2011 Wind Energy Industry Manufacturing Supplier Handbook About the Sponsors
AWEA is a national trade association representing wind power project developers, equipment suppliers, services providers, parts manufacturers, utilities, researchers, and others involved in the wind industry - one of the world’s fastest growing energy industries. The Association provides up-to-date information on wind energy projects operating, new projects in various stages VMKL]LSVWTLU[JVTWHUPLZ^VYRPUNPU[OL^PUKLULYN`ÄLSK[LJOUVSVN`KL]LSVWTLU[HUKWVSPJ`KL]LSVWTLU[Z related to wind and other renewable energy development. People count on AWEA to provide up-to-date, accurate information about the domestic and international wind energy industry.
The BlueGreen Alliance Foundation (BGAF) is a 501(c)(3) organization that works with the BlueGreen Alliance — a national partnership of fourteen labor unions and environmental organizations dedicated to expanding the number and quality of jobs in the green economy — to conduct research and educate the public and media about solutions to environmental challenges that create economic opportunities for the American people. BGAF’s Clean Energy Manufacturing Center focuses on job creation opportunities in the emerging clean energy PUK\Z[YPLZ;OL*LU[LYZLY]LZHZºVULZ[VWZOVW»MVYW\ISPJVMÄJPHSZSVVRPUN[VKL]LSVWJSLHULULYN`Z[YH[LNPLZMVY their communities as well as manufacturers looking to participate in supply chains in the growing wind power and solar energy industries.”
Global Wind Network is an international supply chain advisory group and network of manufacturers whose mission is to increase the domestic content of North America’s wind turbines, onshore and offshore. GLWN helps manufacturers identify and evaluate technical and business pathways in the wind sector and connect [OLT^P[OWV[LU[PHSJ\Z[VTLYZHUK[OLPYZWLJPÄJWYVK\J[ULLKZ;OL`HSZVSPUR^PUKPUK\Z[Y`6,4»ZHUKJVTWVULU[ suppliers to help them expand their businesses and keep pace with market demand as well as supporting smart public policy initiatives and integrated federal/state/industry efforts that are key to expanding the wind industry.
The National Institute of Standards and Technology’s Hollings Manufacturing Extension Partnership (MEP) ^VYRZ^P[OZTHSSHUKTPKZPaLK<:THU\MHJ[\YLYZ[VOLSW[OLTJYLH[LHUKYL[HPUQVIZPUJYLHZLWYVÄ[ZHUK save time and money. The nationwide network provides a variety of services, from innovation strategies to process improvements to green manufacturing. MEP also works with partners at the state and federal levels on programs that put manufacturers in position to develop new customers, expand into new markets and create new products. 4,7ÄLSKZ[HMMOHZV]LY[LJOUPJHSL_WLY[Z¶SVJH[LKPUL]LY`Z[H[L¶ZLY]PUNHZ[Y\Z[LKI\ZPULZZHK]PZVYZ focused on solving manufacturers’ challenges and identifying opportunities for growth.
2 MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry Table of Contents
Overview 4
Section I — Wind Energy Market 8
GLOBAL WIND ENERGY MARKET 9 OPPORTUNITIES IN U.S. WIND ENERGY MARKET 11
Section II — Anatomy of a Wind Turbine 18
Section III — Doing Business with OEMs 28
SUPPLY CHAIN OPPORTUNITIES 29 THE ROLE OF INTEGRATORS 31 ADDITIONAL SUPPLIER OPPORTUNITIES 33
Section IV— Meeting OEM Requirements 34
WHAT IS EXPECTED FROM A NEW SUPPLIER 36 MARKET ENTRY TIPS 38 WHAT SUCCESSFUL COMPANIES HAVE DONE 39 DIRECTORY OF MAJOR INDUSTRY PLAYERS 40
The Wind Energy Supplier Development project is supported by the U.S. Department of Commerce’s NIST Manufacturing Extension Partnership, the Rockefeller Foundation and the Energy Foundation.
Wind Energy Industry Manufacturing Supplier Handbook is a publication of AWEA - BlueGreen Allliance - GLWN
7OV[V(JRUV^SLKNLTLU[!-YVU[*V]LY9V[LR0UJ6OPV)HJR*V]LY.HTLZH7LUUZ`S]HUPH Preface
This wind energy industry manufacturing supplier handbook is designed as a starting point for manufacturers interested in becoming suppliers to the industry. It provides information on the potential growth of wind energy markets, describes the ‘anatomy’ of a wind turbine and it’s JVTWVULU[ZHUKWYV]PKLZHU\UKLYZ[HUKPUNVM[OLWYHJ[PJLZHUK6,4YLX\PYLTLU[Z[OH[HYL relatively common in the utility scale turbine industry.
While the wind industry has seen remarkable growth in the U.S. over the past several years, HZPNUPÄJHU[WVY[PVUVM[OLWHY[ZHUKJVTWVULU[ZMVY^PUK[\YIPULZHYLJ\YYLU[S`Z[PSSILPUN manufactured overseas. The sponsors of this handbook are committed to building a strong domestic manufacturing sector in the wind energy industry and our goal through this handbook is to inform manufacturers of market opportunities and ultimately increase the number of component manufactures that participate in industry supply chains.
However, it’s important to recognize that manufacturing components for the wind energy market PZUV[ULJLZZHYPS`HUHWWYVWYPH[LKP]LYZPÄJH[PVUZ[YH[LN`MVYTHU`JVTWHUPLZ6,4»ZOH]L]LY` YPNVYV\ZZ\WWSPLYX\HSPÄJH[PVUHUKX\HSP[`YLX\PYLTLU[ZK\L[V[OL]LY`OPNOJVZ[VMYLWHPYPU[OL ÄLSKHUKLU[Y`IHYYPLYZTH`ILOPNOMVYZVTLJVTWVULU[Z
As a result, we have made an effort to provide you with information to help you decide if this is [OLYPNO[THYRL[MVY`V\YJVTWHU`^OLYL`V\TPNO[Ä[PUHUK^OL[OLY`V\TPNO[X\HSPM`HZH 1st, 2nd or 3rd tier supplier.
4 MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry The handbook has been divided into several sections, starting with an Introduction that provides you with an overview of wind turbines and basic terminology.
Section IPKLU[PÄLZPUK\Z[Y`VWWVY[\UP[PLZMVYTHU\MHJ[\YLYZHUKJV]LYZ[OL>PUK,ULYN` Markets, both in the U.S. and globally. It describes industry growth over the past decade and projections through 2020.
Section II offers a detailed review of the Anatomy of a Wind Turbine, which describes the major working components. A turbine is a collection of systems that converts wind energy into electrical energy and includes an estimated 8,000 components. Each of the major systems is reviewed with pictorials, schematics and descriptions of the major sub-components.
Section III focuses on the Structure of Supply Chains and requirements for component manufacturing. We describe a manufacturing model that has proven to be competitive and successful in this industry. Quality management system requirements are also reviewed,
Section IVV\[SPULZZVTL5L_[:[LWZ[VOLSW`V\KLJPKL[OLILZ[Ä[MVY`V\YJVTWHU`PU[OPZ industry and how to get connected with existing supply chain partners. A listing of the major ^PUK[\YIPUL6,4ZHUKZ[;PLYZJVTWHUPLZPZHSZVWYV]PKLK
Please feel free to contact us with any questions or comments.
MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry 5 Introduction
>PUKWV^LYHZHJVTTLYJPHSZV\YJLVMLULYN`PZHU(TLYPJHUPU]LU[PVU;OLÄYZ[^PUK[\YIPUL^HZ PU]LU[LKI`*OHYSLZ)Y\ZOVM*SL]LSHUK6OPV^OVJVUZ[Y\J[LKH MLL[[HSSRPSV^H[[[\YIPULPU (see photo on the left). By the 1920s, U.S. factories were producing 100,000 wind turbines per year, mostly for agricultural and rural applications.
;OLÄYZ[SHYNLJVTTLYJPHS\[PSP[`ZJHSL[\YIPUL^HZKL]LSVWLKH[[OL5(:(.SLUU:WHJL*LU[LYHSZVPU Cleveland, in the 1970s, with funding from the Department of Energy and the National Science Foundation. The two-blade turbine (on the right), built in response to the emerging oil crisis, was a 3.2MW unit and PUZ[HSSLKPU6HO\/H^HPPPU 0MUV[KLJVTTPZZPVULKK\L[VM\UKPUNJ\[IHJRZ[OPZ^V\SKZ[PSSIL considered North America’s largest wind turbine.
;VKH`PU[OL<:^PUK[\YIPULZJHUILJSHZZPÄLKPU[V[OYLLJH[LNVYPLZHUK[OPZOHUKIVVR^PSSWYPTHYPS` address issues relating to utility scale turbines.
Residential scale wind turbines are less than 100kW, typically used for a home, farm, or business and can be connected to the electric grid or connected only to a storage battery or a building. According to AWEA, an average American home would need a 5kW wind turbine for its electricity needs. These small turbines are typically about 80 feet tall with a rotor diameter of 18 feet (AWEA). They contain an average of 30 - 80 components.
*VTT\UP[`ZJHSL[\YIPULZHYLR>R>4>[`WPJHSS`\ZLKMVYHZWLJPÄJSVHKSPRLZL]LYHS buildings of a school or a shopping complex, and supplies extra generated energy to the electric grid. They contain an average of 1,000 - 3,000 components.
Utility scale turbines are greater than 1MW, typically connected to a transmission grid. The GE 1.5MW ^PUK[\YIPULHJVTTVU\[PSP[`ZJHSLTVKLSOHZHO\IOLPNO[VM MLL[ T^P[OHYV[VYKPHTL[LY VM MLL[ T.,;OL`JHUJVU[HPUHZTHU`HZ JVTWVULU[Z
1888: 1970-1980 12 kilowatt wind turbine 3,200 kilowatt or 3.2 megawatt wind turbine
6 MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry Terminology
BLADES: Most wind turbines have three blades, though there are some with two blades. Blades are generally 30 to 50 meters (100 to MLL[SVUN^P[O[OLTVZ[JVTTVUZPaLZHYV\UKTL[LYZ feet). Blade weights vary, depending on the design and materials — HTL[LY34>PUK7V^LYISHKLMVYH 4>[\YIPUL^LPNOZ RN [VUZHUKVULMVYH4>[\YIPUL^LPNOZ RN [VUZ
Blades are advanced in design, but labor intensive in the BLADE THU\MHJ[\YPUNWYVJLZZ6,4Z\Z\HSS`OH]L\UPX\LKLZPNUZ for blades, and may manufacture blades or purchase them HUB from suppliers. Manufacturing includes labor-intensive processes SPRLHKKPUNSH`LYZVMÄILYNSHZZ[VISHKLTVSKZHUKÄUPZOPUN[OL NACELLE edges of the blades.
TOWER HUBS: The hub is the component to which the blades are attached; it connects the blades with the drivetrain. It is one of the single largest components of the turbine and each hub can weigh over 15 tons.
NACELLES: The nacelle houses the main components of the wind turbine, such as the controller, gearbox, generator, and shafts. The plants that produce nacelles are primarily assembly facilities. Nacelle components are produced (in-house or by outside suppliers) to the ZWLJPÄJH[PVUZVM[OL6,4HUK[OLUHZZLTISLKH[[OLUHJLSSLWSHU[
6,4Z[`WPJHSS`OH]L\UPX\LKLZPNUZMVY^PUK[\YIPULUHJLSSLZHUK [OLSLHKPUNNSVIHS6,4ZTHU\MHJ[\YLUHJLSSLZPUOV\ZL Some companies license wind turbine designs to other companies and several companies contract out nacelle manufacturing.
TOWERS:;V^LYZHYL\Z\HSS`[\I\SHYZ[LLS[V^LYZ [V TL[LYZ HIV\[ [V MLL[OPNO[OH[JVUZPZ[VM[OYLLZLJ[PVUZVM]HY`PUN heights. (There are some towers with heights around 100 meters (330 feet).
6,4ZKLZPNU[V^LYZ;OLZL\Z\HSS`OH]LZLJ[PVUZLHJOJVUZPZ[PUN of metal rings that are thickest at the bottom of the tower and are conical in shape since towers taper slightly from the base to a narrower opening at the top. During the manufacturing process plated sheets are cut, rolled into the conical shape and then welded into rings. Rings are then welded together and painted.
PERSON
MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry 7 Section I
Wind Energy Market
8 MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry Global Wind Energy Market
US and China are the Leaders
6]LY[OLWHZ[KLJHKLPU[LYLZ[PU^PUKLULYN`OHZNYV^UNSVIHSS`^P[O[OL<:HUK*OPUHOH]PUN established themselves as global leaders. Until 2010, the U.S. had been global leaders in new installations MVYMV\Y`LHYZPUHYV^NYV^PUNI`HSTVZ[ PU ;OLHTV\U[VMLSLJ[YPJHSNLULYH[PUNJHWHJP[` worldwide available from windpower over the past 15 years has risen to close to 200,000MW.
Currently, over 35,000 turbines have been installed in the U.S. and one of every Ä]L^PUK[\YIPULZ^VYSK^PKLPZZLY]PUN<:LSLJ[YPJHSNYPKZ
NEWLY INSTALLED CAPACITY (2010) CUMMULATIVE CAPACITY (2010)
*6<5;9@ 4> *6<5;9@4>
*OPUH *OPUH
<:( <:(
0UKPH .LYTHU`
:WHPU :WHPU
.LYTHU` 0UKPH
0UKPH Italy 5,797 3.0
<2 -YHUJL
0[HS` <2
*HUHKH *HUHKH
:^LKLU Denmark 3,752 1.9
9LZ[VM[OL>VYSK 9LZ[VM[OL>VYSK
World Total 35,802 100 World Total 194,390 100
Source: AWEA and GWEC
MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry 9 Total Installed Global Capacity
200,000
180,000
160,000
140,000
120,000
100,000
80,000
60,000
40,000
20,000
0
Charts Source: GWEC
10 MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry Opportunities in U.S. Wind Energy Market
6]LY[OLWHZ[ZP_`LHYZ[OL<:^PUKLULYN`THYRL[OHZZLLUZPNUPÄJHU[NYV^[OHUKKLZWP[L[OLLJVUVTPJ downturn, opportunities for wind power in the U.S. continue to exist. According to the U.S. Department of Energy’s “20% Wind Energy by 2030” YLWVY[[OL<:WVZZLZZLZZ\MÄJPLU[HUKHMMVYKHISL^PUKYLZV\YJLZ [VVI[HPUH[SLHZ[ VMP[ZLSLJ[YPJP[`MYVT^PUKI`[OL`LHY
(JJVYKPUN[V[OLZLWYVQLJ[PVUZ[OL<:^V\SKOH]L 4>VMPUZ[HSSLKJHWHJP[`I`¶I`[OLLUK of 2010, we were on track to meet these projections (see Chart A).
Driving growth is the fact that our nation wants more wind energy. According to a recent Harris Poll, VM(TLYPJHUMH]VYTVYL^PUKWV^LY(UK Z[H[LZOH]LHSYLHK`WHZZLKYLUL^HISLLULYN`Z[HUKHYKZ (see Chart B).
CHART A U.S. 20% WIND SCENARIO
305,000MW 300
250
200
Installed Capacity as of DEC 30, 2010 150 4> 100
50 0
LEGEND
QOFFSHORE QLAND-BASED
TIP Why “invest” in wind component manufacturing? Because for many it can prove a viable market for GLYHUVLÀFDWLRQLW·VJRRGIRUWKH HQYLURQPHQWDQGLW·VDVWHSLQWKH right direction towards US energy independence.
MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry 11 Renewable Portfolio Standards (RPS) and Goals 29 states and D.C. have an RPS; 7 States and 3 Power Authorities have Goals
CHART B
LEGEND
QRPS ACCELERATED OR STRENGTHENED RPS QACCELERATED OR STRENGTHENED RPS
QVOLUNTARY STATE OR UTILITY STANDARDS OR GOALS QSTRENGTHENED VOLUNTARY STANDARD QPILOT OR STUDY
(A! I` 4,! I`" UL^I` " 6/! I` *(! I` 8 GW wind goal by 2030 62! I` *6! I` 40! 4>/HUK 69! I` ¶JVVWZ 1,100 MW by 2015 ¶ZTHSSLY\[PSP[PLZ *;! I` 45! I` " 7(! I` +*! I` I`¶?JLS 90! I`LUK +,! I` 46! I` :+! I` /0! I` 4;! I` ;?! 4>I` " IA: 105 MW; 5*! I`¶06
Sources: (derived from data in) Lawrence Berkeley Labs, State Public Utility Commission (PUC) and legislative tracking services, Pew Center. Details, including timelines, are in the Database of State Incentives for Renewables and Energy
12 MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry Wind Energy Growth in U.S.
The number of U.S. wind turbine operations has jumped from just one in 2005 — GE Energy — to nine in 2010. During this same period of time, the number of total facilities manufacturing components for the wind PUK\Z[Y`NYL^[LUMVSKMYVTPU [VV]LYPU
The following maps show the current installed wind power capacity in the U.S., as well as the location of the manufacturing facilities.
KEY
6/! I` Turbine Nacelle Assembly 62! I` Towers 69! I` Blades ¶ZTHSSLY\[PSP[PLZ 7(! I` US WIND TURBINE OEM NACELLE ASSEMBLY BY YEAR 90! I`LUK GE Energy Clipper Gamesa DeWind Acciona Northern Power Systems Nordex Siemens Vestas :+! I` ;?! 4>I` "
500 MW non-wind goal 2010 2010 2010 2010 2010 THU\MHJ[\YPUNVM4>[\YIPUL <;! I` =(! I` "NVHS^P[O (UUV\UJLK6,45HJLSSL(ZZLTIS`-HJPSP[PLZ!(SZ[VT(7V^LY4P[Z\IPZOP5VYKPJ production incentives =;! I` "HSSNYV^[O[V TOTAL OPERATING FACILITIES 2012 from RE and EE 6USPUL 6USPUL (UUV\UJLK ;V[HS,_WLJ[LK6USPULPU*VTPUN@LHYZ >(! I` ;V^LYZ >0! I` >=! I` )SHKLZ Nacelle Assembly 3 12 8 20 ;V[HS 6]LY 6]LY Manufacturing Jobs 2,500 20,000 18,000 38,000 Source: AWEA
MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry 13 Installed Wind Power Capacity (MW) in 2010
WIND POWER CAPACITY IN MEGAWATTS
Q< 100 MW Q100 TO 1,000 MW Q>1,00 MW TO 10,000 MW Q>10,000 MW
AL: 10 5/! 69! AZ: 128 NJ: 8 7(! CA: 3,177 NM: 700 RI: 2 *6! 5@! SD: 709 DE: 2 MA: 18 TN: 29 /0! MD: 70 ;?! 0(! 4,! UT: 223 ID: 353 40! =;! 03! MN: 2,192 >(! IN: 1,339 46! >0! 2:! 4;! >=! 5+! 6/! >@! NE 213 62!
14 MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry Section II
Anatomy of a Wind Turbine
15 MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry Anatomy of a Wind Turbine
A wind turbine is a collection of operating systems that transfers the energy from wind into electric energy that ultimately will be used in homes, communities, and businesses. The main operating systems include: tower, blade, rotor, drivetrain, gearbox, generator, electrical systems, nacelle, yaw & pitch, and controls.
This section reviews the construction of standard utility-scale wind turbines that are between one to three MW (Megawatt) PUZPaL;OL[^V[`WPJHSJVUÄN\YH[PVUZMVY[OLZL[\YIPULZHYLHTVK\SHYNLHYIV_Z`Z[LTVYHKPYLJ[KYP]LZ`Z[LT This section will utilize the modular gearbox system, the most common type, to explain the anatomy. This style uses a gearbox to step up the rotor speed entering the generator.
BLADE
HIGH SPEED SHAFT WIND MEASUREMENT BRAKING SYSTEM NACELLE COVER MAIN SHAFT ACTIVE HEAT BEARING EXCHANGER POWER HUB CONTROLLER BLADE FACE BEARING
HYDRAULIC SYSTEM YAW SYSTEM LUBRICATION SYSTEM MAIN FRAME GENERATOR
LOW SPEED SHAFT CONTROL SYSTEM GEARBOX TOWER
COLOR KEY QFABRICATED QCOMPOSITE QCAST QFORGED QELECTRICAL
16 MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry Tower
Rolled tower section
Tower internals
TOWER OVERVIEW Supports the wind turbine Maximizes height for good wind Rolled steel sheet - welded VM[V[HS^PUK[\YIPUL^LPNO[ Attaches to concrete base and foundation
INTERNAL COMPONENTS :[LLS7SH[L-SHUNLZ@H^.LHY*VH[PUNZ7HPU[)YHJRL[Z+VVY(ZZLTISPLZ/H[JOLZ/VPZ[ Climb Assist, Ladders, Platforms, Lighting, Cables
SUPPLIER IMPLICATIONS 100 - 200 tons of steel 50 - 120 meters in height Shipped in three sections or more Internals assembled at tower manufacturer
MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry 17 Blades
Blade for 2.5 MW wind turbine BLADE OVERVIEW Creates lifting force and rotational torque to generate power [V ÄILYNSHZZI`^LPNO[^P[OLWV_`VYWVS`LZ[LYYLZPU
VM[V[HS^PUK[\YIPUL^LPNO[
INTERNAL COMPONENTS Internal Core/Spar, Fiberglass, Skin Composite Laminates, Carbon Fiber, Epoxy or Polyester Resin, Root Insert, Fasteners, Barrel Nut, Protective Painting/Coating, Lightning Protection, De-Icing System
SUPPLIER IMPLICATIONS [VUZLHJO 30 - 55 meters in length Vacuum resin infusion and pre-preg molding (most are two pieces, some are one piece) *VYLWHY[ZPU[LNYH[LKPU[VÄUHSISHKLHZZLTIS`
Hull with core materials Spar caps Spars with sandwich Root section Bolt holes
18 MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry Rotor Hub with Pitch System
Hub with pitch system
ROTOR HUB OVERVIEW Extract the power of the wind and convert it to rotary motion
Hub connects the blades to the main shaft Cast, machined, and coated hub INTERNAL COMPONENTS
Hub , Nose Cone, Pitch Brake (Disc, Calipers, Pads, Hoses, Seals, Housing), Bearings, Lubrication System
SUPPLIER IMPLICATIONS 6ULVM[OLSHYNLZ[JVTWVULU[ZH[ [VUZ Material is typically cast ductile iron ;PNO[JHZ[PUNHUKTHJOPUPUNZWLJPÄJH[PVUZ
MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry 19 Drivetrain
Drivetrain Schematic Source: Romax
DRIVE TRAIN OVERVIEW
Consists of all the rotating components: rotor, main shaft, couplings, gearbox, brakes, and generator
YWTSV^ZWLLKZPKL[V¶YWTOPNOZWLLKZPKL
INTERNAL COMPONENTS Main Shaft, Rotor Lockout , Bearing, Seal, Lubrication, Compression Coupling, Rotor Lock, Connector Plate, Slip Ring Assembly, Transmission Shaft, High Speed Shaft, High Speed Coupling
Brake System (Disc, Calipers, Pads, Hoses, Seals, Housings)
SUPPLIER IMPLICATIONS Main shaft is forged steel, machined and ground at 15- 25 tons weight
Machined steel couplings, bolted, keyed,some with rubber
20 MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry Gearbox
Gearbox Schematic Source: Romax
Gearbox TIP Gearbox Manufacturing occurs at 3 US locations: GEARBOX OVERVIEW :LQHUJ\ *(&OLSSHU 10 - 20 rpm to 1500-1800 rpm on high speed shaft 3 more locations 6ULVM[OLOLH]PLZ[HUKTVZ[L_WLUZP]LJVTWVULU[ZVMH^PUK[\YIPUL in process: Normally planetary or parallel-shaft gearboxes =)0RYHQWDV%RVFK
Not used on direct-drive wind turbines Two more plants
INTERNAL COMPONENTS are beginning construction Housing, Planetary Gears (ring gear, sun gear, planet gear, carrier gear), Hollow Shafts Bearings (planet bearing, carrier bearing, shaft bearing), Hoses, Torque Arm Systems, There is a growing Lubrication System, Cooling System, Hoses, Sensors (temperature, particulate) market to main- tain and repair the WXUELQHVLQ operation today
MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry 21 Generator
diagram
Generator and heat exchanger Source: Ingeteam
Generator
TIP Most generators GENERATOR OVERVIEW have been imported Converts mechanical energy into electric power Generators represent [`WLZHYLZ`UJOYVUV\ZHZ`UJOYVUV\ZKV\ISLMLKPUK\J[PVUNLULYH[VY a growing industry 4VZ[JVTTVUPZ+-0.+V\ISL-LK0UK\J[PVU.LULYH[VY potential investment PMG (Permanent Magnet Generator) most commonly used on direct-drive turbines opportunity and are growing in popularity Northern Power builds their own INTERNAL COMPONENTS Housing, Windings (stator & rotor), Lamination, Rotor Magnets, Ingeteam from Commutator and Brushes, Bearings (rotor front bearing, rotor rear bearing, autolube system), Spain is building Encoder, Shaft, Slip Rings (slip ring and brush), Exciter, Couplings, Generator Temperature Sensor, an assembly plant Coils, Cooling System (Radiator, Hoses, Filters, Cooling Fan, Pump, Pump Motor, Reservoir, in Wisconsin Heat Exchanger)
22 MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry Electrical
diagram
Power converter TIP Source: Ingeteam Most opportunities ELECTRICAL OVERVIEW are manufacturing Power converters change electric power from one form to another; to the Tier 2 & 3 DC to AC or AC to DC, or one voltage to another components Inverters convert DC to AC Switchgear connects or disconnects wind power plants from the grid Transformer adjusts the voltage /0./,9-9,8<,5*@9,73(*,4,5;7(9;:6567,9(;05.;<9)05,:
Electrical System parts Electronic Control parts Sensors
INTERNAL COMPONENTS Power Converter , Converter with IGBT Module (on the rotor side), DC Intermediate Circuit, Power Inverter, (on NYPKZPKL7V^LY-HJ[VY*VYYLJ[PVU:`Z[LTJHWHJP[VYZOHYTVUPJZÄS[LYJVU[YHJ[VY:VM[:[HY[LY4V[VY*VU[HJ[VY Wiring and Connections (main contactor), Main Disconnect, Fuse Main Circuit Breaker, Relay, Cabinet Heater, Power Supply, Grounding System, Main Transformer (pad mounted or nacelle mounted)
MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry 23 Nacelle Housing
TIP These housings are built as subassembly containing many components and Nacelle housing shipped to assembly NACELLE HOUSING OVERVIEW SODQWIRUÀQDO assembly Is the housing for all major components of a wind turbine Provides weather protection
5VYTHSS`THKLMYVTSPNO[^LPNO[TH[LYPHSZZ\JOHZÄILYNSHZZHYV\UKHZ[LLSMYHTL
INTERNAL COMPONENTS Fiberglass Shell with Structural Steel Frame, Brackets, Exit Hatch and Latches, Wiring, Lightening Rod, Landing Pad, Ducting
24 MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry Yaw System
)\SSNLHY¶ [VTL[LYKPHTL[LY TIP Have been mostly imported and represents a good manufacturing opportunity for US companies YAW SYSTEM OVERVIEW 6YPLU[Z[OL^PUK[\YIPULPUSPUL^P[O[OL^PUKKPYLJ[PVU VYTV[VYZ\ZLK[VYV[H[L
Includes a parking brake system
INTERNAL COMPONENTS Brake, Calipers, Housing, Pads, Seals, Hoses, Electric or Hydraulic Drive, Reducer Gearbox, Lubrication System, Fan, Pinion gear, Polymer Slide Pads/Discs, Encoder
MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry 25 Pitch System
Pitch Control Cyclinder
TIP If you supply components for View of Pitch System HOHFWULFDO hydraulic or PITCH SYSTEM OVERVIEW PHFKDQLFDOV\VWHPV Feathers the blades to best capture the energy from the wind you could have an Used to stall the rotor to help slow down the turbine opportunity Geared slew ring with electric or hydraulic driver in this part of a wind turbine Each blade controlled separately
INTERNAL COMPONENTS ,3,*;90*70;*/:@:;,4 Motor, Cooling Fan, Motor Brake, Pitch Gear, Gear Reducer, Limit Switch , Battery, Battery Charger, Seals, Auto-Lube System, Rotary Electric Drive (pinion, power electronics/drive, cabling, contactor/circuit breaker fuse, encoder, power supply, heater, misc. electrical)
/@+9(<30*70;*/:@:;,4 Linear Hydraulic Drive, Accumulator, Pump & Pump Motor, Proportional Valve, Position Sensor, Hoses/Fittings, Spherical Bushing, Cylinder, Linkage, Position Controller, Limit Switch
4,*/(50*(370;*/:@:;,4 Bearings and Lubricants, Motors, Gears, Pitch Cylinder Linkage
26 MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry Control System
Wind sensor TIP Source: NRG If you supply VHQVRUVFRQWUROOHUV SRZHUDPSOLÀHUV CONTROL SYSTEM OVERVIEW actuators or related Balances and optimizes machine operation and power production FRPSRQHQWVWRGD\ you could have Maximizes fatigue life an opportunity in Maximize energy production wind today Provide means to monitor
INTERNAL COMPONENTS :,5:69: Speed, Position, Flow, Temperature, Current, Voltage
*65;9633,9: Mechanical Mechanisms, Electrical Circuits, Computers
76>,9(4730-0,9: :^P[JOLZ,SLJ[YPJ(TWSPÄLYZ/`KYH\SPJ7\TWZHUK=HS]LZ
(*;<(;69: Motors, Pistons, Magnets, Solenoids
INTELLIGENCE Computers, Microprocessors
MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry 27 SectionSection III III
Doing Business with OEMs
28 MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry SectionSection III III Doing Business with OEMs
Supply Chain Opportunities
>PUKLULYN`6,4ZMVY[OLTVZ[WHY[KVU»[THU\MHJ[\YL[OLJVTWVULU[ZWYVK\J[ZYLX\PYLK[VI\PSK a wind turbine. These companies are primarily engaged in designing the turbine, outsourcing parts, assembly, testing and shipping.
6,4ZNLULYHSS`W\YJOHZLTHU\MHJ[\YLKJVTWVULU[ZPU[^V^H`Z;OLTVZ[JVTTVUTL[OVKPZI`OPYPUN HU0U[LNYH[VYJVTWHU`^OPJOWYVJ\YLZHUKHZZLTISLZJVTWVULU[ZKPYLJ[S`MYVT;PLY Z\WWSPLYZ¶ 6,4ZW\YJOHZLHIV\[ VM[\YIPULJVTWVULU[Z[OV\NO0U[LNYH[VYZ
6,4ZVUS`W\YJOHZLHIV\[ VMJVTWVULU[ZKPYLJ[S`¶THU\MHJ[\YLKI`;PLYZ\WWSPLYZ The total number of parts purchased directly by OEM’s for each turbine is estimated to total between 800 and 1000 – out of the 8,000 components in a turbine.
Following are the types of components that are purchased directly as well as through intergrations. Please note that each of these categories includes a number of sub-systems.
TOWER: NACELLE: FOUNDATION: Towers Nacelle Cover Rebar Ladders Nacelle Base Concrete Lifts Heat Exchanger Casings Controllers ROTOR: Generator OTHER: Hub Power Electronics Transformers Nose Cone Lubricants Bolts/Fasteners Blades Filtration Wire - Composites Insulation Paints and Coatings - Blade Core Gearbox Lighting Pitch Mechanisms Pump Lightning Protection Drives Drivetrain Steelworking/Machining Brakes Ceramics Communication Devices Rotary Union Shaft Control and Condition Monitoring Equipment Electrical Interface and Connections Batteries Bearings Brakes
MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry 29 Tier One Direct Purchase
DIRECT PURCHASE - TIER ONE Foundry Electrical Hydraulics Composites Misc. Forge Machine Fabricator & Electronics Shop Bases Bus Bars Accumulator Insulators Packaging Main Shafts Bases Brackets Housings Cables, Wires, Ducting Spinner Plastic Shrink Discs Housings Plates Covers Components /\IZ *HIPUL[Z -PS[LYZ 9\IILY @H^.LHYZ /\IZ 9LHY-YHTLZ Components Controls Heat Signage Large Main Shafts Structural Exchangers Fasteners Supports
Electronic Hoses Transportation Retainers Seal Components & Logistics Labyrinths Frames
Harnesses Lube Systems
Heating Motors Elements Instrument- Pumps ation Lighting Rotary Unions Motors Seals Sensors Valves
Software
30 MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry The Role of Integrators: OEMs’ Other Customers
0DLQ,QWHJUDWRUV8VHG%\:LQG7XUELQH2(0VDQG7KHLU7LHU 6XSSOLHUV
These tiers of suppliers supplies the following general types of components: castings, forgings, fasteners, YVKZ[\IPUNOVZLZZ[LLSWSH[LJVWWLYWSH[L^PYPUN^PYPUNOHYULZZLZJHISLS\IYPJHU[ZJVVSPUNÅ\PKZ coatings, rubber isolation mounts, seals, gears, and retainers.
6[OLYJVTWVULU[ZPUJS\KL!
BRAKES: calipers, discs, hoses, housings, pads, seals
BEARINGS: lubricants, rolling elements, steel, seals
GENERATORS AND TRANSFORMERS: brushes. coils, bearings, cooling systems, couplings, housings, laminates, shafts, windings, controls
GEARING AND DRIVES: actuators, bearings, brakes, cooling systems, drive systems, gears, housings, lube systems, pitch drive, UPS, shafts
TOWERS:JVH[PUNZKVVYZLSLJ[YPJJHISPUNLSL]H[VYZÅHUNLZOVPZ[ZSHKKLYZSPNO[PUNWSH[LWSH[MVYTZ
BLADES:ÄILYNSHZZYLZPUZJVH[PUNZJVYLTLZOWYV[LJ[P]LÄSTYVV[ZZ\IZ[YH[LZZ[\KZIHYYLSU\[Z
NACELLE STRUCTURE:IYHJRL[ZJYHULZ`Z[LTK\J[PUNÄILYNSHZZZOLSSMYHTPUNOHYULZZLZ insulation, lighting, polymer enclosure, power distribution
TIP In addition to OEM SDUWV\RX may also want to investigate supplying service parts
MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry 31 Tier One Integrator
The following is an example of a tier one integrator within the tower supply chain. The tower manufacturer is a focused fabricator who forms, welds, and assembles a complete tower. They are responsible for integrating components from the following suppliers:
Product Supplier Steel plate Steel mill -VYNLKÅHUNLZ -VYNLYZ Tower top Fabricators Door frames Fabricators Platforms Fabricators Ladders Fabricators Fasteners Forgers Electrical components Extruders, molders, assemblers Coatings Coaters
6[OLY4HPU:`Z[LT0U[LNYH[VYZ!)SHKLZ)LHYPUNZ)YHRL:`Z[LTZ Generator, Transformer, Gearing & Drives, Towers, Nacelle Housing
TIP A majority of the components found in a wind turbine are produced by tier WZRWKUHH IRXU VXSSOLHUVQRWWKH wind turbine manu- IDFWXUHU7RÀQG\RXU FXVWRPHUFRQWDFWWKH integrator who pro- vides a sub-system for the turbine.
32 MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry Additional Supply Chain Opportunities
0UHKKP[PVU[VZLSSPUNWHY[ZKPYLJ[S`[VHU6,4VY[OYV\NOHUPU[LNYH[VY[OLYLHYLV[OLYVWWVY[\UP[PLZMVY manufacturers to participate in the wind energy market.
This includes supplying parts for maintenance, repair and operations of wind farms. The frequency of repair ranges from 1 out of 2 turbines per year on electrical components to 1 out of 10 on larger gearboxes, generators and blades. The goal is to minimize downtime which ranges from 1 day for LSLJ[YPJHSJVTWVULU[ZHUK\W[V KH`ZMVYNLHYIV_LZNLULYH[VYZHUKISHKLZ
0[»ZHSZVPTWVY[HU[[VYLJVNUPaL[OH[J\YYLU[S`[OLYLHYLHIV\[[\YIPULZV\[VM^HYYHU[`HUKZVTL additional 5,000 wind turbines go out of warranty each year. Some of the types of services/products that are needed for wind farm operations are listed below.
6[OLYUKHUKYK[PLYVWWVY[\UP[PLZL_PZ[MVYZ\WWSPLYZVMWHY[ZPU^PUKMHYTJVUZ[Y\J[PVU;OLZLPUJS\KL JVUZ[Y\J[PVUZP[LLSLJ[YPJHSJVTWVULU[ZSVNPZ[PJZHUKLYLJ[PVUÄ_[\YLZHUJOVYPUNZ`Z[LTZMHZ[LULYZ JHISPUN[YHUZMVYTLYZSPNO[PUNZ\IZ[H[PVULX\PWTLU[HUK6 4Z[Y\J[\YLZ0U[OLZLZP[\H[PVUZ[OL JVU[YHJ[PUNJVTWHU`^V\SKNLULYHSS`IL[OLKL]LSVWLYVM[OL^PUKMHYTUV[[OL[\YIPUL6,4VY0U[LNYH[VY
O&M SERVICES AND PRODUCTS NEEDED:
MAINTENANCE SERVICES: OFF-SITE SUPPORT: >HYYHU[`HUK6\[VM>HYYHU[` Generators Uptower Upkeep (PM) Gearboxes Cleaning Blades Accompanying Repair CONSTRUCTION SITE: Fixtures MAINTENANCE AND REPAIR PARTS: Embed Rings Electrical System Parts Rebar Electrical Control Anchor Rods Sensors Fasteners Hydraulic System Electrical Cabling @H^:`Z[LT Transformers Rotor Hub Tower Wiring Mechanical Brake Lighting Rotor Blades Substation Equipment Gearbox 6 4)\PSKPUN Generator Support and Housing Drivetrain
MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry 33 Section IV
Meeting OEM Requirements
34 MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry Meeting OEM Requirements
>PUK[\YIPUL6,4ZHYL]LY`JVUZLY]H[P]LPU[OLPYZ\WWSPLYX\HSPÄJH[PVUWYVJLZZHUKOH]LL_[YLTLS` demanding quality requirements. They require consistent and zero defect quality.
>OLUZJYLLUPUNWYVZWLJ[P]LZ\WWSPLYZ6,4ZSVVRMVYJSLHYL]PKLUJLVM[OH[JVYLJVTWL[LUJ`4HU` YLX\PYL0:6 [VILNPUX\HSPÄJH[PVUWYVJLZZHUKJVUK\J[YPNVYV\ZH\KP[ZHIV]LHUKIL`VUK[V0:6 Z[HUKHYKZWYPVY[VWSHJPUN[OLÄYZ[VYKLY)LJH\ZLVM[OLZLOPNOX\HSP[`Z[HUKHYKZP[TH`[HRL\W TVU[OZ MYVT[OLÄYZ[JVU[HJ[\U[PSYLJLPW[VM[OLPUP[PHSWYVK\J[PVUVYKLY
Driving the need for these high quality standards revolves around the extremely high cost of repair.
Wind turbines are designed for a 20+ year lifespan, operating in harsh environmental conditions usually in remote locations and with the most sensitive components being 300’ up in the air. The cost of repairing a UHJLSSL¶^OPJOT\Z[ILKPZTHU[SLKVU[OLNYV\UK¶LHZPS`Y\UZ\W^HYKZVM 2HUKYLWHPYLZ[PTH[LZ often cost 10 times that of original manufacturing.
TIP Wind turbine engineering often takes years and requires formal design FHUWLÀFDWLRQ$IWHUGHVLJQV DUHFHUWLÀHGFKDQJHV are rarely permitted. $VDUHVXOWFRPSRQHQW production for wind turbine parts is almost always contract manufacturing. OEM–Supplier builds to print O&M– Supplier repairs or replaces part.
MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry 35 What is Expected From a New Supplier
:LQG7XUELQH2(0VDUH&RQVHUYDWLYHDQGKDYH+HDY\4XDOLÀFDWLRQ5HTXLUHPHQWV
6,4ZOH]L]LY`ZWLJPÄJL_WLJ[H[PVUZ^OLUJVUZPKLYPUNHUL^Z\WWSPLY These include:
CONSISTENT QUALITY COST COMPETITIVE 0:6 VY*VTWSPHU[ 6MMZOVYL7YPJL7VPU[Z Logistic Advantages PRODUCTION CAPABILITIES >VYSK*SHZZ6WLYH[PVU High Mix - Low Volume Job Shop < Wind > Auto RELIABILITY OF DELIVERY Available Capacity Equipment Redundancy Right -Sized Vendor Redundancy Expandable Demonstrated Results Liquidated Damages
DRIVING FACTORS IN THE WIND INDUSTRY: ;OL[LJOUPJHSKPMÄJ\S[`VM[OLHWWSPJH[PVU The challenges of performing maintenance The high cost of repair
36 MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry Comparison of Automobile Gearboxes vs. Wind Turbines Gearboxes
Auto Wind Turbine Production per week ¶ \UP[Z ¶ \UP[Z
Typical operation OV\YZKH` ¶OV\YZKH`
Design life ¶`LHYZ ¶ `LHYZ
Where maintenance is performed Network of garages/ 90 meters in the air in a dealers remote location
Machinery replacement 7LYMVYTLKH[NYV\UKSL]LS 6M[LUYLX\PYLZJYHULHUK by hand & portable equipment special transport
Cost of major mechanical repair
MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry 37 Market Entry Tips
FIND THE BEST FIT 6YPNPUHS,X\PWTLU[)LZ[;PLY Repair and Maintenance
INVEST IN ROBUST OPERATIONS Quality Management Systems Multiple processes Ultra responsiveness
MARKET YOUR COMPANY Identify the buyers Differentiate yourself Get to the buyers!
TAKE A RUTHLESS APPROACH TO COST REDUCTION Focus on LEAN operations Think world class
REMEMBER OEM MANUFACTURING REQUIREMENTS Capital equipment Long-term planning Hyper-competitiveness
KEEP IN MIND CHANNEL OPTIONS Start at a lower tier Team with a partner Try component repair
38 MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry What Successful Companies Have Done
MAKE SMART INVESTMENTS Begin at a Lower Tier .YV^6UL*\Z[VTLYH[H;PTL
PLAN FOR NEEDED INVESTMENTS Process Improvement Quality Systems Capital
DEVELOP MARKETING STRATEGY Identify Target Customers Create a Winning WIND “Pitch” Launch Cost-Effective Sales Effort
MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry 39 Wind Turbine OEM and Tier One Suppliers in the United States*
OEM COMPANY US HEADQUARTERS STATE WEBSITE
Acciona Energy West Branch IA www.acciona-na.com American Tower Co. :OLSI` 6/ ^^^HTLY[V^LYJVT Ameron Rancho Cucamonga CA www.ameronwindtowers.com Broadwind Energy Naperville IL www.bwen.com Clipper Windpower Cedar Rapids IA www.clipperwind.com Danotek Canton MI www.danotekmotion.com DMI Industries Fargo ND www.dmiindustries.com DMSE/Dewind 9V\UK9VJR ;? ^^^KL^PUKJVJVTLUN Dragon Wind 3HTHY *6 ^^^TVKLYU\ZHJVTKYHNVUWYVK\J[ZKYHNVU^PUK Fuhrlaender Bristol RI www.fuhrlaender.de/index_en.php Gamesa Langhorne PA www.gamesacorp.com/en GE Energy Atlanta GA www.gepower.com Goldwind Chicago IL www.goldwindglobal.com Katana Summit Columbus NE www.katana-summit.com LM Wind Power Grand Forks ND www.lmwindpower.com Mitsubishi Newport Beach CA www.mpshq.com Molded Fiber Glass (ZO[HI\SH 6/ ^^^TVSKLKÄILYNSHZZJVT Nordex Chicago IL www.nordex-online.com/en Nordic Windpower Berkley CA www.nordicwindpower.com Northern Power Systems Barre VT www.northernpower.com REpower +LU]LY *6 ^^^YLWV^LYKLPUKL_WOW&PK$ 3$ SIAG Aerisyn Chattanooga TN www.siag.de Siemens Wind Power 6YSHUKV -3 ^^^LULYN`ZPLTLUZJVTLU[Y`LULYN`\Z SMI & Hydraulics Inc. Porter MN www.smihyd.com Suzlon Chicago IL www.suzlon.com TBailey Anacortes WA www.tbailey.com Thomas & Betts Corp. Memphis TN www.tnb.com TowerTech 6RSHOVTH*P[` 62 ^^^[V^LY[LJOPUJJVT TPI Composites Scottsdale AZ www.tpicomposites.com Trinity Structural Towers +HSSHZ ;? ^^^[YPUP[`[V^LYZJVT Upwind Solutions 4LKMVYK 69 ^^^\W^PUKZVS\[PVUZJVT Vestas >PUKZVY *6 ^^^]LZ[HZJVTLU
6US`6,4Z^P[O\[PSP[`ZJHSLPUZ[HSSH[PVUZPU HYLPUJS\KLKVU[OPZSPZ[
40 MANUFACTURING SUPPLIER HANDBOOK FOR The Wind Energy Industry For additional information on Supplier Handbooks, contact: GLWN™ - Global Wind Network www.glwn.org 4855 West 130th Street, Suite 1, Cleveland, Ohio 44135-5137 [email protected] AWEA - American Wind Energy Association www.awea.org 1501 M Street NW, Suite 1000, Washington, DC 20005 [email protected] BGAF - BlueGreen Alliance Foundation www.bgafoundation.org/cemc 2828 University Ave. SE, Suite 200, Minneapolis, MN 55414 [email protected]