Projects Anticipating and Meeting Wind Farm Site Challenges • Conversation: Rob Morgan, RES Americas

WIND SYSTEMS WIND MAGAZINE

GIVING WIND DIRECTION Projects Anticipating and meeting wind farm site challenges • Conversation: Rob Morgan, RES Americas

PROJECTS » Study: Price of • Project Profile: wind in the U.S. at Chokecherry and Sierra all-time low, Madre Wind Project page 12 » Maintenance cost reduction achieved through comprehensive fleet monitoring, page 38 SEPTEMBER 2014 SEPTEMBER

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16 Avoiding an Ill Wind By Andrew Zlotnick, LEP, LEED AP and M. Michael Callahan, PE Anticipating and meeting site challenges on wind projects ALSO IN INFOCUS 20 Record project development 26 PROFILE: spurred by PTC and other Chokecherry and Sierra Madre Wind market factors Energy Project 22 EDF EN Canada aligns with 28 CONVERSATION: Rob Morgan McLeod Lake Indian Band for RES Americas three possible wind farms in British Columbia

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SECTIONS Volume 06 Issue 09 08 DIRECTION Policy • Advocacy • Business • Finance • Legal • Environment • International BOEM defines 10 Fishermen’s Energy signs Department offshore areas off of Energy grant the coast of North 12 Study: Price of wind in the U.S. at all- Carolina time low

CONSTRUCTION INNOVATION 30 Gamesa concludes 32 Technological advances to take turnkey construction center stage at WindEnergy of its first wind farm Hamburg in Chile MAINTENANCE 31 Nordex to build 37.5 40 Maintenance cost reduction achieved MW Orla wind farm in through comprehensive fleet Poland monitoring

MANUFACTURING CROSSWINDS 48 Vestas sponsors first-ever Danish 45 Acciona to pilot entry to Volvo Ocean Race Moventas’ high torque density gearbox

44 ROEMHELD launches maintenance- free rotor locks

Wind Systems (ISSN 2327-2422) is published monthly by Media Solutions, Inc., 266D Yeager Parkway Pelham, AL 35124. Phone (205) 380-1573 Fax (205) 380-1580 International subscription rates: $72.00 per year. Periodicals Postage Paid at Pelham AL and at additional mailing offices. Printed in the USA. POSTMASTER: Send address changes to Wind Systems magazine, P.O. Box 1210 Pelham AL 35124. Publications mail agreement No. 41395015 return undeliverable Canadian addresses to P.O. Box 503 RPO West Beaver Creek Richmond Hill, ON L4B4R6. Copyright 2006 by Media Solutions, Inc. All rights reserved.

4 SEPTEMBER | 2014

editor’s desk September 2014

Recently, on a rare occasion of watching one of the network morning shows, I caught the show’s “tech guru” reviewing the newest gadgets. Among them was the newest cell phone to hit the market.

During the two-minute segment, he is limited when you’re moving in gave a general overview of the de- a direction that takes you through vice’s many features, most of which different zones. didn’t differ from other phones In other words, the bars can be currently on the market. misleading. in the U.S. These projects are expect- At the end of his vocal sprint — I was reminded of this when ed to be completed by the end of the reminiscent of a Micro Machines browsing through AWEA’s U.S. Wind year in order to take advantage of the commercial — he felt the need to Industry Second Quarter 2014 Market Production Tax Credit. add the following: Report — specifically the graphical rep- That’s not just traveling along jump- “Oh, and it makes phone calls.” resentation of annual installed capacity ing to a new cell tower. That’s upgrad- That’s what we expect, right? A reported over time. ing from a flip phone to the iPhone 8. “phone” is useless if it can’t place or When separated into blocks of years, It’s an accomplishment worth cele- receive a call. With all the advance- the installed capacity graph mimics brating. But before we get too carried ments in mobile technology, the cell the little icon at the top of your phone away, please take into consideration carriers still tout the availability and screen indicating signal strength. what AWEA and other groups have robustness of their network above For the last several years, it looks as been stressing for last few years — con- all else. though the industry has been cruising sistency and stability. We want to be able to make a call down the highway at a pretty good In order to keep from dropping the when we need to do so. When we clip, bouncing back and forth between call, we have to be focused on not drop- can’t, we get frustrated. Think about cell towers — strong, then weak, then ping the ball. it. How many times have you been strong again. Can you hear me now? … Good. driving down the highway and had In 2013, we might as well have the call drop out? thrown up the “No Service” icon. But Thanks for reading, If you’re like me, you likely here we are, halfway through 2014, and uttered something to the effect of: judging solely by this graph, you’d think “What the what?! I just had four we’re scratching our heads and holding bars!” our phone skyward, searching for a In that moment, our intense focus signal. But that’s not the case. on that phone call is interrupted by Again … the bars can be misleading. something that is out of our control. As AWEA’s Emily Williams points Stephen Sisk, editor If we were to look at the situation out in this issue of Wind Systems, there Wind Systems magazine logically, we’d realize that we’re are currently more than 14 GW of wind [email protected] in-between cell towers. Coverage projects currently under construction (800) 366-2185 ext. 209

6 SEPTEMBER | 2014 Contributors Michael Callahan is Vice President at Fuss & O’Neill. With over 25 years of experience in electrical and mechanical engineering, Mike’s areas of expertise include all aspects of electrical building systems, as well as energy systems with a focus on economic assessment and design.

Jack Wallace started in the wind industry as a wind turbine technician in 1985. Since then he has trained hundreds of technicians in electrical troubleshooting, mechanical systems, com- posites, and wind energy related safety. He has deep understanding and experience of what it takes to run a wind farm and is always ready to help others in wind to successfully run their wind power plants. Jack is listed as an inventor on multiple patents related to wind energy improvements. He has been working with the same wind group for 20 years, currently Frontier Pro Services.

Ashley Crowther is vice president of engineering at Romax Technology and runs the mechanical engineering group based out of Boulder, Colorado. He holds a Ph.D. in rotating machinery engineering and has run hundreds of consultancy projects for the wind turbine industry in the U.S. His focus covers both practical engineering, such as failure analysis, vibration di- agnostics, and machine design; as well as academic topics such non-linear dynamic behavior in the drivetrain. Tugan Eritenel is a senior engineering analyst at the Romax Wind Engineering Technical Center in the U.S. His work experience in wind energy since 2011 includes vibration based condition monitoring of wind turbines, operational data analysis, nonlinear dynamics of gears, torque converters and clutches, and basic gear and bearing design. He has a PhD in mechanical engineering from The Ohio State University, where he has worked as a research assistant in the Gear Dynamics and Noise Laborato- ry and the Vibrations and Dynamics Laboratory. Matthew Whittle has over four years of experience in wind turbine reliability and condition monitoring. He has worked on many R&D and consultancy projects to reduce the cost of O&M in the wind industry through predictive maintenance technologies. He is currently the Prod- uct Manager for InSight, Romax’s wind turbine condition monitoring software. Emily Williams is Manager, Industry Data & Analysis for the American Wind Energy Asso- ciation. In this position, she manages AWEA’s data collection and analytical agenda, including energy sector statistics, wind project and manufacturing data, and wind market economics. She also is the staff liaison to AWEA’s Operations & Maintenance Working Group. Andrew Zlotnick is Senior Vice President at Manchester, Connecticut-based Fuss & O’Neill. A Licensed Environmental Professional, Andy has over 29 years of experience working on investigation and remediation projects, including Superfund, RCRA Corrective Action, TSCA, UST closure, and property transfer sites for industrial clients. He has expertise in brownfield site investigation and remediation for developers, municipalities, and public utility companies. windsystemsmag.com 7 10 Fishermen’s Energy signs Department of Energy grant 14 Hoosier Energy signs PPA with EDP Renewables DIRECTION Policy • Advocacy • Business • Finance • Legal • Environment • International BOEM defines offshore areas off the coast of NC Three sites amassing over 300,000 acres have been designated for commercial offshore wind energy development

In mid-August, the Bureau of Ocean “Today represents an important conflicts with other important uses. Energy Management (BOEM) has step forward for North Carolina in We look forward to working with the defined three Wind Energy Areas harnessing the vast wind energy state of North Carolina, industry and offshore North Carolina, which total potential along the Atlantic Coast a broad range of stakeholders as this approximately 307,590 acres, for to power homes and strengthen our exciting process continues to further potential commercial wind energy clean energy economy,” Department commercial wind development in the development. of the Interior Secretary Sally Jewell United States.” The areas include the Kitty Hawk said regarding the announcement. BOEM has awarded five commercial Wind Energy Areas (about 122,405 “This milestone is the result of wind energy leases off the Atlantic acres), the Wilmington West Wind collaboration with stakeholders and coast: two non-competitive leases (for Energy Areas (about 51,595 acres) and partners at all levels to identify areas the proposed Cape Wind project in the Wilmington East Wind Energy off the coast with great resource Nantucket Sound and an area off Del- Areas (about 133,590 acres). potential while also minimizing aware) and three competitive leases

8 SEPTEMBER | 2014 (two offshore Massachusetts-Rhode BOEM is only considering the plan and a site-specific environmen- Island and another offshore Vir- issuance of leases and approval of tal analysis. ginia). The competitive lease sales site assessment plans at this time. If generated more than $5 million in leases are issued, any proposal for a high bids for more than 277,500 acres commercial wind energy facility will — U.S. Department of the Interior, in federal waters. BOEM will hold a require a construction and operations Bureau of Ocean Energy Management competitive auction for an area offshore Maryland on Aug.19, 2014, and expects to hold additional competitive auctions for wind energy areas offshore Massachusetts and New Jersey in the coming year. “Today is a significant step forward in facilitating the responsible development of renewable, clean energy offshore the United States and a true testament to the dedication of the North Carolina Intergovernmental Renewable Energy Task Force to ensure that we are moving forward in a safe and smart manner,” said BOEM Acting Director Walter Cruickshank. Each of the three Wind Energy Areas has been designed to make available areas that are attractive for commercial offshore wind development, while also protecting important viewsheds, sensitive habitats and resources and minimizing space use conflicts with activities such as military operations, shipping and fishing. BOEM worked closely with the United States Coast Guard to ensure that development in the identified areas would not pose significant risks to navigational safety. BOEM also worked with the National Park Service to address concerns regarding potential visual impacts to the Cape Hatteras National Seashore and the Bodie Island Lighthouse. As a result, BOEM refined the areas originally considered for commercial wind energy development during the process of defining the Wind Energy Areas. Before any leases are offered for competitive auction, BOEM will complete an Environmental Assessment to determine potential impacts associ- ated with issuing leases and approving site assessment activities in the Wind Energy Areas, in accordance with the National Environmental Policy Act.

windsystemsmag.com 9 DIRECTION

Fishermen’s Energy signs Department of Energy grant

At the end of Steel Pier, with the ocean as a backdrop, infrastructure,” said Chris Wissemann, Fishermen’s Fishermen’s Energy, U.S. Senator Robert Menendez, Energy CEO. “The support provided by Congress, State Senator Jim Whelan, Atlantic City Mayor Don specifically the NJ delegation, and the Department Guardian, Jose Zayas, U.S. Department of Energy of Energy is critical to bringing offshore wind to Director of the Wind and Water Power Technologies the United States. Our goal here in Atlantic City is Office, and numerous officials, memorialized the to build a commercially operational wind farm that $46.7 million of grant funding over four years to demonstrates job creation and specifically to show accelerate the commercialization of innovative that these types of projects create benefits that far offshore wind technologies in the United States. exceed their costs,” Wissemann continued. This funding will supplement the investment Fishermen’s Energy has all Federal and State by Fishermen’s Energy principals to finalize permits necessary for construction of the first construction planning, fabrication, and deployment demonstration offshore wind farm to be built in the to achieve commercial operation by 2016, of a US, making the Atlantic City resort the birthplace demonstration wind farm of five turbines 2.8 miles of offshore wind in the Americas. Construction in off of Atlantic City, potentially the first offshore Atlantic City is planned to commence onshore in wind farm in America. 2015 with offshore construction and commissioning “Clean, responsible energy development projects by Fishermen’s of the first grid connected US like this bring good - paying jobs to our state and offshore wind farm in 2016. help us modernize New Jersey’s economy,” said In 2012, DOE announced the start of an initiative Senator Robert Menendez. “We must continue to capture the potential of wind energy off looking into innovative energy options — like clean American coasts. As part of a planned six-year $180 wind and solar projects — that can one day become million initiative, these offshore wind projects the next energy giant and can reinvigorate our will accelerate the deployment of breakthrough workforce in the 21st century global economy.” wind power technologies that will help diversify “Projects like Fishermen’s Atlantic City wind our nation’s energy portfolio, promote economic farm and the other projects sponsored by the development, and launch a new industry here in Department of Energy are a first step in the America. direction of a building a robust sustainable energy — Source: Fisherman’s Energy

Juhl Energy acquires two wind farms in Iowa

Juhl Energy, Inc. has announced that the company “We believe that building our asset ownership and has completed its previously announced acquisition operating division, with its predictable revenue of two operating wind farms in Iowa. The $4 million and cash flow, is the foundation for the ongoing acquisition closed on August 11, and the wind strength of our company. These two Iowa projects projects are now wholly-owned by Juhl Energy. are representative of the hundreds of projects under The two GE XLE 1.62 MW wind turbines are 50 MWs — the market sector where Juhl stands head located in North Central Iowa near the towns of and shoulders above others in its ability to own, Manley and Kensett. The wind turbines are installed operate and maintain such assets.” on private farmland approximately 10 miles apart “The Iowa projects are being acquired with from each other and have been commercially bank financing and our Juhl Renewable Asset, Inc. operating since 2011. preferred stock,” continued Mitola. “Currently our “This transaction underscores our ongoing JRAI Preferred stock is only available to accredited commitment to building our residual, independent investors who have an existing relationship with the power production business made up of wind farms company.” today and other forms of renewable energy in the future,” stated John Mitola, President of Juhl Energy. — Source: Juhl Energy, Inc.

10 SEPTEMBER | 2014 Vestas, EP Global expand Wind for Prosperity into Africa

Vestas and EP Global Energy have been energy infrastructure within Africa Morten Albæk, Vestas Group Senior working since March on developing a and the Middle East. Vice President & CMO, concludes, donor-funded wind farm in Jordan to According to Efthyvoulos “This agreement is another important help the country address its growing Paraskevaides, chairman of EPGE, milestone — especially for Jordan, energy challenges, which are being “We are delighted with our expanded which is facing growing challenges exacerbated by the influx of refugees alliance with Vestas, to become in providing clean, affordable, and as a result of the ongoing conflict in an official Wind for Prosperity reliable power. Our partnership Syria. The burdened communities will Development Partner within with EP Global Energy continues benefit from the clean, reliable, and Africa and to further solidify our to expand, and look forward to locally produced electricity provided collaboration with Vestas in our establishing Wind for Prosperity by the project to meet the power needs other developments with our focus projects in other markets.” of local consumers. The project is countries of EMEA. Bringing clean, The Memorandum of expected to be completed during 2015. cost-effective, and locally produced Understanding signed on August With the signing of the expanded electricity to those communities that 5 expands on the MOU the parties MOU EP Global Energy becomes need it most is among our highest signed in March and further solidifies an official Wind for Prosperity priorities, and we look forward to the collaboration between Vestas and Development Partner for the African working with Vestas to bring multiple EP Global Energy, which also includes continent. Vestas and EPGE will projects to fruition. We are focused the 117 MW Al Tafila project in collaborate to deploy wind-diesel on jointly delivering our donor project Jordan, announced in December 2013. hybrid systems to help improve access for Jordan as a first priority, and to electricity for communities that to progress our efforts in Africa in currently have no or only limited parallel.” — Source: Vestas

windsystemsmag.com 11 DIRECTION

Study: Price of wind in the U.S. at all-time low Report from Berkeley National Laboratory shows that wind’s competitiveness with other generation sources has also improved

Wind energy pricing is at an 1.87 MW in 2013), the average MWh. This level is lower than all-time low, according to a new turbine hub height has increased the previous lows set back in the report released by the U.S. De- by 45 percent (to 80 meters), 2000-2005 period, which is nota- partment of Energy and prepared and the average rotor diameter ble given that wind projects have by Lawrence Berkeley National has increased by 103 percent increasingly been sited in lower Laboratory (Berkeley Lab). The (to 97 meters). This substantial wind-speed areas. Wind energy prices offered by wind projects to scaling has enabled wind project prices are generally lowest in the utility purchasers averaged just developers to economically build central portion of the country. $25/MWh for projects negotiat- projects in lower wind-speed The continued decline in aver- ing contracts in 2013, spurring sites, and is driving capacity fac- age wind prices, along with a bit demand for wind energy. tors higher for projects located of a rebound in wholesale power “Wind energy prices — par- in given wind resource regimes. prices, put wind back at the ticularly in the central United Moreover, turbines originally bottom of the range of nation- States — are at an all-time low, designed for lower wind speeds wide wholesale power prices in with utilities selecting wind as are now regularly employed in 2013. Wind energy contracts the low cost option,” Berkeley higher wind speed sites, further executed in 2013 also compare Lab Staff Scientist Ryan Wiser boosting expected capacity very favorably to a range of said. “This is especially notable factors. projections of the fuel costs of because, enabled by technology • Low wind turbine pricing con- gas-fired generation extending advancements, wind projects have tinues to push down installed out through 2040. increasingly been built in lower project costs. Wind turbine • The manufacturing supply chain wind speed areas.” prices have fallen 20 to 40 has experienced substantial Key findings from the U.S. De- percent from their highs back growing pains in recent years, partment of Energy’s latest “Wind in 2008, and these declines but a growing percentage of the Technologies Market Report” are pushing project-level costs equipment used in U.S. wind include: down. Based on the small projects has been sourced do- sample of 2013 wind projects, mestically since 2006-2007. The • Wind is a credible source of new installed costs averaged $1,630/ profitability of turbine suppliers generation in the United States. kW last year, down more than rebounded in 2013, after a num- Though wind power additions $600/kW from the apparent ber of years in decline. Five of slowed in 2013, with just 1.1 GW peak in 2009 and 2010. Among the 10 turbine suppliers with the added, wind power has com- a larger sample of projects largest share of the U.S. market prised 33 percent of all new U.S. currently under construction, have one or more manufacturing electric capacity additions since average costs are $1,750/kW. facilities in the United States. 2007. Wind power currently • Wind energy prices have Nonetheless, more domestic contributes more than 4 percent reached all-time lows, improving wind manufacturing facilities of the nation’s electricity supply, the relative competitiveness of closed in 2013 than opened. more than 12 percent of total wind. Lower wind turbine prices Additionally, the entire wind electricity generation in nine and installed project costs, along energy sector employed 50,500 states, and more than 25 percent with improvements in expected full-time workers in the United in two states. capacity factors, are enabling States at the end of 2013, a deep • Turbine scaling is boosting wind aggressive wind power pricing. reduction from the 80,700 jobs project performance. Since After topping out at nearly $70/ reported for 2012. Despite these 1998-99, the average name- MWh in 2009, the average level- challenges, trade data show plate capacity of wind turbines ized long-term price from wind that a decreasing percentage installed in the United States power sales agreements signed of the equipment used in wind has increased by 162 percent (to in 2013 fell to around $25/ projects has been imported,

12 SEPTEMBER | 2014 when focusing on selected trade trade codes. Domestic content builds anticipated in 2014 and categories. When presented as a has increased and is high for 2015. However, as noted by fraction of total equipment-re- blades, towers, and nacelle Mark Bolinger, Research Sci- lated wind turbine costs, the assembly; domestic content is entist at Berkeley Lab, “Projec- combined import share of se- considerably lower for much of tions for 2016 and beyond are lected wind equipment tracked the equipment internal to the much less certain. Despite the by trade codes (i.e., blades, nacelle. attractive price of wind energy, towers, generators, gearboxes, • Looking ahead, projections are federal policy uncertainty — in and wind-powered generat- for solid growth in 2014 and concert with continued low nat- ing sets) is estimated to have 2015, with uncertain pros- ural gas prices and modest elec- declined from nearly 80 percent pects in 2016 and beyond. The tricity demand growth — may in 2006–2007 to approximately availability of federal incentives put a damper on medium-term 30 percent in 2012-2013; the for wind projects that began market growth.” overall import fraction is higher construction at the end of 2013 when considering equipment has helped restart the domestic — Source: U.S. not tracked in wind-specific market, with significant new Department of Energy

GE to invest in Atria Power’s wind farms in India

arrangements for the projects have not yet been finalized. The projects will use GE 1.6-87.5 wind turbines, serviced by GE under an operations and maintenance agreement, to generate 76 megawatts of the total capacity. Additional turbines will be supplied and serviced by another manufacturer to generate 50 megawatts. Atria Power is managing construction and operations. “GE’s global experience, financial structuring capabilities and commitment to advanced technology complements our strategy to develop low-cost renewable energy projects GE Energy Financial Services has in tariffs. Financial details were not with maximum energy output,” said invested equity in three Atria Power disclosed. Sunder Raju, Director at Atria Power. wind projects under construction in Located in Ananthapur district of Raghuveer Kurada, business leader India, supporting GE’s commitment Andhra Pradesh, the 25.6-megawatt for India and South East Asia at GE to invest USD $1 billion annually in first project is expected to reach Energy Financial Services, added, renewable energy projects worldwide. commercial operations in September. “Partnering with Atria Power, a The wind farms will have a combined The two other projects, each 50 strong and accomplished regional capacity of 126 megawatts and will megawatts, are located in Betul energy player, accelerates our global support the Indian Ministry of New district of Madhya Pradesh, and growth and India wind portfolio.” and Renewable Energy’s program to are expected to reach commercial generate competitively priced grid- operations in December and interactive wind power through feed- June 2015 respectively. Off-take — Source: GE

windsystemsmag.com 13 DIRECTION DOE boosts distributed wind manufacturing funding through competitiveness project The Energy Department and the De- residential, agricultural, commercial, • Endurance Wind Power of Spanish partment’s National Renewable Energy industrial, or community sites, and can Forks, Utah, will test the prototype of Laboratory recently announced fund- range in size from 5 kilowatts (kW) their expanded rotor that allows for a ing for projects led by Pika Energy, to multiple megawatts depending on larger wind-sweep area, leading to a Northern Power Systems, Endurance their application. While these wind more efficient turbine. Wind Power, and Urban Green Energy systems vary widely in size, the CIP • Urban Green Energy of New York that will help drive down the cost of focuses on small and medium-sized City, New York, will test their vertical small and medium-sized wind energy turbines up to 250 kW in rated capac- axis wind turbine against the Ameri- systems. Through the second round ity. Here are the projects announced can Wind Energy Association’s Small of the Competitiveness Improvement for funding: Wind Turbine Performance and Project (CIP), the teams will receive a Safety Standard. The standard was total of $1.27 million between them. • Pika Energy of Westbrook, Maine, created by the small wind turbine In support of the Energy Depart- will improve the performance of industry, scientists, state officials, ment’s Clean Energy Manufacturing their existing components and man- and consumers to provide consum- Initiative, this funding aims to help ufacturing process. Pika will scale ers with realistic and comparable U.S. manufacturers improve their up their existing turbine compo- performance ratings of competing turbine designs and manufacturing nents to roughly twice their current products. processes to reduce hardware costs, size to produce a turbine capable of improve efficiency and eventually producing more energy at a reduced This second round of CIP awards earn certification from accredited end-user cost. Pika will also imple- builds on the success of the first round third-party certification bodies, which ment the use of an injection molding awarded in 2013, through which issue easy-to-understand labels show- technique for manufacturing in Bergey Windpower identified the ing a turbine has met performance and order to produce lighter and stronger component improvements necessary safety testing requirements set by the components. to optimize a turbine for increased wind industry. • Northern Power Systems of Barre, performance and reduced end-user Comprising more than two-thirds of Vermont, will develop and deploy costs, while Pika Energy developed an all wind turbines installed in the Unit- an innovative blade designed for low advanced blade manufacturing process ed States in the last decade, distributed wind speed applications. Northern they plan to further improve in this wind energy systems provide clean, Power Systems will also model and second round. renewable energy to consumers and test an advanced control method reduce their energy bills. Distributed that will help increase the amount of wind systems are typically installed on energy produced by their turbine. — Source: U.S. Department of Energy

Hoosier Energy signs PPA with EDP Renewables Hoosier Energy has entered into a 15-year power purchase wind, hydro, landfill methane and coalbed methane agreement with EDP Renewables North America that will generation.” add 25 MW of wind energy from an Illinois wind farm The purchase agreement will provide approximately beginning in December. 74,000 megawatt-hours of energy annually to Hoosier The wind power agreement is for 25 MW from the Energy’s cooperative member systems and their consumers Rail Splitter Wind Farm located roughly 25 miles west of in southern Indiana and southeastern Illinois. Bloomington, Illinois. The Rail Splitter project has been in Hoosier Energy will also earn Renewable Energy credits operation since 2009 with installed capacity of about 100 (RECs) for the wind power. RECs certify the environmental MW. attributes of renewable energy production. “Hoosier Energy is focused on providing cost-effective “We are excited about this opportunity for partnership renewable energy for our member systems,” said Steve with EDP Renewables,” said Heath Norrick, Hoosier Energy Smith, Hoosier Energy president and chief executive renewable energy manager. “The Rail Splitter Wind Farm officer. “Our agreement with EDP Renewables adds more is a proven Midwest provider of renewable energy that will wind resources to our portfolio, which already includes provide benefits for our members.”

14 SEPTEMBER | 2014

inFOCUS: PROJECTS Avoiding an ill wind Anticipating and meeting the site challenges that arise on wind projects

By Andrew Zlotnick, LEP, LEED AP and M. Michael Callahan, PE

fter a lackluster 2013 for to the success of any project. It wind power development, needs to undergo strict mitigation A the wind market is once to assure that the energy-produc- again growing. According to a ing equipment can operate safely, Bloomberg New Energy Finance and the structural integrity of the report, installations this year soil needs to be established so it could reach 6.5 GW and grow to can support the heavy equipment 8.5 GW in 2015. As wind develop- that’s necessary to provide wind ment continues on its upturn, the power. focus is moving from “whether” to What’s located below ground is invest in wind power to “how” to just as important as what’s located make sure projects succeed. above. Therefore, it is essential This is no small issue. The for a project’s environmental team development of wind projects — to be actively involved from a whether a single turbine or larger wind project’s earliest days. wind farms — are huge under- Most sites retain historic relics takings. They require substantial from the past. For the typical equipment and complex infra- brownfield site, which may have structure to support and operate seen any number of previous that equipment. industrial uses, that could mean One of the most important presenting a smorgasbord of dif- infrastructure elements, yet one ferent types of processed waste, that is virtually invisible, is site metals, petroleum byproducts, preparation. Large-scale energy and chemical contaminants. So, projects aren’t typically devel- the essential first step in devel- in order to properly handle and oped on pristine, undeveloped oping a site for wind development dispose of the impacted material. land. Rather, they are often locat- is to conduct a comprehensive For instance, if the subsurface ed on brownfields or other sites environmental investigation material includes polychlorinat- that have previously been used to determine what contami- ed biphenyls (PCBs), there could for industrial or other functions, nants are present and provide be requirements to obtain both and which have been abandoned the necessary information for State and Federal (EPA) approvals or deemed unsafe for tradition- creating a successful mitigation while characterizing the site, and al usage. But even though wind plan. Some of the contaminants before the material is disposed. projects are often located on dis- can require significant interac- Depending on the concentration carded land, that land is essential tion with regulatory authorities of PCBs, environmental samples

16 SEPTEMBER | 2014 containing PCBs detected at con- authorities and depending on the ALSO IN THIS SECTION: centrations >50 mg/kg (or at any site history and conditions, EPA concentration if not authorized may authorize more practical 20 Record project development for use under 40CFR §761.61) sampling, clean-up, or disposal spurred by PTC and other market would be subject to the Toxic procedures that are not pre- factors Substances Control Act (TSCA), scribed in the regulations. and the site would be regulated In addition, if there is subsur- 26 Profile Chokecherry and Sierra Madre for both cleanup and disposal face material encountered that Wind Energy Project under §761.61. Cleanup activi- contains asbestos containing ties may require notification to material (ACM), there may be 28 Conversation: Rob Morgan the EPA and the State regulatory requirements to prepare and RES Americas

windsystemsmag.com 17 InFOCUS: Avoiding an Ill Wind

... even though wind projects are often located on discarded land, that land is essential to the success of any project.

obtain approval for an Asbestos stakeholders prior to construc- not, contaminants can be safely Abatement Work Plan. The plan tion and regulatory approval. capped and left onsite. Capping must comply with the Environ- When performing construction involves containing contaminated mental Protection Agency’s (EPA) on impaired property, the public soil within retaining walls and National Emissions Standards notice activities and regulatory placing it upon an impervious for Hazardous Air Pollutants approval process can take from liner cap. The contaminated soil (NESHAPs) regulations. Person- as little as a few weeks to several is then covered with an addition- nel that are hired to perform this months. This should be factored al two to four feet of clean soil. work must be have specific state into the overall permitting and Using the capping approach rather licenses to prepare work plans, construction schedule to avoid than removing and disposing of perform construction administra- any surprises. contaminated soil can cut reme- tion, conduct project monitoring While there are certainly con- diation costs by as much as 75%, and inspections. taminants, such as radioactive so it’s easy to see why private and These additional regulatory waste, that will pose immediate public developers would prefer to activities may also require that and continuous health risks if go this route. public notice be provided to area left in place, more often than When creating a turbine foundation and assuring the integrity of the cap, it’s not enough to merely consider the weight of the piles that will support the turbine and the depth to which they will MAEDC AREA be driven. The piles and turbines Moberly-edc.com 660.263.8811 are enormous and they require area::edc very large equipment to transport and install them. The cap and site Amazing Transportation Access

BEST foundation need to be designed to Regulatory Air: Local Airports Environment withstand the rigors of installation, as well as the day-to-day op- Truck: Interstate 70 US v MAEDC erations once the turbines are up Average Wage and running. This is particularly US: $22 Port: Via Missouri River important when building on his- MAEDC: $14 toric urban fill. Urban fill almost

Rail: Multi Rail Access always is a mixture of heteroge- Broadband + 4G neous materials, making it very economic @ difficult to design the founda- Our region is located near competitiveness the center of the population tion. This has generally required of the US called the Missouri is ranked 7th by the American Legislative population mean. Making Exchange Council making a unique site-specific distribution centralized. BEST manufactured fill by mechanically

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Indianapolis Kansas City terial to create a satisfactory fill Los Angeles Phoenix San Diego Memphis State and Local Dallas Incentives material suitable for development. San Antonio Houston $ This often means implementing construction controls to prevent

18 SEPTEMBER | 2014 excessive equipment loads from sedimentation control plans are trucks, cranes, and other installa- key elements of any development. tion equipment. A cribbing system This typically includes the in- can also be implemented to dis- stallation of silt fencing, haybale tribute the weight of construction protection around groundwater equipment. extraction wells, and catch basin The threat of erosion is also a inlet filters to catch and contain key consideration, both during storm runoff when it rains. construction and when the tur- Additional protection can be bines are operational. If the land offered through the installation of on which the wind technology is a subsurface stormwater detention installed suffers erosion, brown- system, which can temporarily most serious issues will be found field contaminants can escape the store stormwater from the site below ground, and at first glance, site and infiltrate adjacent land. and manage its infiltration into will be undetectable. That’s why At the same time, erosion can the site. Stormwater mitigation is a project’s environmental team undermine the structural integ- particularly important in this era should be involved from the very rity of the wind equipment itself. of climate change because major beginning of the planning stage The potential threat of erosion to storms are becoming severe and and to the project’s completion. the structure can’t be overstated. frequent. By including environmental pros Wind turbines are large struc- With the turbine revolution who can identify contaminants tures that require considerable once more gaining steam, de- and other risks, and create plans sub-surface2.13_GE-Half_WindSystems.pdf supports. It is es- 1 velopers5/22/14 of10:17 wind AM power projects to address them, wind power sential to create an environment need to be aware of all of the developers can save themselves beneath the turbines that is safe infrastructure challenges they numerous headaches — as well as and stable. Therefore, erosion and are likely to face. Some of the a lot of money.

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windsystemsmag.com 19 InFOCUS: Projects

Industry at Large Record project development spurred by Production Tax Credit and other market factors The wind energy project pace set hardest hit by recent and ongoing late last year continues — and then drought. As wind power uses no some. water for electricity generation, its That’s the story told by AWEA’s water-saving attributes are hugely latest quarterly industry market attractive to utilities and jurisdic- report, which reveals continued tions. strong under-construction numbers headed into the second half of Other factors converge the year. Second quarter numbers Other factors are also allowing reveal a record number of projects companies to focus on what they currently under construction, as do best — build wind farms. The the wind industry ramps up to IRS’s recent guidance on the phys- capitalize on the 2013 Production ical work test, project ownership Tax Credit (PTC) extension. transfers and safe harbor provi- Currently over 14,000 mega- sions adds additional clarity for watts of wind energy are under wind projects going forward. construction in the U.S. across Meanwhile, still another factor more than 100 projects and 21 driving the current construc- states. The bulk of the activity By Emily Williams tion boom is at play. Corporate is happening in the wind-rich American Wind Energy Association purchasers are investing in new regions — from North Dakota and wind generation. 2014 has seen Minnesota, down through Kansas, advancements and coupled with new PPAs announced by Microsoft, Oklahoma and Texas. the extension of the PTC, have for electricity coming from an signed more than 9,000 MW of Illinois wind farm, and Walmart, Technology taps wind-rich long-term contracts in 2013-14. for power provided by a Texas regions These contracts have been touted facility. This year also has brought In those regions, technological infor their economic benefits: con- agreements between Google and novations including larger rotor di- sumer savings delivered over the Facebook for wind power from ameters and improved control sys- life of the project, all while offer- MidAmerican Energy’s Wind VIII tems and gearboxes have allowed ing long-term hedges against fuel project in Iowa, IKEA’s purchase developers to offer historically low price volatility and future carbon of an Illinois wind project and the power purchase agreement (PPA) regulations. Mars Corporations’ investment in prices. One notable difference on Stuart Solomon, president and a Texas project. the technology front: Whereas COO of Public Service Company This activity is driven by cor- several years ago turbine designers of Oklahoma (PSO) recently de- porations’ internal sustainability pushed to develop turbines with scribed his company’s purchase of goals, but also by the opportunity higher capacity ratings, today’s nearly 600 MW of wind power as to save on energy bills — high- turbine technology focuses more “extraordinary pricing opportu- lighting how wind power is both on higher capacity factors. The nities that will provide substan- good for the environment and good outcome: Preliminary data from tial savings for our customers.” for these businesses bottom lines. the Department of Energy reveals Solomon knows what he’s talking Even behind the meter, on-site an average 2013 wind PPA price about: PSO’s contracts will reduce generation is on the rise, with utili- of $25/MWh focused around the customer costs by $53 million in ty-scale turbines under develop- nation’s interior region, cheaper the first year alone, with annual ment at a military base, a brewery, than at any time before. savings growing over the 20-year and a produce processing plant. As result, utilities, eager to take contract life. advantage of these historically low These projects are also being Texas still unrivaled prices brought on by technological built in some of the regions Perhaps the greatest driver of this

20 SEPTEMBER | 2014 The bulk of the activity is happening in the wind-rich regions — from North Dakota and Minnesota, down through Kansas, Oklahoma and Texas. construction boom is the completion of the Competitive Renewable Energy Zone (CREZ) transmission lines in Texas. Recognizing that projects wouldn’t get built without transmission, and that transmission providers wouldn’t build lines without generators, the proactive transmission planning and broad cost allocation that took place under Texas’s CREZ initiative is ensuring that the state will remain a world leader in wind power. Texas has led the nation in installed with capacity since 2006. That will continue. At the end of the second quarter, more than 8,000 MW were under construction across the state, in both the Southwest Power Pool (SPP) and the Electric Reliability Council of Texas (ERCOT). In short, more wind is now under construction in Texas than is currently installed in any other state. More than 7,300 MW have interconnection agreements with ERCOT for 2014- 2015 alone. In addition to the 14,600 MW under construction, the U.S. wind industry currently has an installed capacity of 61,946 MW, with utility-scale projects located in 39 states plus Puerto Rico. It is now up to Congress to continue the incentive for private investment in new wind farms so that the wind industry can continue providing clean, homegrown energy to American consumers.

For more information on the Sec- ond Quarter Market Report, please visit www.awea.org/2Q2014.

windsystemsmag.com 21 InFOCUS: Projects

EDF EN Canada aligns with McLeod Lake Indian Band for three possible wind farms in British Columbia

Representatives from EDF EN Canada Inc., a subsid- “The McLeod Lake Indian Band supports EDF EN iary of EDF Energies Nouvelles, and McLeod Lake Canada in the responsible development of sustain- Indian Band (MLIB) today jointly signed a Memo- able, non-polluting and environmentally sensitive randum of Understanding (MOU) during a ceremony wind energy in the Peace Region. We look forward conducted at the McLeod Lake Indian Band Annual to a long and mutually beneficial relationship with Meeting. The MOU concerns the potential devel- EDF EN Canada and the addition of more wind pow- opment of three wind energy projects representing er in our region.” over 500 megawatts (MW) of clean power in the The three projects represented in the MOU are Peace River Region of British Columbia. the Sundance Wind Project, Taylor Wind Project “We are extremely pleased to have entered into and Wartenbe Wind Project. Both Taylor and Sun- this MOU with McLeod Lake Indian Band,” com- dance projects are undergoing a BC Environmental mented Cory Basil, Vice President of Development at Assessment. The projects could deliver power as EDF EN Canada. “The MOU reinforces our relation- early as 2017 subject to clearing the environmental ship and commitment to meaningful engagement assessment process and securing power off-take and consultation. We will continue to work together, agreements from BC Hydro. The Wartenbe project respectfully and collaboratively, with MLIB on proj- is construction ready, having previously received its ects which will bring economic benefits and oppor- BC Environmental Assessment Certificate. tunities to the Band and the Peace River Region.” McLeod Lake Indian Band Chief Derek Orr said, — Source: EDF EN Canada

22 SEPTEMBER | 2014 Learn more about the ITW WindGroup. Experienced manufacturing We put all of our energy companies working together to help power the wind turbine industry. into helping you make With unique expertise in a number of categories, we provide innovative solutions to solve various challenges. It’s an offering that’s making the the most of yours. ITW WindGroup a strong force in the wind energy market. www.itwwind.com | [email protected]

The Products of ITW WindGroup Structural Adhesives & Repair Compounds • Vacuum Bag Tapes Threadlockers • Tapes • Sealants • Mold Release • On & Offshore Grouting Systems • Testing Equipment Tower & Blade Coatings • Equipment Chocking Systems • Electrical Potting & Encapsulants • Protective Coatings • Gaskets & Seam Sealants • Greases, Oils & Lubricants • Anti-Slip & Safety Coatings InFOCUS: Projects

Starwood Energy closes financing for 165 MW EFFICIENT Texas wind project CHANGE Starwood Energy Group Global, LLC, a leading private investment firm focused on energy infrastructure, recently announced that an affiliate has completed agree- FOR A ments to finance and construct its second wind farm, a 165 MW project 45 miles south of Lubbock, Texas. The Stephens Ranch II project, which represents the GREENER second of two phases that will total 377 MW, will use GE 1.7-100 turbines and be built by Wanzek Construc- WORLD tion, with completion scheduled for mid-2015. Affiliates of Citi, Morgan Stanley and MUFG have committed to invest tax equity in the project, and affiliates of Starwood Energy Group have committed 100 percent of the cash equity. Affiliates of Citi, Morgan Stanley and MUFG are also providing a non-recourse construction debt facility (including a letters of credit facility) totaling approximately $207 million. Affiliates of MUFG will act as Administrative Agent, Collateral Agent, and Depositary Bank. “We are pleased to have assembled a team of very experienced partners for this project,” said Himanshu Saxena, managing director of Starwood Energy Group. “We remain committed to this sector as we continue to look for new investment opportunities. Continued Federal support for wind projects is a key enabler for such investments as the nation transitions to a greener economy.” “This is an attractive project and consistent with the successful value-add investment strategy employed by Starwood Energy Group for the last decade,” added Bradford Nordholm, CEO & managing director of Star- wood Energy Group. • Enclosed Clean System Reduces Chance of Spills An investment affiliate of Starwood Energy Group • Vacuum Fill Oil at Faster Rates acquired Stephens Ranch in August 2013 from Mesa • Box Flush and Rinse Capabilities Power, an entity owned by T. Boone Pickens. • All Fresh Fluids Filtered “MUFG is delighted to finance Starwood’s growth in • Safer for Employees and Environment this important sector, where we continue to dedicate • Lower Lifetime Cost of Ownership significant capital and expertise,” said Jon Lindenberg, managing director and head of project finance for the Americas atMUFG. “We are pleased to collaborate with Starwood Ener- gy Group ... and are proud to be part of a strong project that will provide clean, competitively priced power to the state of Texas for many years to come. This transaction exemplifies our strategic objective to be the leading financial solutions provider for the renewable 877-OIL-VACS • WWW.SAGEOILVAC.COM energy industry,” said Lance Markowitz, managing director of leasing & merchant banking at MUFG.

24 SEPTEMBER | 2014 Snap-On_FP.indd 28 8/20/14 2:40 PM inFOCUS: Profile Chokecherry and Sierra Madre Wind Energy Project Carbon County, Wyoming

As the U.S. wind energy industry Anschutz Corporation. As many as 1,000 jobs are continues to champion the cause The wind project will be con- expected to be created during of carbon reduction in energy structed in two phases on 320,000 the project’s construction phase. generation, the largest proposed acres of land, ownership of which When complete, the project will wind farm in the country — iron- is split equally between the feder- employ 114 permanent workers ically to be situated in a commu- al government and private parties. in operations and maintenance nity named Carbon — is pushing Upon completion, the Choke- functions. forward through the development cherry and Sierra Madre project The Chokecherry and Sier- process. will generate enough electricity to ra Madre project is expected to The Chokecherry and Sierra power 1,000,000 average homes, result in $300 million in property Madre Wind Energy Project, and will effectively reduce carbon tax revenue in the first 20 years of located just south of the cities of emissions an estimated 7 million operation, as well as $232 million Sinclair and Rawlins in Carbon to 11 million tons annually. in sales tax revenue and $150 mil- County, Wyoming, is expected to The fact that the project is being lion in Wind Electricity Tax, paid be comprised of up to 1,000 wind built to a large degree on federal to the State of Wyoming. turbines, amassing a total name- lands will make a significant con- Eight years into its develop- plate capacity of 3,000 MW. trubution toward achieving the ment, the project is currently in The project, first proposed in goal of 10,000 MW of renewable the process of completing regula- 2006, is being developed by Power energy generation on federal land tory reviews and permitting prior Company of Wyoming, LLC, a by 2015, as outlined in the 2005 to the start of construction. wholly owned affiliate of The Energy Policy Act. “There are more complexities

PROJECT TIMELINE

June — BLM BLM conducts July 22 — BLM July 3 — BLM October 2 — Carbon issued rights-of- studies and sur- publishes Federal publishes Federal County Commission way grants, and veys; reviews and Register Notice of Register Notice unanimously ap- the initial mete- develops alter- Availability announc- of Availability proved a condition- orological towers natives; prepares ing the Draft EIS. announcing the al use permit. were erected. Draft EIS. 2012 Final EIS.

November — January —PCW filed rights-of-way Rights-of-way July 25 — BLM application with BLM for wind published a Federal applications filed energy development. BLM and PCW August — BLM with BLM for wind Register Notice of conducted pub- agreed that analyzing the proposed Intent to prepare energy site testing wind energy project in an Envi- lic scoping. and monitoring. the Environmental ronmental Impact Statement was Impact Statement. appropriate.

26 SEPTEMBER | 2014 and costs related to permitting a project on federal land than on private land, and it typically takes more time,” said Kara BY THE NUMBERS Choquette, communications director for Power Company of Wyoming, regarding the Location: Carbon County, Wyoming development timeline of the project. Capacity: 3,000 MW; up to 1,000 turbines “The project has received its key Carbon Developer: Power Company of Wyoming, LLC, County permit, its key State of Wyoming a wholly owned affiliate of The environmental and siting permit, and a Re- Anschutz Corporation cord of Decision from the BLM/Department Land area: Apprx. 320,000 acres of the Interior approving the site for wind Land ownership: Alternating “checkerboard” energy development subject to a second-lev- of private parties and federal el review of the site-specific plans of devel- lands (approximately 50/50 opment,” Choquette said. “That second-lev- split) el review is anticipated to be completed by Cost: $5 billion (est.) BLM by the end of 2014.” Jobs: Est. 1,000 during construction phases; Power Company of Wyoming estimates 114 permanent O&M the total project cost at $5 billion. The com- Tax revenue: Est. $300 million property taxes pany has spent more than $45 million thus in first 20 years; Est. $232 million far in the early development stages of siting in sales taxes (more than half and permitting. of which is expected to stay Public support on all levels, from nation- in-county); Est. $150 million Wind al to local, has been positive about the proj- Electricity Tax to the State of ect, Choquette said. In fact, during a two- day permitting hearing in August, no one Wyoming commented in oppopsition of the project. Greenhouse gas reduction: Est. 7 million to 11 For more information on the Chokecherry million annually and Sierra Madre Wind Energy Project, visit — Source: Power Company of Wyoming LLC the Power Company of Wyoming’s website at www.powercompanyofwyoming.com.

October 9 —Interior Secretary Ken September — BLM conducts December — BLM conducts December 4 — U.S. Fish and Salazar signs Record of Decision, public scoping for Site-Specific public scoping for Site-Specif- Wildlife Service publishes a authorizing the BLM to proceed with Environmental Assessment 1, ic Environmental Assessment Notice of Intent to prepare site-specific environmental analysis. addressing the Phase 1 Haul Road 2, addressing the Phase 1 an EIS for the Phase I eagle BLM publishes Federal Register Notice and Facilities, West Sinclair Rail Wind Turbine Development of permit application and of Availability the following week. Facility and Road Rock Quarry. 500 turbines. conducted public scoping.

July 15 — Carbon August 6 — State of Wy- August 11 — BLM BLM anticipated U.S. Fish and County Commis- oming Industrial Siting publishes the final to publish the final Wildlife Service sion unanimously Council unanimously Site-Specific EA1 Site-Specific EA2 anticipated to approves a condi- approves a permit to for infrastructure for Phase I wind publish their tional use permit construct and operate components. turbines. Draft EIS. extension. the wind project. — Source: Power Company of Wyoming

windsystemsmag.com 27 ConversationinFOCUS:

Rob Morgan (303) 439-4200 RESamericas www.res-americas.com @RES_Americas Chief Development Officer [email protected] res-americas RES Americas

Could you tell us a little owned long term by those third about the history of RES parties. More recently, we are Americas? constructing projects for owner- RES Americas has been active in ship directly by a utility, and we North America since 1997, with are supplying power under PPA to a renewable energy and storage non-traditional buyers —compa- construction portfolio of over nies with a nationwide footprint 7,000 MW in operation. Roughly that are managing their carbon half of that portfolio has been footprint. developed by RES Americas with the other half built for third par- RES Americas places a strong ties. RES Americas is a subsidiary emphasis on sustainability. of RES Ltd., founded in 1982 and Can you go into a little detail headquartered in the UK. about how that factors in to the company’s operations? What services and solutions RES Americas is a value-based does RES Americas offer to organization and sustainability is the wind energy industry? a core value of the company. We • Identify and map prospective RES Americas has a robust suite are working on diverting an in- sites of in-house expertise and services creasing percentage of our waste • Establish and maintain strong that we offer to the wind energy stream to recycling, composting, relationships with landowners industry, including resource and re-use. Also, we encourage a and negotiate wind or solar assessment and early project reduced environmental impact by measurement agreements and/or development support, permitting/ all our people through sustainable land leases interconnection and late devel- work/life choices such as partic- • Establish and maintain strong opment support, engineering, ipating in Bike to Work Day and relationships with local stake- procurement and construction, the Green Car Incentive Program. holders, including local govern- and operations. RES Americas is Going beyond our company, we ment, environmental groups, distinguished by our dedicated are working with our supply chain and community groups among staff of professionals throughout to create demand for sustainable others the value chain. products and practices. • Commence project planning, design and engineering using RES What types of clients does Walk our readers through the Americas’ engineering team the company serve? Could process RES Americas takes • Conduct environmental assess- you briefly describe what you in wind project development. ments and studies do for those types of clients? Project development is a pro- • Begin the permitting process RES Americas has a diverse client cess that requires patience and • Discuss and negotiate offtake base. We have historically de- problem solving. From years of agreements with local utilities veloped and constructed projects experience, RES Americas has • Secure interconnection and with an eye toward third-par- broken that process down into the transmission agreements ty ownership where the power following steps: • Secure financing for project production is contracted under a • Identify areas with promising construction PPA with a utility counterparty. wind or solar resources, com- • Construct the project using RES We have also constructed projects patible land uses, and access to Americas’ construction team developed by third parties and transmission lines • Commence operations

28 SEPTEMBER | 2014 How is that process unique? industry. RES Americas has a wind, solar and storage, manu- What sets it apart from com- very high regard for safety on facturers are making efficiency petitors? its job sites and in our everyday and cost improvements - all of Our knowledge of development, work. In fact [at time of print], which show up in an improved, engineering, and construction is we have over a million man- lower price of electricity paid by different from our competitors, hours without a recordable safety consumers. who typically are active on only incident throughout the company. one part of the value chain. Our Construction can be a demanding What other industries does presence across the value chain and risky business, but with the RES Americas serve? With allows us to deeply understand proper training and attention to regard to energy projects, project risks and mitigate those site-specific risks, we can make it are there any efforts toward risks for the project owner. a safe and fulfilling business. cogeneration plants, etc.? RES Americas is pursuing energy RES is built on a long legacy How does the company view projects that have a renewable of construction services. the future of wind energy, fuel supply (or are non-polluting How does that translate both near and long-term? such as storage and transmission) to wind farm projects and We are extremely busy in 2014 so to the extent we go beyond benefit wind customers? & 2015, with over 1 GW of wind, wind, solar, storage and transmis- Having an extensive knowledge solar and storage projects in sion, it will involve some other of the construction industry and construction or planned. We renewable fuel stream such as risks involved in construction are bullish long term as the cost biogas. Cogeneration is a very allows us to manage and miti- of renewable resources hits grid efficient process that captures gate those risks for the benefit parity without any price volatility waste heat for beneficial use, so of project owners and to the that is inherent in the fossil fuel renewable cogeneration would be ultimate benefit of the entire markets. Across the spectrum of an interesting combination.

SEEKING OPPORTUNITY? Scan Wind Systems website to enjoy a host of features, including: – Our new jobs listing, for employers and jobs seekers alike – Events calendar to keep you informed – A searchable articles archive, downloadable individually – View the digital magazine, or download entire issues – Vendor listings, along with our annual Buyer’s Guide – Company profiles and Q&As – Connect to the wind industry through social media – Wind industry news from about the world

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windsystemsmag.com 29 CONSTRUCTION BOP/EPC • Project Status • Siting • Equipment • Project Due Diligence • Services

Gamesa concludes turnkey construction of its first wind farm in Chile

Gamesa has concluded turnkey the most recent wind report by works and infrastructure for the construction of its first wind farm Navigant’s BTM Consult, Chile had project, including more than 20 in Chile — the 36 MW San Pedro 413 MW cumulative installed by the kilometers of roadway, an elec- Chiloé wind farm — for the local end of 2013 and, supported by high trical substation, a 25-kilometer company Transantartic. The project energy demand, is expected to reach high-voltage transmission line and is located on Chiloé Island, in the 1.5 gigawatts cumulative installed a bridge. As part of the project, southern part of the country. by 2018. Gamesa will provide comprehen- The successful commissioning of The wind farm features 18 Game- sive Operations and Maintenance its first project in Chile marks the sa G90-2.0 MW wind turbines. (O&M) services for the wind farm establishment of Gamesa’s com- Construction for the project began for a period of 12 years. mercial presence in a wind market in January 2013 and included the with great potential; according to development of all necessary civil — Source: Gamesa

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said Jim Headley, President of Crane Institute of America. “Cus- tomers in Canada, South America, Europe, Australia, and the Middle East have been asking for a metric version of the book.” Along with the rated capacity tables of slings and rigging hardware, the book covers how to calculate load weight, how to calculate sling loading, and proper load handling techniques. The information is applicable to rigging operations no matter where you are in the world. By offering two Crane Institute of America an- the Rigging Metric handbook versions of the books, trainers nounces the availability of the contains the latest information on and students now have a resource newest edition of the indus- wire rope, rigging hardware, and that improves communication, try’s favorite rigging handbook. slings, including capacity tables understanding, and safety. Rigging, by James Headley, has and charts. For more information, or to been converted from imperial to “For years, the handbook Rig- order the handbook, visit Crane metric. Providing practical infor- ging has been popular outside the Institute’s Online Store at www. mation and great illustrations, United States for use in training,” craneinstitute.com.

30 SEPTEMBER | 2014 Nordex to build 37.5 MW Orla wind farm in Poland Contract awarded for first phase of construction with operation slated for 2015

Wind turbine manufacturer arm of Nordex. “This is going of Poland, the wind farm is to Nordex has been awarded a to be the first realization from generate an annual energy yield contract for the delivery and our pipeline of own developed of up to 100 GWh, resulting in installation of nine turbines projects in Poland. It is a good a capacity factor of an above- from its N100/2500 series. This illustration of how Nordex can average 33 percent. At the same constitutes the first construction provide more value to the market time, it will avoid emissions of phase of the 37.5 MW “Orla” with quality projects,” said Lars around 57,000 tons of carbon wind farm, which will comprise Bondo Krogsgaard, a member of dioxide, which would otherwise a total of 15 N100/2500 wind Nordex SE’s Management Board. arise from thermal power turbines as cold climate The client is the project com- stations. Under the targets set by version. The turbines which pany “C&C Wind” owned by in- the European Union, Poland has have now been ordered are to ternational private-equity inves- undertaken to roughly double the go into operation as early as in tors and an independent power proportion of renewable energies December 2014, with the other producer. The project finance has in its national energy balance to six to follow by mid next year. largely been provided by the Eu- 20 percent by 2021. The Orla project was initiated ropean Bank for Reconstruction in 2008 and developed since and Development (EBRD). — Source: Nordex by the project development Located in the eastern part

Delivering Education and Opportunities for the Wind Energy Industry

AWEA Offshore WINDPOWER Conference & Exhibition October 7 – 8, 2014 I Atlantic City, NJ AWEA Wind Energy Finance & Investment Seminar October 20 – 21, 2014 I New York City, NY AWEA Wind Energy Fall Symposium November 18 – 20, 2014 I San Diego, CA AWEA Wind Resource & Project Energy Assessment Seminar Make your plans to attend December 2 – 3, 2014 I Orlando, FL these AWEA educational events. AWEA WINDPOWER® 2015 Conference & Exhibition Visit www.awea.org/events14 for Save the date! 4 May 18 – 21, 2015 I Orlando, FL more information and to register!

AWEA_FALLEVENTS_6.5x4.25_WS.indd 1 7/9/14 5:58 PM windsystemsmag.com 31 35 Siemens D6 turbine obtains type certification by DNV GL INNOVATION Research & Development • Design & Engineering • Forecasting & Analysis • Consultancy • Certification & Standards • Efficiency • Emerging Technologies

Technological advances to take center stage this month at WindEnergy Hamburg International exhibition in Germany will showcase state-of-the-art products and projects

This month, the international wind energy industry every segment of the value chain. This is a selective will gather at the WindEnergy Hamburg fair. More preview of some of the innovations and develop- than 1,000 companies hailing from over 30 different ments from the wind energy world, which have been countries will be present at the leading international announced for the leading global industry fair at the wind energy industry fair to showcase their latest ‘wind capital’ of Hamburg. products, service offerings and projects for both onshore and offshore wind power. For four days, eight Developments in the large turbine segment halls at the Hamburg fair site will provide exhibitors MHI Vestas Offshore Wind, Gamesa with its and industry visitors with an opportunity to get Joint-Venture partner Areva, and the German engi- the full picture of all the latest technologies from neering consultancy aerodyn (SCD) will all inform

32 SEPTEMBER | 2014 the visitors of WindEnergy Hamburg about the component suppliers are stepping up their efforts to latest status of their product developments in the match the latest supply chain demands ranging from 8MW class. Unlike the quasi-standard three-blade blades to castings, drive trains, towers and support upwind configuration, SCD’s offshore solution is a structures. VEM Sachsenwerk, likewise exhibiting two-bladed downwind SCD 8.0 turbine installed on at the leading industry fair in Hamburg, now offers a floating base. A company spokesperson comment- both asynchronous and synchronous generators for ed this approach: “Our overall turbine-and-floater power ratings up to 7MW. EEW Special Pipe Con- concept offers specific benefits in terms of instant structions has built one of the world’s first XL-type load reduction. We will reveal further details at monopile towers with a 10-metre outer diameter. WindEnergy Hamburg.” The tower can carry 6-7MW turbines with 150 Floating wind turbine technology is evolving at a metre and larger rotors, and be installed in water much faster pace than many had expected just a few depths of up to 40 metres. years ago, and there is a broad variety of design con- Mechanical drive train specialist Winergy (Sie- cepts. One innovative example is the GICON-SOF mens) has delivered two 3MW prototype units of its tension-leg platform. According to the engineering new medium-speed “HybridDrive” solution to Ger- consultancy GICON, it is suitable for water depths man technology developer Wind-to-Energy (W2E). from 20 up to 500 metres. A prototype project with a W2E will be represented at WindEnergy Hamburg, 2.3MW Siemens turbine is to be erected in the Baltic as well. Supplier FWT is marketing the product un- Sea by May 2015. According to the manufacturer the der license as its flagship model for IEC class II sites design is scalable to at least 6MW. under the model name “FWT 3000.”

Component suppliers on track Innovative gearboxes A novelty in the 6MW class is Senvion’s 6.2M152 Winergy will display a further (optional) product geared turbine with an enlarged rotor. A prototype development of this semi-integrated drive system is currently under construction. Meanwhile major at WindEnergy Hamburg. It consists of a two-stage

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windsystemsmag.com 33 Technological advances to take center stage at WindEnergy Hamburg

planetary gearbox with a flange-on permanent are able to implement a much bigger rotor diameter, magnet generator design. What makes this system which is also enabled by advanced controls on basi- unique is the use of journal or plain bearings in both cally the same wind turbine. This helps to increase gear stages with the exception of the planetary car- the AEP while lowering the Cost of Energy for a riers which are fitted with conventional roller-type variety of markets, from regions that are already bearings. Equally new is the use of journal bearings saturated to new emerging regions with lower over- for the generator. The HybridDrive displayed at all wind speeds.” Farell added that AMSC is working the fair will be partly cut open so visitors can take with a licensee to build a prototype and is looking a closer look at the internal components. Winergy for additional licensees. will inform visitors about all the benefits of using journal bearings. Another product development by Taller towers, high-precision instruments Winergy shown at WindEnergy Hamburg will be Several tower suppliers will showcase their latest a 2MW, three-stage, high-speed gearbox likewise product developments in Hamburg. For example, fitted with journal bearings. A prototype unit in- Germany’s Drössler Umwelttechnik will inform stalled in a Vestas turbine has been field tested for about its innovative prefabricated tower solution over 16 months at a cold-climate site in Scandina- called Ventur for up to 120-metre hub heights in via. A complete journal bearing arrangement will be full concrete, and for 200-metre hub heights in con- on display at the company booth. crete/steel hybrid versions. Wikov MGI of the Czech Republic will exhibit Accurate wind measurements are another field its range of wind turbine gearboxes incorporating of expertise receiving growing attention within the flexible pins and a differential split torque arrange- wind energy industry. WindEnergy exhibitor ROMO ment, which according to the supplier combine an Wind will present an innovative, patented measur- increased torque rating with reduced size and mass ing and monitoring solution called iSPIN, consisting characteristics. of three stationary ultrasonic devices without moving parts, mounted to a rotating spinner at 120-de- Onshore turbines from 3 to 5MW and above gree inner spacing. According to the manufacturer, Several international exhibitors will inform Wind- this solution enables effective measurement of both Energy Hamburg visitors about their latest 3MW+ the wind speed and wind direction, with much class onshore turbines. One such product designed greater precision than nacelle-mounted systems. for IEC class III sites is Senvion’s 3.0M122 turbine. The first commercial units will be installed this Energy storage solutions year. Another new IEC III-type turbine model is the Storing renewable energy in a cost-effective, reli- Nordex N131/3000 featuring a record 131-metre able and efficient manner is one of the remaining rotor diameter, the largest in its class. key challenges for a successful transition from Several suppliers have also announced new, high- fossil and nuclear-based power generation towards er rated onshore turbines in the 3.2 - 5MW range. renewable energy sources such as wind. Enercon, Project developer and turbine supplier eno Energy GE, Siemens and other manufacturers will highlight will present its new eno 126 | 3.5MW model, and their latest battery-based and other energy storage XEMC Darwind is developing a 4.5MW turbine for solutions at WindEnergy Hamburg, and inform visi- high-wind onshore sites. Earlier this year Enercon tors about specific benefits and challenges ahead. announced a new turbine model ranging between WindEnergy Hamburg will be held September 23- the current 3 - 7.5MW offerings. 26. Organizers expect more than 1,000 exhibitors U.S.-based AMSC Windtech develops and licenses from all parts of the world. The event will be held at turbine models up to 5.5MW to third-party clients. the Hamburg Fair site every two years. In addition, AMSC’s latest product development is a 2MW the wind exhibition with a focus on the national geared turbine model with a 113-metre rotor for IEC market, HUSUM Wind, will be held in Husum from class III sites, available in a full converter solution 15 to 18 September 2015, likewise organized jointly with either a double-fed induction generator or a by HMC and Messe HUSUM, as a biennial event. synchronous/asynchronous generator. Says Kerry For further information please visit windenergy- Farell, senior manager of corporate communica- hamburg.com and husumwind.com. tions: “Our newest design has one of the largest rotor diameters in the industry. The market is moving towards low wind areas. In low wind speed areas we — Source: WindEnergy Hamburg

34 SEPTEMBER | 2014 Siemens D6 turbine obtains type certification by DNV GL

Siemens Energy has obtained type assembly facilities in Brande as well comparable systems. This weight certification by certifying body as testing facilities at Oesterild, advantage provides improved eco- DNV GL for the company’s inno- Denmark and Hunterston, UK. nomic viability across all project vative D6 offshore wind turbine. Evaluation included an assessment phases, from assembly to transport, The model Siemens SWT-6.0-154 on the maturity of the turbine de- foundations and installation all the is equipped with a modern direct sign, its manufacturing, installation way up to operation. One SWT-6.0- drive generator, rated at 6 MW and commissioning processes and 154 turbine can supply up to 6,000 and equipped with a 154-meter related documentation. households with clean offshore rotor. The official certificate is a The development of the SWT- wind power. This type certification further step in ramping up the se- 6.0-154 marks a significant step for the SWT-6.0-154 includes a 25 rial production of the turbine. The towards reducing the cost of energy. year design lifetime, which is an certification process included DNV With a tower head mass of only additional five years compared to GL experts being given full access 360 tons, the new 6-MW machine the previous turbine lifetime that to the engineering and Siemens is around one third lighter than Siemens has designed.

windsystemsmag.com 35 40 Maintenance cost reduction achieved through comprehensive fleet monitoring MAINTENANCE Operations • Service & Repair • Inspection • Safety • Equipment • Condition Monitoring • Lubrication

Beyond the turbine: Understanding the collector system

Once the wind has been converted ship between voltage and current to mechanical rotating energy and are inversely proportionate. For then to electrical energy, it leaves example, if voltage is increased the turbine. by a factor of 10, the current is For some of us, our job is over. reduced by a factor of 10. It is Some technicians don’t work on important to reduce the current anything beyond the turbine. For for transmitting the energy for others, their responsibilities con- distance to reduce power or line tinue — or have just started — with loss. Line loss can happen just like still many components and miles when you try to use more than one of conductors to maintain. This long extension cord to run a power part of the wind farm is called the tool. There are voltage drops due “collector system,” and without it, to the friction of the electrical the wind farm doesn’t work. current in the conductor. On long The collector system is com- distance power lines, if the voltage prised of many components. An gets too low, then the voltage can important component of this be stepped up again by using an- By Jack Wallace system is the transformer. A trans- other transformer. Frontier Pro Services former is an electrical component Maintaining these transform- that has the ability to change high ers is fairly easy. For pad-mount counts, but when the transformer current, low voltage into high volt- transformers, keep your services is inspected, there is no visible age, low current. trucks from running into them problem found. This is thought to Transformers are used every- and if you are in areas of ice, build be caused by certain manufactur- where in the wind turbine and protective shelters to keep falling ing techniques beyond the scope what is discussed here for the ice from damaging them. Keep the of this article. power transformers is applica- doors closed, seal the conductor When transformers go bad, ble elsewhere. Transformers are entries to keep out the rats, and they can go quiet, or they can go electrical components that only regularly inspect for bad connec- out with a bang. A transformer work in alternating current (AC) tions — safely. explosion is extremely powerful systems. Checking for oil leaks and and can cause significant damage. The transformer takes the rel- proper oil levels, as well as taking Transformer explosions can be atively low-voltage, high current samples of the transformer oil so powerful that some wind farm power from wind turbines and can tell you if there are signs of substations utilize special con- “transforms” it to high-voltage, rel- internal problems. Hydrogen and crete blast walls to separate trans- atively low current for transmis- acetylene are some of the gases formers from other components sion over long distances. Or, when found in the oil of transformers in the substation for protection. the turbine is not producing, the that are considered indicators of In the collector system, when transformer takes the high-volt- problems. the electrical current leaves the age low current and transforms it The concentration threshold of transformer, it continues to flow into low-voltage, relatively higher these gases is up to interpretation through high voltage conductors. current for the turbine to operate of an experienced transformer Sometimes the conductors are its various systems. engineer. Some of today’s trans- underground and sometimes they In a transformer, the relation- formers have high hydrogen gas are above ground, or a mix of the

36 SEPTEMBER | 2014 In a transformer, the relationship between voltage and current are inversely proportionate.

two. Both types have their advan- These high voltage collector circuit breakers and switches to tages and disadvantages. circuits, whether underground control the power flow. Monitor- For underground systems, the or overhead, feed power from ing systems watch the power flow advantage is that there are no the individual wind turbines and the grid operator typically has cables to look at so a better visual and consolidate the power at a control to operate or disengage the view. A disadvantage is the cable substation. At the substation the substation if something is awry. is fairly expensive due to the power is consolidated and usually Hopefully this article has served insulation required to place the transformed once again to a higher as an introduction to the collector cable underground. Underground voltage and then sent out to the system, and raises some curiosity cable is connected together with grid. In the substation, there are a and discussion with your team. It specialty connectors. These con- variety of protection devices that is beneficial that everyone under- nectors are typically called splices, use current, voltage, thermal and stands the specifics of the collec- and consist of conductor and magnetic sensors to ensure things tor system used by your facility. insulator. It is just as important to are safe. In addition, there is light- As always work as safely as properly treat the insulator as it is ning protection and a substantial possible, and work to prevent sur- to connecting the conductor. High grounding system. There are prises. voltage electricity can destroy a high voltage electrical splice even if the conductor is well prepared but the insulation of the splice has not been prepared properly equipment protection or treated well. Just a small nick in the insulation at the splice can cause a early failure. Keep your wind energy With above ground or overhead equipment completely conductors we typically don’t have protected during storage the same issue with insulation or transportation by using as air is used but issues with the premium shrink wrap from power poles and animals can cause problems. Birds can build nest Dr. Shrink! or cross conductors if the lines • Complete Protection Against Weather Damage are not properly designed. The • Cost Effective - Pennies Per Square Foot conductor lines can swing in the • Shrink Wrap Available Up to 60’ In Width strong winds and short between another. In addition, in an effort • Maximum UVI - Warranted for 18 Months to save money during construc- • Full Line of VCI & Desiccants tion, we sometimes have power • All Items in Stock for Immediate Shipment poles that are not properly sized or not spaced properly and become overloaded with weight and line Contact Dr. Shrink Today! tension causing all kinds of havoc Toll Free - (800) 968-5147 with leaning or bent poles and Email - [email protected] overloaded pole to line insulator Web - www.dr-shrink.com connections.

windsystemsmag.com 37 MAINTENANCE product

Des-Case launches Extended Series desiccant filters

Des-Case Corporation has launched a from the headspace of equipment. ing silica gel extracts moisture. When new line of desiccant breathers called “These breathers, as well as our air is expelled from the container, the Extended Series — aptly named, as other contamination control products top foam pad prevents oil mist from the breathers will help companies and services have for years helped contacting silica gel or entering the extend the life of their lubricants, the companies around the world detect, atmosphere. life of their equipment, the amount of prevent and remove contamination The breather is also outfitted with time between maintenance intervals from their equipment and plants,” said a nylon standpipe and polypropylene and, most importantly, maintenance Brian Gleason, CEO of Des-Case. “This oil mist reducer to allow oil mist to co- budgets. new development continues our drive alesce and drain back into the reservoir, The series of four variously-sized to help customers improve lubricant rather than compromising the desic- breathers addresses a number of indus- quality, maximize equipment reliability cant. Six umbrella check-valves are trial needs, bringing greater protection and achieve an entirely new level of located underneath the unit to isolate and productivity to tank farms, wind performance.” equipment from ambient conditions -- turbines, large gearboxes, as well as Contaminants such as dirt and water prolonging breather life and protecting applications in both high humidity in industrial lubricants can lead to system integrity. environments and remote locations. equipment breakdown if not filtered Additionally, more desiccant in the The line features higher airflow, more out, bringing plants to a grinding halt Extended Series breathers provides moisture adsorbing desiccant, check- and costing companies both time and more adsorption capacity and elon- valve technology, and longer life. money. gates breather life. The larger capacity Though simplistic in appearance, As wet, contaminated air is drawn accommodates higher airflow and Des-Case desiccant breathers are high- through the breather, multiple 3-mi- female threaded mountings offer users ly sophisticated filters for industrial cron polyester filter elements remove greater durability, stability, and versatil- lubricants, removing dirt and water solid particulate and the color-indicat- ity with a number of adapters.

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14-URI-1204 WindSystems September_r01.indd 1 8/13/14 4:37 PM MAINTENANCE

Maintenance cost reduction achieved through comprehensive fleet monitoring By Matthew Whittle, Ashley Crowther, and Tugan Eritenel Romax Technology

Figure 1: InSight software architecture

Major component repair costs are a many challenges. A large fossil ety of interfaces and software tools. real issue for wind farms over five fired power station may have only This makes it difficult to monitor years old. Taking as an example data four large machines that need to be efficiently and to a consistently high set of six wind farms that Romax monitored; these machines operate quality. Moreover, there is a shortage monitors, in the last 12 months there in a very predictable manner, in a of the valuable expertise required have been detections of nine failing carefully controlled environment, to interpret the data. Software tools planet bearings and 14 failing main perhaps with the service engineer designed with efficient workflow in bearings. In each case, the damage located just a walk away. A wind mind are essential so that wind farm has been confirmed by inspection farm, by contrast, comprises many owners/operators can get the most and repairs scheduled. These re- turbines, with highly variable op- value from scarce expertise; nobody pairs are expensive and significant eration, located at the top of tower, wants their valuable experts to waste cost reduction can be achieved by often in remote locations and often time waiting while switching be- optimizing the scheduling of repairs. with extreme ambient conditions. tween turbines, or different software Romax customers are using InSight Many independent studies have systems. Fleet Monitor to realize these cost shown that predictive condi- Fleet Monitor is Romax’s web- reductions. tion-based maintenance can sig- based, hardware-independent, nificantly reduce the cost of energy software for wind turbine health Wind turbine Condition from wind but, in spite of the rela- monitoring. The software enables Monitoring tive maturity of condition monitor- condition monitoring engineers to Effective signal processing tech- ing techniques, this value is often not monitor an entire global fleet of tur- niques for condition monitoring of realized. Most owners/operators face bines, whatever turbine type or CMS rotating machinery have existed for the challenge that they have a range type, with one platform. This means decades, but applying these tech- of different condition monitoring that consistent alarm strategies can niques to the wind industry presents systems (CMS) installed, with a vari- be applied so that lessons learned

40 SEPTEMBER | 2014 on one farm can be quickly and efficiently implemented to improve the quality of monitoring on another, without the difficulties created by moving between disparate systems. Using data from existing CMS and SCADA systems, along with lubrication and operations and maintenance data, the software is able to provide a complete picture of turbine health. Often, faults can be detected as much as 12 months in before failure. Once an incipient fault has been detected, various measures, such as main bearing life extension or turbine de-rating, may be taken to increase the component Figure 2: Example of Damaged Planet Bearing Detected by Fleet Monitor life. Multiple main bearing, or gearbox, change-outs may be scheduled together so that the crane cost is spread and the overall OPEX signifi- cantly reduced. Designed with global access and collaboration in mind, Fleet Monitor enables site managers, asset management teams, and condition monitoring centers to communicate and collaborate more effectively.

Fleet Monitor Features • Hardware and software independent so that all turbines can be monitored efficiently and effectively through one platform. • Proven analysis techniques including time domain trending, FFT, envelope, Cepstrum and time syn- Figure 3: Romax Inspection Showing Failed Main Bearing chronous averaging enable faults to be detected early so that repair years ahead, so that operations and Networking costs can be kept to a minimum. maintenance budgets can be based To use Fleet Monitor, no hard- • All data stored and backed up. on real data rather than guesswork. ware or software installation is Many CMS automatically decimate • Automated alarm thresholding, required because Fleet Monitor is historical data, but with Fleet Mon- which embeds best practice. web-based Software as a Service itor no historical data is discarded. • Powerful alarm configuration (SaaS). All that is required is VPN • Libraries of tried and tested enables alarms to be set against access to the site server(s). This alarm rules based on Romax’s vibration, SCADA and lubrication allows Romax to fetch the data and experience of monitoring over 3 data, resulting in confident diag- insert it into the InSight Health GW of wind turbines mean more noses of the turbine condition. Management platform automatical- advanced warning and fewer false • Automated reporting so that ly, see Figure 1. Open an internet alarms. condition monitoring engineers browser on any device, then go • Remaining useful life models: can focus on what really matters to the Fleet Monitor website and these innovative prognostic tech- rather than copying and pasting you’ll be able to log-in and check niques enable forecasts up to three figures and formatting documents. the condition of your wind tur-

windsystemsmag.com 41 Maintenance cost reduction achieved through comprehensive fleet monitoring

Figure 5: Romax Inspection Showing Failed Main Bearing

monitored failing main bearings for 18 months before a repair was made. At the end of useful life Figure 4: Example of Damaged Main Bearing Detected by Fleet Monitor the condition shown in Figure 5 is typical. Romax’s main bearing life extension technology can be applied to suspend or severely slow the failure, which offers a useful O&M strategy for sites with failing main bearings: Monitor and catch early, extend bearing life, optimize repair schedules. Damaged main bearings can also be detected using SCADA data, however not nearly as early as by vibration monitoring. For sites that have no CMS this is valuable and Fleet Monitor provides flex- Figure 6: Using Fleet Monitor to Detecting Main Bearing Damage ibility to include vibration and/ or SCADA monitoring. Figure 6 bines, make rapid diagnoses and or other turbine fault provided no provides an example in which a schedule inspections. indication). This is typical of Ro- damaged main bearing is the outli- max monitoring of planet bearing ers in SCADA temperature data. Case study 1: Planet Bearing failures: 3-6 months warning as Failure Detection the wear out from bearing spalling Conclusion In this example the vibration health is slow. Aging gearboxes that have Crane hire accounts for a large index started trending in September survived infant mortality issues proportion of cost for a main 2013, see Figure 2. The analyst us- (e.g. from poor design, poor steel bearing or planet stage repair; the ing Fleet Monitor recommended in- or heat treatment, grind temper benefits of carrying out multiple spection. The first inspection (No- and so on) are commonly failing in repairs with one crane mobili- vember) showed significant surface this mode. zation are clear. Monitoring and distress on the planet gear teeth. scheduling all major component The turbine could continue to Case Study 2: Main Bearing replacements in the low sea- operate and the trend was carefully Failure Detection son reduces costs dramatical- monitored. A second borescope Main bearings failures (initi- ly. Romax’s proven monitoring inspection was scheduled in Decem- ated from micropitting then technology is available to enable ber and severe damage confirmed progressing to surface initiated predictive maintenance with on a planet bearing. The gearbox macro-pitting) also progress carefully optimized scheduling, was replaced in January 2014. The slowly. Figure 4 provides a typical worldwide, using a range of CMS site had four months warning to ar- example where the trend ran for hardware that is installed on the range the most cost effective repair 12 months. This is typical; Romax original equipment and incor- and avoided a catastrophic failure has not seen a case of less than porating SCADA and lubrication and downtime (temperature trend three months warning and has data.

42 SEPTEMBER | 2014

MANUFACTURING Production • Fabrication • Components • Supply Chain • Materials • Tooling • Machinery

Acciona to pilot Moventas’ high torque density gearbox

Acciona Windpower has agreed with Moventas agreed to together develop a them with new design methods and Moventas on prototype as well as seri- new version of Acciona’s very success- took them to a new level. As a result, al deliveries of a 3 MW wind gearbox ful 3 MW turbine, with the objective with Exceed, Acciona gets more product based on Moventas’s new of reducing size and increasing torque torque out of a smaller and more Exceed series of high torque density density. Outcome of this is the Exceed lightweight gearbox, explains Global gearboxes. Deliveries of the new tech- gearbox series, a 3 MW and up prod- Accounts Manager Pedro Figueiras nology will take place in 2015, adding uct platform with the best ratio price/ from Moventas. to the on-going 3 MW deliveries nominal torque in the market that’s Acciona and Moventas already have Moventas has been making to Acciona now available to the industry. a long-standing partnership. Deliveries since 2009. Exceed provides 20 percent more of the existing gearbox concept will The recently entered agreement torque density with 10 percent less also run alongside the serial deliveries concerns two Exceed prototype de- size with 100 percent proven Moven- of the new Exceed technology in 2015. liveries as well as serial production of tas technology. Over time, Exceed will replace the the new Exceed gearbox, both of them Our engineers took measured gear- existing gearbox deliveries. The deliv- expected to take place in 2015. box values of the technology we’ve eries are made from Moventas’ highly In 2012, Acciona Windpower and been using for a decade, recalculated modern wind gear factory in Finland.

OFS adds new look, increased functionality to website

OFS is recently announced the launch of its new website — www.ofsoptics. com — incorporating simpler naviga- tion, a comprehensive product catalog and a fresh new look. “We listened to our customers. We overhauled our website to enhance our customers’ internet experience and to make it easier to do business with OFS,” explained Michael Fortin, senior director of branding, content marketing, and communications for OFS. The new website combines all the products, capabilities and published technical data offered by OFS. Custom- ers will be able to navigate the site by product or by industry and application. The catalog is now fully searchable and will enable side-by-side comparisons of OFS products. “We look forward to our customers’ comments as we roll out this new website. Our ultimate goal is to make every interaction with OFS a high-quality one. This new website will help,” For- tin concluded.

44 SEPTEMBER | 2014 PRODUCT ROEMHELD launches maintenance-free rotor locks

Roemheld has introduced new rotor locks that are introduced to offer longer life and high availability. A designed to deliver increased availability and simpli- non-contact switch checks if the bolt is in stand-by po- fied maintenance to wind power plants. A new, special sition or if the rotor is locked. As there are no mechan- coating prevents the locking bolt from rusting when ical contacts to wear out, replacement is not necessary. not in use for a long period and non-contact position Roemheld manufactures hydraulically or electro-me- monitoring avoids mechanical wear and extends the life chanically operated rotor locks to customer specifica- of the component. tions and supplies to companies all over the world. The A permanently corrosion-free coating of the bush- rotor lock resists side loads up to a maximum of 7,000 ings prevents rusting between surface intervals and the kN and can be used to lock the rotors of onshore and need for regular greasing. As a result, the rotor lock is offshore wind power plants with up to 6.5 megawatts permanently ready for use, which also reduces the need of power. The locking module, with its compact design, for plant maintenance. The surface protection of all is adapted to the limited space in the nacelle. The rotor lock components corresponds to DIN ISO 12944, use of standardized components makes it possible to C4, so that they can also be used in offshore operations. produce complex special designs quickly and cost-ef- Non-contact position monitoring has also been fectively.

windsystemsmag.com 45 GIVING WIND DIRECTION

David C. Cooper Chad Morrison Publisher Associate Publisher [email protected] [email protected] ext. 200 ext. 202

EDITORIAL DEPARTMENT

Stephen Sisk Tim Byrd Editor Associate Editor [email protected] [email protected] ext. 209 ext. 205

SALES DEPARTMENT

Glenn Raglin Mike Barker National Sales Manager Regional Sales Manager [email protected] [email protected] ICE SENSORS ext. 204 ext. 203 The smallest, lightest, most sensitive. Tom McNulty Lowest cost ice detectors available anywhere Regional Sales Manager [email protected] 954-776-1900 CALL NOW CIRCULATION DEPARTMENT [email protected] Teresa Cooper Kassie Boggan www.newavionics.com Manager Coordinator [email protected] [email protected] ext. 201 ext. 207 Jamie Willett Assistant

DESIGN DEPARTMENT

Jeremy Allen Michele Hall Creative Director Graphic Designer [email protected] [email protected] ext. 206 ext. 211 Rebecca Allen Graphic Designer [email protected] ext. 210

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PUBLISHED BY MEDIA SOLUTIONS, INC. Coop wants to use this one for the website P. O. BOX 1987 • PELHAM, AL 35124 (800) 366-2185 • (205) 380-1580 FAX David C. Cooper Chad Morrison Teresa Cooper President Vice President Operations Director [email protected] [email protected] [email protected] ext. 200 ext. 202 ext. 201 46 SEPTEMBER | 2014 AD INDEX

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TorkWorx ...... 3 United Rentals...... 39 STAY CONNECTED Vaisala ...... 11 Scan the Wind Systems Website to enjoy a host of features, including: – Our new jobs listing, for employers and jobs seekers alike – Events calendar to keep you informed – A searchable articles archive, downloadable individually Wind Systems ...... 29,47 – View the digital magazine, or download entire issues – Vendor listings, along with our annual Buyer’s Guide – Company profi les and Q&As – Connect to the wind industry through social media Women of Wind Energy...... 22 – Wind industry news from around the world Visit windsystemsmag.com today!

windsystemsmag.com 47 CrossWinds

Vestas sponsors first-ever Danish entry to Volvo Ocean Race

Greenmarine

Vestas Wind, the first-ever Danish boat to compete in most important markets. This supports our new cor- the Volvo Ocean Race, will showcase Vestas’ products porate strategy ‘Profitable Growth for Vestas,’ ” says and services, enhance customer relations and bolster Runevad. Vestas’ profitable growth strategy on its race around “Volvo Ocean Race is the world’s preeminent boat the world. race, and as in our business, success hinges on utiliz- Starting in October, the Volvo Ocean Race will em- ing the wind most effectively,” says Morten Albæk, bark on its 12th edition, calling at 11 ports and taking Vestas Chief Marketing Officer. “This is a privileged sailors on a 38,739-nautical-mile race around the opportunity for Vestas to present our industry-leading world. By harnessing the power of the wind, Team Ves- products as well as create intimate surroundings for tas Wind will strengthen Vestas profitable growth strat- our key customers and stakeholders and promote wind egy as the race visits many of Vestas’ most important energy’s competitiveness.” markets, from Brazil and China, to South Africa, the The Vestas Wind boat will fly under the Danish flag United States and the Middle East/North Africa region. and have Tuborg Harbor as its official homeport. All Vestas is well familiar with nautical challenges. In crewmembers will be members of the Royal Danish November 2012, the Vestas Sailrocket 2 broke world Yacht Club, which will provide its clubhouse for activi- speed records, reaching a top speed of more than 68 ties and for a “welcome home” gathering in June 2015. knots. With this passion for the wind, Vestas CEO An- Olympian and World Champion sailor Chris Nicholson ders Runevad is confident the Volvo Ocean Race will will skipper the Vestas Wind boat, teaming up with be a success for Vestas. Shore Manager Neil Cox to lead Team Vestas Wind on “In terms of wind energy and where we have our the round-the-world challenge. Two Danish sailors, market focus, the Volvo Ocean Race is a perfect match Peter Wibroe and Nicolai Sehested – the youngest for us to engage with our customers, showcase our Dane ever to participate in the Volvo Ocean Race – will technology and strengthen our brand in some of our make up part of the eight-man crew.

48 SEPTEMBER | 2014 canwea-conf14-ad-WindSystems-1pg-print-v2.pdf 1 14-08-19 8:18 AM

CANADIAN WIND ENERGY ASSOCIATION 30 ANNUAL CONFERENCE & EXHIBITION OF ACHIEVEMENTS MONTREAL, QUEBEC | OCTOBER 27–29, 2014 IN CANADA’S WIND ENERGY INDUSTRY

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COME AND NETWORK AT CANADA’S LARGEST WIND ENERGY CONFERENCE

Projects Anticipating and Meeting Wind Farm Site Challenges • Conversation: Rob Morgan, RES Americas

Projects Anticipating and Meeting Wind Farm Site Challenges • Conversation: Rob Morgan, RES Americas