The Wind Revolution

BONUS SECTION MARKET OUTLOOK Giving Wind Direction THE FUTURE OF WIND

SYSTEMS THE WIND REVOLUTION

IN FOCUS Lubrication & Filtration  Turbine Foundations A FOUNDATION OF BEST PRACTICES

PROFILE American Chemical Technologies

AUGUST 2018 windsystemsmag.com [email protected]

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MARKET OUTLOOK THE FUTURE OF WIND

THE WIND REVOLUTION Forecasts show American wind power is on track to supply 10 percent of the country’s electricity by 2020.

]]ALSO East Coast offshore wind forecast. 16 Balancing advancements and risks. 20 12 State spotlight on Wyoming. 24

]]PROFILE IN FOCUS American Chemical Technologies has offered its polyalkylene glycol-based lubricants to a variety of industries, and A FOUNDATION now the company is showing how it can OF BEST PRACTICES help turbine gearboxes. 34 Understanding what to look for today can save millions tomorrow when it comes to inspections and maintenance of turbine foundations. 28

SIGNIFICANT ENERGY BENEFITS Sine pumps optimize high viscosity resin delivery for Enercon, one of the world’s largest wind ] turbine manufacturers. 32 ]CONVERSATION Uptake’s managing director of global energy solutions Sonny Garg talks about how sharing data is crucial to performance. 38

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HydrOgenics_Windsystems_75x10_daryL.indd 1 7/12/18 2:08 Pm SECTIONS August 2018 VOLUME 10  NUMBER 8

]]THE FUTURE OF WIND TAILWINDS

THE BUSINESS OF WIND

DIRECTION 8 ]]MAINTENANCE Seacat sends ships to Beatrice U.S. wind repowering returns stand up against wholesale prices, Wind Farm 45 for now  Be Power and ABB team up for power generation project ]]CONSTRUCTION Siemens Gamesa to install two large onshore projects in South Africa 40

]]MANUFACTURING CROSSWINDS Siemens Gamesa secures 52 Brazil’s largest-ever contract 50 CUTTING PRODUCTION TIME ]]INNOVATION Sandia National Laboratories recently led an effort Suction bucket concept gets to use 3D printing to slash more than a year test installation 43 from turbine blade R&D time.

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 AUGUST 2018 WINNING THE BATTLE AGAINST BEARING WEAR

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CAS_2434_WSM_7.5x10_AD_OPTIGEAR_US_WAMO_AW.indd 2 12/09/2017 17:53 Giving Wind Direction FROM THE EDITOR

Enjoy our new and improved Wind Systems David C. Cooper Publisher hile pulling your new issue of Wind Systems from your mailbox or Chad Morrison mail pile, you may have noticed something different. Associate Publisher For the past few months, we have been hard at work redesigning Wthe magazine in order to better present to you the fascinating information EDITORIAL the industry has to offer. Kenneth Carter We’ve given Wind Systems a fresh, updated look specifically designed to Editor make it easier to find the wind energy news you’ve grown accustomed to read- Jennifer Jacobson ing every month. The features are packaged with a bolder, more energetic ap- Associate Editor proach, pulling you in with breathtaking photographs of wind farms from around the world, while keeping SALES you reading with educational and informative articles David Gomez from the best and brightest in the wind industry. Regional Sales Manager We’ve kept the Direction section as its own entity, Tom McNulty because it helps look at the future of wind, while our Regional Sales Manager other departments you’ve come to know — Construc- CIRCULATION tion, Innovation, Maintenance, and Manufacturing — have been packaged into a quick and easy-to-read Teresa Cooper Manager format we’ve dubbed “Tailwinds.” In addition to our InFocus section, which this month highlights Lubrica- Cole Morrison Assistant tion & Filtration and Turbine Foundations, this issue also includes a bonus section: our annual Market Outlook. Jamie Willett Assistant In this special section, experts from AWEA, Business Network for Offshore Wind, and S&P Global Ratings share their extensive knowledge on the state DESIGN of wind in the U.S. — both on and offshore — as well as the future of the Rick Frennea industry on a global scale. Creative Director Market Outlook also spotlights the state of Wyoming, where one of the Michele Hall largest wind farms in the world is set to deliver more than 3,000 MW of power Graphic Designer when it goes live in the next few years. Wyoming has had a few starts and stops in its wind production in the past, but several projects are set to make No part of this publication may be reproduced or Wyoming a major contender in the renewables arena. transmitted in any form or by any means, electronic In addition to our redesigned magazine, we are also busy putting finish - or mechanical, including photocopy, recording, or any information storage-and-retrieval system ing touches on a new Wind Systems website that will bring you digital books, without permission in writing from the publisher. the latest industry news, our 10-year archives, and much more in a dynamic, The views expressed by those not on the staff of Wind Systems magazine, or who are not easy-to-navigate format. We’ve been working on it for months, and I’m excited specifically employed by Media Solutions, Inc., are to bring it to you in the coming weeks. purely their own. All “News” material has either been submitted by the subject company or pulled There’s definitely a change in the wind, and I’m eager to share it all with directly from their corporate web site, which is assumed to be cleared for release. Comments and you. As we continue to roll out these changes, please let me know what you submissions are welcome, and can be submitted to think of them. I always want to hear from our readers and make sure we areVertical Logo [email protected] Logo serving you to the best of our abilities. So, enjoy our new and improved Wind Systems, and, as always, thanks for reading!

Coop wants to use this one for the website Published by Media Solutions, Inc. P.O. Box 1987 • Pelham, AL 35124 (800) 366-2185 • (205) 380-1580 fax Kenneth Carter, editor [email protected] Wind Systems magazine David C. Cooper President [email protected] (800) 366-2185, ext. 204 Chad Morrison Vice President Teresa Cooper Operations Director 6 AUGUST 2018 FYI IRONCLAD

How much does it cost · Grout Sleeves are More Effective in Protecting Bolts to bail out uneconomic from Grout power plants? · Saves Labor – Enhances Safety – No More Cutting From AWEA Foam As the administration continues developing · Displace Almost No Grout, 800.359.0372 plans to prop up aging, uneconomic coal and Resulting in a Considerably [email protected] Stronger Foundation nuclear plants, many have wondered what NTCWIND.COM the price tag for consumers would look like. A Call to inquire about our special limited time pricing! recent new report from the Brattle Group gives a glimpse of what a two-year down payment for bailing out these plants could cost: between $9.7 and $35 billion a year. Here’s a rundown of what cost figures could look like:  $16.7 billion per year, or roughly $34 billion for two years as proposed, if every coal and nuclear plant in the country were given a uniform ($ per unit of capacity) support at the level of the average financial shortfall experienced by such plants.  $9.7 billion to $17.2 billion annually, or roughly $20 billion to $34 billion over two years, if only those plants now facing shortfalls were given payments sufficient to cover their operating losses.  $20 billion to $35 billion annually, or $40 billion to $70 billion total, if power plant owners were also granted a return on their invested capital in addition to payments for operating shortfalls.

The American Wind Energy Association (AWEA) is the premier national trade association that represents the interests of America’s wind energy industry. For more information, go to www.awea.org

windsystemsmag.com 7 DIRECTION

U.S. wind repowering returns stand up against wholesale prices, for now U.S. production tax credits (PTCs) have accelerated wind repowering activity as operators look to use technology advancements to optimize aging fleets. Falling costs and growing wholesale market exposure have pressured margins for suppliers and operators. Most recently, PacifiCorp ordered 260 MW of turbines from Vestas to repower the Marengo 1 & 2 wind farms in Washington. The Marengo wind farms were built in 2007 and 2008, and the turbines will be upgraded from 1.8 MW models to more advanced 2.0 MW units from the second quarter of 2019, Vestas said June 29. Repowering allows operators to install larger, more efficient turbines and introduce operations and maintenance (O&M) improvements. Operators may choose to perform a “full repowering” of major wind farm infrastructure or a “partial repowering” where typically the existing tower and foundations are kept in place. About 2.1 GW of U.S. online wind capacity were repowered in 2017 and more than 15 GW of capacity is “ripe” for repowering in 2018, ICF consultancy said in a report published in May. Repowering could add 300 MW of additional U.S. wind capacity in 2017-2022, according to Bloomberg New Energy Finance (BNEF). Projects installed between 2003 Repowering offers output gains and operational efficiencies but tax credit is falling 20% per and 2010, underperforming plants year. (Courtesy: ZU_09) and those with high maintenance costs are likely candidates for par- PTC drops by 20 percent for projects to ICF. This is based on a captured ener- tial repowering, ICF said. Similarly, started in 2017 and is scaled down by gy price of $24/MWh (flat) and capital turbines from suppliers no longer in 20 percent annually with zero support expenditure of $950/kW. business can be swapped out under a from 2020. This means projects start- Even with the reduced PTC level repowering program. ed in 2018 can capture $13.8/MWh of this year, “repowering can make eco- Extended in 2016, the PTC support credits. nomic sense,” ICF said. But ICF warned program provides 10 years of tax cred- Partial repowering projects in 2018 falling margins demand more careful its at $23/MWh for greenfield and re- can earn an Internal Rate of Return scrutiny of energy output gains, capi - powering projects started in 2016. The (IRR) after tax of 11 percent, according tal costs and O&M efficiency.

8 AUGUST 2018 “It may make better financial sense A 1 percent change in wholesale ing, grid solutions, forecasting, and this year than it will next year or the prices can affect IRR by about 0.4 tailored financing solutions.” year after,” said Chris Mertes, ICF’s percent, based on the above project Wind Practice Lead and co-author of assumptions, it said. MORE INFO newenergyupdate.com the report. Repowering projects have the advantage of actual historical site per- REPOWERING STRATEGIES formance and market data, the ICF ICF’s indicative IRR calculation is based consultants noted. Be Power and ABB on an increased net capacity factor and team up for power a 10-year extension of asset life. OPERATIONS AND Energy production gains are clearly MAINTENANCE generation project a crucial driver of repowering econom- Repowering decisions must also factor ics. According to the consultancy, a 1 in O&M costs over the lifetime of the percent increase in capacity factor can project. increase IRR by 0.8 percent. Aging turbines incur higher O&M To qualify for the PTC, the value of costs, and the average turbine age in the repowering project must be at least North America will rise from 5.5 years 80 percent of total plant value. in 2015 to 11 years by 2025, IHS Markit Partial repowering work can differ said in a recent report. between projects, but longer blades U.S. O&M costs are forecast to rise are typically fitted, and it often in- from $45,000-$50,000/MW per year volves the replacement of the entire for turbines aged between five and 10 rotor and the refurbishment of other years, to about $50,000-$60,000/MW parts of the wind turbine, such as the per year for turbines aged between 10 nacelle or hub, said Eric Soderlund, se- and 15 years, IHS Markit said. nior manager and structural engineer According to ICF, O&M contracts for at Sargent & Lundy. new projects currently range between Some partial repowerings have fo- $15,000 and $25,000 per MW per year. cused primarily on generator replace- “The O&M cost delta is a significant ment, Soderlund said. driver in the economics of a repower “This is done to increase the wind project: A $5/kW-yr difference in our turbine capacity … PTCs are received so base case makes for a difference in IRR Paolo Martini, managing director of Be long as the 80/20 rule is met,” he said. of 1.4 percent,” the ICF consultants said. Power. (Courtesy: Building Energy) In a recent report covering 23 U.S. Market competition also has repowering projects, partial repower- spurred a widening choice of repower- Be Power and ABB will cooperate in ing projects retained — at the very ing “add-ons” that can further reduce the Dispatching Service Market (MSD). least — the existing wind turbine foun- costs over the lifetime of the asset. Be Power is the Digital Green Utility dations, turbine tower,s and electrical Original equipment manufactur- of the Building Energy Group with a balance of plant (BOP). Some of the proj- ers (OEMs) are now offering repower- business model based on the syner- ects reused yaw systems, nacelles, and ing packages that include upgrades to gies between the markets of energy generators, while replacing hubs, main main equipment as well as O&M, grid, and mobility. This model aims at in- shafts, main bearings, and gearboxes. and forecasting solutions. tegrating the opportunities arising In one example, GE supplied the from the opening of the MSD to wide- MARKET RISK turbines for Leeward’s Sweetwater spread facilities of power generation The contracting of wind-energy sup- 1 & 2 repowering project along with (demand/response) with a proprietary plies is evolving as costs fall and sub- O&M services and tax equity financ- infrastructure of charging stations sidies are removed. While some proj- ing through the GE Energy Financial and e-vehicle fleets. The partnership ects will benefit from long-term PPA Services arm. with ABB — a technological leading contracts, many will be exposed to “Repowering is so much more than player in the industrial automation wholesale market prices that have been simply providing new wind-turbine and power grids as well as in the elec- flattened by the U.S. shale gas boom. equipment,” Anne McEntee, GE Renew- trification products, robotics, and mo- The economics of repowering can able Energy vice president and Services tion control solutions — will allow Be be “feasible” if captured wholesale pric- CEO, said in 2017. “We’re bringing the Power to join the Terna pilot project es are in the mid-$20’s/MWh range, ICF entirety of GE to the table for our cus- that has opened the participation to said in its report. tomers, providing options for servic- the MSD also to the distributed gener-

windsystemsmag.com 9 DIRECTION

ation, including the generating units MW of the total capacity in the last we will benefit from the consolidated powered by renewable sources and years, while ABB will provide ser - experience in trading of our subsidi- storage systems. vices of advanced analysis, aggrega- ary 4energia to offer the energy pro- By setting up the pilot project tion, and data management through ducers and consumers an additional (AEEG SI Resolution 300/2017), the its advanced services, ABB AbilityTM value through the optimization of national grid operator intends to op- Collaborative Operations. ABB will be their assets. The companies that will timize the provision of dispatching responsible for creating, qualifying, join our grid will be able to obtain resources encouraging a wider par- and managing the Aggregated Virtu- additional margins by entering more ticipation in this market as already al Units (UVA) assigned to the MSD profitable markets.” happens in some European countries. for production and/or consumption “This pilot project fully under - Hence, consumption and production with the relevant measurement de - stands the essence of the ABB Ability units of any size and technology — in- vices in each plant (UPMx) and the Collaborative Operations, a true evo- cluding non-significant generating installation of a central unit (UVAx) lution in the data analysis and aggre- plants with capacity lower than 10 to gather the data toward the Terna gation, said Danilo Moresco, head of MVA — can offer dispatching services grid. All the data will be processed the Power Generation & Water Unit through an “aggregator” by estab - by the ABB AbilityTM Collaborative in Southern Europe. “This new ap - lishing production, consumption, Operations Center in Genoa. proach is able to gather in a unique and mixed units (UVAP, UVAC and “We are proud to take part in the circular flow the plant data as well as UVAM). pilot project of Terna entering the both the Be Power and the ABB con - Be Power will enter the Market Market for Dispatching Services trol centers in an ongoing exchange for Dispatching Services as “aggrega- together with ABB, a company spe- of accurate and timely pieces of infor- tor” through its subsidiary 4energia, cialized in the development of this mation to optimize the performance the energy trader specialized in pur- technology,” said Paolo Martini, man- of the monitored assets.” chase of electricity from independent aging director of Be Power. “Thanks producers managing more than 700 to this partnership as ‘Aggregator,’ MORE INFO www.buildingenergy.it.

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MODERN. COST-COMPETITIVE. CLEAN. MARKET OUTLOOK THE FUTURE OF WIND THE WIND REVOLUTION

Forty-one states now have utility-scale wind projects, and by the end of the year, the U.S. had enough installed wind capacity to power the equivalent of 27 million American homes. (Courtesy: AWEA)

12 AUGUST 2018 THE WIND Forecasts and trends show REVOLUTION American wind power is on track to supply 10 percent of the country’s electricity by 2020.

By JOHN HENSLEY

t turns out that tapping into a free and abundant natural resource that exists everywhere is among the cleanest and most efficient ways of producing electricity. In- vestments and innovations over the past decade have brought wind’s costs down to their lowest levels ever — 66 percent cheaper than in 2009 — making wind power a mainstream source of reliable, affordable energy. IOver the past five years, the United States has more than tripled its wind-generating capacity, with wind represent- ing 25 percent of new power generating capacity that came online. Wind also surpassed conventional hydropower as the largest renewable energy source by capacity. Recent market trends show this impressive growth should continue in the years ahead, as wind has become the cheap- est source of new electricity in many parts of the country. Continued technological and manufacturing improvements also allow new turbines to reach stronger, steadier winds, meaning more electricity can be generated at a lower cost. As we continue adding new chapters to this American success story, let’s take stock of the state of U.S. wind power.

ALL IN FOR WIND Utilities and Fortune 500 companies continue to show a strong appetite for wind. Their demand has helped grow the number of new wind projects under construction or in advanced development 40 percent since this time last year. In 2017, the industry added 7,017 MW of new capacity across 24 states, enough to power millions of homes. For- ty-one states now have utility-scale wind projects, and by the end of the year, the U.S. had enough installed wind capacity to power the equivalent of 27 million American homes. windsystemsmag.com 13 MARKET OUTLOOK THE FUTURE OF WIND

Overall, wind now supplies more than 6.3 percent of buyers such as Adobe Systems, AT&T, Brown Forman, Kohler, America’s electricity. However, figures are even more im- and Nestlé. Every month, the list of companies that have pressive at the state level. Iowa, Kansas, South Dakota, and committed to buying wind gets longer. Oklahoma now all generate at least 30 percent of their elec- “As one of the world’s largest companies, we know how we tricity using wind. In total, 14 states generate at least 10 source our energy is important,” said Scott Mair, president percent of their electricity with wind. of AT&T Operations. “Many companies are focused on their Though Texas remains the country’s largest wind pro - own carbon footprint, but we believe our industry can do ducer, New Mexico has made headlines by tapping into its more. We’ve been working for a long time to ensure our wind large and abundant wind resources. In 2017, it had the high- projects deliver for both our business and the environment.” est rate of new wind-power growth in the country, putting Corporate procurement and PPAs will continue to play the Land of Enchantment on pace to join the ranks of other an important role in wind’s growth in the coming years. wind powerhouses. 2018 has seen a healthy start, with non-utilities account- “I’m proud that New Mexico’s wind power capacity ing for nearly a third of PPAs. During the first quarter of this grew at a faster rate than any other state and generated an year, project developers have signed more than 3,560 MW of unprecedented level of private sector investment and job PPAs. That makes Q1 the strongest quarter for PPA growth growth,” said U.S. Senator Martin Heinrich. “As consumers since AWEA began tracking it. and major companies demand cheaper and cleaner pow - er sources, our state stands to benefit and become an even THE PROMISE OF OFFSHORE bigger leader in this booming energy sector — especially in While land-based wind continues to expand, the U.S. is also rural communities.” on the cusp of developing more offshore capacity. The de- In many states like New Mexico, wind offers new job oppor- velopment of offshore wind in the coming years represents tunities and much-needed tax revenue that helps revitalize billions of dollars of investment and thousands of new man- rural communities. It has not only allowed communities to ufacturing and shipping jobs. Offshore wind farms offer the profit from the passing breeze but has also done so in a man- promise of efficiently providing electricity to major popula- ner that leaves 98 percent of the land undisturbed, so that it tion centers along the coast, allowing us to tap into a new can remain useful for farming, ranching, or natural-habitat ocean energy resource. Offshore wind is a proven technol- preservation. ogy that holds enormous potential for the United States. “The European offshore wind market is 27 years old,” said Roy Francis, vice president of Business Development for  Because of the success at the Block Gulf Island Fabrication, a Texas-based offshore energy construction firm. “We are taking the best from the mature -Eu Island Wind Farm, America’s first ropean industry and pairing it with American know-how.” offshore project, states are looking to tap Because of the success at the Block Island Wind Farm, America’s first offshore project, states are looking to tap into into vast wind resources off the coast.  vast wind resources off the coast. By the end of 2017, there were already 17 offshore wind projects in various stages Fortune 500 companies have also recognized the benefits of development, spanning 11 states off the East, West, and of wind power. Many of them have committed to procuring Great Lakes coasts. These new offshore projects represent wind energy for their energy-intensive manufacturing and more than 11,600 MW of wind-power development. data center operations. To guarantee a reliable and price-sta- Many states are looking to offshore wind to secure af- ble supply of renewable energy, many companies have en - fordable energy, achieve renewable goals, and reduce car- tered into power purchasing agreements (PPAs). PPAs allow bon pollution. For example, Massachusetts utilities intend companies to contract with a wind-energy provider to buy to procure 1,600 MW of offshore wind by 2027. New Jersey electricity over a specified period of time at a fixed rate. has also launched massive plans to develop more than 3,500 In fact, corporate buyers account for 94 percent of to- MW of offshore wind by 2030. tal non-utility wind deals. In 2017, companies contracted Other projects also are coming along. In 2017, Maryland’s for more than 2,000 MW of wind energy. This helps them Public Service Commission awarded Offshore Renewable plan for the long term while also reaching internal sus- Energy Credits (ORECs) to U.S. Wind and Deepwater Wind, tainability goals. which together will produce more than 368 MW. “Helping to grow the renewable energy market is not New York also has announced ambitious plans to develop only good for the environment, it is a strategic business up to 2.4 GW of offshore wind over the next decade to help move as we strive for long-term sustainability,” said Anheus- meet its goal of 50 percent renewable energy by 2030. The er-Busch CEO Joao Castro Neves. state released its Offshore Master Plan in January, which Already in 2018, companies such as Nike, T-Mobile, Face- identifies areas for wind development and potential path- book, and Bloomberg have entered into new agreements to ways to procurement. New York also intends to hold two re- buy wind power. The complete list includes first-time wind quests for proposals (RFPs) over the next two years to launch

14 AUGUST 2018 Corporate buyers account for 94 percent of total non-utility wind deals. (Courtesy: AWEA) development. On top of that, New York will invest $15 mil- “In pre-wind, our county taxable value was $500 million in education programs to train workers for offshore lion,” said Ken Becker, executive director of the Sweetwater wind jobs and developing its port infrastructure. Economic Development Corp. “In 2008, it was $2.8 billion.” Offshore is a new frontier for the American wind indus- For some landowners, this translates to nearly $1,000 per try, and it promises to support thousands of new manufac- month for a single turbine on their property. For the town turing and shipping jobs across the country. This is only the of Sweetwater — population 10,000 — wind means stable job beginning of the country’s ability to tap into the strong and prospects for 18 percent of residents. steady winds off our coasts. The reality of new career opportunities has not been limited to Sweetwater. These benefits are being felt across the A CONFIDENT INDUSTRY WORKS FOR AMERICA United States. Today, more than 105,000 Americans across As interest from utilities and companies steadily increases all 50 states work in wind, and as wind continues to expand, and technological advances continue to drive down costs, this number will only increase. Already, wind technician is American wind power will keep growing. And that means the country’s second fastest-growing job according to the more benefits for local communities in farming and factory U.S. Bureau of Labor Statistics. towns that need new opportunities. The U.S. wind industry has made massive strides over American wind power invested $14 billion in new wind the previous decade. Forecasts and trends show American projects last year, and farmers and ranchers hosting turbines wind power is on track to supply 10 percent of the country’s on their property received $267 million in lease payments in electricity by 2020. As a mainstream source of clean, afford- 2017 alone. Added wind revenue for local budgets also lessens able energy for the United States, wind continues to work for the tax burden on many host communities, helping them pay America. for school improvements, road repairs, and law enforcement. Every community has a story. For example, Nolan Coun- ABOUT THE AUTHOR ty, Texas, about 190 miles west of Fort Worth, has increased John Hensley is the senior director for Research & Analytics at its taxable value five-fold since wind arrived. the American Wind Energy Association.

windsystemsmag.com 15 MARKET OUTLOOK THE FUTURE OF WIND

EAST COAST OFFSHORE WIND OUTLOOK

Block Island wind farm construction. (Courtesy: Mott MacDonald)

16 AUGUST 2018 When it comes to the offshore wind industry, progress is being made with a regional approach.

By LIZ BURDOCK

here is no question that 2018 is BOEM has stated offshore wind fits the admin- emerging as a watershed year for the istration’s “All of the Above” approach to energy offshore wind energy industry in the development and is working to streamline the U.S., with several large wind farms offshore approval process, while DOE just issued having their site plans approved and an $18.5 million grant for offshore wind research states increasing their commitments and development, administered by NYSERDA (see and goals for offshore wind energy. New York below). TIn the midst of this energy and excitement, we BOEM also recommends a regional approach. need to keep in mind that regional cooperation “The offshore wind industry is experiencing between developers, suppliers, and between the exciting momentum as a result of growing in- states is going to be critical to building a healthy dustry-wide confidence in the U.S offshore wind and sustainable industry supported by a viable market, thanks to decreasing global costs, stron- supply chain. ger state policy commitments, and this Admin- We use the term “co-opetition” to describe the istration’s commitment to American energy,” combination of competition and collaboration, said BOEM’s Jim Bennett, Chief of the Office of and apply it to remind the industry that no single Renewable Energy Programs. “However, experi- state is going to own the entire supply chain. The ence has shown that it will take a concerted effort U.S. offshore wind energy pie is big, and there by the Federal and State governments to propel is enough for every state so they don’t need to this industry forward. States and regions often fight but work together on complex issues such find themselves with shared economic interest. as commercial fishing, navigation, environmen- To realize the full potential of offshore wind, we tal impacts, and supply chain development on a need to take a regional look at how the offshore regional basis. wind industry is going to come together.” To those waiting for this technology to come Here is where we see the northeastern and online and start replacing fossil fuel power mid-Atlantic coastal states going in the next six plants, a year or two or even five years may seem months or so: like a long time to wait, but timing projects so we have a “good pipeline” — a steady, consistent MASSACHUSETTS stream of projects throughout the 2020s — is im- Perhaps the most dynamic of the East Coast portant, so construction projects don’t stack up states, Massachusetts has aggressively moved into on each other and we don’t have huge, expensive a leadership position in offshore wind, highlight- pieces of customized offshore wind equipment ed by its announcement that Vineyard Wind had and highly skilled labor forces standing idle one been selected out of three bidders for the state’s year and strained to the breaking point the next. first, 800 MW solicitation in May. Vineyard Wind is a joint venture of Avangrid Renewables and Co- FEDERAL ROLE penhagen Infrastructure Partners. The Trump Administration is streamlining per- The Power Purchase Agreement (PPA) for Vine- mitting, accelerating design, and reviewing a rec- yard Wind’s 800 MW project was scheduled to be ommendation for a future offshore wind leasing submitted to the Massachusetts Department of program that could cover 20 GW of capacity, or Public Utilities for approval July 31, 2018.Vineyard 2 GW per year over a decade. All of these factors Wind has continued to advance the planning of present a strong business case for offshore wind its project and should be soon selecting some of investment in the United States. its tier 1 contractors — including turbine manu- The two main federal agencies overseeing the facturers, foundation suppliers, and installation offshore wind process, the Department of Interi- contractors. It hopes to start construction next or’s Bureau of Ocean Energy Management (BOEM) year and begin delivering clean energy by 2021. and the Department of Energy (DOE), support the BOEM is scheduled to auction the two re - industry with auctions of offshore wind-energy maining offshore wind energy lease areas in areas, research, environmental and engineering the Massachusetts Wind Energy Area (MAWEA) review, industry guidelines, and outreach such as by the end of the year, which provides the pos- regional task force meetings and presentations at sibility of having additional offshore wind de- industry events. velopers competing for the next Massachusetts

windsystemsmag.com 17 MARKET OUTLOOK THE FUTURE OF WIND

Offshore Wind Solicitation next year. ergy Research and Development Authority (NYSERDA) has To coordinate with the commercial fishing industry, the requested and BOEM has agreed to a call for four new wind state is working with the Massachusetts Fisheries Working energy areas (WEAs) in the New York Bight between New Group, Rhode Island Fisheries Advisory Board, BOEM, Na - Jersey and Long Island. BOEM has held several meetings on tional Marine Fisheries Service, and others to establish the the proposal and set a July 30 deadline for comments from Southern New England Fisheries Science Panel to track in- the public. BOEM hopes to hold auctions for the New York teractions between fisheries and offshore wind structures. Bight properties in late 2019. They also are working with the Massachusetts Clean Energy On June 15, NYSERDA was awarded an $18.5 million Center to create a state-wide workforce training program. grant from the U.S. Department of Energy to lead the Na- In June, the state Senate passed a law to raise its Renew- tional Offshore Wind Research and Development Consor- able Portfolio Standard (RPS) to 100 percent by 2047. The tium. The agency already has begun bringing together the state also has supported investing millions to redevelop and offshore wind industry, utilities, research laboratories, and modernize dock space in the old whaling and fishing village other states (New Jersey has signed on). This national and of New Bedford for offshore wind. independent consortium will help reduce industry barriers; advance technologies and methods to reduce siting and in- RHODE ISLAND stallation costs; address operations challenges; and foster On the same day that Massachusetts announced the selec- job growth throughout the supply chain. tion of Vineyard Wind, Rhode Island awarded Revolution Wind — a wind farm led by Deepwater Wind — its solicitation of 400 MW. Jeff Grybowski, CEO for Deepwater Wind, called the joint announcements “the first really large- scale procurement ever for offshore wind in the United States.” Deepwater Wind also developed the nearby Block Island 30-MW wind farm. Revolution Wind hopes to start local construction of the project by 2020, with 50 turbines operating by 2023.

CONNECTICUT Deepwater Wind scored again on June 13, when it won a competitive bid to Sunset at Block Island wind farm. (Courtesy: Dan Clark) supply Connecticut with 200 MW of wind power. The state’s Department of Energy and Environ- On July 12, Cuomo announced NYSERDA will procure mental Protection (DEEP) noted the project is expected to approximately 800 MW of offshore wind through a solici- create about 1,400 direct, indirect, and induced jobs. Deep- tation issued in the fourth quarter of 2018, in consultation water Wind has committed to invest $15 million in the New and coordination with the New York Power Authority and London State Pier. the Long Island Power Authority. Awards are expected to be Deepwater Wind will now work on negotiating 20-year announced in the second quarter of 2019. If needed, a second contracts with electric utilities Eversource and United Illu- solicitation will be issued in 2019. minating, which will then be reviewed by the state’s Public Utilities Regulatory Authority (PURA) for final approval. NEW JERSEY Despite being a little late to the party, New Jersey inaugu- NEW YORK rated a new governor in January whose administration is Another regional powerhouse, New York is moving quick- strongly committed to offshore wind. On May 23, Gov. Phil ly to stake out its offshore wind territory and compete Murphy signed the Clean Energy Bill, which increased the with Massachusetts to the north and New Jersey to the state’s RPS to 50 percent by 2030, with an objective of 3,500 south. Gov. Andrew Cuomo kicked off the year with a call MW of offshore wind power built in. for a solicitation for a total of 800 MW of offshore wind Also on May 23, Murphy signed Executive Order No. 28, in 2018 and 2019, part of his goal to generate 2,400 MW requiring state agencies to update the Energy Master Plan of offshore wind by 2030. (EMP) that prepares a strategy for achieving 100 percent Equinor, formerly known as Statoil, leased 80,000 acres clean energy by January 1, 2050. The new EMP is scheduled for $42 million at auction just south of New York City and to be finalized and published by June 1, 2019. Long Island in December 2016. Now the New York State En- The state has three active projects, led by the small (24

18 AUGUST 2018 MW) Fishermen’s Energy wind farm posted a Request for Proposals May 22 located about three miles off Atlantic from qualified contractors to “develop City. Fishermen’s Energy, now owned a plan to position Virginia as the East by EDF RE, was scheduled to file a new Coast offshore wind supply chain and application with the NJ Board of Public service industry location of choice.” Utilities (BPU) by the end of July, and the BPU will have 90 days to review MAINE their proposal. If approved, Fishermen’s A large northeastern state with 378 could have its four 6-MW turbines pro- land-based wind turbines and good off- ducing electricity by 2020. shore wind potential, Maine is being The Danish developer Ørsted has held up because its governor opposes the Ocean Wind project under way wind energy and claims that it would 10 miles off Atlantic City, which will be too expensive for ratepayers (much provide electricity to 500,000 homes like New Jersey’s former governor). In Department of Interior Secretary Ryan when fully built. Ocean Wind had its Zinke speaking at the International Offshore January, Gov. Paul LePage imposed a Site Assessment Plan (SAP) approved Wind Partnering Forum in April. (Courtesy: moratorium on new wind-energy proj- May 17, the same day it opened a new Business Network for Offshore Wind) ects until a new Maine Wind Energy office in Atlantic City. Just to the north, Advisory Commission reports on wind U.S. Wind has a second major wind development planned power’s economic impacts. The commission also could affect for 183,353 acres. the experimental Maine Aqua Ventus floating wind farm, New Jersey BPU is also working on its Offshore Wind which is being developed by the University of Maine. Renewable Energy Credits (OREC) funding mechanism, a The governor leaves office in January, and offshore devel- solicitation for 1,100 MW of offshore wind, and an Offshore opers and investors are waiting to see who wins the election Wind Strategic Plan, all due by the end of this year. in November before making their next moves.

MARYLAND NORTH CAROLINA The first state to pass legislation that uses ORECs as the fund- Like Maine, North Carolina has a long coastline and tre- ing mechanism for offshore wind, Maryland has one active mendous wind resources off its shores but is being held offshore wind project: U.S. Wind near Ocean City. up by state politics. The state has three WEAs: Kitty Hawk On March 22, BOEM approved the SAP for the U.S. Wind (122,000 acres), Wilmington West (52,000), and Wilmington project. The SAP approval allows for the installation of a East (134,000), but similar to Maine, it is facing resistance, meteorological tower; a seabed-mounted acoustic Doppler in this case from the state Senate. current profiler (ADCP) sensor; and a conductivity, tempera- In a report released March 28, offshore wind advocates ture, and depth (CTD) sensor, so U.S. Wind can conduct the demonstrated the steady winds blowing off the North Caro- testing required for the next critical step, the Construction lina coast could provide 4.7 times the state’s electricity usage and Operations Plan (COP). each year. Avangrid Renewables, which won the offshore wind lease for the Kitty Hawk parcel in 2017, stated in March VIRGINIA that plans for a massive wind farm off the North Carolina Another state that is catching up on offshore wind, Virginia coast are “moving faster than I think anybody anticipated,” doesn’t have a formal RPS, but its Grid Transformation and according to CEO Laura Beane. Security Act of 2018 declares that 5,000 MW of renewable However, the company still faces some challenges, includ- energy are in the “public interest,” including a carve out for ing the lack of infrastructure in that area, the relatively low 12 MW of offshore wind. cost of competing energy sources, and political obstacles. Dominion Energy Virginia (a utility) is partnering with Overall, it’s clear the U.S. East Coast as a region is mov- Ørsted to build the Coastal Virginia Offshore Wind project ing forward and seizing the opportunities provided by the 27 miles off Virginia Beach. This 12-MW demonstration proj- offshore wind-energy marketplace. ect of two 6-MW turbines could be installed by 2020 and is As the projects move toward completion, supply chains directly adjacent to an 112,800-acre site leased by Dominion. develop, and scale drives costs down, it will be essential Once the Virginia State Corporation Commission (SCC) for developers and state governments to team with the approves Dominion’s funding request for 12MW of offshore federal agencies and work together to avoid missing out wind to be paid by the ratepayers — approval is expected this on this chance to make the most of the global clean energy year — then construction may start. The state would then need revolution. to increase its offshore wind carve out beyond 12 MW to use the much larger commercial lease area held by Dominion. ABOUT THE AUTHOR To accelerate the state’s offshore wind development, the Liz Burdock is the executive director for Business Network for Virginia Department of Mines, Minerals, and Energy (DMME) Offshore Wind.

windsystemsmag.com 19 MARKET OUTLOOK THE FUTURE OF WIND

BALANCING ADVANCEMENTS AND RISK

The Global Wind Energy Council (GWEC) predicts that worldwide wind-energy capacity will reach 817 GW by 2021. (Courtesy: Global Wind Energy Council) 20 AUGUST 2018 While there are still a number of risks for project owners to consider, what’s clear is that renewables projects are seemingly trending toward more advanced technologies at lower costs.

By JESSICA WILLIAMS

reater decarbonization efforts are driving the continued advancement of clean power. As a result, cost-competitive renewable technologies — such as solar and wind — are increasingly being incorporated into the global electricity grid. By 2040, the share of all renewables in total power generation is expected to reach 40 percent — by which time Gthe International Energy Agency (IEA) estimates that global photovoltaic (PV) solar energy will become the largest source of low-carbon capacity [1]. Meanwhile, the Global Wind Energy Council (GWEC) predicts that worldwide wind-energy capacity will reach 817 GW by 2021, as wind power continues to make its mark on the market — second only to hydropower in terms of capacity in 2017. However, as the renewables surge continues, there are changing technological, regulatory, and political landscapes to consider. On the one hand, assets are becoming increasingly viable — and by exploiting technological advancements, renewable power can provide solutions to regions suffering from less predictable supply and demand trends (often in remote geographical locations). On the other hand, the rate of industry development is still bound by restrictive policies, technology risk, and unpredictable weather conditions. If wind and solar projects are to further leverage the vast potential of renewable energy sources around the world, the risks should be understood and appropriately mitigated.

ADVANCEMENTS TAKE HOLD As wind and solar power become increasingly viable, S&P Global Ratings is observing a burgeoning pipeline of projects that are addressing local electricity challenges. Take the U.K. market, for example, where costs for offshore wind projects have fallen by a little under a third in just five years. In windsystemsmag.com 21 MARKET OUTLOOK THE FUTURE OF WIND

turn, we are increasingly seeing wind projects employing enhanced turbine and submarine cable technology — the Western Link initiative, for example, is a 1 billion pound bi-directional cable project that will transfer 900 MW of onshore and offshore-generated electricity from Scotland to England and Wales. Similar projects are coming to fruition elsewhere. For instance, in the U.S., Cross Sound Cable is an under-sea transmission line moving excess clean electricity from renewable-rich New England to Long Island, New York, which has historically faced both gas and electric transmission constraints. The project can transmit 330 MW of hydrolog- ic and wind power, and it and will deliver carbon savings equivalent to approximately 600 MW of wind capacity. Chart 1: Potential wind capacity by weater depth. What’s more, the cable is bi-directional, allowing electricity to flow in either direction according to the grid’s demand needs. The U.S. also has considerable offshore wind power potential that is yet to be explored — a 2012 study by the U.S. government-owned National Renewable Energy Laboratory (NREL) estimates potential offshore capacity at 4,200 GW. Wind speeds off the Atlantic coast and in the Gulf of Mexico are generally lower than wind speeds off the Pacific Coast and Hawaii, but the Atlantic has shallower waters that are more economically attractive due to the likely lower costs of installing turbines (see Chart 1). There have been significant technological advancements for wind turbines, too — most notably in Europe. For example, one trend is the production of larger and more Chart 2: Solar photovolataic global capacity and annual additions, efficient rotors — and wind-turbine generators (WTGs) es- 2006-2016. tablished on better foundations. And because offshore wind projects typically spend the largest proportion of capital and operational expenses on WTGs, rotor sizes will like- MITIGATING RISKS ly continue to increase as operators pursue economies of Yet, with technological developments materializing at scale — thereby reducing their costs per MW produced and pace, there are myriad risks to address — not least possi- optimizing their yields and efficiency ratios. And as the ble environmental ramifications during the assembly and costs continue to fall, the number of wind projects will implementation phases. These can include considerations continue to increase. during the construction phase (including technology and Advancements to PV technology also have resulted in counter-party risks) or during the operation phase (such solar power becoming more viable — with solar additions as resource, regulatory, and market risks). Importantly, as to the grid increasing at pace every year (see Chart 2). In technologies continue to advance, we can expect their as- Asia Pacific, for example, the Asian Renewable Energy Hub sociated risks to evolve, too. project will harness Western Australia’s wind and solar re- Notably, wind-farm projects face significant construction sources and export the electricity generated to Indonesia. In risks. For example, the U.K.-based Greater Gabbard wind farm, addition to the 2,400 MW of electricity produced by PV solar a 504 MW-capacity project constructed by Shanghai Zhenhua panels, more than a thousand 300-meter-high onshore wind Heavy Industries Ltd., was subject to cost and schedule over- turbines will also generate electricity to power 7 million runs after cracks in the monopiles were discovered. However, homes — enough renewable energy to offset almost 1 billion we believe that as the industry matures, construction risk is metric tons of CO₂ during the project’s lifespan. being better understood — and with understanding comes Elsewhere, U.S.-based Hannon Armstrong Sustainable In- the improved ability to mitigate. There are also operational frastructure Capital, Inc. last year issued $163 million of sus- considerations, namely resource risk. For example, project tainable yield bonds to refinance its land leases, which support owners must consider whether the project has the necessary a portfolio of 57 utility-scale solar electricity generation proj- wind resources to meet performance requirements. The de- ects, with a total generating capacity of approximately 1,200 velopment of more sophisticated undersea cables also means MW; 73 percent of that is in California, adding to the state’s that projects are moving farther from shore — which, in turn, rapidly growing solar power capacity — in 2010, California laid may also bring heightened risks (particularly in the form of claim to just 7 MW of capacity; today it boasts 8,618 MW [2]. harsher weather conditions and deeper sea levels).

22 AUGUST 2018 There have been significant technological advancements for wind turbines. (Courtesy: Global Wind Energy Council)

These complexities can become accentuated when the So, while there are still a number of risks for project technologies installed are different to those proposed owners to consider, what’s clear is that renewables projects during the bidding phase. Notably, we are observing that are seemingly trending toward more advanced technologies some Germany-based utilities are factoring in immediate at lower costs — and deeper market penetration globally. As technological advancements as part of their assumed costs both wind and solar advance, one can expect the technologi- for offshore wind projects to be built in the next decade. cal risks, in some scenarios, to become increasingly complex Limiting the environmental impacts during construction — a factor that project owners must be prepared to balance. has also become progressively more significant for market That said, the industry is not deterred. Renewable projects participants: The TenneT project, for instance, requires all (and market opportunities) continue to be launched — ben- contractor ships to certify they do not discharge waste into efiting from the promise of abounding renewable energy the North Sea while installing undersea cables. potential around the world. Similarly, solar power generators can come up against construction risk, market risk, and the risk of inconsistent energy REFERENCES generation because of a lack of sunshine. However, new tech- [ 1 ] www.iea.org/publications/renewables2017/ nologies could help to mitigate this risk, with battery storage [ 2 ] www.energy.ca.gov/renewables/tracking_progress/documents/ technology expected to be the next major disruption to the installed_capacity.pdf American grid. As the U.S. heightens its reliance on solar energy — often through state-based Renewable Portfolio Standards ABOUT THE AUTHOR (RPS), such as in California — its intermittent nature could see Jessica Williams is an analyst with S&P Global Ratings’ grid stability become a risk. That is, unless large-scale batter- Sustainable Finance team. ies can come online to secure power consistency.

windsystemsmag.com 23 MARKET OUTLOOK THE FUTURE OF WIND

A wind project in Carbon County, Wyoming, under construction. (Courtesy: CCWYED)

24 AUGUST 2018 STATE SPOTLIGHT  WYOMING HARNESSING WIND’S POTENTIAL

Wind power is on the verge of turning Wyoming into a major player in the field of renewable energy.

By KENNETH CARTER  Wind Systems editor

yoming has some of the best wind in the country, but the Cowboy State’s contribution to renewable energy has been sporadic at best, ranking it 16th in the nation of wind energy production, according to a recent study by the University of Wyoming. WThat study’s ranking translates to roughly less than 1,500 MW of wind energy currently produced in the state. All that could change when several planned large-scale wind-energy projects go online within the next two to eight years. Those projects would total 7,500 MW of new capacity. That could bring Wyoming up to the No. 2 spot in wind production based on current capacity levels, according to Wyoming officials.

CHOKECHERRY AND SIERRA MADRE One in particular, the Chokecherry and Sierra Madre Wind Energy Project will be a 1,000-turbine wind farm south of Rawlins in Carbon County. With approximately 3,000 MW of capacity, it is expected to be one of the largest wind-energy projects in the world. “Construction for the project started in September 2016 (permitting began in 2007-2008),” said Kara Choquette,

windsystemsmag.com 25 MARKET OUTLOOK THE FUTURE OF WIND

A wind farm between Hanna and Medicine Bow, Wyoming. (Courtesy: CCWYED)

director of communications with the Power Company of Wyoming. “We an- ticipate Phase One to be complete in 2021 with the first 500 turbines. Phase Two with up to 500 turbines should be complete by 2023.” Some of the challenges that have faced wind energy in Wyoming include the state’s small market for power, according to Cindy Wallace, executive director of Carbon County Economic Development Corporation. “Wyoming is farther from the largest markets on the western grid than other western states,” she said.” Our transmission capacity that went out of state was limited, so that’s the reason why some of our wind growth quit because of the lack of transmission lines to deliver power out.”

LAND RED TAPE Another unique scenario for Wyoming is dealing with the wind project will only cover 5/10ths of a percent of the land itself. ranch, or 2,000 acres, according to Wallace. “Some people don’t understand that in some states you “So, they’ll still be able to continue their cattle ranching can just go to farmland and ask the farmer, ‘Can I lease your and operations on there,” she said. land?’” Wallace said. “In Wyoming, not quite half of our land is federal. So there’s quite a bit of land, in other words, WIND VS. COAL where every other section is all federal land.” Another challenge springs from the fact that, for decades, Permits are required by the Bureau of Land Management Wyoming has been synonymous with coal and fossil fuel and the Federal Government, which adds quite a bit of time production, but officials say they believe there is room for and effort to do these projects, according to Wallace. all forms of energy production, old and new. “That’s part of the reason that the Power Company in “There’s always the belief that, if renewable wind energy Wyoming’s Chokecherry and Sierra Madre has taken so long, is succeeding, then that means that other traditional energy because they have had to go through all the permitting sectors are going to be facing a harder future,” said Nathan and necessary requirements required by the BLM and the Wendt, vice president of initiatives with the Jackson Hole Federal Government,” she said. Center for Global Affairs. “We don’t believe that’s true. We The Chokecherry and Sierra Madre Wind Farm is being believe that it can be an all-of-the-above pathway for the built on land owned by the Overland Trail Cattle Company. state to take. Because Wyoming is an energy-producing The ranch spreads out over 320,000 acres, but the massive state, a lot of people make their livelihood by producing

26 AUGUST 2018 energy. Sometimes there’s a perception that if wind is succeeding, then that means that traditional fossil fuel sources of energy are failing. We think that’s a false choice, and that this is an additional opportunity that will be useful to the state and be helpful in driving economic diversification.” Part of that breaking with tradition is evident in the logo designed for Rawlins’ 150th anniversary, according to Choquette. A locomotive from the Union Pacific Railroad illustrating the past shares the picture with a quintet of wind turbines, signifying Rawlins’ future. It also shows how Wyoming is set to embrace renewable energy on a scale larger than it ever has before.

TRANSMISSION LINES But before the turbines for the big projects can start going The logo designed for Rawlins 150th anniversary indicates how up, first transmission lines and actual roads need to be con- Wyoming is set to embrace wind energy. (Courtesy: Carbon County structed, Wallace said. Visitors Council) For the Chokecherry and Sierra Madre project, that includes the TransWest Express, a DC transmission line more Operations and maintenance of the wind farms during than 650 miles long that will deliver power to the South- their 20-year lifespan has the potential to create $3.6 bil- west. Other wind projects also are developing transmission lion in new economic activity, according to the university networks to accommodate the expected power generation, study, which also estimates another $2.6 billion would including Rocky Mountain Power’s Gateway West Transmis- be created by direct plant expenditures and yet another sion line project. $1 billion in additional indirect and induced economic Thousands of miles of roads are under construction now activity. using gravel from a nearby quarry, according to Wallace. But In addition to the Chokecherry and Sierra Madre proj- once construction begins, it will be the beginning of a job ect, several other projects — both large and small — are boom thanks to the project. scheduled to be built within the next two years, according “At the peak of construction, which would be the months to Wallace. of April through October, there will be 975 construction Four projects from Rocky Mountain Power are expected workers,” she said. to generate more than 1,300 MW of power, and the Ekola Once completed, the Chokecherry and Sierra Madre proj- Flats Wind Energy project plans another 250 MW with ect would create 116 permanent, high-paying jobs, accord- up to 100 turbines. The TB Flats Wind Energy Project is ing to Wallace. The transmission line projects would bring another wind farm in the works that will deliver up to even more jobs, and that doesn’t include ancillary jobs that 500 MW of energy. will be created by these massive wind projects. And making it off the drawing board is a project from “There’s a lot of promise in those projects, and they will Viridis Eolia that would see a nine-phase 1,870 MW facility generate a lot of jobs and generate a lot of tax revenue,” built in Shirley Basin. Wendt said. “And also, we believe that it would really open “When you combine all these projects, we’re going to be up some of these additional opportunities like attracting generating a lot of energy out here,” Wallace said. wind manufacturers to the state and tapping into the cor- These projects have put pressure on state legislators to porate demand for renewable energy. That’s really where we find new sources of revenue to replace lost energy revenue see the future and the vision that we’re working to promote.” from oil, natural gas, and coal, which account for up to 80 percent of the state’s operating budget needs, according CREATING JOBS to the university study. As of now, how to take advantage That job potential is already showing up years before Wy- of potential revenue without have a negative effect on oming’s massive wind projects go online. The Wyoming planned and potential wind projects is still being debat- Wind Coalition, which is a part of the Jackson Hole Center ed, the study said. of Global Affairs, recently worked with Goldwind Americas Wyoming is set to be a major player in the wind indus- to roll out free training to anyone who wanted to become a try over the next decade with billions in new revenue and wind technician, a position that is one of the fastest grow- thousands of work hours at play. It’s just a matter of time. ing occupations in the U.S., according to Wendt. “The real story in Wyoming is what could be,” Wendt “I think there’s definitely interest in the job potential that said. “Because there are huge wind projects that are wind can bring to the state and the extent that the wind planned, that if they came online, would catapult Wyo- industry can contribute to that,” he said. ming into being the top wind producer in the nation.”

windsystemsmag.com 27 IN FOCUS

LUBRICATION & FILTRATION  TURBINE FOUNDATIONS

A FOUNDATION OF BEST PRACTICES

Typical spread footing prior to pouring concrete pedestal. (Courtesy: Wind Secure Inc.)

28 AUGUST 2018 Understanding what to look for today can save millions tomorrow when it comes to inspections and maintenance of turbine foundations.

By JESSE TARR

s our fleet of wind turbines continue to age, understanding the structural integrity of its foundations becomes increasingly important. With millions of fatigue cycles annually, the punishment foundations must withstand is immense. When constructed properly and maintained within engineering specifications, the founda- Ations are up to the task. However, when subjected to neglect, the minor deficiencies will almost certainly compound, exposing significant economic liabilities and perhaps safety concerns for those working above. In order to better care for a foundation, it’s important to better understand them. First off, foundations are not a dead, static mass. They’re precisely engineered structures designed to properly dissipate the tremendous forces coming from above. The anchor bolts, grout, concrete, and reinforcing steel have very relevant jobs to this happening properly. Though several different designs exist, the majority of U.S. wind turbines are built on “spread” footings. Differing designs rely on certain components more than others, but the general principle stays the same: to keep your turbines anchored to the earth.

FOUNDATION COMPONENTS Anchor Bolts: The anchor bolts are generally held in tension, which is effectively pulling the turbine to the foundations. As an example: A turbine has 160 anchor bolts times 100,000 pounds of specified post tension each equals 16 million pounds of collective “pull.” The design engineer, based on complex calculations, determined this turbine needs 16 million pounds pulling it down to the foundation. Grout: The grout is the buffer of the 16 million pounds of pull (plus weight of turbine) between the base flange and the pedestal concrete. The grout is the first line of defense from the forces above. It evenly distributes the loads from above to the foundation concrete. Concrete: The concrete is the ballast or weight keeping the turbine from overturning. Simply put, it’s a giant weight. Reinforcing Steel: This keeps the concrete as one cohe- sive mass and distributes the loads evenly. It is important to know that in the past 15 years, design standards have changed (twice), increasing the amount of reinforcing steel within the foundations.

windsystemsmag.com 29 IN FOCUS TURBINE FOUNDATIONS

A grout failure requiring repair. (Courtesy: Wind Secure Inc.)

INSPECTION AND MAINTENANCE PROCEDURES To mitigate the potential for major foundation problems, a foundation maintenance and inspection procedure should be implemented: AWEA’s Operations and Maintenance Best Practices has detailed procedural recommendations. A proper foundation inspection and maintenance program doesn’t need to be overbearing, cumbersome, or expensive. The best programs are based on common sense, with an escalation of service, based upon preliminary findings. Foundations require much less maintenance than the rest of the structure but should be systematically inspected and tested for abnormalities. For starters, it’s extremely important to know if the anchor bolts are holding their specified tension. There are many reasons why an anchor bolt could be holding improper tension: ] Design data. ] Construction techniques. ] Material/construction deficiencies. ] Concrete shrinkage. ]Anchor bolt relaxation. ] Seating losses. ] Corrosion. ] Turbine abnormalities. ] Incorrect equipment. ] Improper calibration. Corrosion of the anchoring hardware can lead to significant and ] Neglect. unexpected costs to fix and jeopardize the integrity of the foundation. ] Weather/seismic events. (Courtesy: Wind Secure Inc.)

30 AUGUST 2018 Besides ensuring proper anchor bolt tension, each foundation should be visually inspected yearly for the first several years after construction. A visual inspection could simply be documenting hardware condition (corrosion?), concrete cracking or spalling, interior water, and any other abnormalities. Whatever conditions are discovered during the first inspection, they need to be recorded as the benchmark, with future inspections referencing the known problems. Remember the fatigue cycles? If your foundations are not in proper shape, you will be point-loading the grout, concrete, and steel near the failing areas, greatly jeopardizing the total number of fatigue cycles your foundation can withstand. Not all foundations are perfect, and some small failures may be inevitable, but the larger more expensive issues can often be greatly reduced, if not prevented entirely.

SUBTERRANEAN INSPECTIONS If significant cracking is visible at ground level, re-powering is being considered, or your foundations were designed before 2007, inspecting the interface between the pedestal and spread footing can save a catastrophic event. Exposing and inspecting the critical interface between the pedestal and spread footing during operating conditions is becoming common practice when one or more of these conditions exist. If the pedestal is found to be moving independently of the spread footing, you have a big problem that needs to be fixed before a catastrophe ensues.

CORROSION CAUSE AND EFFECT Properly greased anchor bolts ensure all exposed surfaces are Hardware corrosion is often an indicator to the health of the adequately coated, with extra attention given to the washers and foundation. If the hardware is excessively corroded, there is nuts where the hardware is most susceptible to corrosion. (Courtesy: a higher likelihood of larger foundation concerns. Ultimate- Wind Secure Inc.) ly, there are two problems that corrosion will lead to: The first is the degradation of hardware (particularly washer dation’s long-term structural longevity. It is a compounding and lower nut), resulting in post tension loss in the anchor issue that can lead to significant problems with the rest of bolts. Fractions of millimeters of lost washer/nut thickness the structure over time. will directly result in tension losses to the anchor bolt. The other major issue stemming from corrosion is im- CONCLUSION properly functioning hardware. In many cases this prob- A foundation will tell you how it’s doing. It’s your job to pay lem continues to elude operators who don’t know what to attention. A simple maintenance plan with periodic tension look for. We’ve come across stuck nuts in every state we’ve testing and annual visual inspections will go a long way worked, in every type of atmospheric environment. Stuck in preserving a foundation’s integrity. If small problems hardware can generally be overcome, but it takes the con- are found, fix them before they become large problems. It scious wherewithal to identify and then rectify the problem. seems common sense, yet as our industry ages, it’s increas- You need to use the right equipment to properly identify ingly clear that every component can be replaced except the stuck hardware. If the tensioning system doesn’t allow for foundation. With extended lifespans and re-powering now full visibility of the anchoring nut during tensioning, how commonplace, it is valuable to know your foundations can do you know what you’re doing? Secondly, you need enough handle the job long into the future. torque in the tooling to free corroded hardware. Anything less than a large wrench often won’t work. It’s important not ABOUT THE AUTHOR to assume hardware that looks visually OK is functioning Jesse Tarr is founder and president of Wind Secure Inc. and properly. Frequently, an uncovered anchor bolt may look Corrosion Control Solutions Inc. Based in Lake Orion, Michi- fine but is severely stuck. Unless a high quality never-seize gan, Tarr’s companies have provided products and services to was applied under the nut during construction, the hard- the wind sector since 2007. For more information, go to www. ware is more than likely stuck. Proper testing will identify windsecure.com or contact Tarr at [email protected] or such issues. Corrosion is one of the largest threats to a foun- (248) 563-6234.

windsystemsmag.com 31 IN FOCUS LUBRICATION & FILTRATION

SIGNIFICANT ENERGY BENEFITS

One of the world’s largest wind turbine manufacturers, Enercon, is using MasoSine SPS sinusoidal pumps from Watson-Marlow Fluid Technology Group to optimize the delivery of protective impregnating resin at its Magdeburg production facility in Germany. (Courtesy: Watson-Marlow Fluid Technology Group)

32 XXXXX 20xx Sine pumps optimize high viscosity resin delivery for Enercon, one of the world’s largest wind turbine manufacturers.

By RUSSELL MERRITT

ne of the world’s largest wind turbine manufac- grape are absolutely no problem,” Müller said. turers, Enercon, is using MasoSine SPS sinusoidal pumps from Watson-Marlow Fluid Technology CONTINUOUS COOLING PREVENTS GELLING Group to optimize the delivery of protective im- Despite the attributes of MasoSine SPS technology, the Opregnating resin at its Magdeburg production facility in impregnating resin used at Enercon has proven to be an Germany. extremely problematic fluid to pump. These robust and efficient positive displacement pumps “Without a cooling system, the resin naturally begins to were selected for their powerful suction capability. gel quickly, which, particularly with high rotational pump speeds, can lead to clogging, especially of the shaft seal,” RING GENERATORS Müller said. “As a result, the service life of the seal — and Among the core wind-turbine components produced at Mag- consequently the whole pump assembly — can decrease deburg is the ring generator, which is exposed to particu- significantly.” larly high stresses during operation. Thanks to intensive cooperation between Enercon’s Mag- “In the interests of long service life, resin impregnation deburg plant and MasoSine, these initial difficulties were is an important process stage,” said Manfred Müller, the quickly resolved, and both pumps were retrofitted with a plant’s technical operations manager. continuous cooling system that delivers coolant from heat By performing impregnation, several objectives are exchangers through the pump housing and front cover. achieved: Firstly, the windings of the SIGNIFICANT generator are protected against hu-  midity, dirt, and chemically aggressive Without a cooling system, the resin naturally begins substances. Secondly, a potentially dis- to gel quickly, which, particularly with high rotational turbing hum from the wind turbine is ENERGY prevented and any resulting heat can pump speeds, can lead to clogging.  be better directed to the environment. At Magdeburg, two MasoSine SPS 400 sine pumps were The cooling system ensures a certain temperature is deployed. Each of the pumps delivers approximately 40,000 maintained on the mechanical seal, and gelling of the resin l/h of (15,000 mPas) impregnating resin at a pumping pres- as well as clogging of the seal is thus reliably and perma- BENEFITS sure of about 4 bar (58 psi), to coat the copper windings of nently prevented. the ring generator. ENERGY EFFICIENT PUMP PRINCIPLE INNOVATIVE DESIGN Sine pumps also offer significant energy benefits, especially MasoSine sine pumps are particularly suitable for use with in applications with high-viscosity fluids. In contrast with high-viscosity fluids as the rotation of the sinusoidal rotors other operating principles, the rotor of the sine pump does creates four equal circumferential chambers into which not cut through the product to be delivered, meaning that, the impregnating resin is delivered. Sealing from the pres- even with high-viscosity media, there are only minimal fric- sure side to the suction side is ensured by means of a gate tional losses. Nor does the torque need to be appreciably on the rotor, which diverts the pumped material by 90 de- increased, so there is practically no rise in energy consump- grees in the direction of rotation, or to the outlet. Since the tion even with higher viscosity fluids. chambers are moved as a whole and the volume during the Depending on the medium and the application, sine pumps process does not change, MasoSine sine pumps process even consume up to 50 percent less energy than comparable dis- viscous and highly viscous media with ease. placement pumps. Another benefit of the MasoSine pumps at Enercon is Watson-Marlow Fluid Technology Group (WMFTG) is a their high suction capability. The impregnating resin is first world leader in niche peristaltic and sinusoidal pumps and pumped from a reservoir through a pre-filter before it is associated fluid path technologies. It is founded on nearly directed to the dipping tank. However, this task proves no 60 years of supplying engineering and process expertise, problem for the SPS sine pumps, which, with a vacuum of with more than 1 million pumps installed worldwide. up to 0.85 bar (12 psi), have the necessary suction capacity. Since the formation of small lumps in the resin can nev- MORE INFO www.wmftg.com er be ruled out (despite using a pre-filter), the pumps also must be capable of transferring larger particles without ABOUT THE AUTHOR sustaining damage. Russell Merritt is the marketing manager for Watson-Marlow “For the SPS 400 pumps, lumps of resin up to the size of a North America. Contact him at [email protected].

windsystemsmag.com 33 PROFILE

AMERICAN CHEMICAL TECHNOLOGIES, INC. MAKING A BETTER LUBRICANT

AMERICAN CHEMICAL TECHNOLOGIES, INC. ACT Product FOUNDED Manager Steve 1977 Kovanda says he HEADQUARTERS expects ACT to continue to impress Fowlerville, Michigan the wind industry WEBSITE with its PAG lubricant. (Courtesy: www.americanchemtech.com Shutterstock)

34 AUGUST 2018 American Chemical Technologies has offered its polyalkylene glycol-based lubricants to a variety of industries, and now the company is showing how it can help turbine gearboxes.

By KENNETH CARTER  Wind Systems editor

or more than four decades, American Chemical Tech- a lot of different corporations, looking to get some trials nologies has supplied lubricants to a variety of indus- done, hopefully before the end of this year or early 2019. tries. But over the last several years, the company has We’re also doing some work with NREL and Argonne Na- been making inroads in getting its special lubricants tional Laboratory. We are gathering data, which obviously Finto wind turbines. takes time, but is necessary for us to gain a foothold in the ACT is offering a lubricant unlike what has been tradi- industry.” tionally used in turbines. The big benefits of EcoGear and PAGs in general are that “Since the beginning of the wind industry, there have they are hydrolytically stable, and that they have excellent been issues with the lubricants,” said Steve Kovanda, prod- wear characteristics, according to Kovanda. uct manager for ACT. “They have been — over 99 percent of the time — PAO-based fluids (PolyAlphaOlefin).” PAOs VS. PAGs ACT, however, offers polyalkylene glycol-based lubricants “Everything in the industry right now on these PAO fluids (PAGs), which have proven to have much longer life for ma- is that you want to keep it at 100 ppm of water or less,” he chines in other industries, such as said. “With a PAG, you can handle combustion and steam turbines, 16,000 ppm of water without hav- according to Kovanda. ing any issues. That’s because that “There’s only so much you can water in the fluid is not free water. do to change a PAO,” he said. “You PAGs have oxygen in the backbone have your set spectrum of addi- of the molecule, and that acts as tives. They’re all using similar base a bonding site for each of the wa- stocks, so, at the end of the day, you ter molecules. They can’t group can keep beating your head against together and form droplets. Once the wall trying new PAOs, or you they form droplets, that’s where could go a different route and you have your rusting issues, in- think, ‘these PAGs have worked creases in acid, foaming problems, fantastically in gas turbines, mo- etc. So, right off the bat, we totally bile equipment, air compressors, Typical varnish seen when running a PAO lubricant. crushed that in terms of eliminat- and other industrial gearboxes, so (Courtesy: American Chemical Technologies) ing that issue.” instead of trying another new PAO Keeping moisture out of gear- product, why not go for a different boxes is a constant challenge, so base stock and see how it works.’ That was the real driver much so that some companies invest in dryers, according for it. Because, at the end of day, a PAO is never going to to Kovanda. be a fill-for-life fluid in a wind turbine, but PAGs have that “They’re constantly blowing dry air across the top of the capability.” gearboxes in hopes of keeping the water out,” he said. “You don’t want that humidity in there. They are effective, but it’s GETTING INTO WIND just another piece of equipment you have to pay for. It’s an- ACT got that chance when an engineer with a leading ener- other expense, and it’s another potential maintenance item. gy company in Oklahoma decided to use a variant of ACT’s I’m sure those things will have their own issues as well.” turbine fluid in its wind turbines. With PAGs, that extra expense is unnecessary, according “They ended up converting 63 units to our EcoGear 270 to Kovanda. And chemically, PAGs don’t create sludge or XP,” Kovanda said. varnish. But he expressed how important it was to get a foothold “It’s not as big of an issue in wind as in combustion tur- in the wind industry with ACT’s PAG lubricant. bines, for example, but I still have talked with engineers and “The fact that we are uptower in 63 units in Oklahoma is site managers who have absolutely had issues where their a very big deal in itself,” Kovanda said. “Getting uptower is gearboxes are just coated with varnish,” he said. “Another no easy feat at all. Turbines are expensive. To get up into 63 big benefit is that PAGs have a lower coefficient of friction of those, you’re talking about people who are really putting and a higher load carrying capacity. Overall, they are just their trust in you. I’ve been making a lot of progress with better lubricants. They can carry a higher load, and there

windsystemsmag.com 35 PROFILE AMERICAN CHEMICAL TECHNOLOGIES, INC.

Excellent wear characteristics for EcoGear XP. (Courtesy: American Varnish-free reservoir. (Courtesy: American Chemical Technologies) Chemical Technologies)

is less friction created when the lubricant is used, meaning dreds of thousands of dollars you will see a reduction in wear.” because of these trips. For us to then come in and take that OFFSHORE POSSIBILITIES from four to seven years, now The ability to work when excess moisture is present is cer- we are at 10 years, and the fluid tainly an advantage that could lead to PAGs being used in is projected to run for another the offshore wind market, according to Kovanda. 25 years. With the life of a gas “Because the U.S. is far behind in offshore, we haven’t turbine being roughly 30 years, made much progress in offshore,” he said. “That is what we should be a fill for life fluid my next goal is: to figure out who’s who in the offshore in gas turbines.” Hydrolytic stability shown: applications.” On the left is a PAG with 20,000 ppm water added, Kovanda admits that PAGs can sometimes be a hard sell GAINING A FOOTHOLD and it remains crystal clear. when PAOs are often the norm, but he said that’s just part Kovanda said he expects ACT On the right is a PAO product. of ACT’s overall philosophy. to continue to impress the (Courtesy: American Chemical “We’re always trying to think outside the box,” he said. wind industry with its PAG Technologies) “We’ve always taken the hard road. We are a formulator/ lubricant. blender. We can choose any base stock we want to make “I definitely see us having a foothold in that market,” he our own products. We could have easily formulated a PAO said. gear oil, gone to the industry, and just tried to push that. Eventually, ACT will have enough data from product The end users — the OEMs — they’re all familiar with PAOs tests to prove to other OEMs that its PAG lubricant is the and would have been much more receptive to PAOs. But we better choice for longer gearbox life. know that PAGs bring you an entire other group of benefits. “Instead of going for trials, we’ll definitely have all the They can do so much more for these customers. So, we’d data that people want to see so they will be comfortable,” rather go with that uphill battle and truly try to help these Kovanda said. “We’ll be converting full wind farms for cer- industries out.” tain users.” ACT’s success with gas turbines is what has helped with Part of Kovanda’s mission with the wind industry is to the company’s expansion into the wind industry. convince OEMs of the benefits of his PAG lubricant, knowing “We have now been in two GE 7FA units at two different full well that OEMs are a slow-moving group that will have power plants for over 10 years now,” Kovanda said. “And the to be convinced of the lubricant’s attributes, but he said units have been varnish free, trip free, for those 10 years. he’s up for the task. That is a very big deal. Before we got into the gas turbine “Is it awful at times taking the hard road and going industry, we were seeing that plants were getting anywhere against everyone? Yes,” he said. “But do I also know that from four to seven years of life before the units would be the products that we sell will outperform our competitors? varnishing, tripping, and they would be losing out on hun- Absolutely.”

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JULY 2018 CONVERSATION

Sonny Garg Managing Director, Global Energy Solutions  Uptake

‘A lot of this is about sharing information in a way that everyone knows what’s going on’

] When equipped with better data and insights, what to find value there. But, what surprised us was the returns can wind companies accomplish? Is there an urgency to we saw by tracking the health of smaller parts, such as an get more out of their data? anemometer, for example. That’s a $5,000 part. Another ex- Yes. There is an urgency for this reason: What we’re seeing ample was a site where a turbine was broken. It was under- is power prices continuing to go down. As power prices go performing by 12 percent, and it was costing them $20,000 a down, you have to be better at your operations. You’ve got year — that’s just for one turbine. So that one turbine needed to do two things: You’ve got to make sure you’re producing a $5,000 part. And if you multiply that by 100 turbines on a as much power as you can and get it into the market and site, you get real money. get paid, and you’ve got to reduce your costs. Data can help The other thing we’re seeing is there’s a bunch of stuff you with both of those significantly. They go together if you that’s really hard. Solving some of these problems that we’re do them intelligently. trying to optimize on-site really takes some serious process- [As a power producer], the first thing you need to do is ing, data science, and ingenuity. Take wake management. be available. With insight and data, you can begin to not When you’re on-site, there’s a wake effect on that site, which only detect anomalous behavior, but you can move faster affects the performance of the turbine. We’re starting to and take action to fix it. You’re trying to be much more pre- figure out how we actually model that so you can actually dictive. You’re not only trying to detect failures, but predict understand what that wake effect is and how to optimize them so you don’t have the downtime. And if you know the turbine. And right now, it’s something that people ha- what’s going to happen and you can predict that, you can ven’t done. If you’re an individual company trying to solve integrate that into your work plan and your parts ordering this problem by yourself, it’s going to be really hard. and fix it at the right time and at the lowest cost. If it breaks, then you’re scrambling and reacting to a problem that will ] Uptake works across several industrial sectors, such cost you even more money. as rail and transportation. You recently announced a The second reason why data is important is even when partnership with the U.S. Army to support their Bradley you are performing at the level you should be, there’s a max- vehicles. What can the wind industry learn from these imum amount of megawatt-hours that you’re supposed to sectors’ adoption of AI and data analytics? be producing when you’re operating. The question is: Are Stepping back, all industrial sectors can first learn from you actually producing those number of megawatts? It’s the how the consumer and retail sectors used data and data equivalent, basically, of your car is running, but your fuel science. Take Uber. That’s a $60 billion digital company, and efficiency stinks. We want to give you the insights to tell they don’t own any assets. There’s a broader message here you you’re available, but you’re not actually performing at regarding the digital transformation of industries: It starts the level you should be; you’re not actually getting the fuel with looking for ways to use your existing data to optimize efficiency. So, here’s why you’re not, and here’s what you your assets. should do about it so you can get more out of that asset. There are lots of lessons to be learned from other industries on how they use data to improve their asset perfor- ] Working with MidAmerican Energy and other wind mance. At Uptake, we built a platform within data science operators, what are some things you’ve learned that with a machine-learning engine that are industry agnostic. surprised you? Many of these problems are similar across industries. We One thing we learned across multiple customers that was have a failure prediction engine; we have an anomaly detec- pretty shocking is that little things can result in big things. tion engine. We can tune those to each asset type. Typically, with a gearbox fix or a blade failure, you expect The way digital typically works is you bring it in and you

38 AUGUST 2018 optimize your current business model and make it better, which is what we’re doing through the Uptake platform right now. But typically, digital also changes the way a business model works. And what industries can learn from each other is: What happens when you start getting really good at data science and predictive failures, and what does that mean about your industry? An example is the Rolls Royce engine. They sell those on sort of a power-by-hour basis. They’re not even selling you the asset itself. The reason they do that is they have so much confidence to predict and monitor the health of that asset. And that’s where one industry can look at another’s history and say, you’re going to end up there. You may not be there today, but you’re probably going to end up there, which changes every way of how you’re going to sell your product.

] What different value does predictive maintenance provide to different team members at a wind company — from a technician to a site manager to a CEO? In most sites and most farms in most places, there isn’t a single version of the truth. With the Uptake software, you are getting a single version of truth across all the major stakeholders. Here’s why that matters: As an executive, I can An Uptake employee climbs a wind turbine. (Courtesy: Uptake) use the software and see what’s going on with my turbines. I know what’s down. I know why it’s down. I know how much some kind of work management system, then we generate money I’m losing because it’s down. the insight through an Application Programming Inter- And that ties into what the engineer is seeing, who’s ac- face (API). You want to be able to deliver those insights into tually monitoring the performance of the turbine. They’re your existing work management system. The main thing actually creating cases around what problems they should is you want that insight to be on the radar of the site super- go fix based upon what they’re seeing in the data based upon visor and the technician supervisor who are prioritizing the insights that we’re giving them. the work. Once they have that, then they can easily send a That also ties into the site supervisor who is looking at, technician who’s already going to the site. The other option from an availability perspective, what work do I need to is: We have a front-end application that can be deployed on prioritize, what work do I need to put into the order system a mobile device that makes it easy for someone to prioritize to get it done at the right time, so I don’t have any downtime. the work and pick it up on their mobile, iPad, iPhone, or And that feeds to the technician supervisor who’s on the whatever device it is. And it can get integrated into their ground doing the plan of day, so they can see that and say, plan for the day. “OK, this is the plan of day and the priority of what I need to go fix today.” ] Uptake released a report earlier this year showing if That gets to the technician, who gets that work order, the U.S. eliminated downtime in its wind fleet, it could and they know what to go do. Once they do the job, they add 12 terawatt hours of energy (enough to power all the report it back through the same system, and if I’m the ex- homes in Chicago for a year). How realistic is that and ecutive, then I know that job is done. what would it take to get there? A lot of this is about sharing information in a way that To get there, it’s going to take a willingness for companies everyone knows what’s going on, and there’s a single version to embrace data-driven insights. And there’s a network ef - of the truth. It’s about everyone agreeing with the priority fect in that — the more people who use it, the smarter the of the work, when it needs to be done, and how it needs to algorithms become and the better we will become at it. The be done. And a lot of it is about how do I do that work in a reason we put out that report is to show the opportunity. way that is predictive, so I’m not reactive, and I’m actually Having grown up at Exelon, knowing that their nuclear getting ahead of it, so I don’t have downtime, and I can also plants operated at 48 percent capacity, and by really focus- align my cost structure in a way that I’m getting the lowest ing on it, they got it up to 93 percent, and now that’s pretty unit cost possible. standard across the industry. So, our belief is it’s infinitely doable if we focus on it in the same way we focused on nucle- ] How can wind developers get the insights down to the ar. And if we share insights, I think we can get there faster. technician in a way that they can easily act on? There are one or two ways that we do it. If you already have MORE INFO www.uptake.com

windsystemsmag.com 39 NEWS ABOUT INNOVATION, MAINTENANCE, TAILWINDS CONSTRUCTION AND MANUFACTURING

Siemens Gamesa will supply two wind farms with a combined capacity of 250 MW. (Courtesy: Siemens Gamesa)

mance of the wind farms, which will services with a localized team based ]]CONSTRUCTION together supply enough clean electric- in Johannesburg with long-lasting ex- ity for approximately 214,000 South perience and determined to generate Siemens Gamesa African homes. value for South Africa by creating jobs, A consortium led by Mainstream supporting local manufacturing, and to install two projects Renewable Power was awarded the driving development projects within in South Africa contracts for the wind farms by the De- local communities.” partment of Energy in South Africa as Present in South Africa since 2014, Siemens Gamesa Renewable Energy part of the Renewable Energy Indepen- the accumulated base installed by Sie- will supply two wind farms in South dent Power Producers Procurement mens Gamesa accounts today for 324 Africa, including 109 units of onshore Program (REIPPPP). While Siemens MW of rated capacity, and two wind wind turbines. The SWT-2.3-108 tur- Gamesa will start the supply of the projects totaling 280 MW under con- bine will each feature a rated capacity wind turbines in early 2019, the wind struction. of 2.3 MW and a 108 meters diameter farm’s completion is planned for 2020. Owner of the wind farms is the rotor. “This is the next big milestone for Mainstream Renewable Power consor- While the 140-MW Kangnas wind Siemens Gamesa in South Africa and tium. Mainstream is an independent farm project is near Springbok in the with adding these two wind farms, global developer of renewable energy Northern Cape, another 110 MW Per- Siemens Gamesa will have installed based in Dublin, Ireland, with offices dekraal East wind farm is situated 80 more than 850 MW of wind capacity in seven countries with one of their kilometers northeast of Ceres in the in the country,” said Janek Winand, largest in Cape Town, South Africa. Western Cape. A 10-year full-service managing director of Siemens Game- Siemens Gamesa has already delivered agreement will secure the perfor- sa South Africa. “We are proud to offer several projects to Mainstream in the

40 AUGUST 2018 past with a total of 498 MW. The first cio-economic and environmentally In all, the company will install 138 MW were supplied for the Jeffreys sustainable growth.” 92 turbines at 10 wind farms being Bay wind farm in 2014, another 80 MORE INFO developed in Guadalajara, Lugo, Mala- MW for Noupoort wind farm in 2016, www.siemensgamesa.com ga, Zaragoza, Huesca, La Coruña, and and in 2017 a total of 280 MW were Cadiz. Delivery of the new turbines commissioned for Loeriesfontein and will begin in October, depending on Khobab wind farms counting 140 ]]CONSTRUCTION each project. The company will also MW each. Siemens Gamesa secured operate and maintain all of these new full service agreements of 10 years for Siemens Gamesa facilities. Nouport, Khobab, and Loriesfontain Most of the turbines correspond and five years for Jeffreys Bay. to supply 92 of its to two of Siemens Gamesa’s most cut- “We are very proud to have won newest turbine models ting-edge and sought-after models: the further projects, part of the ambi- SG 3.4-132 (58 units) and the SG 2.6-114 tious renewable energy program of Siemens Gamesa, Spain’s leading wind (28 units). The six remaining turbines South Africa in line with the nation- turbine OEM, continues to fortify its will be the SG 2.1-114. al commitment to transition to a low strong position in the market with More specifically, the company will carbon economy,” said Enrique Pedro- new orders for the supply of 289 MW supply Grupo Jorge with 23 of its SG sa, CEO Onshore for South Europe and to five different customers: Viesgo, 3.4-132 turbines (82 MW) for the Co- Africa at Siemens Gamesa Renewable Grupo Jorge, Comunidad General de scojar II and El Aguila II wind farms Energy. “We are strongly committed Riegos del Alto Aragón, and two im- in the Zaragoza towns of Pedrola and to continuously support the country portant energy companies. All of these Plasencia de Jalón, which it will ser- on its path to provide more and more projects fall under the scope of the re- vice for 10 years. Africans with clean energy and will newable capacity allocated in recent Elsewhere, it will provide Viesgo do everything to contribute to its so- auctions. with seven of its SG 3.4-132 turbines

windsystemsmag.com 41 TAILWINDS THE BUSINESS OF WIND

Siemens Gamesa will install 92 turbines at 10 wind farms. (Courtesy: Siemens Gamesa)

(24 MW) for the El Marquesado wind Hornsea One with a capacity of 1,218 farm in Puerto Real (Cadiz), a facility it MW and which similarly was devel- will operate and maintain for 15 years. ]]CONSTRUCTION oped by Ørsted and is currently under Under the terms of the agreement construction. with the Comunidad General de Ørsted orders 165 “Ørsted is one of Siemens Gamesa’s Riegos del Alto Aragón, a public irri- key partners to transform offshore gation scheme, Siemens Gamesa will turbines for Hornsea wind from wind farm level to a clean build the El Balsón wind farm under Two wind power plant energy source in real power plant an EPC arrangement, fitting it with scale,” said Andreas Nauen, Offshore nine SG 3.4-132 turbines for total ca- With the official signing of the CEO at SGRE. “We are proud and pacity of 31 MW. This wind farm is wind-turbine order with Siemens pleased to meet this challenge within being developed in Gurrea de Gállego Gamesa, the developer and operator the framework of a strong and long- (Huesca). Ørsted has now kicked off the largest term collaboration with an experi- In addition, it will supply 25 tur- offshore wind project to date. Once enced player like Ørsted.” bines (19 SG 3.4-132 turbines and six SG commissioned in early 2022, Hornsea “We are delighted to continue our 2.1-114 turbines) to an energy company Two will provide clean energy for ap- partnership with Siemens Gamesa,” for three wind farms in Lugo, Malaga, proximately 1.3 million British house- said Duncan Clark, Ørsted’s program and Guadalajara, with aggregate ca- holds. The installation of the 165 large director for Hornsea Projects One and pacity of 79 MW. Lastly, it will install direct drive wind turbines at the proj- Two. “We’ve worked with them on another 28 of its SG 2.6-114 turbines for ect site 89 kilometers off the British many other U.K. projects, including another energy company at three wind east coast is expected to start in 2021. Race Bank, ... and was the first project farms, two of which are in La Coruña. The record-breaking project with to use blades manufactured at the fa- These new agreements are incre- a combined rating of 1,386 MW is cility in Hull.” mental to the Spanish order intake of not only the largest wind project in The nacelles for Hornsea Two 352 MW announced by the company Siemens Gamesa’s history but also will be produced at SGRE’s factory in recent months. the largest single order in the history in Cuxhaven, Germany, while the MORE INFO of offshore wind energy. So far, this majority of the blades will be made www.siemensgamesa.com leading position has been defended by at the factory in Hull, U.K., where the

42 AUGUST 2018 pre-assembly work will also be carried imizing the associated costs and risks. The wind farm will be exclusively out. Towers are expected to be partly MORE INFO owned by the Dutch public once it is sourced from U.K. suppliers. A single www.siemensgamesa.com completed in May 2019. The windmill 8-MW turbine is capable of generat- will be virtually divided into thou- ing enough electricity for more than sands of pieces, each of which will 8,000 average European households. ]]CONSTRUCTION represent 500 kW/h. People who live Originally planned for up to 300 tur- in close proximity to the farm can bines, Hornsea Two has been adapted Lagerwey builds first acquire a piece of the windmill at a to the progress of the significantly discounted price, which means they more powerful hardware. With only 100% public wind farm will gain the most benefits. De Wind- 165 units at the same total output, the in the Netherlands centrale has already used this formu- project benefits from significantly -im la to great success with existing wind proved economic efficiency and simul- Lagerwey has been contracted to build turbines. But this is the first time they taneously reduced LCoE. a new wind farm for De Windcentrale, are personally overseeing the con- The new SG 8.0-167 DD is equipped which will be the first 100 percent pub- struction of a whole wind farm. with a rotor 167 meters in diameter. lic-owned wind farm in the Netherlands. “We are proud that a Dutch turbine The blades, 81.5 meters long, deliver The wind farm consists of three L82- manufacturer has been selected for an 18 percent wider swept area and 2.3MW wind turbines that will generate this local project,” said Daniël Dubbel- 20 percent more annual output than wind energy for about 8,000 households. huis, sales manager at Lagerwey. “The its predecessor, the SWT-7.0-154. It The wind turbines will be in the munic- construction of this 100-percent coop- features the technology proven in the ipality of Staphorst, between Nieuwle- erative wind farm is part of the Lager- direct drive platform combined with usen and Rouveen. Lagerwey will start wey Lokaal initiative, which aims at a larger-scale rotor in order to offer constructing the foundations at the end maximizing public participation in customers higher returns while min- of September 2018. wind energy, thereby considering local surroundings while also improv- ing employment opportunities in the Netherlands.” MORE INFO www.lagerwey.com

]]INNOVATION Suction bucket concept gets test installation Universal Foundation continues its partnership with Siemens Gamesa to showcase suction bucket technology with focus on industrializing suction bucket technology. The overall target is to decrease the cost of foundation construction and installation by 40 percent to support continued decreas- es in the Levelized Cost of Energy. A consortium including Siemens Gamesa, Universal Foundation, Aal- borg University, Fred. Olsen Windcar- rier, and Offshoreenergy.dk has been awarded 3.8 million euros by the En- ergy Technology Development and Demonstration Programme (EUDP) via the Danish Ministry of Energy, Utilities and Climate. The partnership seeks to demonstrate how an industri- The nacelles for Hornsea Two will be produced at SGRE’s factory in Cuxhaven, Germany, while alized suction bucket concept can slash the majority of the blades will be made at the factory in Hull, U.K. (Courtesy: Siemens Gamesa) the installation costs of offshore wind

windsystemsmag.com 43 TAILWINDS THE BUSINESS OF WIND

foundations. The specific purpose of ensure the structural integrity of the rate on solving challenges within the this Part 2 project is to complete an foundation both during installation industry related to logistics, installa- offshore trial installation campaign and operation. During Part 2 of the tion, and service. Despite different using the new suction bucket concept project, we are excited to prove the backgrounds, Vestas and Maersk Sup- prototype. installation integrity of the system.” ply Service have overlapping long-term The partnership builds on an on- “The project is interesting in many goals — Vestas’ ambition is to be the going project (Part 1) under which a ways,” said Søren Andreas Nielsen, global leader in sustainable energy next generation suction bucket con- head of R&D, Universal Foundation. solutions and Maersk Supply Service’s cept has been designed and an 8x8 “We all share the view that suction vision is to actively take part in solving meter prototype has been fabricated. technology provides some obvious in- the energy challenges of tomorrow. During Part 2, the prototype will be stallation advantages, both in terms As the partnership’s first step to- used for the offshore trial installation of environmental impact and costs. ward addressing these goals, the two campaign. The new concept merges Cost of fabrication and supply securi- companies are developing a crane the noise-free installation advantages ty continue as one of the challenges solution for both onshore and offshore of suction buckets with industrialized to overcome for suction buckets. The wind turbines that could significant- fabrication methods using coil steel competitive environment of offshore ly bring down the cost of installation. (instead of classical plate steel). The wind drives us to think innovation, The installation concept, called Verti- fabrication method was originally de- and this project enables us to cut the cal Installer, involves a crane that will veloped between Siemens Gamesa and total system cost by 40 percent.” enable the use of lower cost assets in the Danish steel specialist Ib Andresen The aim is to mature the industri- the logistics value chain. The project is Industries for application in onshore alized suction bucket concept toward being developed in cooperation with towers. full commercial scale. MHI Vestas Offshore Wind, and has MORE INFO received $7.4 million in funding for www.universal-foundation.com the next three years from the Energy Technology Development and Demon- stration Programme (EUDP) via the ]]INNOVATION Danish Ministry of Energy, Utilities, and Climate. Vestas and Maersk “The partnership with Maersk Sup- ply Service will significantly improve Supply Service partner and expand Vestas’ existing mar - to lower energy costs ket-leading capabilities for advanced installation and logistics solutions,” Vestas and Maersk Supply Service have said Bo Svoldgaard, senior vice presi- entered into an innovation partner- dent for Innovation & Concepts at Ves- The new concept merges the noise-free ship to jointly develop solutions and tas. “We have a strong strategic fit, and installation advantages of suction buckets next-generation technology for the the new Vertical Installer crane under- with industrialized fabrication methods using sustainable energy industry. The part- lines how the partnership will support coil steel (instead of classical plate steel). nership aims to address the industry’s our goal to improve our efficiency in (Courtesy: Universal Foundation) future challenges within installation an area that will grow in importance and logistics to decrease the cost of as turbine components get bigger and “By applying this innovative fabrica- energy. infrastructure become more complex.” tion method to suction bucket technol- Driven by consumer demand for “This is an exciting step for Maersk ogy in offshore wind, the steel plate sustainable energy and continuous Supply Service and a great example of thickness can be reduced to below 20 reduction in levelized cost of energy, how our marine knowledge and versa- millimeters, compared to today’s typ- global wind energy production is set tile fleet can be leveraged in new indus- ical thickness of 30 to 40 millimeters to double by 2027. One of the industries,” said Steen S. Karstensen, CEO of for this type of foundation,” said Finn try’s main challenges to continue this Maersk Supply Service. “Our partner- Daugaard Madsen, project manager trajectory is to lower the cost of trans- ship with Vestas and the development with SiemensGamesa. “This means porting and installing wind turbines of Vertical Installer demonstrates that use of lower costs steel with higher as they increase in size and will be we are taking action to overcome in- supply availability. The assembly pro- installed in remote locations. dustry challenges and ensure that the cess is much more suitable for high Combining Vestas’ insight into energy needs of the next generation volume manufacturing, and hence sustainable energy with Maersk Sup- are met.” supply bottlenecks can be eliminated ply Service’s marine and logistics ex- “The Vertical Installer crane is the and costs reduced. A key element is to perience, the companies will collabo- latest example of innovation that will

44 AUGUST 2018 continue to drive offshore wind for- off- and onshore, which will reduce ward,” said Flemming Ougaard, chief project risks and the time required operations officer at MHI Vestas Off- before the solution is available in the shore Wind. “The concept will allow market. for improved logistics and more effi- MORE INFO: cient installation — critical areas for www.maersksupplyservice.com our customers’ business case. We are proud to participate with Vestas and ]]MAINTENANCE Maersk Supply Service in bringing this concept to life.” Seacat Mischief and her sister vessel, Seacat sends ships Seacat Magic, provide logistical support to Maersk Supply Service initiated manufacturer and service provider Siemens and continues to drive the Vertical In- to Beatrice Wind Farm Gamesa Renewable Energy (Siemens staller project with the aim of finding Class-leading offshore energy support Gamesa) throughout the operations and a more efficient method to install off- vessel (OESV) operator, Seacat Services, maintenance (O&M) phases. (Seacat Services) shore wind turbines using its current has secured a further charter agree- fleet. Vestas and MHI Vestas Offshore ment at Beatrice Offshore Wind Farm The pair of 23-meter jet propulsion Wind are providing the industry in- (Beatrice). catamarans will be based out of Wick sight necessary to ensure the new solu- This latest two-year contract will Harbour in Scotland, with Seacat Mis- tion is tailored to industry needs and see Seacat Mischief and her sister ves- chief arriving on site in mid-August, developed with the most up-to-date sel, Seacat Magic, provide logistical and Seacat Magic in April 2019. They knowledge of challenges, logistics, support to manufacturer and service will become the third and fourth Sea- operator requirements, and poten- provider Siemens Gamesa Renewable cat Services vessels to work at Beatrice, tial design modifications for future Energy (Siemens Gamesa) through- joining Seacat Resolute, which has just wind turbine models. They are also out the operations and maintenance commenced a separate nine-month providing access to test facilities both (O&M) phases. construction charter for Siemens

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windsystemsmag.com 45 TAILWINDS THE BUSINESS OF WIND

Chevron Marine Lubricants’ Taro® range of cylinder lubricants provide solutions for a range of engines, fuel types, and operating requirements. (Courtesy: Chevron Marine Lubricants)

Gamesa, and Seacat Intrepid, which offshore wind project team, consisten- teer, they safely completed more than remains on charter for project devel- cy and familiarity is a real advantage,” 27,000 crew and equipment transfers, oper Beatrice Offshore Wind Limited said Ian Baylis, managing director, Sea- covering a total distance exceeding (BOWL). cat Services. “It ensures that lessons two trips around the globe. With a milestone development learned are transferred effectively MORE INFO such as Beatrice — Scotland’s first and, in turn, that efficiency continues www.seacatservices.co.uk major offshore wind farm — there is to improve from site to site and proj- an opportunity to set a benchmark ect to project. As we continue to work when it comes to bringing new gen- at Beatrice, we’re looking forward to ]]MAINTENANCE eration capacity online efficiently. In building on our existing relationships particular, flexible and versatile vessel with Siemens Gamesa, BOWL and the Chevron Lubricants support is required to overcome the wider team based out of Wick.” technical and logistical challenges of “Having worked with Seacat Ser- receives NOLs from the time-sensitive commissioning and vices in the past, we’re aware of the MAN Energy Solutions early operational phases, ensuring that critical role versatile and reliable OESV a wind farm gets up and running on support plays for a project like Beatrice Following successful field testing, Chev- budget and on schedule, and then per- as it enters long-term operations,” said ron Marine Lubricants has been issued forms effectively over the long term. Craig Morton, chartering manager at with two NOLs (No Objection Letters) This charter not only extends Sea- Siemens Gamesa Renewable Energy. from equipment manufacturer MAN cat Services’ presence at Beatrice; it “For us, it is essential that our techni- Energy Solutions, for the use of three also extends the vessel operator’s re- cians get around the site, safely, quick- of its Taro® cylinder oils with their cyl- lationship with the Siemens Gamesa ly, and in the best possible condition inder oil mixing system, ACOM. service team, following a two-year deal to carry out the work that ultimately “Receiving the NOLS from Man En- signed last year to support O&M activi- keeps the turbines performing at their ergy Solutions demonstrates the im- ty at the 336-MW Galloper Wind Farm. full potential.” pressive performance of our products Seacat Services’ crews and shore-based Seacat Mischief and Seacat Magic in the field,” said said Ian Thurloway, team are therefore familiar, both with are two of the most capable OESVs Chevron Marine Lubricants Brand & the demands of the project site and serving the U.K. and European off- Marketing Manager. “The Taro range the technical and logistical require- shore wind markets. They have re- of cylinder lubricants provides solu- ments of supporting Siemens Gamesa cently returned from Ørsted’s Race tions for the varied range of engines, throughout initial operations. Bank project, where, together with different fuels, and the increasingly “When it comes to the make-up of an Seacat Courageous and Seacat Volun- complex operating requirements that

46 AUGUST 2018 we are faced with. It also highlights Chevron Marine Lubricants, a lead- the publication of a new standard ad- our continued strong working rela- ing provider of marine products and dressing the need for dropped object tionship with this leading OEM.” services, continues to provide reliabil- prevention and tool tethering. It was Both sets of field tests were carried ity and innovation for its customers, approved July 2 and formally known out on a 6S90ME-C8 MAN B&W two- being among the first to market with as ANSI/ISEA 121-2018, American Na- stroke engine using MAN’s Automated both a 100 BN and 140BN cylinder lu- tional Standard for Dropped Object Cylinder Oil Mixing (ACOM) system. bricant, providing a range of cylinder Prevention Solutions. The first NOL demonstrates the oils suitable for the majority of two- This standard addresses the real high performance of Taro Special stroke vessels and engine types, com- need for reducing workplace accidents, HT Ultra, a 140BN product that has patible with a wide sulphur range of injuries and deaths due to falling ob- achieved impressive results helping fuels and most alternative bunker jects. combat cold corrosion in slow speed fuels. Dropped or falling objects from vessels burning high sulphur fuel and MORE INFO height present a significant safety which Chevron Marine Lubricants was chevronmarineproducts.com hazard in many industries around first to market with in 2017, blended the world today and the numbers are with Taro Special HT LF, a 25BN lubri- staggering. According to the Bureau cant ideal for low sulphur, distillate ]]MAINTENANCE of Labor Statistics, more than 52,000 and alternative fuel types. “struck by falling object” OSHA record- The second NOL allows for blending ANSI approves able incidents occur every year in the Taro Special HT 100 (100 BN) and Taro U.S. alone. In 2015, the BLS reports 247 Special HT LF. These successful tests Dropped Object fatalities from being struck by a fall- prove that the Taro range of cylinder Prevention standard ing object, accounting for 5 percent of lubricants can provide maximum flex- all workplace fatalities. ibility for operators, as well as reliable ANSI, the American National Stan- Most contractors rely on catching service for vessels. dards Institute, recently approved the falling object (netting, toe boards,

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