dry adhesive technology.

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to create new operating efficiencies — and new and disruptive business models,” commented Lucy Craig, Director Technology and Innovation at DNV GL – Energy in a press release. AI systems are also likely to accelerate due diligence processes. Planning and analysis today might require many hours of human labor to collect and digest thousands of documents. AI may reduce the job considerably and with improved accuracy. Diving robots capable of performing undersea chores from inspections to repairs will further remove humans from hazardous conditions. For corrosion detection, autonomous underwater vehicles (AUVs) already carry hammers that tap underwater welds along with sensors and analysis capability. Simply automating the tasks robots are doing now will provide lots of ideas and challenges for applying artificial intelligence. “AUVs could help in the construction and maintenance of offshore wind farms. One could imagine a situation where, after a severe storm, the onsite drones and AUVs are sent out to inspect the structures above and below the waterline and report on damage or critical issues that need attention,” said Craig. W

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Storing power in superconducting coils still a possibility says U of Houston researcher THERE IS MORE THAN ONE WAY TO STORE A WATT. For instance, about seven years ago, the DOE funded development of a project titled "Superconducting Magnet Energy Storage System with Direct Power Electronics Interface.” The $5.25 million effort was to develop an affordable system capable of large-scale energy storage that would be a game-changing advance for the U.S. electrical grid. In a cryogenic environment, near absolute zero, even copper is super conducting. A coil of it charges just like a battery or capacitor. “What’s more, energy can be stored in a superconducting coil for a long period. And when the power is needed, connecting a load across the coil taps the power,” says Dr. Syed Ahmed, Executive Director with the Advanced Superconductor Manufacturing Institute at the University of Houston’s Division of Research. Superconducting Magnet Energy Storage systems (SMES) use magnetic fields in superconducting coils to store energy with near-zero energy loss, have instantaneous dynamic response, and nearly infinite cycle life. Researchers are now working on materials that superconduct at relatively high-temperature, around 77°K, (-372°F), the temperature for liquid nitrogen. A superconducting cable made with such a material can be smaller than conventional cable yet carry a large current. For instance, the AMSC website says its superconducting cable made with its Amperium can carry 10 times more power than conventional cables. The initial group proposed an ultrahigh-field SMES-based storage that would bring down storage costs to a WINDPOWER ENGINEERING & DEVELOPMENT

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Energy can be stored in a superconducting coil for a long period. And when the power is needed, connecting a load across the coil taps the power.

2/14/18 10:31 AM

W I N D W A T C H

SMES coil blocks (brown) inside a (gray) mechanical structure. Several of the coils, arranged as they are to the right, would provide the superconducting storage.

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point where they would be comparable in cost per kilowatt-hour to conventional storage systems. Scaling would be easy if the super conducting materials were available. Unfortunately, developing ultra-high-field SMES systems presented greater technology challenges than expected. The project came up short and was ended when the funding ran out. However, energy storage remains one way to make renewable energy more useful. SuperPower Inc, one of two U.S. manufacturers for hightemperature superconducting materials was to develop a next generation HTS wires. These would be a key component to a costeffective grid-scale SMES systems that would offer megawatt-hours of stored energy and thereby support a growing infrastructure for renewable energy.

Millions of dollars are being invested by other governments that see SMES as huge potential. SMES is already proven to work, says Ahmed. Commercially available and relatively small SMES units are often used as shortterm power devices designed to compensate for fluctuations in an electrical power system. By about 2002, AMSC came up with the D-Var, a superconducting device for wind-farm grids. It works as energy storage when connected to the grid. “When it senses a voltage drop, the device discharges into the line to maintain the voltage. They have been used on the long transmission lines in the Midwest,” added Ahmed. “It is a good example of superconducting magnetic-energy storage. It works. However, making them into a grid-scale energy storage solution is a whole new ballgame.” Ahmed had worked on superconducting magnetic storage at an earlier position. “It was a small 10-kilowatt scale version for aerospace applications. The attractive feature of superconducting

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W I N D W A T C H

wire is that has no resistance, so once it is charged the current keeps on circulating and does not dissipate.” But scaling such a device from kilowatts to megawatts, however, calls for more superconducting wire. A lot of research in manufacturing superconductors is underway. Over 35 companies are members of Advanced Superconductor Manufacturing Institute (ASMI). Although projects are expensive, Ahmed says they are worth it. “Such power storage

could be a $220 billion market and if it is not developed here, it will be imported. In 2006 there were only two companies making superconducting wire, but at this time there are 12 in the world including some in China, Russia, Germany, and more are getting interested in tapping this upcoming market. Millions of dollars are being invested by other governments that see SMES as huge potential. We are leader but cannot maintain our leadership without proper support,” cautions Ahmed. W

Magnetic field (in Tesla) superimposed over one SMES coil unit made with the second generation High Temperature Superconductor (HTS)

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LEFT: Sufficiently light blades would allow mounting two rotors on a turbine for greater power outputs. RIGHT: The six components for a 50-m WyndBlade (top to bottom) include the leading edge, airfoil control rods, core, root, airfoil blades, and frame.

Classic wind-mill blade inspires a modern design A NEW DESIGN FOR TURBINE BLADES is said to overcome most of the handicaps of conventional designs including cost, manufacturing complexity, and maintenance. Inspiration came from a classic Dutch wind mill that used several sections of canvas on each blade. Instead of canvas, student pilot and inventor Phillip Ridings began to question conventional reasoning, “Why not use small and more aerodynamic winglets supported by a frame? The blade would cut through the air, like a knife, yet capture all the wind's power by simply connecting these smaller more efficient airfoils to the leading and trailing edges?” “The blade would be lighter than conventional designs of the same length, made of only six components, and modular so that worn or damaged sections could be easily replaced.” Ridings began thinking about different designs after hearing news of a wind-farm’s turbine blades that needed replacing well before the end of their expected lifespan. Conventional blades come with high costs in their manufacturing and transport. They are also difficult to maintain and inspect. Ultrasound and acoustics analysis provide limited insight. Ridings states that this new blade design would remove the guesswork because there are no hidden internal components.

What’s more, he adds, the new design would produce more power because it generates torque all the way to the root. Through his own research, he discovered that one-third of a conventional blade from the root does nothing to generate lift. It is merely there to support the full weight of the blade. Computer models looked promising, so Ridings is currently working on printing a 3D, three-foot scale model for physical tests. He calls his design “WyndBlade.” 12

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WIND ENERGY SOLUTIONS to keep your systems turning.

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The computer model shows an assembled concept.

The six components include: The frame, an extrusion, which holds the entire blade together. Reinforced 40-ft sections lock in place with connections to create longer or shorter blades. As part of the customization, blades can be as short as 40 ft or 200 ft and more. The blade airfoils, extrusions, produce lift. The designed, placement, and precise angle help generate lift and rotation as air passes over each individual airfoil. The root, a custom component, connects the blade to a hub. Hubs come in different sizes so each blade can be customized to fit any other manufactured model as a replacement. The core is also a custom construction. It supports the root by making the connection more stable. The core also helps control the pitch angle for the entire blade. This means for better survivability, the blade can rotate to a zero angle of attack, lowering air resistance in higher than normal winds. Two airfoil control rods extend the length of the blade, one on each side. This device alters the angle of all the airfoils to optimize airflow. “The fully closed WyndBlade captures the slightest of breezes. When opened, the airfoils will let air pass through to help maintain a rotational speed. When fully open, blade rotation would slow, like an airbrake and help with over-speed issues. When winds become too fast, the entire blade would pitch to a zero-degree angle for its protection. Also, in a fixed-blade design, all blades are optimized for any wind speed. A spring-loaded version of the design would help dissipate heavier than normal gusts to protect the entire blade from extreme wind pressures and damage. 14

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The leading edge is foam core. On the Wyndblade, it is easily replaceable as are all the other parts. “It’s a hard-foam structure with an airfoil shape. The airflow resistance is 80% less than conventional blades because the air has a shorter distance to travel as it passes over the smaller surface of the leading edge. There is no major airflow resistance and it generates smaller, low-pressure areas that bleed off into the open airfoils framed in the main body,” he notes. Ridings adds that this new blade design eliminates a range of problems related to conventional designs, such as flexing issues, high loads and pressures, rotor-tip damage, leading-edge damage, complex manufacturing, and high transportation costs. Additional advantages, he notes, include a weight reduction, easier maintenance, a reduction in turbulence, the 40-ft sections would be transported and assembled at the work site in conventional 53-ft trailers, and a major increased aerodynamic performance. Cost reductions would come in maintenance, manufacturing, and repair. Also, he points out, conventional blades create huge, low-pressure vortices or wakes that may kill bats if they stray too close. WyndBlade would not generate these vortices or wakes because the bulk of the low-pressure wind is sliced into smaller sections and would dissipate faster. Thus, the design reduces the turbulent pressures bats have been known to fly through. So far, he has concepts for nine different models using these three arrangements of the interior blades: vertical (the Hawk), angled (the Falcon), and curved (the Eagle) all of which could come with variable, spring loaded or fixed angles on the airfoils. He’s currently working on another configuration for smaller wind turbines. W

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Developing national offshore wind standards in the U.S. A SOLID OFFSHORE WIND INDUSTRY offers great potential and benefit to the United States. In fact, according to the Department of Energy (DOE), if the country could develop 86 GW of offshore wind by 2050, it would create at least 120,000 jobs, cut greenhouse-gas emissions by 2.8%, and provide American with much-needed clean energy. The DOE is stepping up and putting money where its mouth is by offering $18.5 million in funding for an offshore wind research and development consortium that will conduct U.S.-specific research aimed at reducing costs. The offshore industry still faces several costrelated challenges that may impede its progress. For example, the nascent industry lacks an efficient supply chain for project installation and O&M. Also missing are a deep-waterfoundation models and solutions (such as floating foundations) along with safeguards against weather events such as Atlantic hurricanes. To succeed, the industry also requires a solid set of offshore standards. “We have to create national standards that reflect a common language between developers, stakeholders, and all industry players to ensure best practices are followed at all stages of project development and deployment,” said Walt Musial, during a presentation at the American Wind Energy Association’s (AWEA) Windpower Conference in New York in late fall. Musial is the principal engineer and the manager of Offshore Wind at the National Renewable Energy Laboratory (NREL), the only federal laboratory dedicated to research, development, and deployment of renewable energy. “And I mean not just for the design and install of an offshore wind project, but we need standards that encompass siting, operations, construction, fabrications, manufacturing, testing, and so on — all the way through decommissioning.” In 2012, AWEA published its Offshore Compliance Recommended Practices (AWEA OCRP) that are based on existing standards FEBRUARY 2018

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(including from the International Electrotechnical Commission, International Organization for Standardization, and the American Petroleum Institute) and guidelines (from the American Bureau of Shipping and DNV GL). Although the AWEA recommended practices provides an early pathway for U.S. offshore wind development, Musial said more is needed. “Granted, we already have the AWEA OCRP, which is a consensus-based roadmap to facilitate best practices in the industry. It refers to about 126 different written standards, and tells developers and the regulators which ones to review and what the best standards are for particular development applications,” he explained. “And it is a good starting point, but it is now five-years old and it fails to cover everything.”

We have to create national standards that reflect a common language between developers, stakeholders, and all industry players to ensure best practices are followed at all stages of project development and deployment. A review of the existing offshore wind standards is currently underway. “This won’t be a rewrite as much as an upgrade of critical information. We’re attempting to fill the gaps,” Musial said. “The objective is to develop a comprehensive set of consensus-based guidelines and standards that can be used to guide the safe and orderly deployment of offshore wind in the country. It will account for the unique offshore conditions in different regions of the U.S., and include input from regulators at the BOEM and state-level.” By using the basic standards and regulatory process already in place, the NREL aims to collaborate with industry stakeholders to specify a complete set of standards. “Ideally, we want to make the regulatory process that exists right now more clear and efficient,” he said. windpowerengineering.com

WINDPOWER ENGINEERING & DEVELOPMENT

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W I N D W A T C H

There are a couple of anticipated outcomes should this process prove successful. “We want to increase transparency to the public so that when an offshore project gets approved, there is some understanding of the development process and what happens next,” said Musial. “But we also want to give more confidence to regulators so that when they go to approve a project, they can be certain that a project’s design is safe and that it will meet up with current best practices.” A clear and complete set of standards should also lead to shortened regulatory timelines. “If there is one set of guidelines to follow, it should create a kind of certainty in terms of the pathway to follow for approving and developing projects.” There’s more. Current U.S. guidelines, including the AWEA OCRP, fail to cover practices for metocean (meteorology and oceanography), geotechnical issues, ice loading, breaking winds, and floating wind turbines. “To address these issues, we’ve developed the Offshore Wind Technical Advisory Panel (OWTAP), supported by the NREL and Business Network for Offshore Wind,” he said. The Network is dedicated to delivering education, creating partnerships, and advancing the offshore wind industry in the U.S. OWTAP will work below the AWEA Wind Standards Committee, which is already in place, and represent four subworking groups with an aim of developing a set of national standards and guidelines for offshore wind that are recognized by ANSI, the American National Standards Institute. The proposed sub-working groups are: 1. Update of AWEA OCRP (Offshore Compliance Recommended Practices) 2012 2. Geotechnical Data Requirements for U.S. Waters (seabed soil and geology for foundations) 3. Metocean Data Requirements for U.S. Waters (wind, waves, currents, turbulence, vegetation, and more) 4. Floating Offshore Wind Turbines in U.S. Waters “We are adding a fifth group to cover Electric Cable Risk, including the array cables and the export cable,” shared Musial. “We plan for one group of industry experts to focus on upgrades to the AWEA OCRP 2012, and another to deal with geotechnical data — which is completely absent from the original OCRP. A third group will learn how to best collect and use metocean data, and a final one will delve into floating structures, which We want to increase transparency to the just got its first commercial project in Scotland.” The recently commissioned 30-MW Hyland Scotland public so that when an offshore project gets project is the world’s first floating wind farm. Floating approved, there is some understanding of the foundations can be installed in much deeper waters than conventional offshore wind farms. development process and what happens next. OWTAP is expected to be a three-year process that includes collaboration between the NREL, the Network, AWEA, BOEM, and the DOE. “This initiative, thanks to industry-wide collaboration, will ultimately provide more clarity and set the U.S. offshore market on a pathway to cost-effective, commercial development,” said Musial. W 16

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W I N D W A T C H

Wind industry leadership for 2017 ALL LAST YEAR, Windpower Engineering & Development readers were asked to vote for the company they thought was providing notable leadership in the wind industry. The companies nominated were posted at windpowerengineering.com and are listed below. A new crop of candidates is also listed in this issue. For 2017, leadership was a precious commodity because of the uncertainty that came from Washington D.C. The good news is that cool minds and solid leadership among wind advocates were found in many places and at many levels in business and government. While the recently passed tax and jobs bill was in flux, local groups petitioned their elected congress men and women along with senators to support the terms of the previously agreed upon Production Tax Credit. Equally vocal and persuasive groups such as the American Wind Energy Association and its members, made visits to the power brokers in government to make sure the wind industry was headed in the right direction. All this effort provided certainty to the business of developing the wind industry. The effort paid off. The PTC, omitted from early drafts of the bill, was reinstated for the final version and is now law. Such certainty, always good news to those guiding and growing businesses, is a key ingredient of a successful industry. Leadership also comes on the technical side. If 2018 can repeat the success of 2017, there will be more reason to celebrate. The Energy Information Administration is forecasting 2019 to be the first year wind overtakes hydropower as the leading source of renewable electricity generation in the U.S., which suggests this year will be a busy one. 18

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Weâ&#x20AC;&#x2122;re guessing the challenges that come with new wind development and wind-farm O&M will be met with entheusiasm, given the list of nominated candidates. So from last year's list, here are the companies you readers have selected for 2017 leadership recognition:

You vote, we report Bearings Electrical or electronics Fastening & Joining Hardware, Components Operation & maintenance Sensors Simulation services Support services Towers

www.windpowerengineering.com

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Wind work around North America Good news is on the horizon for the wind industry. The U.S. Energy Information Administration is forecasting that 2019 will be the first year wind overtakes hydropower as the leading source of renewable electricity generation. This means 2018 should be a busy year for wind power with strong growth and development expected in the industry. Fortunately, the uncertainty that threatened renewable energy tax credits late last year has been reconciled, preserving the phase-out of wind credits through 2019. This will ensure stability for investors, developers, and manufacturers committed to building new wind farms in America.

W I N D W A T C H

5 2 8

Power storage added to two Texas’ wind farms

E.ON’s Texas Waves energy storage projects have officially kicked off operations. Texas Waves consists of two 9.9-MW short-duration energy storage projects that employ lithium-ion batteries. The storage facilities are co-located with the existing Pyron and Inadale wind farms, and will provide ancillary services to the Electric Reliability Council of Texas.

1 4

Powering Oklahoma with wind

New York’s Cassadaga wind farm: approved

Route decided for Wind Catcher Energy Connection

BOEM proposes offshore windpermitting guidelines

7 5

Avian protection system added to Wyoming wind farm

Alberta sets record-low price for wind

Duke Energy Renewables is installing 24 avian-protection units to its Top of the World wind project in Wyoming. The IdentiFlight system blends AI with high-precision optical technology to detect eagles and prevent them from colliding with rotating wind turbine blades. Duke Energy is the first wind operator to commercially deploy this technology.

To help reach its goal of 30% renewable energy by 2030, the province of Alberta chose three wind companies (Capital Power, EDP Renewables, and EGPNA) in its competitive Renewable Electricity Program process. The weighted average price of the successful bids is CDN 3.7 ¢/kWh — a record low in Canada.

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The New York Siting Board says it undertook a rigorous review process that included public participation, and has approved the 126-MW Cassadaga wind farm. The New York project will include up to 48 wind turbines with transmission lines. It is expected to provide 470 construction and full-time jobs, and pay more than $10 million to governments and schools over 20 years.

Offshore wind development is expected to accelerate at a rapid pace in the U.S. To ensure quality standards, BOEM has introduced draft guidelines for the use of a “Design Envelope” approach in construction plans for U.S. offshore wind facilities. The practice is standard in many European countries and affords developers a degree of flexibility when permitting offshore wind projects.

windpowerengineering.com

Enel Green Power North America (EGPNA) has become the largest wind operator in Oklahoma, with more than 1,700 MW of managed capacity across 10 wind farms. EGPNA reached this milestone thanks to the operations of two new wind farms: the 298-MW Thunder Ranch wind farm and the 300-MW Red Dirt facility. These projects are the first incentive-free wind farms in Oklahoma.

The Wind Catcher Energy Connection is a $4.5 billion, 360-mile transmission line project, which aims to bring 2,000 MW of wind-generated energy to customers in Oklahoma, Arkansas, Louisiana, and Texas. After extensive study and public input, a proposed route has been presented for final review (view map at windcatchenergy. com). The project is expected to deliver wind power in 2020.

Minnesota EV drivers can also support wind energy

Revolt is a first-of-its-kind program that lets electric vehicle (EV) owners support windgenerated energy. The program was given a green light in Minnesota to continue in 2018. How it works: Cooperative members of energy provider Great River Energy simply opt for an “upgrade” for their EV. The utility will then dedicate enough wind energy to cover the electricity used to charge an EV for that vehicle’s lifetime.

WINDPOWER ENGINEERING & DEVELOPMENT

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B O LT I NG Jason Junkers CEO HYTORC

Ergonomics are the real hazard of some bolting tools

aving the right tool for every job is part of the fun in fixing and maintaining equipment for a living. But what if the tools wind techs typically use are more harmful than helpful? For instance, breaker bars and slugging wrenches are time consuming and can lead to debilitating injuries. Impact guns generate tremendous vibration and noise, and are banned at many jobsites. Manufacturing and repair shops may be full of potential hazards such as fumes, electrical malfunctions, and sharp or heavy parts. The tools used there should help manufacturers and wind technicians, not hinder performance. Also consider that messy long cords and airsupply hoses can get in the way or make a worker trip and fall. Repeated use of heavy and unwieldy clicker wrenches and impact guns can do significant damage to hands, wrists, and elbows. The resulting sprains, strains, and overexertion that result may lead to serious—and even fatal—accidents, or cause debilitating chronic conditions, known as workrelated musculoskeletal disorders or WMSDs. There is a lot of pride in being a wind technician. You keep complex machines working properly. You have many of the same challenges as auto mechanics. For example, according to a report by the U.S. Bureau of Labor and Statistics, “mechanics are more likely than the average worker to be injured or killed on the job, as evidenced by higher rates of fatalities and injuries and illnesses.” The report presents chilling statistics. Wind techs also work in hazardous environments, and may face similar risks. The reports adds: “the median number of days away from work for injured or ill mechanics in 2005 was five days,” which is “less than the median of seven days for all occupations.” It’s good to be a hard worker, but does the work itself need to be this hard or this dangerous? 20

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Recent battery-powered wrenches provide solutions to the trip hazards and vibrations of conventional power tools. For example, the LION-.25 from HYTORC is affordable, accurate, and delivers repeatable results. The lightweight, cordless torque gun is made for smaller bolting applications. At seven pounds (with battery), the tool weighs less than a typical impact gun or a manual clicker wrench.

Cost of injuries According to the 2016 Liberty Mutual Workplace Safety Index, “U.S. businesses spend more than a billion dollars a week on the most disabling, nonfatal workplace injuries.” Overexertion and falls at the same level are the leading causes of this staggering financial burden.

www.windpowerengineering.com

FEBRUARY 2018

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B O LT I N G

Better tools for a better workplace WMSDs can be prevented or minimized by providing workers with tools designed for optimal performance, safety, and user comfort. Ergonomic tools may help reduce worker fatigue and injuries, while increasing overall workplace efficiency. According to the National Institute for Occupational Safety and Health, the goal of ergonomics is “to reduce stress and eliminate injuries and disorders associated with the overuse of muscles, bad posture, and repeated tasks. This is accomplished by designing tasks, work spaces, controls, displays, tools, lighting, and equipment to fit the employee’s physical capabilities and limitations.”5 In addition, reducing the weight of heavy power tools or combining features of several tools into one (to avoid downtime from having to switch from one the other), may increase Mechanics are more likely than the average worker to worker safety and efficiency. to be injured...on the job, as evidenced by higher However, it’s important to use caution when rates of fatalities and injuries and illnesses. choosing tools because claims can be misleading. A manufacturer may use the term “ergonomic” or “ergonomically designed” without fully vetting the claim. So before selecting a tool, do a thorough evaluation of the expected tasks and work environment. What may work well for some workers, may be less than ideal for you. Following basic guidelines will help you make a more informed decision. W

EHS TODAY TOP TEN When selecting power tools, EHS Today, a workplace safety publication, recommends paying special attention to vibration and contact stress that can result from using the tool. It also offers guidelines to help you be smart about using these tools. Its advice: 1.

Use the right tool for the job and the right tool for the user. 2. “Bend” the tool, not the wrist. Use tools with angled or “bent” handles when appropriate. 3. Avoid high-contact forces and static loading. 4. Reduce excessive gripping force or pressure. 5. Avoid extreme and awkward joint positions. 6. Avoid twisting hand and wrist motion by using power tools rather than hand tools. 7. Avoid repetitive finger movements or reduce the number of repetition if possible. 8. Minimize the amount of force needed to activate trigger devices on power tools. 9. Avoid thumb triggers. 10. Use two or three-finger triggers for power tools. Use four-finger triggers only when the tool is balanced. 22

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For further reading 1, 2, 3 Occupational Injuries, Illnesses, and Fatalities to Automotive Service Technicians and Mechanics, 2003 to 2005 - U.S. Bureau of Labor Statistics https://www.bls.gov/opub/mlr/cwc/occupational-injuriesillnesses-and-fatalities-to-automotive-service-techniciansand-mechanics-2003-to-2005.pdf 4 The table comes from the 2016 Liberty Mutual Workplace Safety Index https://www.cdc.gov/niosh/topics/ergonomics/ 5 Ergonomics and Musculoskeletal Disorders - The National Institute for Occupational Safety and Health (NIOSH) https://www.libertymutualgroup.com/about-liberty-mutualsite/research-institute-site/Documents/2016%20WSI.pdf 6 Ergonomic Guidelines for Selecting Hand and Power Tools http://ehstoday.com/health/ergonomics/ehs_imp_37964

www.windpowerengineering.com

FEBRUARY 2018

2/14/18 10:51 AM

BEAR ING S Phillipp Schmid Application Engineer SKF

The generic turbine with a gearbox sports a two-point suspension provided by the two large bearings. The arrangement is used on turbines in the 6-MW range.

How large offshore wind turbines are challenging bearing designs

ince 2012, offshore wind farms with total power outputs in excess of one Gigawatt (GW) have been coming on stream in European waters every year. According to WindEUROPE, Offshore wind in Europe saw a net 1,558 MW of additional gridconnected capacity installed in 2016. Despite the challenges of constructing offshore turbines, the capacity there is expected to grow as suitable land based sites become scarcer and operators take advantage of the greater consistency of wind at sea. The output power of offshore turbines also tends to be greater than their land based counterparts. According to WindEUROPE the average power output of offshore turbines installed in 2016 was 4.8 MW. Turbines of 9 MW or more capacity are now in the launching stage – Vestas’ V1649.5 MW development is a prime example. Offshore wind turbines also tend to have longer blades which impose FEBRUARY 2018

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greater forces on drivetrains. In addition, drivetrains and their bearings are at greater risk of corrosion due to the saltwater environment. Conducting maintenance offshore is difficult, potentially dangerous and costly, so operators are keen to reduce the frequency of maintenance visits, which places considerable demands on the rotor bearings and their ability to continue to function reliably in these conditions for long periods. There are four common bearing design concepts for turbine rotor shafts. The first is a two-point suspension with a toroidal roller bearing on the rotor side and a spherical roller bearing on the generator side. This is used for turbines in the 6-MW category for example. For higher performance classes, the trend is to use a ‘rigid’ bearing arrangement that features a non-locating and locating bearing combining a cylindrical roller bearing and a double-row tapered roller bearing. Alternatively, a purpose designed bearing combines the two into one bearing, such as SKF’s Nautilus. Other arrangements comprise two adjusted tapered roller bearings. In all cases, the design, materials of construction and mechanical geometries of these bearings will have a considerable impact on their ability to function reliably between maintenance intervals. windpowerengineering.com

WINDPOWER ENGINEERING & DEVELOPMENT

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BEARINGS

The generic turbine is designed with a three point suspension. One point for the large mainshaft bearing and two other points on either side of the gearbox.

The cut-away shows how one OEM handles a direct drive configuration with a two-point suspension, on either side of the rotor.

Other bearing features have also gotten attention. Bearing cages, for example, are generally made of machined brass or sheet metal, the latter being more often found in larger bearings. Where possible, cages are always installed in one piece, but for larger bearings, they may comprise rows of segments which are manufactured individually and positioned one behind the other. All types of cage can be innerring centred, which produces less wear and thus prolongs the service life of the bearing. These are clearly important where offshore wind turbines are concerned. Gearbox bearings have also gotten upgrades. One of the most important recent advances is a surface chemical treatment that places black oxidation on the raceway. Compared with untreated bearings, black-oxidised bearings offer a range of benefits for wind turbine applications, including reduced risk of premature bearing failure caused by white etching cracks, greater resistance to chemical attack by the more aggressive components of some lubricants, lower hydrogen permeation, and improved resistance to corrosion. Moreover, black oxidised bearing surfaces can offer reduced friction, decreased risk of slip damage, and greater tolerance of poor bearing-lubrication. In addition to the offshore environment, bearings must also cope with the potentially damaging effects of high electric currents. For example, wind turbine generators are equipped with frequency converters which pose a new set of problems for bearings. The threephase, ac-voltage outputs of the converter take the form of a series of rectangular pulses, rather than true sine waves, with the result that the total of these voltages is not zero and there is a common mode voltage. This common-mode voltage can result in leakage currents to the generator rotor via its bearings, damaging raceways and compromising lubricant properties.

The four profiles show how drivetrain design has evolved with outputs. Rotor diameters and nacelle weights are posted below each. Below that in the grey bar are figures for the turbine weights if the designs were enlarged for a 10 MW rating. The Direct Drive HTS, from AMSC, refers to high temperature superconducting with a material that promises to significantly reduce generator weight.

WINDPOWER ENGINEERING & DEVELOPMENT

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FEBRUARY 2018

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BEARINGS

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For higher performance designs, the trend is to use a ‘rigid’ bearing arrangement with a nonlocating bearing combining a cylindrical roller design (just behind the rotor) and a double row tapered roller bearing (just before the gearbox. The turbine with gearbox moment bearing separates the gearbox.

218.683.9800 / 877.436.7800 To prevent the passage of these leakage currents, the rolling elements of generator bearings are constructed from ceramic materials, which also have a lower inertia than is possible with equivalent steel ball bearings. In addition to non-conductive rolling elements, bearings are also available with ceramic-coated rings, which provide additional insulation to prolong bearing service life. Of equal importance is the ability of the turbine nacelle to align itself according to the wind direction and the blades to ‘feather’ in response to wind speed. These functions are supported by slewing bearings, which have also become larger with the rise in turbine power capacity. Double-row four-point contact bearings are normally deployed in blade feathering mechanisms, while the tower bearings are usually single-row, four-point contact bearings. However, new concepts are in development due to the increasing blade length. These bearings are spray galvanised to prevent corrosion, and because of the extreme weather conditions of the offshore environment, they are also fitted with special seals. W The hybrid design concept shows a single main shaft bearing and a single planetary stage driving the generator.

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2/14/18 11:14 AM

INSU R ANCE

Jatin Sharma Head of Business Development GCube Insurance gcube-insurance.com

Risky Business: Reducing threats to onshore wind projects & portfolios

he wind market is growing — up some 21% globally, according to Global Wind Energy Council — and expanding into new territories. This is good news for the industry, but also means a changing risk profile that can pose a concern for asset owners. For example, low-wind regions are providing new opportunities for wind-farm developers but they must be willing to invest in a less established location and marketplace. A few of the challenges of charting new wind regions may include longer project lead times, less policy or political certainty, and a lack of supply chain expertise. An investor may label the challenges as too risky, particularly when compared to regions with a foundation in wind development. Climate change, extreme weather, and Natural Catastrophe (Nat Cat) events also jeopardize project performance and pose risks to an investor’s profile. Fortunately, the industry is evolving to cope with challenging and changing risk profiles, and the insurance market is developing new products to protect wind-farm developers and operators. Here are a few risks typical of onshore wind projects with tips on how to protect wind portfolios.

Natural perils have contributed to an increase in insurance claim severity over the past five years, and this trend is likely to continue as climate change causes volatile weather conditions. Nat Cat losses typically fall into the “sudden and unforeseen” category accounted for by an all-risks’ insurance policy. Tip: Asset owners in high-risk areas are wise to take precautions by ensuring that the design and specifications for their site are robust, and that appropriate contingency measures are in place.

Weather safeguards Extreme weather and Nat Cat events are risk factors typically associated with offshore or less established wind markets, such as with remote island projects. However, recent weather in the United States shows that Nat Cat events also pose a threat closer to home. Severe storms and wildfires across the U.S. and Central America in the last few years have caused billions of dollars in losses to wind-energy asset owners, including turbine blade failures and tower damage or collapse. 26

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INSURANCE

What’s more, the push for bigger turbines with more complex infrastructure means mechanical and electrical problems pose the greatest threat to a successful wind farm. For example, the production process for composite materials in turbine blades is precise and complex. Minor errors or material inconsistencies can have a large impact on a blade’s structural integrity. Third-party certification bodies have been slow to keep up with the advances in design, which has led some blade manufacturers to self-certify. Although self-certification reduces costs for wind-farm owners, it also results in greater risks. In addition, the longer lead times for blades over 50 meters in length have led to an increase in the number of Business Interruption (BI) claims on newer turbines.

Underperformance The U.S. “wind drought” of 2015, in which some of the lowest wind speeds in history were recorded in key markets, such as California and Texas, alerted the industry to the necessity of protecting project revenue against underperformance. Resource unpredictability is posing an increasingly prominent threat to profitability as lulls in wind speeds diminish asset output below expected levels. Although inaccuracies in the data used to project asset outputs are partly to blame for financial vulnerability, wind-farm underperformance is typically the result of unpredictable climate phenomena. Tip: Unforeseen lulls in wind speeds are covered by the insurance market, but it is important to find a flexible product. For example, Weather Risk Transfer (WRT) structures are adaptable to individual projects and portfolios. In a nutshell, WRT mechanisms provide project stakeholders with a means to stabilize future cash flows and minimize the impact of unexpected and adverse weather on revenue. In addition, a safeguarded minimum revenue enables banks and lenders to offer more favorable debt service coverage ratios, increasing a project’s value. Mechanical issues Wind turbines are assembled from thousands of components, so expect mechanical and electrical breakdowns at some point during operation. While quality components and a good O&M program can minimize turbine downtime, pressures to lower manufacturing and construction time and costs can compromise turbine reliability. FEBRUARY 2018

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Tip: Over the last five years, GCube has seen an average of 5,000 annual incidents of blade and gearbox failures. While gearbox failures typically result in losses of around $200,000 to $300,000, blade failures can cost up to $1 million to resolve. Hence, do your homework. Use quality components designed to tolerate your site’s specific wind conditions, and ensure components such as blades are third-party certified. Location. Location. Location. Location can make or break real estate deals, and the same can be said for wind farms. Most utility-scale projects are in remote areas, which can hinder maintenance and repair visits when something goes wrong. The rising costs of mechanical and electrical turbine breakdowns are partly attributed to the remote locations of many new wind developments. Simple logistics can extend already lengthy lead times for new components or O&M teams. A lack of supply chain expertise in the remote markets of Asia and Latin America, for example, has resulted in damage to transformers and blades during transit, and serial defects in equipment manufactured closer to project sites. The availability of certified blade repair technicians and quality replacement equipment can also extend a project’s downtime and increase BI costs. Tip: The North American market has its share of these challenges, so it is important to plan for adequate O&M and BI costs. Project developers in Canada must also account for accessibility issues, particularly during the winter months. windpowerengineering.com

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INSURANCE

Political risks Wind developers drawn to remote locations because of abundant weather resources may face other risk factors. Many emerging renewables markets exist under politically volatile regimes, or lack the statutory or legal systems to protect developers from the confiscation, expropriation, nationalization, or deprivation (CEND) of assets. American firms have already been affected by changes to governmental policies. For example, U.S. developer Invenergy LLC recently filed a lawsuit against a Polish state-controlled company, Energa, citing actions that are â&#x20AC;&#x153;tantamount to expropriation.â&#x20AC;? In 2013, Energa terminated a long-term contract for the sale of green certificates with an Invenergy wind farm company. Invenergy has pursued its rights in court against Energa to overturn the contract termination Tip: The insurance sector has responded to these developments with Political Risk Insurance (PRI) products. While regulatory challenges are expected to decrease as wind energy becomes independent of subsidy support, risks from CEND are only set to increase as developers expand their portfolios into territories where wind power is less established. The risks posed to wind-energy assets indicate the need for developers to complete proper due diligence. Risk transfer and insurance mechanisms are an important part of that due diligence. After all, the right insurance products can make or break a project and portfolio. W 28

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www.windpowerengineering.com

FEBRUARY 2018

2/14/18 11:19 AM

S OFTWA R E

Wa r w i c k E l k i n s Senior Engineer Project Development DNV GL

Analytic software brings more certainty to predicted wind farm production

f the wind industry is to account for a predicted 36.4% of the energy mix by 2050, large stepups in process efficiency are needed to ensure that todayâ&#x20AC;&#x2122;s cost-reduction trends continue. At the design stage, a drive for efficiency will emanate through wind-farm development providing more certainty in its financial models to bring more projects successfully through to close. WindFarmer: Analyst, a new energy analysis software from DNV GL, provides developers with more certainty and drives efficiency further than had been previously possible. It empowers our consultants with an ability to make energy assessments with increased accuracy, efficiency, and repeatability. Then,

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by sharing this platform, customers have the opportunity to reduce the disparity between their design phase predictions and our final bankable numbers. The new software incorporates all elements of an energy-assessment process with a focus on usability, automation, and accuracy.

The top panel plots data collected from several locations and with different sensors over a particular site. The bottom panel shows valid data in blue and excluded data in orange.

Usability When development of the software began, we gathered users together and mapped all the tasks they need to do. We refined this map and tried to

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SOFTWARE

look past what we do today, towards the fundamental activities in their analysis. The design concept behind WindFarmer: Analyst was to follow these activities and make them intuitive. The final design is comprised of chapters, and within each chapter are a series of tasks in which users are supplied with only the relevant visualizations and tools. This let’s analysts quickly adopt the tool with little training. A few key features include a: • Map setup which defines co-ordinate systems and downloads or imports GIS data. • Measurement site setup defines the physical specifications of the equipment that recorded the wind measurements. Create settings files to import time series wind data in many formats, correct time offsets and re-calibrate mis-programed loggers. • Cleaning measured data allows visualizing and exploring time-series data to find sensor malfunctions and remove these from the analysis.

• Long-term and shear calculations use DNV GL’s methodology to define relationships that ensure climate predictions represent longterm expectations for the hubheight of the chosen turbines. • Site setup configures turbine types and locations in the wind farms. It also defines air density and enables wind-sector management turbine shutdown rules to be applied. • Flow model lets users import their own flow model results, or automate WAsP, the industry standard linear wind flow model, without having to leave the WindFarmer: Analyst user interface. • Energy calculation defines settings and runs validated energy and wake models. Users then review the results. • Optimization helps users design a better wind farm layout within their constraints by iterating through hundreds of possible turbine positions until the layout achieves maximum energy. • Reporting exports data and produces attractive, informative reports.

The two plots present wind data. The left window compares the frequency distribution with the power curve. The wind rose on the right presents similar information in another manner.

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Automation In addition, a powerful C# scripting module facilitates the automation of any function within WindFarmer: Analyst. Scripting gives the user many possibilities for automating repetitive tasks, extending user interface functions, and even connecting with external tools. Scripting is also where users perform complex procedures on their cleaned wind time-series data to predict the long-term, hub-height wind climate at each measurement site. These wind climate predictions are key inputs in the wind flow, wake, and energy modelling. The layout optimizer in the software links directly with the scripting feature and allows changing the maximum energy yield target to a user’s costbenefit algorithm. Furthermore, scripting can be used to connect the optimizer to other DNV GL software products, such as Bladed and the Site Suitability Tool, so that every layout iteration can be checked for ‘pass’ or ‘fail’ against the load design parameters for a specific turbine model. Users have access to example scripts and tutorials. The company also provides custom script writing as a service to tailor the software to individual requirements. Accuracy Amidst the array of new features, the software is built on the firm’s widely validated wake and energy models. These have migrated from its predecessor WindFarmer 5.3, which has supported over 200 GW of preconstruction wind farm analyses globally performed by DNV GL. In 2018, we will introduce advanced turbine mode switching, time series FEBRUARY 2018

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energy analysis, and the automatic download of Virtual Met Data and satellite reference data. Also, we will shortly deploy a link between WindFarmer: Analyst and our online data management service, Resource Panorama, so users can schedule the download of professionally cleaned wind data into their workspace. Beyond 2018, we see this analytical software providing improved process efficiency and reliability to ensure the wind industry delivers a smarter and greener future. W

TOP: A few of the optimization functions appear here. For this exercise, 14 turbines will be optimized while 12 are locked, installed, or in neighboring wind farms. LOWER: Wake-energy monitoring shows six turbine locations for which wakes will be calculated at a height of 46 m and in a 10-m/s wind.

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OPE R AT I ONS & M AI NT E NANCE

Michelle Froese Senior Editor Windpower Engineering & Development

Proper lubrication is fundamental to wind-turbine component reliability. Implementing the right lubrication strategy can help deliver long-term results.

Mitigating turbine downtime with proper lubricant care

il has been called the “lifeblood” of a wind turbine, and for good reason. Proper lubrication mitigates friction between key components, such as the bearings in a gearbox, and keeps a turbine running reliably. What is less well known is that lubricants also help control equipment temperature and transport dirt and other debris away from the friction surface. To endure the variable load, speed, and temperature conditions under which gearboxes operate, regular oil analysis and the occasional change are critical to a long operating life. However, maintenance checks and oil changes are costly and labor intensive. Turbine downtime halts production, but a trip up tower also poses a safety risk to any wind tech. So the wind industry has developed certain mitigating strategies to lengthen lubricant performance. Some are more effective than others.

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Extending drain intervals The cost of a lubricant alone for a complete “drain, flush, and fill” for a mid-sized turbine can exceed $5,000. Then, there are the overhead charges for the O&M crew, transport, and potential crane call-out. It is no wonder that extended oil drain intervals are of interest to wind-farm operators looking to lower high maintenance costs. “A typical wind-turbine lubricant will have an oil drain interval of 36 months, but more advanced synthetic lubricants formulated specifically for wind can help extend those intervals,” shares Gary Hennigan, a National Account Executive with ExxonMobil. The key to maximum performance is choosing a gearbox lubricant that is correctly specified for a wind-turbine’s operating conditions. A poor lube choice or ignoring oil cleanliness because of a desire to extent drain intervals means a turbine’s gearbox will likely fail to function properly or with much longevity. In fact, Hennigan says that when selecting gear oil, one of the least considered factors is a balanced formulation. “Equipment performance depends on using lubricants developed with a balanced formulation approach, which means using optimal base stocks and a tailored additive

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OPERATIONS & MAINTENANCE

package that meets the specific needs of the wind turbine.” Take micropitting, for example, which can form on surface-hardened gears within the first several hours of operation if a gearbox is not properly lubricated. The result is reduced gear tooth accuracy. “To mitigate this effect, operators should look for oils formulated with a micropitting additive package, such as conventional extreme pressure additives.” Hennigan says it is also important to employ a gear finish (a surface finish on gear teeth), as specified by the American Gear Manufacturers Association’s AGMA 6006 standard. “Furthermore, an oil formulated with advanced base fluids that provide a high viscosity index – typically 160 or higher – and lower traction co-efficient, also helps. The higher viscosity index provides a thicker lubricant film at operating temperature while the lower traction co-efficient helps increase energy efficiency,” he adds. Top treating oil Additive top treating gearbox oil is another trend that has developed in the wind industry to mitigate lubricant degradation, extend oil life, and potentially save costs. Wind operators identify when an oil’s additives start to deplete and then “readditize” that oil with the addition of an after-market formula. The concern with this approach is that additive top treating may introduce new contaminants that could impact equipment performance. For example, surface active additives, such as anti-wear additives and rust inhibitors, compete for space on the metal surfaces in a gearbox. Formulating an oil so that both of these additives are present in the correct amounts is a delicate balance not typically achieved by top treating. Hennigan adds that topping up oil with different ratios or types of these additives could cause more harm than good in the long run. “Top treating may lead to an uneven distribution of additives, rendering the lubricant less effective than originally formulated,” he said. Baking a cake provides an analogy. FEBRUARY 2018

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CHOOSING A WIND-TURBINE LUBRICANT When choosing a wind-turbine lubricant, formulation matters. To optimize gearbox performance, look for advanced synthetic lubricants that are formulated with base stocks and additives that offer: • • • • •

High performance in extreme temperatures Enhanced oxidation and water resistance Protection against wear and micropitting Long equipment life, and Energy efficiency benefits

“It is like forgetting to include vanilla Analyzing for contaminants & debris Lubricant performance can deteriorate extract in the mix, and then deciding to over time, particularly under the harsh and add it after the cake is baked. Even if variable conditions to which wind turbines you tried to douse the cake in extract, are typically exposed. If the lubricant is it would not taste right and result in inadequate to protect turbine gears, such as an uneven distribution of flavor.” He when gusts produce load spikes, the oil may says if you want to bake a quality cake, lack the consistency to do its job and lead to it is necessary to include all of the component failure and turbine downtime. ingredients in order from the beginning. To prevent such events, effective and Quality lubrication is a similar process. regular oil-analysis monitoring is essential “Granted, while topping up with because it allows tracking the condition of additives may not be as invasive as flushing equipment and lubricants, and may lead and completely replacing gear oil, regular to longer intervals between oil changes. top treating actually requires operators An oil analysis assesses the condition of to increase site visits and equipment the lubricant to ensure it has maintained interaction — which in turn increases the correct viscosity and necessary the potential for safety issues,” explains additives for its application. Importantly, it Hennigan. “The longer you can rely on also checks for contaminants in the oil. your lubricant to perform reliably in-service For example, water is one of the without the need for maintenance, the most critical contaminants in a windbetter for your staff and operation.” turbine gearbox. Even small amounts This means wind operators should can significantly shorten gear, bearing, instead use a lubricant with a balanced and oil life. formulation, including the right mix of advanced base oils and additives, to While topping up with additives may not ensure long-lasting performance. “Highbe as invasive as flushing and completely quality formulations replacing gear oil, regular top treating are designed to protect equipment actually requires operators to increase site from common issues such as scuffing, visits and equipment interaction — which in micropitting fatigue, turn increases the potential for safety issues. rust, and corrosion. A proper formulation also ensures protection at extremely high temperatures and good reliability at low temperatures.” Some oils today have been proven to perform reliably for up to seven years, says Hennigan, demonstrating the capability to protect the machine even after 60,000 hours in service. windpowerengineering.com

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“To obtain the greatest benefit from oil analysis, it is imperative to work closely with an expert lubricant manufacturer and conduct an oil analysis typically every six months,” says Hennigan. Although, he points out, particle detectors are now available to continuously monitor gearbox oil for contaminants. “These sensors look for debris in oil. However, some wear debris sensors are limited to the size of the particles they can detect, so it is important to work with an expert that knows your equipment,” he says. The most damaging particles are less than 10 µm in size, which are small

enough the pass through standard oil filtration. Fortunately, improvements in analysis techniques and particle sensors can help mitigate potential damage to gearbox components and keep wind turbines running smoothly. “Instead of cutting corners, say by extending oil analysis intervals or top treating oil, take the proper steps to mitigate potential problems from the start. This means finding the right oil formulation for your wind turbine and the conditions it must endure and analyzing oil on a regular basis.” W

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Synthetic lubricants that offer a balanced formulation can help maximize a wind-turbine’s gearbox performance and longevity. For example, ExonnMobil says its MOBIL SHC GEAR 320 WT is scientifically engineered with balanced proprietary additive technology to deliver benefits in micropitting, viscosity index, air release, and low-temperature flow characteristics compared to other synthetic gear oils.

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CON DITIO N MONITORING

Gorka Prada NEM Solutions US

Lots of data is confusing. Actionable information is gold

he main objective of the big players in the wind industry is to lead in an increasingly competitive market. For them, leadership is about adapting to the inevitable change to a digital environment and then, somehow, sift through the mountains of information available to managers and making good decisions. Achieving the so-called digital transformation is a big challenge that companies will have to face. It will not be easy because more than 60% of the companies have failed in their digitalization strategy. So how might that figure be lowered?

An example One example of how to successfully implement information technology that makes data more useful comes from Siemens Gamesa, a company often considered a wind industry leader. To achieve its digitalization goals, the company recently collaborated with NEM Solutions to implement the A.U.R.A. desk solution. It lets Siemens GamesaÂ´s wind-farm operators better understand the current status of their fleets, make more accurate business decisions, and bring them even faster into the digital world.

Getting a grip First, define the problem. It is common to see a lot of digital solutions and new tools are offered as a Digital Holy Grail. Why should a wind industry player need these digital tools to handle information? The problem in many companies is not a lack of digitalization. The problem is simpler and older: They do not have the needed information to make decisions at the right time. And if they have the information, it is not in a useful format. Second, companies try to do everything inhouse to avoid cooperating with other firms. This is common in the wind sector. The assumption is that avoiding outside assistance lowers O&M costs. The consequences of this trend have been observed when companies occasionally announce they are lowering their digitalization goals because they have problems achieving them. It is natural to have problems. Winning this daily race calls for making fast decisions to solve these problems. Winning also requires asking for support from those who can lower the risk profile and make the race a bit more comfortable.

The A.U.R.A. Desk workstation displays charts, graphs, and tables of information from a wind farm or other facility so operators can make timely and informed O&M decisions.

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CONDITION MONITORING

The big picture in the A.U.R.A Desk dashboard

A.U.R.A. Desk dashboard shows the key performance indicators for a wind farm. For example, the top three panels show.availability, overall health, and which turbines are not working.

“One of the best system advantages that we have is easy access the information,” says Eduardo Llorente, director of Services Operations North America. “From now on we will be able to concentrate on the content rather than on the way we obtain the information. All of us will see the same information at the same time. This will be a key factor in any decision-making process.”

From now on we will be able to concentrate on the content rather than on the way we obtain the information. All of us will see the same information at the same time. A closer look The solution Siemens Gamesa found useful in managing its mountains of data combines in-house expertise with big-data techniques and business intelligence. This 36

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approach lets A.U.R.A. desk provide a view of the wind farm or the fleet, also notifying the future needs of the assets and their efficiency by continuously monitoring them. An advanced workstation and algorithms compare, analyse, and extract knowledge from the entire fleet. It is a way to reduce risk because the information that the company needs is collected and presented in a way to make tough decisions faster than previously possible. It is not about data, it is about transforming data into knowledge. A.U.R.A. desk is the result of a consultancy project carried out by NEM Solutions and is based on customer objectives, processes, and key performance indicators (KPIs). For example, KPIs for a wind farm might include power output from each turbine and the farm, hourly power forecasts, which wind turbines are down and why, and so on.

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Accomplishing total digital transformation Mountains of data are difficult to climb, and expertise is needed to make sense of it all. To fully accomplish digital transformation goals we recommended a twofold approach: data analytics and business intelligence. A.U.R.A is patented technology for critical system failure anticipation. The system accurately predicts the future of each of wind turbine. Instead of simply comparing the

A.U.R.A Desk makes it easy to interpret the KPIs. These indicators are calculated with the most updated information. The system can also benchmark assets performance. Comparisons can be made between technologies, wind farms, or wind turbines based on economic and technical issues such as maintenance expenses, evolution (corrective and preventive), availability, production, and reliability. W Visualizing data on the dashboard makes it easy to use, even when it comes from all over the world. The same data can be available for handheld and portable devices such as laptops, smartphones, and tablets.

behavior of assets with standard statistical data, A.U.R.A. individually models the normal behavior of each asset and subsystem in its own context. While this method almost guarantees the best performance of the fleet, it is not enough to help the main players in the wind sector because they need a big-picture view to make the best decisions. This is where A.U.R.A desk comes into play, closing the circle: digital transformation accomplished. FEBRUARY 2018

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F ILT E R S & F LU I D S

Paul Dvorak Editor Windpower Engineering & Development

Smarter sensors let a gearbox tell how it’s doing

recent spinoff from the University of Wyoming’s Technology Business Center has set itself the goal of improving the quality of oil monitoring in wind turbines. The company, LogiLube, says its SmartGear product provides real-time lube oil condition monitoring, predictive analytics of a lubricant’s remaininguseful-life, automated collection of in-service lube oil, and even status of the gearbox filter. The oil flow-through device is about the size of a shoe box and mounts on the gearbox. As the oil flow through it, several sensors examine the oil’s condition. Company CEO William Gillette says the company is

sensor agnostic which let them use the best available and those the client prefers. “The device looks for the three killers of any windturbine gearbox: foam, water, and particles,” says Gillette. “SmartGear auto detects the air ratio or foam in the oil, and we do that through viscosity which is measured by several different meters or sensors. They’re typcially acoustic based. We select one over the other based on the viscosity range of the oil at the operating temperature.” Water is detected and measured two different ways. One is by measuring the viscosity. “In fact, lab technicians have characterized each of the different oil brands used in the industry.

SmartGear mounts on a gearbox and includes a purpose-built computer with controls that include A.I. and machine-learning capability. AI includes a realtime decision engine that considers the individual discrete values and applies them to an algorithm, which can triggers events, take an oil sample, or send alarms. The system is mounted to a gearbox in an NREL lab. A smartphone application lets the wind tech retrieving an oil sample simply photo the QR and bar codes to identify the sample, without writing anything down.

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So say it’s a particular lubricant recommended by Mobil. We would determine and measure its viscosity and dielectric constant for a range of temperatures. That data is programmed into a firmware library so we can measure and report on a temperature corrected viscosity.” Gillette says they do the same thing for the dielectric constant. “In the lab, virgin oil is purposely contaminated with incremental parts-per-million of water, up to and beyond the condemning limit of the water contamination.” That analysis provides the behavior of the oil and dielectric constant so when it appears again during a 30-second measurement, it is possible to identify a shift in the dielectric from water contamination or a depleting additive package. The company has built a library of oil characteristics for those lubricants used most often. Particles are more interesting, says Gillette. “NREL, other key players, and us believe that if you can monitor, alert, and alarm on the detection and behavioral change of wearparticle generation, you can catch an event before it turns catastrophic. It’s also important to define ‘wear’ particles. That could be the smallest detectable particle coming from a metalto-metal contact. So we have identified abrasion and wear

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F I LT E R S & F LU I D S

in a poorly lubricated or compromised scenario. The smallest wear particle detectable in real time is four microns.” The oil cleanliness spec, ISO code 4406, lists cleanliness factors for three different particle sizes. Another monitored characteristic is the differential pressure (DP) across a gearbox filter. “Suppose a lot of water has emulsified the gearbox oil. Eventually, the filter clogs with emulsification and agglomeration of additive particles. That makes the DP sky rocket. This is not usually SCADA data. So it is important to know it happening and to correct it before the DP gets high enough to damage the filter.” When called for, the system also extracts a sample of oil. “The system triggers the SmartGear to fill in a sample bottle with up to 500 milliliters of oil, which is sent to a laboratory where personnel will perform a Flender foam test under highly controlled lab conditions.” He adds that real-time The chain of custody for an oil sample starts with a time recording for Gillette adds that this is more than condition-based monitoring, when the sample was collected and just oil sampling. “It’s a full on intelligent combined with fleet-wide data a signal for its retrieval and exchange machine help system.” The system signals analytics and real-time reporting for a new bottle. The chain ends a tech that a sample has been taken so it will help wind-farm operators avoid the next day with the oil delivered can be retrieved and sent to a lab. costly downtime. Maintenance to a lab, analyzed, and actionable Lubricant manufacturers also have information returned to the wind-farm plans previously based on a operator with recommended action. condemning limits on oil cleanliness. calendar schedule can now be “Wear particles are the clue. We have tailored to an as-needed basis. spent close to two years vetting half a Gillette says his company is dozen different in situ detection methods part of an NREL cooperative R&D from around the world for finding particle grant that includes SKF Bearings, contamination. We’ve selected one, Siemens, Amsoil, and Flenders, wrote firmware around it, and software which is part of Winergy. “We’re to control it. It filters out air bubbles that providing the onboard analytics might be considered particles. That lets and computing power, and in the sensor count ferrous and nonferrous situ particle sensors,” he says. W particles.” The device captures data NREL, other key players, and us believe that if you can monitor, alert, in real time and and alarm on the detection and the behavioral change of wear-particle reports it out to the cloud every generation, you can catch an event before it turns catastrophic. 30 seconds so the owner gets real time data, up to 100 million data points a year. “So when the system fills a bottle with a sample, we know most everything about the oil it holds.” FEBRUARY 2018

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Offshore

wind industry

needs a new paradigm for managing dispute claims Should construction companies in the wind industry design components to an accepted specification or “fit for purpose”? A landmark ruling by the UK Supreme Court has shifted the legal landscape surrounding offshore wind farm design and construction, which presents the industry with a new paradigm in dispute claims.

L o r n e G i ff o rd • Civil Engineer • Brookes Bell Group G r a n t G re a t re x • Managing Partner • ELAN Forensic

OFFSHORE WIND HAS EVOLVED from alternative energy to a primary one with an essential role in the global energy transition. The installed capacity of offshore wind will increase thanks to recent cost reductions that provide a strong economic case for investing in this growing industry. However, significant challenges must be overcome before the offshore wind industry can thrive. One challenge wind developers face is in offshore construction. The components that make up an offshore wind farm (OWF) are typically larger than for onshore projects. OWFs are also being sited in deeper waters and further offshore. With regards to design, construction, and operation, OWF asset owners, operators, and contractors must navigate a changing legal landscape, exemplified most notably in a landmark judgement passed last year in the UK’s Supreme Court. 4 0 WINDPOWER ENGINEERING & DEVELOPMENT

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The case and the judgement In August 2017, the Supreme Court handed down judgement in the high-profile case of MT Højgaard v. E.ON Climate & Renewables. The case concerned the foundation structures of two OWFs, Robin Rigg in the Solway Firth, which were designed and installed by MT Højgaard. The foundations failed shortly after project completion because of grouted connection problems, which also occurred at other offshore projects. The failures came from a fundamental fault in the industry’s standard design code (DNV-OS-J101) that E.ON had specified for use.

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Offshore

wind industry

needs a new paradigm for managing dispute claims

The legal dispute concerned who should bear the remedial costs in the sum of €26.25 million. After hearings in the Technology and Construction Court and the Court of Appeal, the final judgement of the Supreme Court concluded that MT Højgaard was contractually responsible for the problem because it failed to deliver foundations that were fit for their purpose.

Current installed OWF capacity in Europe (12.6 GW) is set to more than double in the next five years with an additional 16.3 GW added to the OWF network. The UK will maintain the lead in total OWF installed capacity.

This judgement sets a precedence of responsibility on suppliers and contractors that their work is “fit-forpurpose,” even where clients have specified the use of a standard that proves to be flawed. [In April 2016 DNV withdrew OS-J101, which was the standard when the building was completed in 2010, and replaced it with DNVGL-ST-0126, noting that ‘This document has been totally revised’.] The consequences of this ruling for suppliers and developers in the offshore wind industry is significant and will affect future project contracts for design and management. Drivers of disputes The case of MT Højgaard versus E.ON Climate & Renewables is just one example of an increasing number of offshore wind disputes relating to project development, design, construction, and contract management. As the table Current landscape of legal dispute shows, these disputes reflect the current stage of industry maturity in offshore renewables. In terms of risks and disputes, a recent study by GCube revealed that more than 40% of the total number of OWF insurance claims relate to cables, 15% to foundations, 13% to electrical issues, 7% to both collision and assembly, with blades, lightning, and fire

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making up the remainder. According to Genillard & Co, since 2010 there have been over 10 claims per year regarding these problems, with about 100 days of downtime per incident and a cost of over €350 million to the industry. It is estimated that 95% of OWF construction projects have experienced cable claims with the average cost of a claim around €2.5 million. Inter-array cable damage can vary from €1.4 million to €2.4 million, while export cable damage can cost from €8 million up to €27.5 million. Support vessel costs on larger projects can cost more than €300,000 per day. Subsea interconnectors, which transfer electricity from one country to another, also pose construction risks. UK interconnectors today total 600 km. By 2023, the figure is expected to rise to 5,500 km. During concept and early development, risks may include the site and landfall locations, routes, technology, and external threats such as collision impacts from shipping and trailing anchors. At this stage, risks can be misjudged due to a high reliance on opinion, imperfect industry practices, a failure to heed past lessons, and an intuitive dismissal of low probability risks. Additional risks come from a poor understanding of subsea geology, which may impact measurements or equipment performance. For example, a vessel’s position and control during underwater cable laying is critical. A loss of tension control or poor accuracy while transitioning between geologies may result in cable damage. Similarly, the measurement of thermal conductivity as well as sediment movements may lead to the cable overheating during operation or becoming exposed and at risk from fishing activities. Future claims The offshore wind industry is developing rapidly. New turbine classes of 8 MW-plus and floating platforms for deep-sea OWF mean there are new technical challenges facing future project developers. These challenges include:

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• • • •

Technology, such as floating platforms and increasing structural loads Topography, such as distance to shore and zoning conflicts Construction, including design innovation, joint ventures, and cost reduction Contracting, including multicontracting, risk management, and supply-chain management

It is likely that a broad range of disputes will occur as offshore wind developers’ deal with the impacts of a harsh operating climate on project performance, turbine

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durability, and asset management. Design and construction flaws initially unapparent during construction or wind-farm commissioning may impact the integrity, safety, and performance of offshore wind farms as the number of cumulative operating hours increase. These may require costly remedial action. One of the greatest threats to asset design life will be corrosion. Marine environments (salt water) contain aggressive species such as chlorides (Cl-) that will attack unprotect steels in the form of pitting corrosion. This can lead to catastrophic failure mechanisms such as

fatigue. Supply conditions for structural steel or bolting, in particular, is important because excessive material hardness can lead to failure by mechanisms such because hydrogen embrittlement and hydrogen induced cracking (HIC). This type of cracking can lead to unexpected catastrophic failure. Significant secondary damage to the turbine also a concern. Mitigating claims, risks, and costs OWF owners, operators, and contractors must prepare for potential litigation threats, or lay sound foundations for potential legal action that may arise during project execution or after commissioning. One way to do so is through legal support. New to the offshore wind industry is a ‘one-stop shop’ that amalgamates expertise and contract management, and supports Alternative Dispute Resolution processes. Brookes Bell and ELAN Forensic have launched a commercial partnership that delivers expertise for every offshore windfarm project and dispute. It is important to choose legal support based on experience and skills in evidence gathering, such as with non-destructive testing, to prepare the necessary evidence in litigation and arbitration cases. This is essential if claims are to be assessed and technically evaluated to the highest standards. External experts can be appointed at any stage of the project, but early involvement provides the greatest returns. This ensures that consistent contracts with good case law are used from the outset. Internal teams can be trained in contract management approaches incorporating robust decision making processes, correct allocation of responsibility, transparent and documented processes and the maintenance of records. Amid changes in the legal landscape, it is essential that all those involved in the offshore wind supply chain are fully apprised of their legal position, and proactively manage their contracts and project execution to minimize the risks of disputes and to prepare in advance should commercial litigation arise. W

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Artificial intelligence is being applied to most every industry in efforts to improve operations and trim costs. Here’s how early efforts are already benefitting the wind industry.

R o b B u d n y • V P, R e l i a b i l i t y E n g i n e e r i n g Sandeep Gupta • CEO E n s e m b l e E n e rg y

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e n s e m b l e e n e rg y. a i

THE WORLD IS ENTERING the early stages of a technology revolution called artificial intelligence (AI). It is showing an impact in many different fields such as image recognition, fraud detection, and self-driving cars, to name a few. Machine learning techniques have resulted in remarkable performance improvements in each field to which it has been applied. The best definition of artificial intelligence is that it is set of methods or algorithms that use large amount of data to learn rules or patterns. Another aspect of AI is that it continuously improves with additional data and without being explicitly programmed to do so. Even though AI is considered the broader concept, machine learning and artificial intelligence are often used interchangeably. FEBRUARY 2018

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The use of artificial intelligence requires three basic elements: • Learning algorithms, • Large data sets, and • Large-scale, inexpensive computing AI dates back as far as the 1970’s but has only recently become practical due to low cost, powerful, cloud computing. The wind industry is well suited to benefit from this technology revolution. The best way to do so combines wind-turbine engineering and operations expertise with the latest artificial-intelligence methods. However, AI cannot fully deliver the technology’s potential benefits without a complete understanding of wind-turbine loads, control strategies, and component-failure modes. The shortcomings of conventional O&M Today’s wind turbine operations-and-maintenance work is less effective than it could be because it is: • Reactive − Maintenance actions are taken in response to faults or failures. • Static − Turbine behaviors have fixed upper and lower fault limits, which are not situation dependent, and are not customized to the known behavior of each turbine. • Labor Intensive − Developing and running SCADA queries takes many hours of time which strain resources. Useful insights in the data are overlooked, resulting in lost opportunities to increase production or reduce costs. Wind farm O&M with input from artificial intelligence will pay off several ways. For instance, AI will be: The cage segment comes from a failed pitch bearing.

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• Predictive − Anomalies will be identified in early stages and addressed before faults or failures occur. • Dynamic − Turbines will have dynamic fault limits that will be situation dependent, and can be customized for each turbine. • Automated – A machine learning platform continually analyzes data in the background, and provides automated notifications to operators, along with suggestions for the most effective corrective actions. Skilled human operators will be freed from tedious data analyses, and their time will be spent on higher value activities. Improving O&M A few examples can show how our company is using the best combination of machine learning and physics to improve wind-turbine operations and maintenance. For example, the premature failure of pitch bearings is just one issue facing many wind operators. Several of their different failure modes include false brinelling, macropitting, cracking of the bearing’s outer ring, and failure of the cage that separates the bearing’s rolling elements. An accompanying photo shows the cage segment from a failed pitch bearing. Repairing these failures is extremely expensive and leads to downtime and lost energy. They can also be dangerous because they have resulted in the loss of a blade. One client company experiencing pitchbearing failures had been relying on time consuming and costly visual inspections to identify failing units. We developed an alternative detection method by combining our wind-turbine expertise with the latest machine learning techniques

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in a model of expected pitchbearing behavior under all turbine operating conditions. The AI platform we have developed continually monitors turbine operation in the background, so it needs no operator input. Recently, the platform identified a deviation between the expected pitch-bearing behavior and actual behavior which triggered the sending of a notification. When the pitch bearing was inspected, its cage failure was spotted. For this AI system, the average early notification time for pitch bearing failure has been about four months prior to the bearing needing replacement. This let the operator plan the replacement work with a similar task on another turbine, thereby saving one crane mobilization charge, almost $100,000.

This main bearing failed because its insufficient lubrication was undetected.

Preventing main bearing failures provides another example of how machine learning benefits the wind industry. Premature failure of main bearings is unfortunately a widespread problem in the wind industry, and is one of the most expensive unplanned maintenance events, costing up to $250,000 per failure. While there are several root causes of main-bearing failure, including bearing design issues and excessive rotor thrust, poor FEBRUARY 2018

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lubrication is one of the most important root causes. Poor lubrication comes from by an insufficient amount of grease in the bearing, a lack of grease in the correct locations, or by grease that has thickened and is no longer capable of lubricating the bearing. An accompanying image shows an example of a lubricant related, main-bearing failure. Our proprietary methods were used by another wind-farm owner to confirm that the lubrication anomaly in a main bearing would have been detected almost six months prior to failure. The methods include a combination of expertise in wind-turbine loads, bearing operation and lubrication, and advanced data analysis. Had our predictive analytics platform been in use, the operator could have performed a simple, inexpensive maintenance action that would prevented, or at least significantly delayed the failure. The bar chart Health scores shows one for a main bearing compiled over almost a year. When the health score reaches a pre-determined value, the system sends an alert along with a recommendation to add grease to the bearing.

In this example, notice that an abnormal condition (indicated by falling health scores) was identified at least three months before significant main bearing damage occurred. No fault was generated by the turbine, even though the behavior was abnormal. Predictive actions such as these can effectively prevent failures, or significantly extend the life of critical components, resulting in large cost avoidances for operators. Anomaly detection provides another example of how machine learning applies to wind turbines. Detecting underperforming turbines is notoriously difficult using the power curve that OEMs provide. Although turbine manufacturers publish reference power curves, the actual power produced by a turbine is affected by factors other than wind speed. Such factors include site elevation, seasonal factors, wind shear, turbulence intensity, and more. Furthermore, the power curve for similar individual turbines from the same OEM can vary by as much as 10%.

Each vertical line represents a health score that was calculated about every day. It is not difficult to spot a failing bearing from the negative slope of the plot.

If adding grease to the bearing corrects the condition, the alert is cleared. However, if adding grease does not correct the condition, the alert escalates so an operator can purge the bearing of hardened grease and replace it with fresh lubricant. FEBRUARY 2018

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Peer-to-peer analysis provides another performance evaluator. Although somewhat more effective than comparing to a reference power curve, the turbine peer-to-peer method requires a careful consideration and understanding of turbine positioning

and wind regimes. The Ensemble Energy approach allows for both peer-to-peer comparison and individual turbine performance deviation. The curve in Predicted power shows a power curve created by our machinelearning platform. The model incorporates many factors in addition to wind speed and accounts for their effect on power production. Unique models are created for each individual turbine. This model allows identifying a deviation in power production as soon as the same day the deviation begins, letting owners take immediate corrective action, and limit lost production. Machine learning techniques, when created and applied in combination with domain expertise, are resulting in increased energy production and reduced maintenance costs. Furthermore, these improvements are being made by making better use of existing SCADA data, with no additional sensors required. The use of machine learning to increase energy production and reduce costs will be the standard in the near future. W

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201 8 I N T RO D U CTIO N LEADERSHIP IN WIND ENERGY

Vote for the company you think has provided leadership to the wind industry

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The year has just begun, but 2018 has a lot to live up to in terms of wind power if it is to grow and best last year’s accomplishments. For instance, the U.S. wind industry installed over 7,000 MW during 2017, says GWEC. Just flip through the pages of this issue and you’ll get a sense of the innovation that permeates the wind industry. For instance, it’s getting a good grip on what causes gearbox problems and how to solve them. Improved reliability is driving down the cost of wind-generated power to the point that wind energy is less expensive than gas-generated power. That has caught the eye of many utility CEOs. There is more.

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For instance, in the U.S. the offshore industry has finally launched with more offshore wind farms to begin construction in the coming years. And because U.S. waters are deeper than the North Sea, expect to see a few floating wind turbines. Furthermore, one feature story in this issue highlights initial efforts of putting artificial intelligence to work spotting bearing problems. Watch for the mention of AI in a lot of wind industry maintenance, particularly when making maintenance more predictive or a robot smart enough to take a wind tech out of harm’s way. To keep wind-generated power flowing, we at Windpower Engineering & Development know it is important to recognize the leaders that push the industry forward. In the pages that follow, you’ll see the accomplishments of fellow engineers and companies in a range of categories. Your vote for one or more of the companies listed will be recorded on our website through November 2018. Winners will be recognized in the first issue of 2019.

FEBRUARY 2018

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LEADERSHIP IN WIND ENERGY

2018

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

Windblade repair solutions Blade repairs in the past have mostly been based upon old “polyester and fiberglass” repair techniques, similar to those used for years in the marine industry. Current materials and techniques may not be sufficient for today’s structures. As turbine blades grow in size and are being designed using new materials and optimized fibers forms, the importance of producing high-performance structural repairs becomes even more critical to the durability and efficiency of the blade. Abaris specializes in teaching technicians how to best identify and remove damaged structure in away that minimizes the risk of damaging good structure. Repairs are then carried out in a manner which results in maximum load replacement and consideration to both the aerodynamic and aeroelastic performance of the blade.

Abaris Training Resources, Inc. 5401 Longley Ln, Ste 49 Reno, NV 89511

The good news is that the repair materials used, and methods and techniques taught by Abaris instructors apply to all composite wind turbine blades (and other structures), both currently in service and those still in design. An Abaris trained technician learns not only “how” to perform repairs but “why” each step in the process is vital to the end result. Knowledge and skills necessary to that of today’s workforce.

775.827.6568 Training@abaris.com www.abaris.com

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LEADERSHIP IN WIND ENERGY

2018

AMSOIL understands the complexity of oil analysis and the oil change process better than any other supplier on the market. We have successfully supported our customers worldwide by devoting a dedicated staff of industry focused application engineers, global strategic distribution partners, industry leading tribologists, and a global sales support team experienced in the industrial and wind industries. As a product solutions and technically driven company first, AMSOIL’s devotion to the customer and devotion to protection, sets us apart from the competition making AMSOIL the first and last choice when it comes to a trusted name providing only the best in

AMSOIL IS DEVOTED TO INNOVATION

lubrication solutions.

Since 1972, AMSOIL has been innovating and creating a legacy of being first. First to bring advancements in synthetic lubricants to market that were inspired and built by aerospace technology. AMSOIL became the first synthetic motor oil in the world to meet the American Petroleum Institute’s service requirements. That tradition continues today and over 40 years later, AMSOIL is still the leader in synthetic lubricants.

AMSOIL IS DEVOTED TO PROTECTION

AMSOIL INC. 715.399.6305 www.amsoilwind.com windsalesgroup@amsoil.com

Entering the renewable energy market, AMSOIL’s PTN 320 Power Transmission EP Gear Oil solved the ongoing issues found in wind turbine power transmission gearboxes. Formulated to meet the extreme high demands of the industrial applications found within a wind turbine, AMSOIL PTN 320 quickly became the only name trusted by more Owner/ Operators and OEMs when selecting a main gearbox oil. Today, AMSOIL PTN 320 is approved and factory filled by the world’s largest OEMs. Coming into our 10th year of real world operations, with an industry leading warranty and installation in over 30,000 MW. Where others continue to battle, AMSOIL PTN 320 oil has been tested and proven.

AMSOIL IS DEVOTED TO QUALITY

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AMSOIL PTN 320 leads the industry with a proven record of being the best in water resistance, engineered wear control, and superior foam control, maximizing your assets ROI. AMSOIL was the first to bring a proven flushing procedure, later adapted by the American Wind Energy Association (AWEA), and the largest OEMs across the globe. AMSOIL PTN 320 has won the war on gearbox wear without the need for additional additive boosters or anti-foaming top treats.

www.windpowerengineering.com

FEBRUARY 2018

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

2018

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

bearings. Configurations range from 2-piece economy commercial and molded race construction through 3-piece precision designs. Aurora also produces a full line of military spec rod ends, spherical bearings, and journal bushings. Custom designed rod ends, spherical bearings, and linkages are a specialty. For more information, contact: Like all Aurora Bearing spherical bearings, the LCOM series features a one piece steel raceway, swaged around the ball for a smooth, precise, close tolerance fit, along with the benefit of the strength and vibration resistance of steel. In addition, this series is optionally available with Aurora’s proprietary AT series PTFE liner, for a zero clearance, self lubricating fit.

630-859-2030 Fax: 630-859-0971 aurorabearing.com

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

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Aurora LCOM Spherical Bearings were designed to offer a higher level of performance with dimensional interchangeability for the “LS” spherical bearing category; a market segment which has remained largely unchanged since the 1950s. “LS” bearings are characterized by being of 3 or 4 piece construction, with an inner ball, an outer ring, and a one or two piece brass, bronze, or copper alloy race between. Since the early 1950’s users of these bearings, which are also marketed with a “FLBG”, “RS”, or “VBC” prefix, have had to accept their low strength and poor vibration resistance due to the low strength race material. Aurora’s LCOM bearings incorporate superior materials and manufacturing processes to overcome the performance deficiencies associated with “LS” bearings.

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

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

to a deformation of the relatively soft race material. This weakness is addressed in the Aurora Bearing Company’s COM-M series spherical bearings. Like all Aurora inch dimension spherical bearings, these metric bearings all feature a 1 piece steel raceway, cold formed around a chrome plated, alloy steel ball for strength, precision, and structural integrity. Aurora COM-M series bearings are available in sizes from 3mm to 30mm., and follow the dimensions of DIN 648 schedule K. Bearings are optionally available with Aurora’s self lubricating AT series ptfe liner, for a smooth, zero clearance fit that is self lubricating and maintenance free.

Maintenance free & corrosion resistant rod ends from Aurora

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

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LEADERSHIP IN WIND ENERGY AZTEC BOLTING SERVICES, INC. has been a leading provider of bolting tools to the wind energy industry for over 30 years. Aztec Bolting utilizes the latest products from Enerpac to Skidmore for all your torque and tension requirements. We offer the finest tools available for sale or rent, including hydraulic tools that can yield up to 80,000 ft./lbs. Aztec Bolting also provides calibration services and repairs through our ISO 17025 accredited mobile fleet and calibration facility at the company headquarters in League City, Texas. Working alone, or on site with your labor force, Aztec is committed to delivering the right solution, to meet your timing and budgetary requirements. Aztec Bolting Services, based in League City, TX, has expanded our service area with new offices in Midland, TX, and continues to provide a state-ofthe-art mobile fleet division with additional office locations in Corpus Christi and Sweetwater, Texas, and Oklahoma City, Okla.

Aztec Bolting Services 520 Dallas Street League City, TX 77573

2018

Since 1987, Aztec Bolting Services has been providing innovative equipment and superior technology. As a distributor of Enerpac Bolting and Tensioning Products, Skidmore-Wilhelm, Stahlwille, and Norbar hand torque wrenches, electronics and torque multipliers, we are prepared to assist our customers in achieving their Wind Power Construction and Maintenance goals. As a premier distributor of Enerpac products, Aztec Bolting is proud to introduce the new Enerpac Wind Power Generation Bolt Tensioners. Designed by a highly experienced group of tensioning professionals, who specialize in creating customized solutions for unique applications, the new Enerpac tensioners offer high precision with low maintenance. If your project requires critical fastening applications whether in high performance or tight spaces, the new line of Enerpac PGT, FTR, and FTE Series Tensioners offer universal solutions with precision and speed.

“Aztec’s mission is to provide quality products and services to meet every torque and tension need with the utmost care, quality and service.” Our professionals can be on-site anytime, anywhere with our ISO 17025 Accredited Mobile Calibration Fleet. Our Mobile Units can provide more versatile services than ever before from Controlled Bolting Training to on-site calibrations of your products.

1308 South Midkiff Road, #305 Midland, TX 79701 802 Navigation Boulevard #106 Corpus Christi, TX 78408 1113 Lamar Street Sweetwater, TX 79556

800.233.8675

Enerpac S-Series

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

www.aztecbolting.com

Enerpac W-Series

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

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

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FEBRUARY 2018

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LEADERSHIP IN WIND ENERGY Bronto Skylift manufacturers high-reach

Over 7,500 aerials built and in operation

truck-mounted aerial devices from 36m to over 112m working height for wind turbine blade and tower inspection, maintenance and repair and other overhead applications.

Bronto machines have been used in wind farms globally for over 50 years and have been time-tested in the toughest conditions. Over 7500 Bronto aerials have been built and are in operation throughout the world. Aerial work platforms are by far the safest and most productive method of accessing turbine blades. And, they produce huge savings in both time and money for operators of wind farms over methods like rappelling or using a crane basket. When using aerial work platforms workers are lifted to the overhead area in an 8-foot x 3-foot platform that they control directly from the platform. They control how fast it rises and where it is positioned, and they can lift up to 1000-pounds of men and materials to full working height in a matter of minutes. And, because the platform is telescoped up from a stable base on the ground, it can withstand winds speeds up to 28 mph (12.5m/s) when fully elevated.

Photos courtesy of TGM Wind Services

Bronto aerials can also be configured with a variety of options that increase productivity when elevated. They can be equipped with electrical, pneumatic, hydraulic and water lines running inside the telescoping boom from the ground to the platform so that workers can operate powered tools and washers in the platform. This not only saves time, it is much safer as it eliminates having lines or hoses running down from the overhead platform to ground level.

Bronto Skylift 47 Taft Vineland Road Orlando, FL 32824 www.brontoskylift.com

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2018

LEADERSHIP IN WIND ENERGY Dexmet Corporation manufactures precision expanded metal foils and polymers for applications in aerospace, power generation, filtration and automotive industries. Dexmet was founded in 1948 and is based in Wallingford, Connecticut. For over 60 years Dexmet has been at the forefront of expanding technology and has redefined the standards for micro mesh materials providing the greatest range of products and capabilities for foil gauge metals and thin polymer films. Dexmet manufactures thin, light-weight precision expanded Copper and Aluminum from .001” thick and widths reaching over 48” that can meet specific weight, conductivity and open area requirements required by aerospace or wind generation applications. Precision MicroGrid® materials from Dexmet are the industry standard for expanded materials used in lightning strike protection, on carbon fiber structures with OEM aircraft manufacturers as well as EMI/RFI, and ESD protection for sensitive internal instrumentation. The Dexmet Quality System is ISO 9001:2008 and AS9100 certified.

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

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AS THE POWER OUTPUT requirements increase for wind turbines, wind generator manufacturers are moving towards larger blades to rotate these larger turbines at lower wind speeds. As the wind blades increase to over 45 meters in length, blade construction is moving away from the more traditional all fiberglass construction to utilize more carbon fiber. The carbon fiber provides a substantial weight savings and increased strength to combat the extreme stress loads exerted on the blades during operation. Carbon fiber, however, is conductive and more prone to be struck by lightning. Without proper protection, they are susceptible to severe damage and catastrophic failure. For two decades Dexmet has been working with aircraft designers developing precision expanded MicroGrid foils for lightning strike protection on carbon fiber composite aircraft and its components. Benefiting from the development work done in the aircraft industry, Wind Blade Manufacturers are now realizing the importance of having the proper lightning strike protection for larger carbon fiber blades. As with Aerospace applications, weight is always critical so Dexmet provides different conductive materials to minimize the weight based on the different strike zones. As with all rotary blades, lighting is more prone to hit the leading edge and the outer blade surfaces towards the tips where the highest amount of static energy is generated. For these locations, the heavier, more conductive materials are utilized. As you move towards the root of the blade, a lighter weight material can be incorporated to reduce weight and cost. The variability with Dexmet’s expanding process provides the capability of producing a custom material based on desired weight, conductivity, or open area to meet exact application requirements.

Dexmet MicroGrid® Proven Lightning Strike Protection

• • • •

Proven Technology for Lightning Strike Protection Highly Conductive Patterns Matched to Specific Requirements Open Area Design for Easy Dry or Wet Layup without Delaminating Easily Repairable for Low Maintenance Costs and Minimal Downtime

MicroGrid® Materials For Hybrid-Carbon Fiber Wind Turbine Blades

Dexmet MicroGrid materials are thin, open area products applied to a layer on the top of the structural carbon fiber spar/web or other systems that utilize carbon such as de-icing solutions that consume carbon heating mats on the leading edge. Dexmet materials can achieve the critical conductivity, sometimes in conjunction with the carbon components, to dissipate 20-25 years’ worth of lightning strikes. Dexmet expanded copper and aluminum MicroGrid meshes are essential at extending the life of hybrid carbon fiber composite blades.

Dexmet LSP material are used in conjunction with the other parts of the entire lightning strike protection system for a wind turbine blade. Dexmet mesh can provide connections between receptor(s) and anchor blocks/root through which high voltage current pass to ground connections. To learn more about the benefits of Dexmet materials, witness its lightning protection performance or understand how it can reduce your maintenance costs and down time, contact us at products@dexmet.com or visit our web site and let us show you how to incorporate the innovative MicroGrid® materials into your composite designs and start recognizing the benefits today.

www.windpowerengineering.com

FEBRUARY 2018

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LEADERSHIP IN WIND ENERGY

2018

HARTING is the global choice connectivity solution provider for Wind Energy and other high demand markets. Although we’re best known for our world-class connector and cabling solutions for getting power, signal, and data quickly and reliably from point A to B, our expertise also includes cost competitive Hall-Effect Current Sensors, board level and backplane development and manufacturing, network components for Fast/Full Gigabit Ethernet, complete RFID systems for asset control and management, and, most recently, a product to connect already existing systems, such as wind turbines, to the IIOT.

HARTING: The educational Go-To-Source for engineers HARTING 1370 Bowes Rd. Elgin, IL 60123 www.HARTING-usa.com

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As an expert in the industry, HARTING is committed to educating the North American market. HARTING-U is HARTING’s free, web-based, educational portal that keeps the engineering community up to date with the info they need and empowers them to find the technology that is right for their application. Visit HARTING-U.com for more information.

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LEADERSHIP IN WIND ENERGY

2018

HELUKABEL: The Worry-Free Cable Experience HELUKABEL USA, based near Chicago IL, is a global manufacturer and supplier of cables, wires and cable accessories. Our extensive product line includes flexible and continuous-flex control cables, data/ network/BUS cables, VFD/servo cables, torsion cables for wind turbines, singleconductors, and multi-norm cables with domestic and international electrical approvals. HELUKABEL combines excellent cable quality, innovation and technical expertise with a vast product portfolio and smooth logistics operations. We call that the worryfree cable experience!

New automation technology means new cable challenges. With almost 40 years in the cable business, we have designed our products to provide an uninterrupted flow of power and data to todayâ&#x20AC;&#x2122;s automated manufacturing systems, regardless of working conditions. Our cable engineering expertise allows us to meet and exceed customer expectations as industry technology becomes more advanced. We continuously provide new cable solutions for our customers, which allows them to maintain their position at the forefront of the market. HELUKABEL cables have long service lives, and have been tested to multi-million flexing cycles. This makes the automated manufacturing process leaner by reducing downtime and increasing productivity. We also develop and manufacture complete cabling protection systems for robotics applications.

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

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

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LEADERSHIP IN WIND ENERGY HYDAC was founded in 1963 as a company producing hydraulic accumulators and filters. Today, we are internationally active with 9000+ employees, 30+ manufacturing locations and 500 trade and service partners throughout the globe. Our fluid engineering solutions are defined by the scope and complexity of our customers’ requirements. Our products range from individually designed components in the fields of fluid engineering, hydraulics and electronics right up to complete systems for specific functions. All components and systems are conceived and designed in-house. Experienced industrial and product specialists develop innovative products and efficient solutions for high-quality, cost-effective production. Our production facilities share one common goal; quality. We take pride in both our products and solutions.

2018

With a strong nationwide presence and over 50,000 system installations, HYDAC stands out as a leader in the Wind market. Our dedicated Wind field sales and service team is supported by a network of experienced engineers to meet any and all challenges, from new designs and solutions to upgrades and retrofits. Multiple USAbased manufacturing facilities provide our customers the flexibility to meet immediate needs and the ease to develop and implement solutions. HYDAC’s broad knowledge base and product offering includes lube, generator, and converter cooling systems, as well as HPUs and HR flex cable management systems. HYDAC offers numerous upgrades to improve filtration efficiency, increase element life, optimize heat removal, reduce energy use and improve high voltage

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

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

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management. These upgrades include in-line and off-line filtration options, complete filter replacements, system component upgrade/ replacement including heat exchanger and accumulator replacement/rebuild kits, and an exchange program for all Wind Turbines. Add-on filter assemblies, designed specifically for the Wind market, improve ISO Codes and protect heat exchangers. All designs and offerings take into consideration limited tower hatch space.

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

FEBRUARY 2018

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WINDPOWER ENGINEERING & DEVELOPMENT

2/14/18 1:21 PM

LEADERSHIP IN WIND ENERGY

2018

Mattracks, Inc., the world innovator in rubber track conversion systems, with headquarters in Karlstad, Minn. has produced over 100 models of rubber track conversion systems for ATVs, UTVs, vehicles, tractors, trailers and custom applications for the last 22 years.

Mattracks, Inc. 202 Cleveland Ave E. PO Box 214 Karlstad, MN 56732 Phone: 218-683-9800 (direct) 1-877-436-7800 (toll free US & Canada) Mattracks.com Facebook.com/Mattracks Twitter.com/Mattracks YouTube.com/Mattracks

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WINDPOWER ENGINEERING & DEVELOPMENT

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MATTRACKS CONVERSION SYSTEMS are the most technologically advanced, independent, rubber track systems used for recreation, work, commercial, military and agricultural applications. Mattracks can equip most any four-wheel drive vehicle from a small ATV, SUV or trucks up to 80,000 lbs. GVW. Mattracks is the solution to being mobile in the worst conditions. The rubber track conversion system transforms most any 4WD vehicle into an all-terrain vehicle, capable of traveling over soft terrain like mud, snow, sand, swamps and bog, with minimal impact on the environment. Mattracks has been providing the tracks for what customers need. If mobility is an issue, Mattracks is the answer. “Our trusted, innovative products can provide a new approach to getting where you need to go. We are committed to our customers’ needs and making sure to get them the right track to access their worksites,” said Mattracks CEO, Mr. Glen Brazier. Mattracks equipped vehicles are at work in all 7 continents and over 100 countries, exploring for oil and gas, installing and servicing telecommunication systems, construction, mining, drilling, logging, forestry, surveying, military, power transmission lines and pipeline construction. www.windpowerengineering.com

FEBRUARY 2018

2/14/18 1:22 PM

LEADERSHIP IN WIND ENERGY In 1942 the “North Bar Tool Company” (as Norbar was then known), became the first company in Britain to commercially manufacture a torque wrench. The initial demand was driven by the need for the gasket-less cylinder head of the Rolls Royce Merlin engine to be accurately tightened. Bill Brodey and his partner Ernest Thornitt obtained a license from Britain’s war-time Government to begin

2018

Norbar EvoTorque2 – A radical change comes to electric torque multipliers! Norbar Torque Tools introduces EvoTorque2, where we have brought together durability, low cost-of-ownership, Norbar quality and accuracy, and all the features you need, and rolled them into one, price-competitive tool. EvoTorque2 is easy to program, presents a small and lightweight package, stores thousands of readings, and can be serviced in the field. There are too many features and advantages to list in a few short lines of text, so the best way to measure the advantages and value of EvoTorque2 is to try it yourself. Stack us up against the competition – you’re going to be amazed!

manufacture of torque wrenches and Norbar was born. Since then, Norbar has continued to invest in the very latest design, manufacturing and quality control technology to achieve the highest level of innovation and precision in the field of torque control equipment.

Norbar Calibration Fixtures – Accuracy and durability brought to the field! Norbar Torque Tools knows how critical it is to have and prove the calibration and accuracy of your torque tools. We have been providing calibration equipment to the Wind industry around the world. We can package and configure equipment to suit all your needs, and our modular design allows your equipment to grow and change as your needs grow and change. Whether you need fixtures to calibrate hydraulic wrenches, or joint-simulators to calibrate your non-impacting torque tools, or just a way to calibrate or verify torque wrenches, Norbar has the equipment and expertise to cover all your needs!

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

Norbar HandTorque Multipliers – Big range and a small size, with a Certificate of Calibration! Norbar Torque Tools Compact Series Torque Multipliers are designed to deliver high torque ranges, in user-friendly gear ratios, packaged in a small and lightweight package. Because size and weight considerations are critical to your business, Norbar has developed a line of torque multipliers that make life in the tower easier by providing a powerful 27:1 gear ratio – an operator input of 100 lb-ft generates 2700 lb-ft of torqueing power! When it comes to real convenience, Norbar has designed the Compact Series Torque Multipliers to accept the same torque reactions as you will use on your EvoTorque2 tool, saving you even more time and money down the road.

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

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

FEBRUARY 2018

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WINDPOWER ENGINEERING & DEVELOPMENT

2/14/18 1:24 PM

LEADERSHIP IN WIND ENERGY

2018

Advanced Bolting Technology for Wind

More than 20 years of gearbox design and engineering. RAD Torque Systems is a leading Canadian manufacturer of pneumatic, battery powered and electronic pistol grip torque wrenches. We’ve pioneered and patented the first programmable digital torque technology enabling effortless data collection and highly precise Bluetooth calibration. RAD is best known for its innovation and high quality tools. RAD Torque Systems is owned and operated by New World Technologies Inc., a company that continues to invest in and employ the latest technology to achieve the highest kevel of innovation, quality and performance.

RAD Torque is Reliable At RAD Torque Systems we understand that heavy-duty industries like the wind industry need a powerful tool they can trust won’t break down. That’s why we’ve dedicated more than 20 years to designing torque wrenches that have been proven to be reliable job after job.

RAD Torque is Compact RAD specializes in gearbox design, which means we’ve developed very compact gearboxes in comparison to our competitors. This allows for our tools to fit into hard-toreach spots. From a safety aspect, RAD tools have one of the best power-to-weight ratios on the market, which makes them more ergonomic and less “bulky” than other torque wrenches.

RAD Torque Systems 30580 Progressive Way Abbotsford, British Columbia V2T 6Z2 Canada

http://radtorque.com

RAD Torque is Flexible Have an awkward spot you need to bolt? No problem! The RAD team of engineers have the flexibility to custom design any tool to suit any application. Plus, we have a fast turnaround time compared to other companies because we have nearly a dozen engineers on staff and every tool is machined and manufactured in-house.

The System of Choice for Wind Industry: E-RAD BLU

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The E-RAD BLU precision torque wrench tools are designed to provide a high degree of accuracy. Using a patented gearbox design and the precision of an electric AC Servo motor, these tools deliver smooth continuous torque. Best of all, it’s the most affordable system on the market.

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

WINDPOWER ENGINEERING & DEVELOPMENT

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www.windpowerengineering.com

FEBRUARY 2018

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2018

LEADERSHIP IN WIND ENERGY Rotor Clip is a global leader in the manufacture of tapered, constant section and spiral retaining rings meeting Inch, DIN, ANSI Metric and JIS standards. This includes the manual and automatic tools needed to install/remove every ring we sell. Rotor Clip also manufactures wave spring rings as well as self-compensating hose clamps, all produced in a lean environment dedicated to eliminating waste and ensuring quality through ISO/TS 16949, ISO 9001 & ISO 14001 registration, and AS9100C certification.

It’s all about Service

We focus on producing quality products delivered on time to your facilities around the world. We service you after the sale is made by providing technical advice on how to handle, inspect and install our products and help in selecting the best materials, finishes and packaging for your application.

It’s all about Choice

Rotor Clip manufactures tapered, constant section and spiral retaining rings. One ring isn’t better than the other. Rather, it depends on your application. We help you select the right retaining ring for your requirements, ensuring that you are getting the most effective ring at the best price

It’s all about Quality

Rotor Clip is registered to TS16949, but that isn’t why our customers buy from us. They know we are continuously improving our processes to reduce costs and pass savings on to them. Ours is a culture of analyzing data, uncovering problems and solving them through coordinated actions. The result: our customers can depend on quality, reliable products competitively priced. It’s all about servicing our customers. See how Rotor Clip can make a difference in the retaining rings, wave springs and hose clamps you buy. For more information or FREE samples, visit

www.rotorclip.com.

It’s all about Innovation

Our experience producing our product spans 55 years. During that time we have improved on every aspect of producing retaining rings. From rings on wire to shrink wrapping and innovative wave spring designs we have set the bar high in our attempt to meet customer expectations.

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FEBRUARY 2018

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WINDPOWER ENGINEERING & DEVELOPMENT

2/14/18 1:26 PM

LEADERSHIP IN WIND ENERGY

2018

Our Vision: Be the best... Deliver excellence. Founded in 1971, Wanzek grew to be a trusted source for Heavy/Civil, and concrete projects and services. We quickly expanded into bridge and dam construction, mass piling and foundations. Today, the company continues to build better relationships and better projects through our experience, professionalism and client-focused approach.

We take pride in providing the highest quality heavy industrial construction and specialty services to a wide cross section of industries, lead by an experienced and dedicated team: • • • • •

Power Renewable Energy & Services Oil & Gas Infrastructure Agriculture

To support these markets, we align our approach to industry best practices, including the Construction Industry Institute (CII) and Construction Financial Management Association (CFMA) and have a team of construction professionals, from leadership to crew members who ensure project details fit specific client needs.

Wanzek Construction Headquarters

With a portfolio of nearly 10 gigawatts of wind energy projects, Wanzek’s wind team has the experience and knowledge to install a variety of turbine types and sizes. Our teams construct projects with operations and maintenance and Renewable Services as a forethought, proactively identifying challenges that could occur during installation and developing plans to mitigate long-term issues.

Building Renewable Energy We focus on leveraging our skilled crews to build, expand and maintain renewable energy facilities all over the nation. Our role in the sector includes long-term maintenance services, shutdowns and capital expansion projects. We work closely with owners to balance organic growth with customer demands to meet market needs. Through our involvement with American Wind Energy Association (AWEA), we stay apprised of industry-specific details that positively affect our project approach.

2028 2nd Ave NW West Fargo, ND 58078 Amarillo Service Center: 833.873.2470 www.wanzek.com

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FEBRUARY 2018

2/14/18 1:30 PM

INDEX

LEADERSHIP IN WIND ENERGY Abaris Training.................................................................... 17 AMSOIL ..............................................................................BC Aurora Bearing Company................................................25 Aztec Bolting.......................................... cover/corner, IFC Bronto Skylift........................................................................ 3 Dexmet Corporation..........................................................9 HARTING, Inc. of North America...................................34 HELUKABEL USA.................................................................11 HYDAC International........................................................ 13 MATTRACKS.......................................................................25 Norbar Torque Tools........................................................... 5 RAD Torque........................................................................ 21 Wanzek Construction, Inc.............................................IBC

Abaris Training....................................................................49 AMSOIL................................................................................50 Aurora Bearing Company................................................ 51 Aztec Bolting......................................................................52 Bronto Skylift......................................................................53 Dexmet Corporation........................................................54 HARTING.............................................................................55 HELUKABEL USA................................................................56 HYDAC International........................................................ 57 Mattracks.............................................................................58 Norbar Torque Tools.........................................................59 RAD Torque....................................................................... 60 Rotor Clip............................................................................ 61 Wanzek................................................................................62

SALES

LEADERSHIP TEAM

Jim Powers 312.925.7793 jpowers@wtwhmedia.com @jpowers_media

Neel Gleason 312.882.9867 ngleason@wtwhmedia.com @wtwh_ngleason

Michelle Flando 440.381.9110 mflando@wtwhmedia.com @mflando

Tom Lazar 408.701.7944 wtlazar@wtwhmedia.com @wtwh_Tom

Jessica East 330.319.1253 jeast@wtwhmedia.com @wtwh_MsMedia

Garrett Cona 213.219.5663 gcona@wtwhmedia.com @wtwh_gcona

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

EVP Marshall Matheson 805.895.3609 mmatheson@wtwhmedia.com @mmatheson

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

Associate Publisher Courtney Seel cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel

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FEBRUARY 2018

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WINDPOWER ENGINEERING & DEVELOPMENT â&#x20AC;&#x192;

2/14/18 1:42 PM

Hear no turbine, see no turbine BEAUTY IS IN THE EYE OF THE BEHOLDER. While some wind-energy advocates fawn over the sight of a few turbines on the horizon, others may prefer neither to see nor hear the production of clean energy. Canadian turbine manufacturer, Wind-Do, believes community wind turbines can and should work in silence without detracting from their surroundings. The company says its Midscale Networked Wind Turbine creates little noise or visual distraction, despite a unique design. At 20-kW and 20-m tall, a standard Midscale is about the size of an average tree, but can scale in height to meet site requirements. Each turbine has six to 12 horizontal “struts” that support four Darrieus blades. The Darrieus or vertical-axis design means the turbine need not be pointed into the wind. The struts and blades are typically painted to suit a turbine’s surroundings, such as a light blue or green to match the sky or nearby trees. This means that at a distance of 500m, Wind-Do’s Midscale turbine is tough to spot. At 300m, the tower is noticeable but its blades blend into the background setting. While it is visibly spinning at 200m, you won’t hear it working. Quiet operation of wind turbines is critical to the success of many onshore wind projects, particularly those near cities and small

communities. In fact, big wind companies such as Siemens have dedicated extensive R&D and launched aerodynamic, serrated blade attachments to reduce the noise of its wind turbines. WindDo’s Midscale requires no blade add-ons. The vertical-axis “strut” design works in conjunction with a computerized speed control feature, which lets the blades optimize power production based on local wind speeds and direction. They can also generate power in lower than average wind regions, and a full wind farm can produce 100 kW up to 3 MW. What’s more is the Midscale is capable of storing excess power on windy days. Wind-Do offers customers the option of a hybrid, heat-storage system that can store wind energy when there’s more than the transmission grid can handle. Power is stored in onsite GSG modules, which convert energy into high-temperature heat that can be used to power industrial processes, heat greenhouses, or provide low-cost electricity to nearby buildings. Wind-Do says its mission is to provide customers with low-cost, wind-generated electricity without subsidies, noise, or visual disturbances. The company suggests a few comparisons between conventional wind turbines and an entire Midscale wind farm, also available on its website. W

How a Midscale wind farm compares to a conventional turbine

A conventional, mid-scale wind turbine

A Midscale Networked wind farm

Installation costs per MW $2 million to $3 million

$1 million to $3 million

Operation costs per MW

$200,000 to $250,000

50,000 to $200,000

Electricity cost

3.5 to 8 ¢/kWh

1.5 to 3.5 ¢/kWh

Efficiency for the grid

25 to 40%

35 to 80%

All dollars Canadian Wind-Do’s modular Midscale Networked Wind Turbine is available in several sizes to match the site requirements and wind profile of many different locations. It is designed to be quiet, attractive, and affordable to farmers, small businesses, and communities.

6 4 WINDPOWER ENGINEERING & DEVELOPMENT

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FEBRUARY 2018

2/14/18 1:31 PM

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2/13/18 2:27 PM

AMSOIL PTN 320

IN WIND GEARBOX OIL

RELIABILITY & PERFORMANCE

Stick with a proven product and take out the guessing game. Used by more OEMâ&#x20AC;&#x2122;s and Owner/Operators in North America, and around the world. With over 9 years of proven results and an industry-leading warranty, make AMSOIL the first and last choice when it comes to your lubrication solutions.

FOLLOW THE LEADER AT

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OR BY CONTACTING US AT

WINDSALESGROUP@AMSOIL.COM

NO ADDITIONAL TOP TREATS NEEDED 2/13/18 2:20 PM