Windpower Engineering & Development OCTOBER 2016

A FEW GIFT IDEAS FOR THAT SPECIAL WIND TECH /

WindWatch page 6 October 2016

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SHIPPING OUT TO WORK OFFSHORE Turbine two dead ahead How to manage a wind farm from an office or on the road

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HERE’S WHAT I THINK

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

U.S. offshore wind industry officially launched. Now what?

W

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Editorial 9-16 Vs2.indd 1

hat’s the difference between a U.S. wind farm and one in Europe? This may sound like the lead-in to a joke, but the question is serious and comes from a wind-industry veteran at a recent AWEA event. The answer: Everything! In Europe, a land-based wind farm often has less than 10 turbines. In the U.S., dozens. Winds on the Great Plains are stronger than those that sweep Europe. Offshore Europe has hundreds of turbines. In the U.S., maybe six: Block Island and one floater by the University of R.I. Shallow water in the North Sea makes monopiles the preferred foundation. Deepwater Wind south of Block Island used a four-legged design.

The Block Island development, however, is noteworthy because it officially launches the U.S. offshore wind industry. That small, 30-MW wind farm holds five 6-MW turbines built by GE’s division in France, formerly Alstom. Many more offshore wind farms, mostly along the east coast, are in the planning stages. Thus, U.S. planners are thinking big, which is good. And a GE spokesman at the recent AWEA Windpower conference suggested the market could develop faster than anyone imagines.

Now let me ask: What is the difference between building a wind farm on shore and off?

Answer: As with European and U.S. wind farms – everything! By now, building an onshore wind farm is a piece of cake. Most of the engineering is well known and there have been a lot of lessons learned. Offshore is a whole new ballgame.

Land-based wind farms cost less than offshore because…they’re on land. No special ships, barges, or certifications are necessary.

The work is well defined. Not so with offshore where everything is new. One good thing about

offshore, of course, is that turbines can be far enough from the coast to be unobtrusive, but close to load centers so transmission cables needn’t run for hundreds of miles.

As JDR Cable Systems’ John Price points out in an accompanying article, offshore installation vessels will have to come from Europe until U.S. firms assemble a fleet. Technicians will need training, some initially from Europe. But the offshore oil industry can provide some of this, such as Boseit (Basic offshore safety induction and emergency training) certifications. And there are a lot of certifications involved. One installation barge, for instance, could call for 20 or more different certifications, although it is likely that a crew member would be certified for several different jobs. And the Jones Act, always a topic of conversation, was once considered a hurdle. That law, from the 1930s, forbids foreign-flagged vessels from transporting goods between U.S. ports. However, the Act is circumnavigated by simply sending European vessels directly to U.S. offshore wind sites.

Planners for Deepwater Wind did exactly that.

Their turbines were built in France, loaded onto a four-legged jack-up barge, and sailed directly to the site near Rhode Island. John Price suggests that if vessels from Europe must stay longer in U.S. waters, they will probably be reflagged as U.S. ships to get around the Jones Act. So what’s next in offshore development?

Legislators in Massachusetts decreed that the state’s utilities must purchase 1,600 MW of offshore power. And next year, construction could begin on the Ice Breaker wind project in Lake Erie, raising all the uncertainty questions anew. Stay tuned. The offshore wind industry is an interesting experiment. W

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YOUNT

PRIEBE

MIZAEL

MCCAA

DAVIDSON

CLIVE

CLARK

CO NT R I BUTORS

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DAVID CLARK, CEO of CMS Wind, has experience monitoring and analyzing wind turbine from 200 kW to megawatt-class units, and from several OEMs. In addition, he as 11 years of condition monitoring experience in traditional markets such as nuclear power, steel mills, and mining.

David frequently writes for Windpower Engineering & Development.

PETER CLIVE, based at SgurrEnergy’s head office in Glasgow, has been associated with the wind power industry since taking his Ph.D. in physics in 2002. He pioneered the adoption of many remote sensing techniques for wind industry applications, testing Sodars in 2004 and using Lidar since 2007. Since 2008 he has had a central role in development of the Galion Lidar, the pioneering second generation wind Lidar system. This allows surveying wind fields with previously unavailable detail and precision, revealing flow characteristics and structures that significantly impact on the productivity and longevity of wind power assets.

FRANCESCA DAVIDSON is a renewable energy and strategic communications professional with broad industry experience that spans eight years in the clean-energy sector. She received her degree from the University of Washington, graduating cum laude in honors English with additional focuses on architecture, natural sciences, global cultures, and macro-economics.

DR. JIM MCCAA has over a decade of experience in the renewable energy space. He has played a key role in several major integration research efforts around the globe, and personally conducted over 100 wind and solar resource assessments.

Dr. McCaa is a regular author and speaker at industry and educational conferences.

He holds a Ph.D. in Atmospheric Sciences from the University of Washington and a B.A. in Mathematics and Physics from Kalamazoo College.

CAROLINE MIZAEL works and writes for Sweden-based Breeze. The company develops software for the remote monitoring and management of wind-farm assets.

MARYRUTH BELSEY PRIEBE has a special interest in clean tech, green buildings, and renewable energy. In recent years, Priebe has worked as the senior editor of The Green Economy magazine, is a regular blogger for several green business ventures, and has contributed to the editorial content of eco-living websites (including www. ecolife.com and www.greenyour.com). Visit Priebe’s site at www.jadecreative.com RANDY YOUNT, Vice President of Operations at FilterMag International, has responsibility for research, product development, manufacturing, and technical consulting services. For the past five years, he has worked with and developed magnetic filtration solutions for customers in wind energy, oil and gas, trucking, and multiple manufacturing sectors. A former U.S. Army officer, Yount is a Certified Maintenance and Reliability Professional (CMRP), Certified Lubrication Specialist (CLS), Certified Reliability Leader (CRL), and is certified as a Level I and II Machine Lubricate Analyst (MLA I&II). He earned a Master of International Management degree from the Thunderbird School of Global Management and an MBA from the W.P. Carey School of Business at Arizona State University. He also holds undergraduate degrees in Military Science and Architectural Technology.

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OCTOBER 2016

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WINDPOWER ENGINEERING & DEVELOPMENT

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OCTOBER 2016 • vol 8 no 5

CONTENTS

D E PA R T M E N T S 01

Editorial: Block Island wind farm nears

28

Condition monitoring: Planning a profitable strategy for

06

Windwatch: Looking for cracks in

32

Safety: Raising the safety bar offshore

34

Filters: Magnetic oil filtration helps gearboxes work longer

commissioning. Now what?

underwater welds, Revenue streams from power storage, Gift guide for wind techs

20

Policy: Integration study paves way for more wind power in Canada

36

22

Bolting: Two-coat corrosion protection does the work of three

38

Turbines of the Month: The 8-MW club

24

Transmission: Making of the modern

62

Ad Index

64

Downwind: Behold the shroud of turbine

offshore substation

40 UK cable expert offers experience and suggestions for U.S. offshore wind projects

The U.S. offshore wind industry presents great opportunity and more than a few challenges, such as where will the trained crews come from and what to do with the Jones Act.

ON THE COVER

A transfer vessel from Atlantic Wind Transfers takes wind techs to a Block Island turbine.

Photo: Albert Ploeg

WINDPOWER ENGINEERING & DEVELOPMENT

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Software: How to manage a wind farm from an office or

on the road

F E AT U R E S

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offshore O&M

xx

Navigating to work offshore on specialty transfer vessels A successful offshore project takes careful planning, due diligence, and a skilled team of engineers and technicians. In addition, safe and efficient crew transfer to and from an offshore wind site takes careful planning given the variable conditions at sea.

46 Remote sensing offshore: What North America can learn from European experience

When designing offshore measurement campaigns, the flexibility of remote sensing devices means the question on the mind of investors and developers should be “what do I want to measure?” rather than “what can I measure?”

www.windpowerengineering.com

OCTOBER 2016

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A Radical Change in Bolting is Coming Your Way Norbar Torque Tools Introduces a New Generation in AC Powered Torque Multipliers

EvoTorque 2 ®

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Operating ranges from 100 lb-ft to 4500 lb-ft Measures in Torque, Torque and Angle, and Torque Audit mode for pre-tightened bolts Versions for 110 VAC or 230 VAC Lightweight at only 23lbs.

Factory calibrated and certified to ± 3% accuracy regardless of fluctuating voltages USB and Bluetooth® 4.0 data transfer (also called Bluetooth® Smart) 3,000 readings in internal memory, time and date stamped Includes PC software ‘EvoLog’ for data management and tool configuration From factory to field; for fabrication, installation, verification and maintenance

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Let’s Talk Torque Norbar_8-16_Vs1.indd 27

440.953.1175 PH 440.953.9336 FX inquiry@norbar.us norbar.com

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OCTOBER 2016

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AA FEW FEW GIFT GIFT IDEAS IDEAS FOR FOR THAT THAT SPECIAL SPECIAL WIND WIND TECH TECH IN IN THE THE FAMILY FAMILY HAPPY HOLIDAYS, Merry Christmas, and Happy Hanukkah to all you wonderful readers. It's getting close to that time of year so we thought we might suggest a few gifts that you would certainly not find at Macy’s. Wind technicians have special needs and sometimes that pinch-penny company they work for will not spring for the latest cool tool. The staff

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here at Windpower Engineering & Development has been tracking news of the curious, unusual, and possibly useful things that frequently cross our desks. So based on that and timing, we present the first annual Wind Technicians Gift Guide to spark ideas for that person brave enough to climb 80 meters to care for an ailing turbine in the middle of winter.

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W I N D W A T C H

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1. HAND WARMERS

Keep hands warm (and safe) this winter with the SmartShell BKCR4599. This heavy-duty safety glove from Brass Knuckles offers three layers of protection on the palm and fingers. A category jumper, it is designed to provide slip, impact, abrasion, light oil, and moisture resistance. The BKCR4599 is a breathable yet durable mechanic’s glove that delivers ANSI level 4 cut protection. Even the back of the hand is made with sonically welded thermoplastic rubber padding to counter workplace scrapes and strikes.

Expect comfort in a hardy construction that combines fit, form, and function.

Brass Knuckles brassknuckleprotection.com

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2. HOLIDAY TETHER

Tinsel is made to toss and drop.

Tools are not. Thanks to Gear Keeper’s new RT3-5605 heavytool retractable tether, tools stay close to the user’s body for safer climbing and work in cramped quarters. The tether is engineered for accessibility with a balanced recoil and retraction force. It offers a generous reach that extends more than 55 in. and employs a low, 7-oz force to prevent arm strain. The RT35605 also features a thumbcontrolled gear lock to secure a tool regardless of extension length and a lanyard loop strap that can adapt to almost any tool. The strong, impactabsorbing Nylon webbing requires no additional shockabsorbing lanyard end.

Gear Keeper | gearkeeper.com

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3. PINCH PROTECTOR

Cold weather is not the only hazard wind tech’s face on the job. Cuts and bruises to the hands are common, so consider Hydratight’s new Safe T accessory for its line of RSL torque wrenches. It minimizes pinch points — and it makes a great stocking stuffer. Typically, one technician operates the torque wrench and another controls the hydraulic pump.

The Safe T lets a single person simultaneously operate the wrench and its hydraulic pump, eliminating the chance of miscommunication in a noisy work environment. The tool houses a control panel with two main operational buttons, which must be pressed at the same time to ensure safe operation. If the operator releases his hands, the torque wrench and hydraulic pump immediately cease to operate.

Hydratight | hydratight.com

www.windpowerengineering.com

4. STRESS-FREE GIVING

A heavy, uncomfortable safety harness is bound to bring out the Scrooge in anyone. Help lighten the load with the DBI-SALA ExoFit STRATA, the first full-body safety harness designed and tested with data-driven, third-party research.

This full-body device features the LIFTech load-distribution system that takes weight off a user’s shoulders and redistributes it down the torso.

A vertical torso adjuster stores excess webbing and keeps it safely out of the way. Plus, an EZ-Link quick adapter simplifies and reduces connection and disconnection times by up to 80% compared to competitive harnesses. ExoFit promises less strain and worker fatigue and that means a happier, more productive technician.

ExoFit STRATA http://exofitstrata.com

OCTOBER 2016

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W I N D W A T C H

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5. SMART GIFTING

It has been said that the best gift is the gift of education. For the technician interested in brushing up on his or her skills, Abaris Training offers three to five-day manufacturing, engineering, and repair courses intended to provide a semester’s worth of insight in a week’s time. Each course mixes classroom theory with practical experience and industry best practices. For example, Abaris’ wind repair course teaches hands-on structural repairs of turbine blades using advanced materials and methods for producing sound results. Students walk away with a toolkit of skills they can immediately apply in the workforce.

Abaris Training | abaris.com

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6. FIELD READY

Don’t let your tech take a conventional portable computer up tower. They are too delicate.

Give them a GammaTech Durabook R11 rugged tablet PC. It sports features an 11.6-in. TFT LCD capacitive touch display and a 5th gen Intel Broadwell Core processor. The computer is built for workers in the utility and public safety markets. It is the lightest 11.6 in. rugged tablet PC in its class at only 2.73 pounds, while staying tough with Military Standard 810G and IP65 certifications for drop, shock, dust, and water resistance. Its wide operating temperature range of -10° to ~55°C means it can stand up to the daily wear and tear encountered in field settings.

GammaTech | gammatechusa.com

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7. FROSTBITE FREE

Let is snow, let it snow. Workers in cold weather can now enjoy comfort and conspicuity in the latest thermal gear. Ergodyne has taken some of their top-selling thermal gear and enhanced it to provide more visibility on the job. With these Hi-Vis products, wearers can expect the same style and comfort from Ergodyne’s N-Ferno products with the additional benefit of highvisibility through Hi-Vis lime fabrics and reflective accents. Besides a new color variety, the company has also added length to their balaclava and a completely new reversible hat. You can pair it with Ergondyne’s water and wind-proof heated jacket (it’s equipped with three heat settings: low, medium, and high) that features removable sleeves for greater flexibility.

Ergondyne | ergodyne.com

WINDPOWER ENGINEERING & DEVELOPMENT

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8.GIVE ’EM GRIP

All-weather grip protection means the wind technician in your life won’t lose another small part or tool because of oily or wet gloves. Hi-Line Utility’s Power Gripz protectors and work gloves offer adjustable Velcro straps and proprietary grip pads that stretch from palm to fingertips to ensure dexterity. The gloves come in Kevlar or Thinsulate to guard against the elements, and include arc and heat-penetration protection. Available in Class 1 to 4, Power Gripz exceed ASTM F-696 standards.

Hi-Line Utility Supply Co. hilineco.com

www.windpowerengineering.com

9. JOY OF BOLTING

’Tis the season for better bolting. Hytorc’s new ICE series is currently the only industrial bolting system with a built-in auto-release to prevent the inconvenient lockup of tools.

It also has a unique, patented hose connector for improved flexibility on tight jobs to make work a little easier on technicians. ICE tools feature a co-axial drive able to release pressure after bolting for quick movement from nut to nut, thereby improving operator efficiency and safety.

A breakout-assist mechanism prevents the ratchet from moving backward, which makes for a quick and more powerful breakout — even if the nuts and bolts are damaged or corroded.

HYTORC | hytorc.com

OCTOBER 2016

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W I N D W A T C H

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10. TOOLBOX DRONE Eventually, a drone in a toolbox will be as common as a wrench. It’s the trend. The DJI Phantom 4 quadcopter kit, one drone example, is intended for photographers and comes with two spare batteries.

The aircraft includes a gimbal-stabilized 4K, 12-Mpixel camera. A visual sensor allows for obstacle avoidance and lets it also avoid obstacles when returning home. The streamlined shell allows a top speed of 44.7 mph while the controller keeps in touch up to 3.1 miles. A battery provides up to 28 minutes of flying time.

B&H bhphotovideo.com

OCTOBER 2016

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11. WHAT'S HOT & NOT

The FLIR C2 is said to be the world's first full-featured, pocket-sized thermal camera intended for a wide range of electrical and mechanical applications. Wind techs can keep it on them so they’re ready anytime to find and show hidden heat patterns that point out hotspots, energy waste, structural defects, and other issues. One feature adds key details from the onboard visible light camera to the entire infrared image in real time. The result is an all-in-one, undiluted thermal picture with visible light features that allows recognition of the problematic heat pattern. It’s also a reliable way to verify the success of completed repairs.

FLIR | flir.com

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W I N D W A T C H

Underwater sensor can find cracks in turbine tower welds Researchers fitted a test pipe with two sensor-ring demonstrators (the grey bands) for test in the Baltic Sea.

ENGINEERS AT THE FRAUNHOFER RESEARCH INSTITUTE FOR CERAMIC TECHNOLOGIES AND SYSTEMS have devised a way to inspect underwater welds on offshore turbine towers without divers. “The heart of the system is a sensor ring which is placed around the weld for the entire service life of the wind turbine,” says Andreas Schnabel, project manager. Tests have shown that the ring can pinpoint a weld crack and provide its dimensions.

Offshore wind turbines take a lot of punishment, especially the foundations.

Divers periodically descend to inspect the vulnerable welded seams of anchor points.

They must determine if welds are in good order, or whether any cracks or defects have appeared that pose safety risks.

Cracks in offshore wind-turbine foundations can be found using the movable sensor ring.

Fraunhofer IKTS

12

WINDPOWER ENGINEERING & DEVELOPMENT

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For a conventional underwater inspection, divers first blast the weld with a high-pressure cleaning tool to remove growths such as algae and crustaceans.

Then they apply an electromagnetic field to the weld and cover it with iron filings. If a crack is present, the field will be forced outwards, and the iron filings will accumulate there. This is difficult for the divers who must carry down a lot of equipment, while fighting strong currents and allowing themselves enough time to adjust to changing water pressures. Inspecting one wind turbine tower takes about a day.

Schnabel says the sensor ring is composed of numerous sensor elements with fivetoseven-centimetersspacebetweeneach.

To take measurements, a diver first connects a battery-powered handheld device to the interface port on the ring and then begins the analysis with the press of a button.

Each sensor elements takes a turn in functioning as an actuator. A sensor hits the weld with ultrasound waves, which then permeate the entire structure. If there is a crack somewhere, waves will reflect back from the damaged area, while passing unobstructed through the intact areas. The other sensors detect these signals, and in this way can home in on damaged areas. The next sensor then takes its turn as an actuator: it

www.windpowerengineering.com

transfers the data via cable connection to a handheld reader and then to a PC. As a result, researchers receive data similar to that of a CT scanner at a hospital. The end user, or in this case the inspector of the offshore wind farm, receives an image of the weld with damaged areas color-coded according to severity.

Practical trials in the Baltic Sea have been successfully concluded.

The system offers a number of benefits. It is far more precise than other methods used to date, because it can also analyze the dimensions and depth of cracks, which until now was impossible.

Furthermore, this “inspection” sensor is faster than labor-intensive manual methods.

The job is complete in just 10 minutes.

Working together with staff from Baltic Taucher in Rostock, the researchers successfully demonstrated the viability of the process in an on-site trial at Germany’s Baltic 1 offshore wind farm. For this trial, they made a crack measuring 0.9-mm wide, 45-mm long, and 7-mm deep in a branched metal pipe, and lowered 18 m to the bottom of the Baltic Sea. The trial was a success. The system located the crack with excellent precision and determined its dimensions. Researchers are hopeful that the system will be certified and ready for robotic operation in about five years. W OCTOBER 2016

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Fresh air.

Whatever clean technologies the future brings, lubricants will continue to play a key role. For innovative industrial lubricants that extend service life and enhance performance, look to lubricants formulated with NUFLUX™ technology from Evonik.

To learn more, scan the QR code or visit evonik.com/oil-additives.

Aim high — Let it flow.

Evonik 10-16_Vs1.indd 1

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W I N D W A T C H

The best ways to minimize wind-farm opposition?

Community outreach and listening ACCORDING TO THE U.S. BUREAU OF LAND MANAGEMENT, wind energy has been the fastest growing energy technology worldwide for more than a decade.

Paired with each new wind project, however, are an array of challenges that can delay or impede a successful result. “Any large scale development has groups that form to oppose them,” says Juliet Browne, attorney with Verrill Dana LLP. “Wind, in particular, has its own energized set of opponents.

As a result, it is increasingly difficult to permit wind projects and other large scale developments.”

Browne has been practicing in the fields of energy and environmental law for more than 20 years and formerly serving on the Governor’s Wind Power Task Force in Maine. She is glad to share her experience navigating large-scale, complex permitting and development projects.

One key lesson is the importance of local outreach and support. “In the early stages, it is important to identify key opinion leaders and respected members of the community and to reach out to them with in-depth information so they can communicate with others about the project,” says

Juliet Browne

the process, the town adopted several recommendations that the developer voluntarily incorporated into its state application. The collaborative process provided the town with the information and comfort it needed. Following a vote, the town overwhelmingly voted against adopting a wind siting ordinance.

Although there were concerns at the local level, the process was a successful tool for addressing those concerns.

“Not all issues will be resolved to the satisfaction of all stakeholders,” cautions Browne. “However, by engaging with the community and identifying and working with key leaders, opposition can be minimized.”

Wind, in particular, has its own energized set of In addition to community support, it is important to opponents. As a result, it is increasingly difficult to have state and federal political permit wind projects and other large scale developments. support. “Know who the supporters and opponents are to your industry and your project.

You cannot win over every opponent, Browne. These local leaders are also a key resource to identify but you can implement measures community concerns. Having knowledgeable and respected to prevent them from derailing the local allies will help narrow the issues to focus on and will project. By addressing key concerns allow the developer to develop creative solutions that are and providing valuable information to responsive to local concerns. “For example, when looking stakeholders, you can prevent some to permit a First Wind project in Oakfield, Maine, the town from falling into the opponent camp was considering creating its own ordinance to regulate wind based on the inevitable barrage of projects. First Wind and the town engaged in a series of public opposition from vocal opponents.” meetings. The town retained legal, engineering, and sound Also take time to consult with experts paid for by the developer, and there was a substantive agencies that have oversight of the dialogue on key issues including, most significantly, sound project. This step is crucial, says Browne, which had been a contentious issue.” At the conclusion of 14

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because wind developers are increasingly running into state and federal wildlife issues. “Give them a comprehensive view of the project and data. Bat mortality and cumulative avian impacts are an increasing issue. Impacts to song birds have been raised as a concern in Maine, whereas raptor impacts have been a more significant issue in the west. Myotis bat species have declined by 90% in

will be blocked, will also potentially be concerned with the project. The transmission lines required to transport the output as well as migratory paths of potentially affected species raise additional environmental concerns for review agencies.”

Whether the development will be on land or offshore, it is important to be a good listener and to follow through on commitments.

Listen to By engaging with the community and supporters, opponents, identifying and working with key agencies and those leaders, opposition can be minimized. you are working with on the project.

“Listening closely recent years due primarily to White-Nose lets you proactively solve and minimize Syndrome. The decline has resulted in problems and identify opportunities for significant operational and permitting success. For the industry to succeed, challenges for wind projects. For example, individual projects need to succeed. curtailment, an operational protocol Continued support and trust is critical for that prevents turbines from spinning in success on your next development.” W low-wind conditions, is now required for projects in areas where bats are present.”

Maine is conservative and so recommends that turbines not operate until wind speeds exceed 6.0 m/sec each night from one-half hour before sunset to one-half hour after sunrise from April 20 to October 15. Other states have curtailment for a shorter periods and with a lower cut-in speed. “Overall, when looking to develop a new wind project consider the threat it will have on bats in the area and be prepared to take steps to appropriately mitigate those impacts,” she suggests.

When dealing with offshore wind projects, there is significant federal involvement and, depending on the project’s location, state involvement.

“Everyone from commercial fishermen whose routes will be impacted to residents whose views of the waterfront

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Statoil looking for revenue streams from offshore storage project STATOIL’S BATTERY-STORAGE PILOT at the Hywind offshore wind farm presents value beyond the immediate business benefits for the farm. This is the case as the company considers the most profitable combination of storage applications in larger offshore wind farms and other renewables, according to Sebastian Bringsværd, Statoil’s project manager for Batwind (battery plus wind), the power-storage project that compliments the wind farm.

In March, Statoil announced it will install a pilot 1-MWh lithium-ion battery system to store energy from the 30-MW Hywind Park, the world’s first floating wind farm. The company expects that battery storage could improve the efficiency and lower the levelized costs for offshore wind, raising the value of wind.

The Batwind project will capture wind overshoots, reduce balancing costs, and increase the power’s market value.

Energy storage brings additional capital expenditure so projects must also focus on accessing new revenue channels. To that end, Everoze has developed a storage revenue wheel that maps out revenue opportunities, of which there are more than 14 in the U.K.

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Capturing value

Batteries often provide backup power in wind turbines, so that critical operation and safety systems keep functioning in the event of a grid-connection loss.

“The opportunity in wind-generated power storage is whether it can be deployed to access new revenue opportunities,” said Nick Baldock, partner at specialist renewable energy consultancy Everoze.

He added that though the offshore wind industry is driven by cost-reduction targets, cost is just half of the equation. It is normally more helpful to express the economic benefit of storage in terms of new revenue streams, rather than simply reduced costs.

Initial opportunities for energy storage are to capture excess generation, sell at peak price periods, optimize ancillary services, and potentially reduce transmission-cable costs. The lessons learned from the first large-scale offshore wind-storage project will help determine the exact value of storage systems.

Statoil is looking to deploy a battery system with high power rating, capable of quickly charging and discharging to fit specific wind patterns and targeted applications, as well as help maximize the value of the wind farm, said Bringsværd. The company is primarily testing applications and revenue streams, not technology, he said, adding that Statoil plans to remain technology agnostic regarding energy storage.

Statoil expects to choose a technology supplier for the project in the next three to four months and launch the battery system within the next 12 to 18 months.

Pending regulatory approvals, the company plans to combine the battery and converter into the wind farm rather than treat it as a stand-alone project.

Furthermore, placing the battery behind the meter will let the company tap into a wider range of applications and business cases more critical to its core business – such as increasing energy production and revenues from projects – rather than limiting itself to only providing grid network benefits in front of the meter.

The real business value lies in the different applications and ability to stack, combine, or optimize them as necessary, said Bringsværd.

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OCTOBER 2016

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W I N D W A T C H

Statoil says it will install a pilot 1-MWh lithium-ion battery system to store energy from the 30-MW Hywind Park, the world’s first floating wind farm off the coast of Peterhead in Aberdeenshire, Scotland.

overplanting, though its potential benefits could be significant with commercial-scale deployment.

Everoze’s modeling shows that for a 1.2-GW offshore wind farm with a 1-GW grid connection, overplanting could amount to a revenue uplift of up to 4%.

From a grid perspective, this can help make offshore wind projects work a little more like a baseload power plant.

However, according to Baldock, the capex investment required to deliver this overplanting application is currently prohibitively high, though it could change in the future as technology and system costs decrease and companies find an optimal revenue stack. For offshore wind, he said, the bar will always be higher than that for an onshore wind farm because of increased offshore capital and operational costs.

Self-balancing Overplanting

Statoil will also test the use of storage to capture spilled energy from “overplanted” offshore wind farms. That is, where the wind farm’s rated capacity exceeds the grid connection capacity.

Statoil will also use storage to help the wind farm reduce balancing costs by regulating its own power supply and avoiding negative pricing. This could also let the company bid in auctions based on a more reliable and predictable energy delivery.

The opportunity in wind-generated power storage is whether it can be deployed to access new revenue opportunities.

The ability to store excess electricity and sell it when capacity is free could potentially reduce the levelized cost of offshore wind and boost revenue from an increase in the power exported.

Bringsværd added that Statoil expects small initial revenue gains from the pilot's

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Bringsværd added that Statoil could also use storage to reduce imbalance penalties it is charged when it sells intermittent power to traders.

The company currently pays about 15% in penalties, which implies a potential revenue opportunity for storage. W

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Wind work around North America The U.S. has reached a new milestone with 75 GW of installed wind-power capacity, triple that of 2008. According to the American Wind Energy Association, these turbines produce as much electricity as 17 typical nuclear plants or 65 coal plants. What’s more, recent polls suggest Americans’ support for wind power is on the rise, in tandem with the growth of the industry. Results show 70% of registered voters nationally have a favorable impression of wind energy, based on a new mixed-question omnibus poll that was conducted for AWEA of over 1,000 respondents. Further results suggest that the more Americans get to know wind power, the more they like it.

W I N D W A T C H

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Construction of the 147-MW Grant Plains Wind facility located in Grant County, Oklahoma is underway and expected to be operational before year’s end. Siemens has filled an order from site developer Apex Clean Energy to deliver and service 64, SWT-2.3-108 turbines.

They have a 108-m rotor diameter and an 80-m hub height. The nacelles and hubs for the turbines were assembled at Siemens’ facility in, Kansas, and the blades were manufactured at the company’s blade facility in Iowa.

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Vestas gets contract for Iowa’s Wind XI project

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Vestas received the official turbine order from MidAmerican Energy Company for its massive 2,000-MW Wind XI project in Iowa.

The contract is for a total of 214 MW of Vestas’ V110-2.0 MW turbine components, and means MidAmerican has secured the full value of the production tax credits for the project. Wind XI puts Iowa on track to become the first state in the nation to generate more than 40% of its energy needs from wind energy.

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Offshore development company, US Wind, has begun a marine survey to prepare for the final layout design for an 80,000-acre wind-power project off the coast of Ocean City, Maryland. The survey involves data collection along the 35-mile route of the project site through Indian River Bay to a power plant near Millsboro, Delaware. Sediment core samples at 36 locations will be tested to ensure a safe installation of power cables.

After the survey, a meteorological station will assess weather conditions at the site.

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Amazon’s data centers to run on wind Amazon has announced its largest windpower project to date, a 253-MW wind farm in Scurry County, Texas. Amazon Wind Farm will consist of more than 100 turbines — each with a diameter twice as long as the wingspan of a Boeing 747 (over 120 m). The power generated will combine with Amazon’s other wind farms (in Ohio, North Carolina, and Indiana) to generate about 1,000,000 MWh of wind energy annually for current and future data centers.

The impact of wind power on the Canadian grid

Hydro-Québec’s research institute and ENERCON Canada have partnered on a new R&D project regarding the integration of wind power and transmission. The partnership allies Hydro-Québec’s know-how in grid simulation and operation and ENERCON’s expertise in large-scale wind energy converters. The goal is to advance development and understanding of the impacts of new electronic wind-turbine control systems on the transmission grid in Canada. windpowerengineering.com

Siemens supplies Oklahoma with U.S.made turbine components

The Minnesota Governor and state Department of Administration has announced a new partnership with Xcel Energy: The Renewable Connect Government Pilot Program. The initiative will ensure that 33% of the base energy used at the State Capitol Complex comes from renewable sources. If approved by the Public Utilities Commission, the program will provide a reliable and stable supply of wind and solar power on a long-term basis.

Michigan-based SkySpecs got the green light and a business voucher from the Energy Department’s Office of Energy Efficiency and Renewable Energy for a project to deploy autonomous drones for inspections of wind turbines. SkySpecs will work with Sandia National Labs on the validation of turbine blade damage data to assist with the development of machine learning algorithms for automated identification and classification. The project lets SkySpecs access Sandia’s expertise to further advance drone work at wind sites.

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Offshore wind alliance launches in NY

A diverse coalition of organizations has formed the New York Offshore Wind Alliance (NYOWA). Its mission is to educate and advocate policies that will lead to the development of offshore wind off the coast of New York. One NYOWA goal is to secure a state commitment to develop 5,000 MW of offshore wind power by 2030.

NYOWA’s work is guided by a Steering Committee that includes representatives from ACE NY, Deepwater Wind, DONG Energy, Natural Resources Defense Council, and others.

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P OL I CY

D r. J i m M c C a a Manager of Advanced Applications Va i s a l a w w w. v a i s a l a . c o m

Francesca Davidson Energy Communications Expert Va i s a l a w w w. v a i s a l a . c o m

Integration study paves way for more wind power in Canada

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anked seventh in the world for installed wind capacity, Canada has a strong base of operational projects and is no stranger to the wind sector. With outstanding wind resources across the country, the market still holds room for growth as Canada looks to transition to a low-carbon economy. This shift requires decreased dependence on fossil fuels, especially in the energy and transportation sectors, which can expand windpower output over the next 15 years.

However, bringing online a large volume of wind energy in a short time may challenge the

completed Pan-Canadian Wind Integration Study (PCWIS). This research is the first of its kind to cover Canada in its entirety, and includes a number of cross-border opportunities given the country’s access to parts of the northern U.S. electrical grid.

The study also marks a successful public-private collaboration because it brought together the collective resources of government and industry.

It combined CanWEA’s knowledge of Canadian energy markets and Environment Canada’s forecasting infrastructure with the power-system expertise of GE Energy Consulting and the weather

35% wind for Canada The map shows existing and potential wind-energy project across Canada in the PCWIS’ 35% wind generation scenario.

Image: GE Energy Consulting

integrity and reliability of the country’s electrical grid. Adapting Canada’s transmission system to handle a larger percentage of variable renewable sources, while feasible, does not happen overnight.

It requires anticipating pressures the transition may place on the energy system and evaluating options for the change, such as advanced wind forecasting and more flexible dispatching of other generation sources to mitigate affects on grid stability.

To help accomplish this, the Canadian Wind Energy Association (CanWEA) and Natural Resources Canada invested in the recently 20

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and power-modeling capabilities of Vaisala.

Through this work, Canada has made substantial strides toward improving its understanding of the role wind energy can play in its future energy mix.

How much wind can Canada’s grid handle?

When government and energy stakeholders of a country contemplate a shift from about 4% wind generation to a future with a third or more, you can expect apprehension and questions. How much can the current transmission system handle before it breaks? What is the tipping point? Will the benefits of

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POLICY

resulting dataset includes three years of meteorological data at 10-minute intervals and two-kilometer horizontal resolution. It also detailed energy production profiles for nearly 55,000 potential onshore and offshore wind project locations.

GE Consulting then combined the wind generation estimates with transmission, generation, and load data on Canada’s electricity systems to model present and future scenarios. The final report concluded that even under the 20 and 35% wind energy scenarios, Canada can integrate wind reliably and cost-effectively. This is in large part because the levels of required regulation reserves are much lower than initially estimated. Though reserve levels increase with additional wind, it is on average less than 2% of newly added capacity.

Total wind production in Alberta and regulation requirements The top chart shows a 10-minute variability in wind as a function of total wind production in Alberta.

The bottom one shows the regulation requirements for wind variability in the province. More regulating reserves are needed when wind production is at mid-level and less when production is low or high – proportional to the shape of the curves.

Where: BAU: Business as usual (of wind penetration), CONC: Concentrated wind penetration DISP: Dispersed wind penetration, TRGT: Targeted wind penertration Image: GE Energy Consulting

carbon-free wind energy outweigh the risks?

How much back-up reserve generation is required, and what will it cost?

The PCWIS analyzed several future possibilities, including scenarios where wind made up 20 and 35% of the system total. The collaborating organizations went to work to collect and research massive amounts of wind data across Canada and northern parts of the U.S. to quantify the OCTOBER 2016

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impact of integrating these quantities of wind power into the grid.

Together with Environment Canada, Vaisala leveraged the numerical weather prediction (NWP) modeling capabilities of both organizations and then applied advanced statistical techniques to accurately predict wind-power production across large geographic areas and long-term climatological windows. The

Benefits to the Canadian wind industry At COP21 in 2015, the Paris Climate Conference, Canada committed to reducing its carbon emissions 30% below 2005 levels by 2030. The country also supported the more aggressive global warming limit of 1.5°C. The PCWIS has provided good news to Canadian leaders mapping out the pathway toward compliance with these commitments. The modest transmission and regulation reserves needed to ensure a stable grid mean that wind power can play an enhanced role in reducing the carbon footprint of Canada’s electricity industry.

In addition, the study demonstrated the potential for wind energy exports from Canada to the U.S. CanWEA and the Canadian Solar Industries Association have partnered and formed a climate action team. One of the team’s recommendations is to develop a Canadian renewable electricity export strategy. The PCWIS report shows that Canada has the ability to do this while strengthening its own infrastructure.

Given the nation’s extensive wind resources and the amount of new clean energy capacity needed for the country to meet its commitments and achieve its vision for a transformed energy economy, wind is bound to play a key role in Canada’s clean energy future. W

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B O LT I NG Paul Dvorak Editorial Director Windpower Engineering & Development

Two-coat corrosion protection does the work of three for offshore turbines

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eawater and steel just don’t get along, which makes corrosion control for the offshore wind industry far more critical than it is for onshore turbines. A wide range of bolt and tower coatings are commercially available. But inspect the facility of any large structural fabricator and you find the paint shop is the choke point of production. Speed up the application of paints and coatings and production flows faster. One coating in particular from developer Hempel is said to be time and cost-efficient for steel towers. And although recent, it has a history.

A case history Alucrom AB, a supplier to many of Europe’s wind projects, had shot blasted and painted more than 300,000 m² of steel towers in 2008, but was finding it increasingly difficult to keep up with demand. The only way to stay on top of business was to speed up production. The company asked coating manufacturer Hempel A/S if it could deliver a system with faster drying, low-VOC paint which would speed up production.

Hempel turned to Covestro for assistance and the two firms devised a two-coat system based on a zinc-epoxy primer and a topcoat that use Covestro’s Pasquick polyaspartic technology, a range of resins and hardeners. The outcome is a two-coat method instead of the previous three conventional coatings. What’s more, the coatings cure faster. Both factors help to reduce the cycle time and the manufacturing costs of wind turbines.

Tests of the new product consumed about 75,000 liters.

Hemple says the corrosion protection is as long lasting and high in quality as the previous materials and process. This is an important prerequisite for turbines intended for long service lives and minimal maintenance.

Covestro says the coating uses a low-viscosity polyaspartic binder in combination with a polyisocyanate hardener to boost productivity in paint shops.

The layer reduction from three to two is said to have no negative effects on the quality of the film: The total coating thickness is unchanged, providing protection against seawater and other environmental influences.

“This principle of reducing the required number of coating layers also applies to mediumduty applications,” says Ahren Olson, marketing manager with Covestro. “A frequent challenge facing protective coating manufacturers and applicators is increasing the productivity of coating operations. Covestro’s Paskquick polyaspartic technology requires fewer coating layers, which significantly increases painting efficiency and reduces overall painting costs.

This is especially true for the Applying one coating less cuts time and cost for asset owners and coating contractors.

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www.windpowerengineering.com

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B O LT I N G

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fast-growing market of direct-to-metal coatings where Pasquick polyaspartic technology can be formulated into high film build, fast drying, UV and corrosion resistant coating.”

The end client, Enercon Windtower Production AB, now receives six complete towers per week with an exterior coating of a Dry Film Thickness (DFT) 320 μm and an interior coating of DFT 200 μm. ‘’So far all parties involved are very satisfied,” says Hempel’s Lars Rosen. “VOC emission have been reduced by 30%, and more sections can be produced per day thanks to the shorter drying time.’’ The curing process for a complete Pasquick-based coating build-up takes 6 to 8 hours. This is a significant time reduction compared to conventional threecoat systems, which take a total of 18 to 24 hours to cure. The system is now standard in production as Hempathane HS. W WINDPOWER ENGINEERING & DEVELOPMENT

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Making of the modern offshore substation

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ffshore substations — the systems that collect and export the power generated by turbines through specialized submarine cables — are an essential component of offshore wind farms, especially at large, multi-megawatt sites. These systems serve an important function: to stabilize and maximize the voltage of power generated offshore, reduce potential electrical losses, transmit electricity to shore,

and do so in a manner that supplies the greatest return on investment.

But the wind industry is still young, and there is a long way to go before the development of offshore substation systems fully mature. Given that the typical cost breakdown for large-scale offshore wind installations includes 7.5% for platforms, cabling, substation equipment, and more, there is opportunity for greater costeffectiveness and efficiency.

Sizing up substations Early substations for offshore wind farms consisted of simple topside frames with basic modules installed on top or as a covered deck. These structures were intended to operate unmanned, and required few visits from personnel. In many cases, these substations weighed as little as 400 tons.

That’s not much compared to today’s more advanced structures that weigh upwards of 10,000 to about 22,000 tons. These substations are more fully developed, and consist of a topside or a deck installed on monopole or jacket structures. Options now include floating and self-installing structures that eliminate need for expensive marine lifts or cranes.

Before the power generated at an offshore wind farm is fed into the transmission grid, it is combined in a transformer substation, such as the one shown here: Siemens’ Lillgrund offshore wind substation. Voltage there is converted from 33 kV (66 kV is sometimes used) to a transmission voltage of 138 kV by a 120-MVA power transformer.

Platform equipment includes mediumvoltage switchgear, protection and control technology, and a service transformer for the substation.

Photo: Siemens AG

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TRUSTED LEADER IN OPERATIONS & MAINTENANCE

A rendering of Alstom’s floating and selfinstalling HVDC offshore substation, used to connect the 400-MW, MEG 1 offshore wind farm in Germany, shows placement of a helicopter deck for crew transfer.

Photo: Alstom

Over and above serving as an offshore power-converter station, a substation’s platform may be equipped with boat landings, a helicopter deck (yes, a helicopter deck), accommodations, and act as a logistics’ service base during installation and operation of an offshore wind farm. Not surprisingly, one of the greatest cost challenges to developing an offshore substation is the sheer size of the structure. Much like transporting and installing wind-turbine components offshore, careful logistical planning is key.

The two substations installed at what’s been dubbed “the world’s largest wind farm at sea,” the UK’s London Array offshore wind farm, required use of a 3,300-ton lift-capacity floating crane just to maneuver the systems onto a foundation that’s 15 km from shore — undoubtedly a costly venture.

With an area of around 20 x 20 m, the substations are each 22-m high, and feature three levels of structural steel decks. They weigh in at 1,250 tons and are supported on transition pieces, connected to monopile foundations driven into the seabed. The substations WINDPOWER ENGINEERING & DEVELOPMENT

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let the wind farm operate more efficiently by transforming the energy generated from 33,000 to 150,000V, after which electricity is exported through cables 50-km long to an onshore substation.

Self-installing structures One option for overcoming the size and cost challenges related to substation installation is a self-installing platform, a design used by ABB and Alstom Grid. Their floating and self-installing HVDC offshore substation was used to connect the 400-MW, MEG 1 offshore wind farm to the German high-voltage, direct current system.

Alstom’s GIS substations were installed on a platform at the Baltic Sea 2 offshore wind site. The platform was placed on a pre-installed jacket and brought out to the installation site where water depths reached 44 meters. The buoyant and self-erecting platform enabled a high degree of flexibility and independency from crane ships for the transport and installation of the substation. The closed platform layout protects the electrical components from offshore conditions.

Photo: Alstom

According to Alstom, the platform uses a “suction can” method to set the foundations to the seabed floor and is fully self-contained to protect electrical equipment. The method reduces cost, noise pollution, and is believed safer on the environment when compared to conventional options.

Siemens is also working on a more efficient installation system for offshore substations. The company’s WIPOS (wind-power offshore substation) is available in different options, including selflifting, topside and jacket, and floating, all of which involve pre-fabricated sections with flexible configurations for ac and dc applications.

Much like, Alstom’s system, Siemens’ self-lifting platform can self-install to reduce the need, costs, 26

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and risks related to heavy lift vessels. In this configuration, the foundation is the substructure base frame, which connects to piles that are driven into the seabed. The topside includes a rectangular pontoon with customizable internal walls and decks. Self-jacking legs, attached to the topside, are immersed and then connected to the substructure base frame.

Operations & maintenance Configuration of a substation, its access points, and storage areas for maintenance equipment are important when considering the design for use at an offshore wind farm. These factors impact how often a substation may require servicing and its accessibility. But the factors are also difficult to assess because of extreme weather conditions and vibrations an offshore substation must endure, so routine O&M is typically a guess.

Because maintaining anything offshore is more costly and hazardous to operators, there is an inherent risk of unexpected equipment breakdown if maintenance is not made simpler and more efficient. The wind industry is responding to these challenges in several ways. For example, along with using conditionmonitoring systems, the industry is planning more frequent maintenance visits to detect potential equipment failures early on. They are also starting to take notes. With more detailed records, wind technicians can identify issues and pass on their insight for better future substation designs.

One issue that’s been noted is with transformers. They use oil as electrical insulation and are made of thin steel, which leaves them susceptible to corrosion. To overcome this challenge, designers are working with gas-insulated transformers that are safer for personnel to deal with. Additionally, some substation designs are moving transformers indoors to help minimize exposure.

Standardization in substation safety and manufacturing is another topic gaining traction.

If the industry can develop more consistent standards for substation designs and installation techniques, time and cost savings are bound to follow. But this takes time. To date, just over 20 substations for offshore wind farms have been built around the world. W

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OCTOBER 2016

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www.AeroTorque.com 330-590-8105 10/5/16 11:07 AM

COND I T ION MONITORING

David Clark President CMS Wind

Planning a profitable strategy for offshore O&M

F

rom an O&M perspective, there are three ways to care for offshore wind turbines:

• • •

Wait until something fails Replace components at an intervals Predict failures

Guess which is least profitable?

Right, wait until something fails. A recent statistic claims that onshore O&M costs have been three times higher than expected due largely to drivetrain failures and subsequent repair, downtime, labor, and lost production. And at onshore sites, it is possible to use a crane. Offshore work, where turbines are potentially inaccessible for long periods because of poor weather, requires a barge or high-lift vessel. Time and equipment are expensive. They eat into profits and drive-up estimated total cost of offshore O&M from the average 15 to 30%. This range does not include lost production from downtime.

Based on 6 GW of installs, the distribution of drivetrain failures on a wind turbine is about 50% for the gearbox and 50% for the generator with 1 to 3% from main-bearing failures. As an offshore operator, how do you predict these failures as opposed to the less profitable method of reacting to them? What is the associated repair cost and what is the frequency of their occurrence? Budgets, insurance, financing, and of course operations will need to know.

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Predicting offshore failures Predictive strategies mean the use of condition-monitoring technologies. Oil-related sensors and filtering technologies focus on the gearbox (about 50% of the drive-train failures) while vibration focuses on the drivetrain as a whole. Not all products are equivalent and not all are effective for this application, contrary to their advertising. It truly is a buyer beware situation for wind CMS (condition monitoring system).

When correctly implemented, vibration analysis provides the following lead times to failure: • • • • •

Main bearing, 18+ months Gearbox slow side, 9 to 12+ months Gearbox fast side, 6 to 9 months Generator, 6 to 9 months Correctible conditions includes misalignment, electrical, lubrication, looseness and imbalance

www.windpowerengineering.com

OCTOBER 2016

10/5/16 2:53 PM

we are keep it simple people We know you are looking for solutions, not just sensors. Complete retrofit kits, tailored to your turbine make and model, enable you to easily transition from your previous sensor to the Hybrid XT. Engineered exclusively for the wind energy industry, these turbine control sensors offer all-weather performance and durability for increased turbine uptime. All backed by our lifetime technical support and 2-year warranty.

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10/5/16 11:19 AM

CONDITION MONITORING

So when scheduling barges, maintenance vessels, and other parts and equipment, plan several months in advance to find the days that best suit the operator from a production and weather-access standpoint.

Drivetrain repair costs – offshore Onshore, the frequency of drivetrain failures is 11 to 16% annually regardless of manufacturer. And yes, this occasionally includes warranty periods.

Speak with your service provider to better understand the costs of the

There are differences in sensors and the hardware of systems installed in nacelles. Two other necessary components to consider include the software (to store alarming and measurement criteria) and perform analysis. Their outputs vary and few discussions cover these latter topics.

When the core CMS system has incorrect hardware, detections will suffer. To compound this, when measurements are not correctly established, expect missed detections and false alarms. This is typically the

As an offshore operator, how do you predict these failures as opposed to the less profitable method of reacting to them? gearbox or generator replacements versus an up-tower repair.

A single onshore event involving a crane is $300,000 on average for a 1.5-MW wind turbine. Avoiding the crane cost by predicting the failure using CMS drops the per-event cost to $12,000 to $15,000. That is, a single event O&M cost avoidance or saving of $280,000. Offshore, this number jumps significantly per event.

As a rough O&M estimate, take these costs for repair and downtime and multiply by 11% annually. Then multiply the cost of this annual failure rate by the number of years out of warranty (typically 15 to 18 years) and it is easy to see where a reduction in this area would substantially increase profitability.

And more than drivetrains need attention. Conditions and events such as icing are easily detected using the correct sensors and properly configured CMS. Be aware of condition-monitoring options The easy decision is to purchase condition monitoring and avoid all the O&M costs of a reactive maintenance strategy. But not all systems are equal.

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reason behind the mixed acceptance of CMS. Oddly, spotty acceptance is only an issue in the wind industry. In more traditional vertical markets, CMS is accepted and established.

Consequently, owners, insurers, financers, and developers must be cautious selecting CMS for the following reasons: • • • •

Incomplete access to data and configurations Effectiveness of the CMS system Understanding associated costs for the life of the asset Ease of use and understanding analysis, reporting, and time frames

Just because a wind turbine is optioned with CMS does not mean that it is the best solution or even a viable one.

Education and proper RFQ’s are helpful too. Which offshore O&M strategy will you use? W

www.windpowerengineering.com

OCTOBER 2016

10/5/16 2:54 PM

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SA F E TY Michelle Froese Senior Editor Windpower Engineering & Development

Raising the offshore safety bar

I

t’s no surprise that winds are stronger offshore and the elements harsher. This calls for greater care and due diligence when installing and maintaining offshore wind farms. Adding to the challenge is that typical offshore wind-turbine components are larger and heavier than at onshore wind sites, so extra measures for safe transport and logistics are important — for equipment and site personnel.

One misstep by a wind tech off a vessel onto an offshore turbine or substation platform, and a rescue mission is in order.

High winds upwards of 50 knots and unforgiving waters mean safety measures are paramount.

Fortunately, the global wind industry has taken safety standards seriously. Also, new innovations and advancements will undoubtedly improve work in the growing U.S. offshore sector.

Here are just a few examples of organizations that are raising the bar on offshore safety.

Thanks to funding from the U.S. Energy Department, Fishermen’s Energy and Keystone Engineering’s offshore vessel-to-platform access ladder could be adapted for offshore wind projects around the world, improving the safety of offshore workers globally.

Mobilization Permitting, financing, and site design are key aspects of a successful wind farm, but for offshore projects getting workers and equipment out to sea is a big transport and safety challenge.

“Vessel mobilizations represent the most challenging project aspects in the industry. They comprise an extensive scope of work with typically over 100 workers at a time, tight deadlines, numerous lifts, multiple work environment risks, and multiple suppliers — each with differing levels of safety maturity,” shared Kirsten Bank Christensen, VP of Health, Safety, Environment, and Quality at A2SEA. A2SEA is an offshore transport, installation, and service provider out of Denmark dedicated to improving site safety in its own company and with its suppliers. The company’s A2SEA’s ZERO HARM Mobilization initiative calls for projects to achieve zero “lost-time injuries with life-changing effects.” It currently benefits more than 30 suppliers annually.

“Where conventional mobilizations rely on the ability of each subcontractor to manage its own team’s safety within agreed schedules and procedures for the overall project, ZERO HARM requires A2SEA, as the project owner, to dedicate additional administration resources that allow for centrally monitoring, controlling, and optimizing the entire workforce on an ongoing basis,” explains Christensen.

As a result, the company’s suppliers come to share the same rules, focus, and commitment throughout each operation, while augmenting their own safety performance. While ZERO HARM stresses putting 32

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www.windpowerengineering.com

OCTOBER 2016

10/5/16 2:57 PM

SETTING STANDARDS

Standardization The Offshore Renewable Workgroup of the International Marine Contractors Association (IMCA) is also dedicated to offshore safety and has seen an increase in related guidance documents. The association recently published a technical industry study on standardized boat landings.

“There are design differences between boat landings that vary from location to location and, subsequently, workboat operators are having to undergo costly modifications to their vessels’ fender arrangements to accommodate these different boat-landing designs,” says Jane Bugler, IMCA’s Technical Director and Acting Chief Executive Officer.

As a result, the IMCA is working to develop a consensus on the optimal design and configuration of boat landings for accessing wind-turbine foundations from crew-transfer vessels.

The goal is to standardize the structural design to reduce operator costs and

An annual event related to A2SEA’s ZERO HARM Mobilization initiative is Supplier Safety Day. Each year, suppliers are invited to share insights and lessons learned from past projects, and encouraged to network and improve working relationships and workplace safety standards.

Photo: A2SEA

OCTOBER 2016

Safety 9-16 Vs2.indd 33

A2SEA practices what it preaches. The company is a member of IJUBOA, the International Jack-Up Barges Owners’ Association, a group of over a dozen barge owners, founded to raise safety standards for maritime construction using jack-up barges. It offers training and comprehensive guidelines for performing

offshore work, such as wind-turbine installation using jack-up barges, with the intent of turning these guidelines into industry-standard regulations. The code of practice is based on International Safety Management’s code, but tweaked to cater for the special requirements of jack-up barges as a workplace.

Photo: A2SEA

safety first, A2SEA also enforces a “no blame” policy to encourage the reporting of all incidents. The overall objective is to become better and safer through shared experiences and knowledge.

SAFETY

increase safety of personnel when transferring to offshore platforms.

“It is vital that safety in the offshore renewables industry is regarded as of paramount importance,” adds Bugler. “This includes relevance guidance documents and competence frameworks to encourage those involved to strive for the ‘Holy Grail’ of zero incidents.”

Innovation De-boarding a work vessel is easier said than done. Access ladders typically connect to the side of a tower foundation or substation platform. But it is important to make a well-timed step and account for the wind, waves, and a swaying vessel.

Compared to other countries, the U.S. regulations call for a narrower gap between the vessel and ladder, but this can prove more dangerous for those going across.

Unpredictable waves mean the vessel risks bumping into the foundation’s edge or worse, pinning a worker against the structure.

The U.S. Energy Department noted this safety hazard and provided funding to offshore developer, Fishermen’s Energy, and consultant, Keystone Engineering to develop a safer access ladder. The result: a side-step access ladder that meets OSHA regulations and provides a safe worker space between the surrounding fender structural members and the vessel bumper.

“Unlike traditional ladder access where the worker steps from the vessel forward across a gap to the ladder, our innovation is rotated 90° so the vessel deck can be placed as close as possible to the ladder rail, allowing the offshore worker to safely side step onto the ladder,” said Stan White, Program Director of Fishermen’s Energy.

“If the offshore worker were to accidentally fall, the worker won’t be pinned between the vessel and the ladder but, instead, the worker would fall in a clear space protected by the fender system.”

By sharing such advancements in equipment and standards on a global scale, the offshore wind industry can better ensure the safety of workers who will install and service wind farms. W

windpowerengineering.com

WINDPOWER ENGINEERING & DEVELOPMENT

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10/5/16 2:57 PM

F ILT E R S R a n d y Yo u n t VP of Operations FilterMag

How magnetic oil filtration helps gearboxes work longer A typical wind-turbine installation wraps a FilterMag XT8PR around a gearbox oil filter. A stainless-steel band secures the magnets to the aluminum filter housing. Captured particles are wiped from the inside wall of the housing during a filter change.

A

ccording to the National Renewable Energy Lab (NREL), gearbox problems are the number one cause of turbine downtime. Although the wind industry is getting a handle on why gearboxes do not function for 20 years, it is still necessary to keep a close eye on them through condition-monitoring systems and regular oil analysis. The reason a gearbox needs close attention is the failure of bearings, especially on the high-speed shaft. Currently, most bearing failures eventually result in a gearbox change.

NREL also cites the average cost to change a high-speed shaft bearing up tower at about $46,000. What's worse is the average cost to exchange the gearbox. It’s about $424,000.

However, using magnetic filtration to capture the debris from a failing bearing, along with early detection, could save an operator more than $300,000 for a single bearing failure. And when gearboxes are installed in offshore wind turbines, as they will be in some 8-MW units, a long working gearbox life is all the more important.

It is generally accepted that when a failing bearing is detected soon enough and damage

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WINDPOWER ENGINEERING & DEVELOPMENT

Filters 9-16 Vs2.indd 34

to the rest of the gearbox controlled, then it is possible to replace a bearing instead of having to change the gearbox. Condition monitoring

Analysis of gearbox oil subjected to magnetic filtration with a conventional 5­µm filter revealed an overall 78% reduction in oil contamination, which leads to a calculated 50% longer bearing life and 30% longer gear life.

www.windpowerengineering.com

OCTOBER 2016

10/5/16 2:59 PM

F I LT E R S

A typical spin-on oil filter that had been fitted with a FilterMag has been dissected to show the steel particles captured and held in place by the magnets. The image on the right is a microscopic view of captured particles all smaller than 20 microns.

with an early borescope evaluation can identify the bearing problem. The most damaging particles are less than 10 µm in size, small enough the pass through standard filtration. Magnetic filtration can mitigate the collateral damage to the rest of the gearbox by capturing the debris generated by a slowly failing bearing.

To test the magnetic capture of fine steel particles in gearbox oil, three 1.5­MW wind turbines monitored by gearbox­oil analysis were each fitted with a pair of magnetic filters on their existing filter housings. Hydac 5­µm filtration was used on each turbine. Oil sampling was conducted at 1, 2, and 4 months after the magnet installations.

The test demonstrated that a 78% reduction in total particles was possible after four months. Average ISO 4406 particle counts changed from 19/17/14 to 17/15/12. According to data from the Noria Corporation, this change of two code drops would indicate that bearings could last 50% longer and gears 30% longer. Noria is a Tulsa-based tribology consulting and training company.

Magnetic filters are available for most existing oil filters. The outside diameter of a spin-on oil filter or the outside diameter of a filter canister determines which unit fits a particular application. The magnetic traps also work on hydraulic systems.

The magnetic filters are reusable and typically outlast the equipment on which they are installed. Other types of magnetic filtration are available but generally require plumbing equipment in-line. W

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10/5/16 2:59 PM

SOF TWA R E Caroline Mizael Breeze

How to manage a wind farm from an office or on the road

I

f wind-farm owners are to squeeze cost out of their operating and maintenance expenses, they will have to keep a sharp eye on the performance of each turbine. Several monitoring systems are available for that task but a recent version sports clever and customersuggested features.

Sweden-based Breeze’s wind-farm management software (also called Breeze) comes as a service with the goal to assist wind-turbine owners and operators capture the full potential of their assets. Wind turbines remotely connect to the system regardless of model or brand, resulting in a single system to monitor, analyze, and optimize industry-scale, wind-energy portfolios.

The software-as-service has become a valuable tool for many leading wind-farm owners and operators that require powerful monitoring and user-friendly functions.

The product was developed from the ground up in collaboration with experienced wind-farm owners across Europe. Most Breeze features are based on customer feedback. This customer-centric approach to product development has enabled the system to evolve with its users at a rapid rate.

A few of the more recently added features are examples of innovative ideas that came from collaborations with customers. For example:

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WINDPOWER ENGINEERING & DEVELOPMENT

Software 10-16 Vs3.indd 36

•

Turbine models build on recent artificial neural networks are trained on data that represent a healthy condition.

The models look for deviations from the healthy state and notify operators of conditions that need attention.

The Remote Operations Center (ROC) is built from the start with the environment and workflow of a wind-farm control room in mind. The ROC lets users monitor in real time, large and diverse wind-turbine portfolios in one single view. The ROC is well suited for control rooms where higher priority includes a clear overview and A Breeze user is monitoring the performance of a few dozen wind turbines. The Remote Operations Center allows monitoring up to 800 turbines from one screen.

www.windpowerengineering.com

OCTOBER 2016

10/11/16 4:16 PM

SOFTWARE

a short time to action. The Center makes it possible to monitor up to 800 turbines on a single screen with critical information such as energy production, data connections, turbine statuses, and more. Sudden turbine stops and warnings are highlighted as they occur. Multiple customized ROC views for different purposes can be set up throughout the control room.

•

Artificial Neural Networks (ANN). With a downward spiral in electricity prices, wind-turbine owners and operators have started to focus more on methods to predict failures to reduce downtimes and reactive maintenance.

The ANN models are trained on data that represent a healthy condition in the wind turbines. The experience of these models then detects deviations Wind Farm Monitoring app for Android and iOS lets users track asset performance while away from larger screens.

•

A recent Breeze Wind Farm Monitoring app for iOS and Android allows monitoring key metrics for a wind-turbine portfolio while on the go. Users can access live wind-power production data for their entire portfolio or see the status of each wind turbine. The app’s monitoring dashboards on wind farm and turbine levels lets users analyze specific assets to monitor performance in real time.

A map makes use of a cell phone’s built-in positioning capabilities to render a geographical overview of turbines in relation to the user’s location.

OCTOBER 2016

Software 10-16 Vs3.indd 37

from the healthy state. Studies have shown that the ANN models can, in some cases, detect faults as early as three months in advance, leading to valuable insights and potential cost savings in predictive maintenance.

Time and cost saving features, such as the unified remote operations center, mobile access through apps, and Breeze ANN for predictive maintenance are becoming increasingly important to the wind energy industry. Such features are even more important for the offshore industry, which must maintain turbines that are more difficult to access and carry a larger financial investment than onshore versions. W windpowerengineering.com

WINDPOWER ENGINEERING & DEVELOPMENT

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10/11/16 4:17 PM

T UR BI NE OF T HE MO NTH

The illustration of the Vestas 8-MW unit shows a few details inside the nacelle.

Apparently, the large rotor will require two hydraulic cylinders to pitch each blade.

Paul Dvorak Editorial Director Windpower Engineering & Development

The Adwen drive train is lowered onto its test stand.

Siemens 8-MW unit will presumably appear much like the 7 MW turbine pictured.

The 8 MW club

S

iemens has been the latest OEM to join the 8-MW wind turbine club with the introduction of its SWT-8.0-154, so a natural reaction was to nominate it as the Turbine of the Month. But wait. Adwen also announced an 8 with an impressive 180-m rotor earlier this year and, if memory serves, Vestas has two 8-MW units up and running before that and orders for more. So although Vestas gets bragging rights for being first, we nominate these three 8-MW units as our October Turbines of the month.

These 8-MW units are significant developments for several reason. For one, they make it possible to install fewer machines for a required output, which in turn reduces infrastructure costs such as foundations and cabling. In addition, you may recall about six years ago, at least three companies boasted of having 10MW turbines in the works. One from Clipper adorned a cover of this fine magazine. That company is no longer with us. The 10-MW turbine has turned into quite a stretch goal for the OEMs so expect a few years to elapse before someone announces a 9-MW unit. For the time being, let’s celebrate the 8 MW designs.

No surprise, all are three-bladed units intended for duty offshore. Not a lot of tech data is available on the Adwen and Siemen’s units, so here’s a little on each.

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Vestas installed its first 8 MW prototype in Denmark in early 2014, and now has orders for 32 machines for the 258-MW Burbo Bank Extension project off the coast of Liverpool Bay in the UK. The company says the design includes strategies to mitigate risk with features such as: • •

• •

A failure-tolerant mode to run with reduced output should unexpected issues arise Aircraft-inspired component redundancy to avoid unnecessary interventions between scheduled service and to ensure a continuous normal output A medium-speed gearbox for reliable operations All equipment and components are evolutions of proven existing technology.

The Adwen AD 8-180 turbine has the largest rotor in the industry which has led the developer to claim the largest annual energy production.

The turbine is planned for 90-m towers.

The company, a collaboration of Gamesa and Areva, has commissioned and started testing the AD 8-180 drivetrain at IWES Dynamic Nacelle Testing Laboratory (DyNaLab) in Bremerhaven,

www.windpowerengineering.com

OCTOBER 2016

10/5/16 3:11 PM

TURBINE OF THE MONRTH

A few details for the 8 MW turbines DETAIL OEM

Vestas

Adwen Siemens

Turbine designation

V164-8.0 MW

AD 8-180

Cut in & rated wind speeds

4 and 11 m/s

3

Cut out

25 m/s

25 to 30

Wind class

IEC S

Swept area

21,124 m2

25,446 m2

Power density

2.64 m2/kW

3.18 m2/kW 2.33 m2/kW

Operational rotor speeds

4.8 to 12.1 rpm

Output voltage

6.6 kV

Tower height

SWT-8.0-154

18,626 m2

90m

Converter

Full scale

Nacelle size

8 x 20 x 7.5 m

Nacelle weight

390 tons

Gearbox

Medium speed,

single-stage planetary

Generator

710 Vac

NA

None

Head weight (nacelle & rotor) ~500 tons Foundation weight

4,000 tons Source: Vestas, Adwen, and Siemens

Germany where it is undergoing tests that will last until the end of 2016. The validation will cover mechanical and electrical tests on the drivetrain and main tower components.

The tests will simulate operational conditions for extreme and fatigue loads, and validate key components.

The simulations will also allow validating individual and fully integrated subsystems as well as the complete drivetrain operation at full power. These tests are needed to shorten a field test campaign and shorten the turbine’s time to certification.

Adwen started tests at the end of 2015 with the assembly and commissioning of the electrical system. In April 2016 the drivetrain was transported to DyNaLab to start the mechanical assembly as well as assembly of auxiliary structures for sensors, OCTOBER 2016

TOTM 10-16 Vs2.indd 39

lubrication systems, and the set-up and fine tuning of more than 350 sensors that will be used during this verification process.

When this first part of the full drivetrain test campaign concludes, a complete AD 8-180 nacelle will be installed in the prototype, currently being assembled in Bremerhaven.

Siemens’ direct drive wind turbine intended for duty offshore and on has reached its next development milestone. The company says this latest addition to its offshore platform, the SWT-8.0-154, takes a significant step towards grid parity for offshore wind.

The 8-MW turbine is based on the existing offshore direct-drive platform, incorporating only smaller evolutions.

The first SWT-8.0-154 will be installed in early 2017, and will allow for up to 10%

higher annual energy production under offshore wind conditions as compared to the 7-MW model. According to the company, the offshore platform enables a significant reduction in the Levelized Cost of Energy at low risk. Type certification for the 8-MW turbine is expected in early 2018.

Upgrading the Siemens 7-MW offshore direct drive wind turbine to eight MW is made possible through the introduction of new magnet technology with an even higher grade than that introduced in the SWT-7.0154. This allows a rated power increase of more than 14% from 7.0 to 8.0 MW. Similar to the previous upgrade from 6.0 to 7.0 MW, the company says, the 8-MW turbine will benefit from the established supply chain and proven components of offshore direct drive technology. These components include the B75 blade and the mediumvoltage transformer of the SWT-8.0-154.

The higher rating will come from only a few component upgrades.

The company says about 150, 6-MW direct-drive wind turbines have been commissioned for offshore work. Two SWT-7.0-154 prototypes, installed at the Østerild test site in Northwestern Denmark, are performing above expectations, according to Siemens. The SWT-8.0-154 prototype is planned for install by early 2017. W

windpowerengineering.com

Transport company Mammoet shows how to move the world’s longest wind turbine blade, 88.4 m, through a traffic circle. The blade and two others will power the Adwen 8-MW turbine.

WINDPOWER ENGINEERING & DEVELOPMENT

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4 0 WINDPOWER ENGINEERING & DEVELOPMENT

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www.windpowerengineering.com

OCTOBER 2016

10/5/16 3:13 PM

<<< A crewman inspects the storage of a high voltage undersea cable. Inter-array cables and the high voltage version shown will require vessels and talent already in the U.S. inventory.

UK cable expert offers experience and suggestions for U.S. offshore wind projects Th e U.S . o ff sho re wi n d i n d u s t ry p res ent s great opportu n i t y a n d mo re t ha n a f ew challenges , s uc h as whe re wi l l t he t ra i n ed crew s com e from an d what t o d o wi t h t h e J ones Act .

The five turbines installed at Block Island, RI

signal the launch of the U.S. offshore wind industry. The next windfarm will be larger and a more serious shakedown cruise.

The industry’s newness means uncertainty is everywhere in equipment, ships, ports, and personnel. And almost every discussion brings up concern of the Jones Act, a law from the early part of the last century that requires U.S. flagged ships to carry cargo from port to port in the U.S. How will it impede equipment coming from Europe? And new jobs on vessels will call for certifications – where will they come from?

OCTOBER 2016

Feat_JohnPrice_10-16_Vs2.indd 41

Paul Dvorak Editorial Director Windpower Engineering & Development

John Price, global sales director – renewables with UK cable and umbilical supplier JDR Cable Systems, discussed the problems and challenges faced by the nascent U.S. offshore industry and how UK experience can help avoid repeating mistakes made in Europe.

“We can bring vast experience from the UK industry – the know-how to deliver on a large scale. We see the U.S. doing things a little bit differently to what we did in Europe, which is fine. There, we scaled up bit by bit while the U.S. seems to be going from demonstration projects such as Block Island and Fishermen’s Energy, to a large gigawatt windfarm.” windpowerengineering.com

WINDPOWER ENGINEERING & DEVELOPMENT

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10/5/16 3:14 PM

UK cable expert offers experience and suggestions for U.S. offshore wind projects

Deepwater ONE could be number two Deepwater ONE is an offshore wind energy area located roughly halfway between Montauk, NY, and Martha’s Vineyard, MA., with the potential for more than 1,000 MW of offshore wind development. Deepwater Wind plans to build multiple phases in this wind energy area to serve Long Island, Massachusetts, and Rhode Island. A 90 MW South Fork Wind Farm will be the first project constructed in the Deepwater ONE wind energy area. The project won the nation’s first competitive lease auction in 2013 for exclusive rights to develop the 256-square mile site.

With that ambition, the U.S. will certainly need companies that have the knowledge and ability to deliver on a large scale. “That's where we can help,” says Price.

“We've cut our teeth on jobs and equipment to install turbines and lay cables.”

Price notes that there are two elements to an offshore cable array: an offshore substation that collects all power from the turbines, and a

High voltage undersea cables look like this.

Each phase gets its own copper bundle.

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transmission line back to a land-based substation and the grid. “I see U.S. projects evolving into a model similar to that used in the UK. The Germans used a slightly different setup. They use a collector hub for all offshore windfarms and one main export cable back to shore.”

One of the next U.S. projects will likely be near Maryland and possibly a one-gigawatt installation. “There, you're talking several hundred turbines (277, 3.6MW units or 200, 5-MW units, or larger).

In Europe, several turbine manufacturers offer eight-megawatt designs.

Price says he would recommend two things for a one-gigawatt windfarm: consider an installation program divided into two campaigns, and use monopile foundations. A monopile is a single large round steel tube driven into the seafloor.

Block Island uses a jacket foundation or four-leg design. Such foundations on large scale have not yet

appeared in Europe.

Foundations there are dominated by monopiles, a relatively inexpensive technology of rolled steel. The installation knowledge is there for anything up to about 35 to 40 meters’ water depth. “I see no reason why the Maryland project should not use monopiles as opposed to jacket foundations, which are better adapted for deeper water.”

Even the monopiles in Europe are holding turbines up to eight megawatts, although it is a huge piece of steel. The installation process there is well known and well-rehearsed so installation programs can be quicker than with other foundations.

Prices says his message to the U.S. offshore industry is that although it will naturally do things differently, there is a lot of experience in Europe that can expedite projects of the scale this country is

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planning. Why reinvent the wheel? Consider installation vessels. A variety will be needed.

When looking at large-scale U.S. projects, infrastructure such as large installation vessels isn't necessarily here yet.

“Those vessels may necessarily come from Europe because they do not exist yet in the U.S. That raises some issues around the Jones Act because the turbines and foundations will be built and held at U.S. ports. Vessels big enough to deliver a few hundred foundations would have to come from Europe.

Possibly the best way around the Jones Act is to re-flag vessels,” suggests Price.

What else might he recommend for the U.S. industry? “Three things,” says Price. First, consider the contracting strategy. “In Europe and the UK, we’ve had three rounds so far. Round one was led by a leading engineering, procurement and construction (EPC) company. This one contractor executed the whole package.

Many companies struggled because of that and did not make much money. In fact, some firms went bust off the back of it.”

He says, “Don't make the mistake of placing one contract with one developer who will then control all the subcontractors. That just didn't work.

It was too big a project although not too different from a large land-based installation.”

In round two, several developers took control and did the opposite. “They multicontracted every single package, which from the developers’ point of view, scaled up their internal resources to manage those contracts. Again, this did not quite work.”

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In the third round of installs, now in progress and the middle ground between the two previous approaches, the developers are controlling the packages but they're piecing the work together. Cable will be part of the installation package as will the turbines. Maybe the foundations will be part of that package too. They bring large-scale packages together, but not to the extent of a fullpackage EPC – an even middle ground.

The second big mistake to avoid: not ensuring that you have the right capabilities to deliver. “In earlier projects, 10 to 15 years ago, the right vessels to do the work were not always available. What's more, their crews didn't have the right experience or knowledge to execute the work. Having the right knowledge in place and the right capabilities – that's key,” cautions Price.

BOSIET or Basic offshore safety induction and emergency training will be a requirement for offshore wind techs and others. Classes are already available in North America from companies such as Falck Safety Services.

Interarray cables await loading to an installation vessel.

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UK cable expert offers experience and suggestions for U.S. offshore wind projects

Meet the vessels Vessel crews will have to be certified for As the U.S. offshore industry launched with the construction 10 to 20 different tasks. “The certifications of five turbines south of Block Island, R.I., most of our ink are available in Europe. Initially, those went to reporting on the installation of the foundation and people went to offshore construction after turbines. And a few months ago, we featured the 6-MW GE having become qualified just the week (formerly an Alstom design) as our Turbine of the Month. before. So experience is as important as certifications.”

But nothing would have happened without the Another word of caution should the installation vessels, in this case Brave Tern, with a home U.S. offshore industry ramp up: “You port of Valletta, Malta, an island south of Sicily. The vessel might start off with the A team and end up was built in Dubai to specs provided by owner and operator with the Z team because the company ran Fred. Olsen Windcarrier of the Netherlands. out of qualified people. It was a struggle The ship, and sister Bold Tern, sports 132-m long hulls in the earlier days but the situation in with 39-m widths and 9-m hull depths. Both of their legs Europe is getting better,” he says. and spudcans have 92.4-m lengths and 4.5-m diameters. A One installation barge could call for 20 or more different certifications. It is likely spudcan is an inverted cone or foot mounted at the base of that a crew member would be certified for the jack-up leg, which provides stability when the rig is jacked several different jobs. up at a work site. If extended on dry land, the legs can raise Who will teach the classes? “Our the vessel so there is 70.5 m to the bottom of the barge. company is developing a training academy The jack-up vessels were designed by Gusto MCS and for electrical tasks so we can carry out the customized by Fred. Olsen Windcarrier. The vessels are selfdetermination testing on the connections to elevating and self-propelled with large open deck spaces to the turbines. Then others would do training facilitate a range of deck layouts for particular operations. in, for example, working at height, working offshore, getting officer certifications. Basic The vessels have 800-ton "wrap around the leg" offshoreoffshore safety induction and emergency rated cranes and continuous type jacking systems. Each training (BOSIET) is a requirement in vessel also has a dynamic positioning system and is fitted Europe.” The U.S. offshore oil industry with a Voith Schneider propulsion for positioning capabilities. requires some BOSIET certifications as well.

What's more, the installation vessels have high-quality It’s a certification everyone must have.” accommodations, For jack-up barges that execute the main according to the turbine and foundation installations, there are Fun facts to know and tell probably half a dozen training schools in the company, for up about Brave Tern to 80 people in 56 cabins, as well as a CHARACTERISTIC DIMENSION heli-deck to facilitate transfers during Max variable load 7,500 tons offshore work. To Draft at max variable load 5.6 m keep track of Brave Minimum draft 4.25 m Tern’s whereabouts, Deck area 3,200 m2 go here: tinyurl.com/ Wind-turbine capacity 8, 3.6 MW or 4, 8-MW turbines brave-tern.

Aft propulsion 3, 1,750 kW Wartsilla Lips tunnel thrusters Max speed Operation water depth range Fuel consumption at transit speed

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12 knots 5.5 to 60 m 45 tons/24 hrs at 10 knots

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UK alone and more in wider Europe. UK or European companies may establish training schools in the U.S. to service the market.

The third challenge that the U.S. offshore industry deals with is establishing operations maintenance strategies for the projects. “That has been a rapid learning curve in Europe. We had a few isolated projects that we thought we could manage and suddenly turbines are offline. The biggest challenge with offshore projects is getting to them. Consider that in Europe some projects are only accessible with helicopters,” cautions Price.

Some North Sea projects in German waters can be 100 km offshore. “That is over the horizon – out of sight. Most projects in UK waters are getting towards being 20 to 30 km offshore. I think the furthest

we're looking at, for the next round of projects, round three, is for Dogger Bank and that's going to be about 60 km offshore.

I don't know if any of the U.S. projects are anywhere near that far offshore.”

And then there is the weather window to consider.

Price says that JDR has the capability and knowledge to improve U.S. offshore installations: “We lean on that knowledge – UK and European countries can help develop these projects. That's by far the clearest message.” W

Brave Tern (foreground) and Bold Tern are pictured at work in Europe. The vessels are owned by Fred. Olsen Windcarrier.

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The lidar unit is mounted on the transitionpiece walkway of an offshore wind turbine in the North Sea. The lidar provides a larger and clearer look at wind conditions than would be possible with anemometers alone.

Remote sensing offshore: What North America can learn from European experience

When designing offshore measurement campaigns, the f lexibility of remote sensing dev ices means the question on the mind of investors and developers should be “what do I want to measure?” rather than “what can I measure?”

Peter Clive

Senior Scientist

• SgurrEnergy

Both wind-energy applications of remote sensing and onshore wind energy have an unrivalled pedigree in North America. For example, the construction of many pioneering projects took place in North America and the early adoption of remote sensing technologies such as SODAR have contributed to the datasets necessary to make these projects a success. Now, as the industry dips its toe in the water with the construction of the first North American offshore wind farm at Block Island, we have an excellent opportunity to review how remote sensing has helped deliver wind power in places where offshore projects are more established.

Offshore wind energy has flourished in European waters since the 1991 construction of the first offshore wind farm, 4.95 MW at Vindeby in Denmark. Over 11 GW of capacity is operating (representing more than half global offshore capacity), and in 2016, more than 21 GW has been consented and over €14 billion worth of projects have 4 6 WINDPOWER ENGINEERING & DEVELOPMENT

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reached financial close. Remote sensing has played a crucial role in delivering this success, and it is reasonable to expect it to play an important one as developers roll out offshore wind in North American waters.

The economics of data acquisition To achieve a return on the investment, the benefit that accrues from the acquisition of data must exceed the cost incurred acquiring it. One great advantage of remote sensing offshore is the massive reduction in the cost of data. For example, a powercurve test undertaken using scanning lidar installed on the transition piece of the test turbine can cost less than one percent of the cost of the equivalent test that using an offshore meteorological (met) tower.

But it is crucial not to overlook another advantage: the benefits increase as well.

Remote sensing tools such as scanning lidar can give access to information that would otherwise be unavailable, letting us find out much more about the wind. To unlock the full value of lidar, it is important to see beyond using it as a met tower replacement.

Lidar’s capabilities mean that measurement campaigns can go far beyond those of traditional offshore met masts, so why not exploit the vast array of measurement possibilities they offer?

Successfully developing and operating offshore wind-power projects call for detailed information and characterization of wind conditions. The wind cannot be controlled, but it can be measured. Established procedures rely on the limited capabilities of instruments that were available at the time the procedures were written. For example, cup anemometry mounted on met towers features heavily in standards and guidelines. However, in recent years remote sensing methods such as lidar have given us new techniques and methods of characterizing wind conditions offshore. Nacelle-mounted lidar, transitionpiece mounted lidar, and other techniques on offshore projects across Europe have proven to be reliable sources of accurate and useful measurement data. This has provided an unprecedented understanding of the wind.

This more detailed understanding has led to more authentic approaches to uncertainty, and identification and quantification of what were previously ’unknown unknowns.’

This helps establish greater confidence in predictions, more effective project planning, and more suitable financial arrangements.

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Expecting the unexpected The wide-ranging capabilities of lidar mean we can better understand wind conditions. It is now possible to develop tailored methods to employ lidar capabilities more effectively, and mitigate hazards of adverse wind conditions. Lidar techniques give access to data that is otherwise unavailable. As a consequence, we have discovered that real-world conditions are much more complex than anticipated.

We can now observe adverse conditions preconstruction instead of after a project has been built with limited opportunities for remediation. After all, prevention is better than cure.

For example, complex wind-shear phenomena, such as low-level jets, are revealed to have significant impact offshore. Variations in atmospheric stability over the course of a day can create conditions in which a layer of high wind speed develops. This can adversely impact wind turbine mechanical fatigue loads, such as bending moments at the blade root and gearbox

Moving towards gen 3 lidar The first generation of lidar merely emulated met masts, requiring analysts to extrapolate to locations where measurement apparatus had not been installed, the same way one does with met masts.

The second generation introduced long range scanning to assess conditions throughout the volume of interest without requiring redeployment of apparatus or extrapolation from the instrument’s location. However, information about the wind remained incomplete – the device acquired line-of-sight values relative to its location, rather than absolute values – and so wind conditions were still inferred on the basis of a set of assumptions.

The emerging third generation will combine the time resolution of 1st generation devices and the space resolution of 2nd generation devices by allowing direct measurement where currently we rely on inference. The current state-of-theart can be described as perhaps the 2.5th generation, with synchronizedconvergentbeamsystemsstillrequiringtrade-offs betweentime-and-spaceresolution.Butprogressisbeingmade through, for example, the integration of rapid-flow modeling into the data stream. torque variance, influencing component lifetime in a way that should be addressed in strategies for inspection, repair, operations and maintenance.

This understanding came as an unanticipated result of offshore lidar research. One such measurement campaign, using three scanning Galion windpowerengineering.com

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G4000 lidars, was undertaken by Wood Group business SgurrEnergy and AREVA Wind at the Alpha Ventus Offshore Wind Farm in 2013. These were installed on the nacelle and transition piece of an offshore wind turbine in the German North Sea to undertake a wide variety of investigations.

One surprise discovery: wind-turbine compression zones were observed to extend further upwind than expected. This is the region in front of the turbine in which wind conditions are influenced by the presence of the turbine. When conducting turbine power-performance assessment, the incident wind resource is compared to the power production to see if the relationship

the measurements are made. This is because different methods are suitable for different requirements, and a particular method may entail different levels of accuracy under different circumstances.

There are three key benefits to this approach: •

•

It provides a basis for consistent and comprehensive documentation of complex measurements to ensure repeatability and investor confidence in the results It clarifies the procedure for instrument calibration, whereby the verified performance of an instrument with respect to accuracy relates to a specific method employed under well-defined circumstances satisfying meaningful acceptance criteria to demonstrate fitness for purpose, and

The colorful plot of data from a G4000 lidar unit shows more complex flows than previously expected.

conforms to expectations. If the resulting power curve is used with the results of a preconstruction wind-resource assessment to predict annual energy production, it is crucial that wind measurements are not influenced by the presence of the turbine. If so, they will impact power-curve tests and production estimates. This was another result highlighted only by the use of lidar offshore during the campaign at Alpha Ventus.

Choosing the right tool for the job The versatility of lidar lets us choose the right tool for the job when it comes to measuring and understanding offshore wind conditions. Lidars don’t represent just one measurement method.

A wide variety of techniques are available and the most appropriate one can answer a specific project-development question.

This flexibility is driving development of new guidance on the use of lidars by the International Energy Agency (IEA) Wind Energy Task 32. A “use case” approach has been adopted in which the lidar application is described with reference to the data requirements, the measurement method used to fulfil these requirements, and the situation in which 4 8 WINDPOWER ENGINEERING & DEVELOPMENT

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•

It places emphasis on the project-driven data requirements instead of using instrument capabilities for choosing measurements. Previously, constraint-driven approaches to measurement campaigns were adopted because of limitations to met towers. Remote sensing, and lidar in particular, has opened new opportunities that offer an outcome-driven approach to measurement.

Examples of new measurement opportunities include the installation of scanning lidar on a wind-turbine nacelle. This allows direct measurement of wind-turbine wakes behind the wind turbine and an evaluation of their impact. The measurements are compared to computational models, which can then be refined in the light of new evidence. This helps reduce uncertainties in energy yield estimates because wake modeling is one of the principal contributions to uncertainty.

In the absence of a met tower, the same device installed on the transition piece of a wind turbine makes possible the most IEC-compliant method of testing power performance. The location of the device on the transition piece fulfils the requirement in the 2nd edition of the IEC power-curve test standard for ground-based methods. The use of arc scan geometries ensures that lidar-probe volumes are also located in

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accordance with the requirements of the standard.

This method has been used since 2013 to deliver reliable offshore turbine power-performance assessment testing at less than one percent of the cost associated methods based on met towers.

If there is no convenient location to install a device during the pre-construction resource assessment, an offshore floating lidar can be deployed in the absence of any other measurement opportunity, delivering essential valuable data. Recent studies indicate that even when installing a met tower offshore, it is more cost-effective to include a lidar on the platform because the improved financial arrangements achieved by the reduction in uncertainty can pay back the cost of the lidar several times over.

Multiple synchronized lidars can be used to achieve unambiguous, high-frequency measurements of wind velocity vectors throughout an entire offshore wind-farm array.

Fast lidar measurements can also combine with computational flow models to enhance the level of detail and accuracy to describe wind conditions.

The flexibility of remote sensing devices means the question on investors’ and developers’ minds should be “what do I want to measure” rather than “what can I measure” when designing offshore measurement campaigns.

Transforming the way we do wind Lidar techniques can obtain richer datasets acquired at lower costs compared with more established measurements. Sometimes they are required to fulfil the roles of these more limited instruments, such as met towers, to maintain continuity with established wind-energy assessment procedures. However, using lidars to emulate the more limited capabilities of met towers restricts their use unnecessarily. Based on lessons that the industry has learned so far, procedures must be updated to make the most of the measurement opportunities that lidar makes available.

Lidars should be installed for routine monitoring and validation of assumptions, rather than occasional compliance tests and resource assessments. Lidar is changing the way that the wind industry understands the wind, creating new ways to do business, and will continue to do so as the industry and the technology evolves.

Lidar measurements match the sophistication of computational model predictions, providing an invaluable test of their predictions and supporting an unprecedented degree of scientific rigour in wind energy assessment.

It is entirely possible that in the not-too-distant future, lidars will be employed in almost identical roles, pre and post-construction. The measurements will be compared to computational fluid dynamics, aero-elastic, and finite-element models from the pre-construction OCTOBER 2016

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phase. They will then compare the predictions of those models to real wind-turbine performance and condition monitoring post-construction.

The benefit of experience The onshore and offshore wind markets are ever-developing, giving North America a unique advantage in its position, entering the offshore market at a more reserved pace than other regions. With the benefit of extensive years of experience in onshore wind and wind measurement, combined with experience and lessons learned from the European offshore experience, the path is clear to use these lessons to develop the offshore wind industry in North America. Doing so eliminates some of the historical challenges faced by early adopters. W

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A brief glossary of terms • Arc-scan geometries: lidar sourced wind speed measurements require observation of the wind through a range of beam angles. An arc scan corresponds to a configuration where the range of angles is less than 360 degrees, allowing measurements in locations horizontally distant from the location of the device.

• Computational flow models: a set of physics-based calculations solving differential equation that describe fluid flow to shows wind speeds and directions in fine detail.

• Rapid-flow modeling: computational models of flow that execute fast enough to use in a data acquision process, augmenting measurements.

• Transition piece: An offshore wind turbine foundation connects to a tower by the transition piece, on which a walkway, typically provided for access, offers a siting opportunity for scanning lidars equivalent to groundbased operations.

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From shore The work of an offshore transfer vessel A s u ccessfu l offs hore pro jec t ta k es c a refu l p l a nni ng , d u e d i l i g ence, a n d a s k il l e d t e a m of engineers and techn i ci a ns . It a l s o requ i res a l o g i s ti c s ’ tea m w ho c a n s a f e l y a n d e fficientl y trans port wor k ers to s ea . Gi ven the ha rs h co nd i ti o ns o ff s hor e , c r e w t r a n s f e r can be a ris ky bu s i nes s b u t o ne tha t ha s c o m e a l o ng wa y i n r e c e n t y e a r s .

Michelle Froese • Senior Editor • Windpower Engineering & Development

W

ith over a decade of offshore experience under its belt, the UK has learned a thing or two about transferring workers to a wind site. This method of transport wasn’t always as sophisticated as it is today.

“In the early days, you’d buy yourself an old fishing boat, strap on some tires to the front as a bumper, and off you’d go. Granted, it probably wasn’t the smoothest or safest of rides but it got workers to the turbines,” says Ian Baylis, Managing Director of Seacat Services. The UK company is a specialty vessel operator that has had contracts with major

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wind developers, such as DONG Energy, Siemens, SSE, Wind MW, and others. Every vessel in Seacat’s fleet today complies with DNV-GL *1A1 HSLC Wind farm Service 1 and Category 1, which lets them operate up to 150-nautical miles offshore.

“Obviously times have changed and boats have evolved considerably. Now there are options for extremely specialized tonnage, with comfort, noise, and vibration considerations — and at a very high standard for safety.” Baylis says customers have matured in the UK and Europe, and are recognizing the positive impact a quality vessel has on overall project costs and efficiency.

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to sea: Safely navigating waters and pulling up alongside a substation (or turbine foundation) takes skill and, ideally, a customized vessel. This is the riskiest part of the job for a vessel operator.

Photo: Seacat Services

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From shore TO SEA:

The work of an offshore transfer vessel

“Sure, simpler boats cost less but how effective are they on the job? What ramifications does vessel choice have when it comes to a project potentially falling behind schedule?” asks Baylis, who says these are important questions for a

Permission to come aboard – and look around To service the massive, multi-megawatt projects in Europe, Seacat Services’ ship “Seacat Courageous” has impressive features — not the least of which is air conditioning, satellite TV, satellite Internet, and a soft-mounted superstructure to minimize noise and vibration. Most importantly, it was specifically designed for offshore wind-farm applications to maximize passenger safety. It even has crash-tested suspension seats.

Here are the general specs: • Builder: South Boats Isle of Wight Ltd. • Design: South Catamaran, 26 m • Capacity: 24 passengers, 3 crew • Construction: Aluminum • Overall length: 26.77 m • Max beam: 9.12 m • Draft: 1.45 m • GRT: 108 tonnes • Certification: DNV-GL *1A1 HSLC R1 Windfarm Service 1 and UK MCA, Cat 1, qualifications that allow operations up to 150 nautical miles from Safe Haven

In comparison, the Atlantic Wind Transfer’s vessel for work in U.S. waters was built to service Rhode Island’s 30-MW Block Island Offshore Wind Farm. Although smaller, 21 m long, it was also designed by South Boats to maximize passenger safety.

The forward main deck is equipped with a blue PK 6500 M Palfinger marine knuckle boom crane with a maximum lifting capacity of 1,345 pounds and a hydraulic outreach of about 25 feet. The vessel is capable of carrying 15 tons of deadweight cargo, and the company offers these services: • Crew transfers, construction support, and O&M • Container and cargo transport • Cable-laying operations • Dive support (for wind technicians inspecting turbine foundations) • Hydrographic subsea work • Subsea ROV deployment • Fuel transfers

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wind developer to consider. “This is particularly pertinent in the construction of offshore wind farms, where the penalties for delays and work slippage are extremely high. It’s important to mitigate as much risk as possible to get the job done well and on time.”

Building better boats You may also question how a transfer vessel can impact project costs or deadlines. For starters, it has six directions of potential movement at sea: heave, pitch, roll, sway, surge, and yaw. Most wind techs are not sailors or shoreman so a less rocky boat is typically a better one. A vessel must also counteract currents around an offshore turbine as much as possible. One surge from a big wave can send a vessel hard into a turbine’s foundation.

“A lot of work has gone into the designs to make a more stable platform,” says Baylis. “That's why catamarans are mainly used for offshore projects. They are stable as well as comfortable during transit and extremely multi-purpose.

Along with a work crew, they have the capability to carry containers and heavy equipment. Older boats couldn’t carry much cargo, not only because of their size but their stability. Cargo would become a major safety hazard rocking back and forth in the boat.”

And where once tires were strapped to the front of a boat, specialized rubber bow fenders now protect the hull. “This is the riskiest part of the job for operators — to effectively maneuver the waves and steer right up to a turbine’s foundation,” Baylis says the two most critical parts of a transfer vessel are the propulsion system and the bow fender. “Here, we engage a rubber bow fender between two tubes and we push like billy-ho — no joke — with our engines and use the friction of our bow fender and power of our engines to stay stuck to the turbines. We have to make it as safe as possible for a person to step over and onto a ladder and climb up to the turbine or a substation.”

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Can you spot the transfer vessel?

Atlantic Pioneer, the first and only crew-transfer vessel built specifically for the U.S. offshore wind industry was on its way to drop workers off at Block Island Wind, America’s first offshore wind farm. The five-turbine, 30-MW wind farm is now fully constructed, and successfully up and running.

Photo: Atlantic Wind Transfers

The skill and vessel capabilities required to do this well are not lost on Charles Donadio, President and Founder of Rhode Island Fast Ferry, the company that won the tender for America’s first offshore wind farm, the Block Island Wind Farm. Under newly formed sister company, Atlantic Wind Transfers, it signed a 20-year deal with wind-farm developer, Deepwater Wind, to provide construction and now support for the O&M crew-transfer vessel.

“Most captains are taught throughout their career not to hit things while in the water,” Donadio points out.

“But in the offshore wind industry, it is a whole different world. There you have to hit a solid steel foundation to connect to the turbine, and do so as carefully as possible, while contending with wind, waves, and weather.”

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reached out to Baylis and his team at Seacat Services. “No one had done this before in the United States, so it was important for us to learn from those who have to avoid unnecessary errors, and to design a reliable boat that works for the industry on an operational and a safety level,” he says.

Donadio used the same UK South Boat design for the “Atlantic Pioneer” vessel built here in the U.S., only with a smaller design at 21 meters (Seacat Services offers vessels as large as 27 m) because Block Island only has five turbines. A crewtransfer catamaran design and construction company, South Boat maintains that it has constructed three times as many vessels for the offshore wind farm market than its nearest competitor.

He even flew one of Seacat’s lead captains over from the UK to train his crew for three weeks. “He’s a visionary,” says Baylis of Donadio. “Initially, his company was pitching against another that simply

wanted get an old boat and convert it for the Block Island project. Of course, that’s the cheaper way to go. But Donadio did his research and made a compelling case for designing a boat that fit the purpose and that can do as many of the jobs as possible, as safely as possible.

He not only got the contract, but according to Baylis he gave U.S. offshore wind a head start. “By learning from our development challenges in the UK and Europe, the U.S. market has got much more of an opportunity to hit the ground running when it comes to offshore transport and safe crew transfers than did ours.”

Based on their experience, Seacat Services is able to offer a fleet-wide (they currently own 11 vessels) availability of over 98%, which is impressive considering the conditions at sea. “In our business, it’s really about one thing and that’s availability,” explains Baylis. “And we can measure that two ways. The first is capability,

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From shore TO SEA:

The work of an offshore transfer vessel

As weather permits, Rhode Island Fast Ferry is currently offering public tours of the Block Island Wind Farm onboard their high-speed “Ava Pearl” catamaran.

and the ability to safely and efficiently meet a customer’s purpose in a variety of challenging conditions. For offshore wind, this means without technicians throwing up left, right, and center.”

He says the second way to measure availability is vessel uptime. “By building a high standard vessel with quality equipment and a lot of inbred redundancy means organizations like ours can offer extremely high levels of availability to clients.” Seacat’s organization and each vessel it operates work within an Integrated Management System to maximize project planning, logistics, and upkeep. The system was designed and written in-house specifically for wind-related support, and conforms to regulations put forth by the International Safety Management

code, Occupational Health and Safety, and the International Organization for Standardization. It is also audited and certified by DNV-GL. Donadio believes that long-term availability is key to successful vessel transfers. After all, a transport vessel’s job does not end when project construction completes at a wind site. “After the dust settles and a wind farm is commissioned, technicians still need to get out to the site 5 4 WINDPOWER ENGINEERING & DEVELOPMENT

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and maintain those turbines. Every day a crew-transfer service is not running, that wind company is potentially losing money, so 100% vessel uptime is essential.”

Together is better Availability could also be measured a third way if Baylis’ team is any example.

By sharing best practices and serving as mentors for Donadio’s Atlantic Wind Transfers, Seacat demonstrated how important collaboration is for the industry.

“I believe it is critical for us to develop and build relationships with what I like to call our peers, rather than competitors, and work together,” says Baylis. He gives an example: one of his vessels was recently struck by lightning in the middle of a job and required repair. “Fortunately, I've been able to call one of my would-be competitors and sub-charter one of their vessels. As peers, we are working together to make sure that the client, and in this case it’s Siemens Wind Power, receives uninterrupted service.”

Baylis says his team often conducts crew changes for larger vessels and that companies will pool resources and move storage between boats to better meet logistical challenges. His crew is also flexible and open to testing new ideas that better serve their clients. “For wind projects, it’s all about efficiency,” he says. “For example, one of our customers was the first cable manufacturer to decide to put all of their test equipment in one container instead of lifting multiple parts up and down off the deck. Lifting this container onto the substation takes some effort, but without collaboration or the kind of boats we’ve developed, they wouldn't be able to do that.”

That’s where Donadio is on the right track, according to Baylis. “Those who just want to be in competition and not collaboration are, ultimately, not going to succeed in this sector. But Donadio was willing to reach out, ask to partner with us, and listen to our experience. By doing so, he has greatly served the U.S. offshore industry and I’m looking forward to watching it grow.” W

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OCTOBER 2016

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WIND

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Paul Dvorak Editorial Director Michelle Froese Senior Editor Windpower Engineering & Development

The future of wind: A blog entry from 2026 At last, the plane speeds down the runway for takeoff and you sit back and try to relax. It may be the fall of 2026, but you think some things never change. Flight delays, cramped legroom, and snug airline seating. At least you got a window seat. But as the plane departs, you look outside and smile.

Los Angeles looks vast from above and the view of the city is crystal clear. You recall recent reports of reduced city smog and emissions, and think the city is well on its way to meeting 100% clean-energy mandate. Some things do change.

The clear air is, thanks in large part, to the phase-out of coal-fired plants in the state and adoption of renewable energy. Advances in batteries and lower-cost ultracapacitors (to better help regulate battery charges) have also meant a slew of EVs now cover the freeways in much of the country — and in L.A. this has proved key to reducing low-lying city smog. Electricity prices have also dropped and many residents choose to power their cars, homes, and business through the wind or solar-power options offered by utilities.

You’ve been a renewables’ advocate and consultant for years, so it is nice to see progress.

It’s just then that you spot them — a dozen spinning white markers in the dark blue waters below. From the air, these offshore wind turbines don’t do their size justice.

The blades alone are nearly 90 m and the towers are well over 120 m. What’s more is the towers are not embedded to the sea floor but instead float on a tethered steel and concrete base. California’s first offshore wind farm was a floating one, and this was merely the demonstration project. Phase one of a much larger development — think 20-MW turbines with 100-plus meter blades — is now under construction in far deeper Pacific waters.

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One advantage to floating turbines is an ability to tap stronger winds further offshore. Where stability was once a concern because these structures are less secure and face harsher conditions than fixed offshore turbines that are closer to shore, intuitive sensors and predictive weathermonitoring systems have cast worry aside. Digitization and computer modeling has meant operators can preprogram turbines to maximize anticipated wind speed and direction, even in choppy waters.

We really can foresee the future, you think, and throw on your VR glasses. Bringing up the news, you read that Texas is now planning for a floating offshore wind farm using giant, 30-MW turbines. Ever since Maryland succeeded in developing the country’s first large-scale offshore wind farm back in 2020 (at some 750 MW, the project runs through Indian River Bay to a power plant near Millsboro, Delaware), the race for bigger and better has truly begun and the U.S. offshore wind industry has soared. The east coast is dotted with offshore projects so it is about time the southwest caught up, you think.

This Texas project will include a couple of storagefriendly substations that can mitigate variable production and optimize energy output. These specialty substations will house flywheel plants which store power in the form of kinetic energy using a mass spining in a nearly frictionless enclosure. Flywheel energy storage offers longevity and low maintenance, with many full depth discharge cycles.

The growth of the U.S. offshore wind industry is impressive, you think, and decide to review your notes for the presentation you will give at a wind conference in Germany. You work with a wind research firm and know

www.windpowerengineering.com

OCTOBER 2016

10/5/16 3:53 PM

www.bachmann.info

wind.power SCADA We supply advanced automation solutions for wind power plants all over the world. State-of-the art technologies, open systems and highly-efficient development tools impress operators, manufacturers and developers of wind power plants alike. With Wind Power SCADA (WPS) we are bundling our sector know-how together with a futureproof and flexible SCADA solution based on pure web technology.

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11.12.2015 10/5/16 10:30:51 11:10 AM

WIND

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Vision for the future

how much the U.S. has benefitted from experience in the European and UK wind market. It is time to return the favor. Over the last decade, the U.S. has significantly cut wind-related costs in three ways you plan to share.

1. The gearbox is gone. Research has at last led to a synthetic rare-earth mineral discovery that means all new turbines are now direct-drive machines. Without the heavy, difficult-to-maintain gears, the wind industry is benefitting from reduced transportation, maintenance, and turbine downtime costs. It was good timing, too. With an abundance of aging wind farms, the industry has clear-cut many of the old farms and replaced them with fewer, yet higher generating direct-drive turbines. It is no surprise America now has 250,000 MW of wind power on the line.

LOOKING INTO THE DEPARTMENT OF ENERGY’S CRYSTAL BALL The U.S. Department of Energy (DOE) has revisited its WindVision with a goal of 500,000 MW of wind power by 2035 and 800,000 MW by 2045.

2. 3D printers have transformed blade manufacturing. Where once a full-sized representation of a blade was necessary to make the mold used for final production (a time and labor-intensive process), now 3D printing quickly and reliably creates a mold without the model. This is saving blade manufacturers extensive time and costs, and 3D printing costs are expected to drop considerably in the next couple of years. Of course, 3D-printed drones are typical and every wind-farm operator owns at least one.

3. O&M is a drone’s world. Occasionally, a wind tech still must head up-tower. But drones can just as easily repair leading-edge damage on a blade or replace a turbine sensor. In fact, robots take care of a lot these days and can provide visual 3D site assessments, underlay cable, connect offshore foundation tethers, install and maintain transmission lines, and perform many manufacturing and repair tasks. Most wind operators now connect their drones with the wind farm’s predictive software system and that means maintenance and upkeep is automatic.

Here’s what else they see: • The offshore wind industry has already hit the DOE’s Wind Powering America initiative of “54 GW by 2030,” and provides almost 5% of the country’s electricity capacity.

You file your notes and check the remaining flight time.

What used to take 10 hours to get overseas now takes half that time, thanks to supersonic flights. Now if only the plane was powered by the wind, you think. W

• The much-anticipated 50-MW turbine is finally here! An offshore demonstration project is planned off the coast of New England.

• Onshore turbines are now almost silent thanks to lightweight blade materials and serrated edges that reduce the “swosh.”

• Researches have perfected sensors that not only detect bat and avian movement in the vicinity of a wind farm but mimics their ultrasonic calls to stay away.

• The full series of transmission projects initiated by Clean Line Energy and others over a decade ago are nearing completion, delivering thousands of megawatts of lowcost renewable power to U.S. cities and communities.

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

Senior Editor | Windpower Engineering & Development mfroese@wtwhmedia.com

www.windpowerengineering.com

|

OCTOBER 2016

10/5/16 3:53 PM

Wanzek 10-16_Vs1.indd 1

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WIND

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Vision for the future

David Halligan Chief Executive Officer Goldwind Americas

Q: Just how big (tall) will turbines get in the coming years?

A: As demonstrated by the growing size of offshore turbines, onshore

Q: How will big data and wind farm O&M monitoring change over time?

A: As innovations for turbines change so will

big data outputs that accompany them. With the data we are able to assemble now, we’ve already found that there is a direct correlation between utilization of big data and optimizing a wind farm’s operations and maintenance. Big data essentially allows us to better predict turbine behaviors which ultimately feeds into the O&M planning cycle, further allowing organizations to use predictive technology as opposed to reactionary measures.

Ultimately, this accumulation and processing of data will lead to a direct improvement in overall turbine availability and long-term performance.

Q: How will energy storage impact the wind industry?

A: Energy storage is an important next step in the evolution of the wind industry as it creates a balancing act between supply and demand of the energy produced. That balancing act will allow wind energy production to move from intermittent to dispatchable – ultimately, giving wind the ability to compete directly with conventional energy. The industry as a whole is testing and rolling out energy storage solutions that provide a mechanism for wind energy produced during nighttime wind periods to be captured and used, as needed, during peak daytime demand hours. Grid operators are equally bullish on seeing storage deployed alongside renewable installments as they will be better equipped to maintain grid stability and efficient integration of renewables.

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turbines still have room to expand in both height and capacity. In addition to design challenges, the logistics associated with transit of large components can prove difficult and costly, affecting both project costs as well as timelines.

Even still, as long as the regulatory and permitting environment supports an increase in the size of turbines, creative solutions will be brought forward to produce larger turbines, and in turn, improve the cost of energy.

Q: What have you learned about managing innovation in the past ten years?

A: Wind technology in the last 10 years has made leaps and bounds in efficiencies, cost and grid compliance. While turbines have grown in size, they have also grown in knowledge. They are smarter and more efficient than ever before.

New innovations and technologies, while generally well-received by the market due to improved efficiencies and economics, invariably involve an adoption period to demonstrate whether the technology can perform to meet expectations and, ultimately, attain approval from the financing community.

When managing new innovations, it is important to develop rigorous internal processes to ensure that new products and upgrade offerings fundamentally improve value to customers. The customer’s needs are always at the forefront of whatever product is brought to market, and further development of innovative, complementary products to enhance the long-term reliability of the product will be key to ongoing success.

Q: Will a 20-year gearbox life ever be possible?

A: There is no doubt that millions of dollars are being poured into R&D

for gearbox optimization and improvement with the goal being to reach a longer lifespan. Though a 20-year gearbox life may be possible, we’re shifting the discussion away from what may be possible in the future, to what is guaranteed today – permanent magnet direct drive. While PMDD turbines made their debut in the marketplace some time ago, you are seeing the industry shift towards technologies that require less maintenance, have less downtime, and provide higher energy yields. The absence of a gearbox in a PMDD turbine eliminates the technically most complicated elements of the machine therefore improving its overall reliability. W

www.windpowerengineering.com

OCTOBER 2016

10/5/16 3:59 PM

Elegance + Performance WORLDâ&#x20AC;&#x2122;S LARGEST TURBINE MANUFACTURER Goldwind is shaping the future of wind energy through innovative technology and a commitment to partnering with the best. For more than two decades we have been raising the bar - jointly developing the most advanced wind power technologies available. Today, permanent magnet direct-drive (PMDD) technology is being recognized as the new standard and Goldwind has more experience in PMDD than any other wind turbine manufacturer.

With more than 26 GW installed across the globe, Goldwind is now the largest turbine manufacturer in the world.

Goldwind Americas â&#x20AC;&#x201C; Driving the Future, Lighting the World

goldwindamericas.com

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10/5/16 11:11 AM

Behold the shroud of turbine IN THE QUEST TO MAXIMIZE ENERGY PRODUCTION, OEMs are building larger and taller utility-scale turbines to capture more energy. However, smaller, distributed wind turbines (those up to 100 kilowatts) must rely on innovation and clever turbine designs to maximize energy production at lower wind speeds. One such turbine promises that: greater efficiency in a smaller size with an innovative design that could become the Holy Grail of the small-wind sector.

Meet the Ogin turbine. Standing at 151 ft. tall (that’s 46 m with a hub height of 36 m), it is designed “to go where large turbines can’t” with the goal to make distributed wind power more efficient and affordable. What sets the Ogin apart is its aerospace-inspired cone or funnel that circles the blades. The large metal cone, a shroud, it works by changing airflow patterns through and around the turbine and blades to maximize those wind speeds.

According to its designers: “Standard, open-bladed propellertype rotors divert a large fraction of available energy around the rotor. By drawing energy from a larger column of wind, the Ogin turbine significantly improves turbine efficiency – yielding up to three times more energy output per unit of swept area.”

The direct-drive and self-yawing turbine design also translates into reductions in O&M costs per megawatt-hour, and that means increased profits for wind-farm operators. Ogin maintains that annual energy output per unit of rated capacity is increased by 50%, while peak energy output from the compact rotor is increased by up to three times per unit of swept area.

The result: a quieter, more compact turbine that can lower siting impacts and simplify permitting challenges.

6 4 WINDPOWER ENGINEERING & DEVELOPMENT

Downwind 10-16_Vs3.indd 64

The designers say that by siting projects within distribution grids, wind developers can sidestep the lengthy process for high-voltage interconnection.

Standardized manufacturing and sub-assembly enable production of turbines within weeks of initial order. Also, onsite assembly is meant to take days, and not weeks per turbine. These turbines are shipped in standard 40-ft. containers and can be brought in on standard roads.

Ogin’s design is also intended to mix out wake turbulence so that less buffer space is required between turbines. Where conventional turbines are typically spaced at least eight rotor-diameters apart to allow for wake recovery, Ogin turbines can be installed as close as four diameters apart without major performance degradation. Their shorter stature also positions the turbines well below the FAA’s 200 ft. threshold and eliminates the need for avian light markers in most locations So, Holy Grail or wishful thinking? If the shroud design has left you unconvinced, Southern California Edison took a chance and signed up to purchase the power created from seven Orgin turbines that were situated between Palm Springs and Desert Hot Springs. However, reports say the turbines have since been removed from the site and, without confirmation as of press time, we hope that this means a completed testing phase for this promising variation. W

www.windpowerengineering.com

OCTOBER 2016

10/5/16 4:02 PM

YOU CANâ&#x20AC;&#x2122;T CONTROL THE ELEMENTS, BUT YOU CAN CONTROL EQUIPMENT WEAR.

Nature can be unpredictable. With all the stops and starts your wind turbines endure, you need maximum protection from your wind turbine gear oil.

HARNEX TM 320 is formulated with premium additives that defend against the elements, delivering the uncompromised wear protection demanded of a synthetic lubricant. Part of an elite group of gear oils approved by GE and Shanghai Electric, HARNEX 320 provides continuous protection, maximizes the life of your gearbox and ultimately keeps your wind turbine fleet running longer.

CONSTANT PROTECTION. CONSISTENT PERFORMANCE. harnex320.com

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