THE 100-GIGAWATT MAGAZINE

1981–2014 | 100 gigawatts of gearbox capacity delivered worldwide

More than just a number

Why are 100 gigawatts so world use our gearboxes! When we became significant? aware a few months ago of what milestone we were approaching, we wondered what would 100,000 megawatts or 100 gigawatts – it’s an be the best way to celebrate this event and also impressive amount! But why does this mean so to thank all the people who have been part of much to us? Why is 100 GW of delivered gear- this achievement. box capacity such an important milestone for Winergy that we are publishing a magazine to You are holding the result in your hands. It’s a celebrate it and to look back on our 33 years of magazine that serves as a commemorative pub- history in producing wind turbine gearboxes? lication, a chronicle and a customer and com- pany magazine. It’s a document that records this First of all, it’s a number which fills us with pride. success for everyone and offers an insight into We are the first company in the wind industry Winergy as it is today – with pride and satisfac- to exceed the 100 GW mark in terms of installed tion, and also with a wink. But most of all with capacity. And this mark is even more impressive the awareness that it was all only possible with a if you compare it with total worldwide installed huge team of passionate employees. wind turbine capacity. According to the Global Wind Energy Council (GWEC), there were wind Because that’s what we are! turbines with a total capacity of approximately 318 GW in operation around the world at the end of 2013. So the proportion of wind turbines using Winergy gearboxes is just under 30%. That means almost a third of the wind turbines in the

Page 04 Page 06 Page 08 Page 10 Page 14 Page 18 Everything was better in The wind is up offshore What do our employees What are you up to these Our plants: Voerde, Megatrends and outlook the good old days ... say about Winergy? days, Gerhard Reisse and Elgin, Tianjin, Chennai for wind energy Karl Brun? THE 100-GIGAWATT MAGAZINE

Foreword

Dear friends, business partners Dear Winergy employees, and Winergy team,

We have been manufacturing special gearbox- Many of the people who make us what we are 100 GW of supplied wind turbine capacity fills us We would therefore like to use our 100 GW In keeping with the Chinese saying “When the es for wind turbines for more than 30 years. The have been with us for a long time – long enough with satisfaction and pride – not only the sheer anniversary as an opportunity to thank you, winds of change blow, some people build walls, wind energy industry is still very young compared to remember the pioneering phase. Others have scale of this amount, but also the success story our workforce, personally. With your technical others build ”, we are confident that to many other manufacturing industries such as joined us over the years. All of them identify with behind it, which you, the entire Winergy team, expertise, your team spirit and your absolute together we will continue to find the right an- the automotive and aerospace sectors, and only and are excited about what we make. Winergy is have made possible by the way in which you customer orientation, you gain the trust of swers to the challenges of the wind turbine mar- progressed past its pioneering phase a few years all about decades of experience and deep expert- have worked with our customers and suppliers. our customers anew every day, thus laying the ket. We are proud and happy to be part of the ago. A true wind energy industry has only existed ise, combined with a high level of commitment foundations for our ongoing and future success. Winergy community. for about ten years. and a fascination with wind turbine technology. These 100 GW were built on innovative strength And this is something we can be proud of! This and technological progress, and on countless Winergy is a successful segment within Mechan- Sincerely, Our first wind turbine gearbox was a standard in- is also the only explanation as to why we are so customer relationships and trusting cooperat- ical Drives and makes a major contribution to Stefan Tenbrock, Winergy CEO dustrial model from a catalogue that we used in far ahead of our competitors, with 100,000 MW ion, even in difficult times. They were also built the success of our business unit. You can be just- Theo Maas and Ulrich Stock a test turbine in 1977. It was a REDUREX SZN 320 of wind turbine capacity around the world on a great passion for the idea of manufacturing ly proud of what you have achieved and of your Theo Maas, CEO, with power output of 65 kW and weighing just using our gearboxes. That shows how much con- the best gearboxes for wind energy and on a attitude towards your work. Because reaching Siemens Mechanical Drives under 1 t, giving it a power density of 65 W/kg. fidence customers have in our products and in team with the absolute drive to succeed. 100 GW of has quite often meant We started to develop gearboxes specifically to the people behind them. And we have now been 100% or more commitment and effort. We have meet the needs of wind turbines in the early 1980s. working closely with some of them for decades. With this drive, you have, over time, installed been following your success story with great Today, the gearboxes’ power densities are twice power equal to about 100 large power plants, appreciation for some time now and would now as high, meaning just half the material is needed On behalf of the entire management, we would and have therefore played an important part like to express the thanks and respect of our for the same power output. Winergy has had a therefore like to thank all of you – our friends in the success of wind power and made a major business unit and of Siemens AG as a whole. major influence on this development. and business partners, but above all the Winergy contribution to the energy transition. team – for making this possible. Setting aside a brief boom in California in the mid-1980s, business developed slowly at first, but Stefan Tenbrock, CEO then picked up speed starting in 2000 and be- Norbert Vehns, CFO came much more global. We have kept pace with this growth and for some years have had manu- facturing plants in China, the US and India. And with our many co-workers in these countries, the Ulrich Stock, CFO, Norbert Vehns, Winergy CFO Winergy team has naturally become more inter- Siemens Mechanical Drives national. Dear Winergy team,

To date, wind turbine capacity of about 300 GW and the commitment of its employees, it active- sector is on course for positive growth over the has been installed around the world. And with its ly contributed to increasing the acceptance and next decade. Relative growth will be lower than gearbox capacity accounting for 100 GW of that, competitiveness of the wind industry. in the past 20 years, but it will be stable, coupled Winergy can be proud of having made a signifi- with a high level of absolute demand. In the fu- cant contribution to the international develop- During my time as Chairman of the Supervisory ture, we must focus on competitiveness achieved ment of this segment and, with its involvement Board, I always found the international Winergy by means of technological developments and in wind power, to be expanding renewable ener- team to be extremely resilient, flexible, capable efficiency improvements, while bearing in mind gies in general. and responsible. It remains so today across all the the fact that the external factors that have divisions, and the market honours that. Today’s driven decisions in favour of wind and Winergy in Following the early years of wind energy business, position and performance are the basis for to- the past have lost none of their validity, namely How it all began – a report in the Winergy was made a separate, independent en- morrow’s motivation. having a positive impact on catastrophic global company magazine tity within the Flender Group in 2001 in order to climate changes and reducing the political risks Manfred Egelwisse, DER FLENDERANER in 1977 be able to better address the technical and com- For me, the thing that sets the wind business in energy supply. former CEO, Winergy AG mercial challenges as well as the dynamics of this apart has always been the people in it. I have >>>>> new industry. Its success came with its supplying fond memories of working with the “pillars” of I wish Winergy all the best for the next 100 GW! technically sophisticated, competitive gearbox this industry and of some personal highlights solutions to the around the with them, be they customers, suppliers or in- Manfred Egelwisse world. Winergy quickly rose to the challenges of house staff. the market, becoming a true global player on all continents. And with its innovation, investments With a few regional variations, the wind energy

Winergy historical milestones

1981 Delivery 1984 Start of 1986 5,000 gear- 1991 First 1 MW 1998 Devel- 2000 Inaugur- 2001 Start of 2003 First 5 MW 2004 Commis- 2005 Inaugurat- 2006 Pro- 2007 Commis- 2009 Inaugur- 2010 The 2012 Successful 2014 100 GW of of the first gearbox mass production of boxes produced for the gearbox delivered · Inaug- opment of the first ation of the new operations at Winergy’s prototype · Com- sioning of the 7.5 MW ion of the new gear- duction starts at sioning of the world’s ation of the new 5,000th gearbox prototype testing gearbox capacity specially designed for wind turbine gear- US, most of which are uration of the first off- two-stage planetary assembly plant in gearbox assembly missioning of the test bench box assembly plant in Winergy’s assembly biggest test bench assembly plant in made in Elgin leaves and market launch delivered worldwide shore featuring Voerde, Germany 6 MW test bench and Chennai, India plant in Tianjin, Elgin, Illinois, USA wind turbine use boxes, primarily for installed in wind farms gearbox in the plant in Elgin, Illinois, with a capacity of the production line of the 3 MW wind farm projects Winergy components multi-megawatt USA cold-climate test lab China 14 MW HybridDrive in California in the US class in Voerde, Germany

0 0 0 . 0 0 0 0 0 . 2 0 0 0 0 . 4 7 0 0 1 . 1 2 0 0 5 . 7 9 0 0 8 . 5 1 0 1 1 . 7 4 0 1 8 . 2 1 0 2 2 . 0 1 0 2 6 . 9 3 0 3 4 . 7 0 0 4 5 . 3 1 0 6 4 . 9 8 0 7 2 . 1 3 0 8 8 . 0 3 1 0 0 . 0 0

Page 2 Page 3 THE 100-GIGAWATT MAGAZINE

A size comparison A REDUREX gearbox from the 1980s would have needed to be dispropor- tionately large in order to generate an output of 4 MW.

Everything was better in the good old days

This is something that people often say, but let’s 2014. By way of comparison, nuclear power cur- Constructing a turbine with today’s power out- take a look at the truth of it: if we compare the rently costs around 75 euros, coal approximately 1984 2014 put simply wouldn’t have been possible with turbine technology of 10 to 15 years ago with 54 euros and gas roughly 50 euros/MWh.* This the gearboxes of the 1980s: the nacelles would that of today, modern turbines are bigger, but has been achieved by continuously developing A4 pages of have been twice as wide and about one and a specifications per they are also more productive, more efficient all of the components, by high investments and half times as large, not least due to the decen- gearbox solution and more reliable, not to mention cheaper. Not by optimising the supply chain, and has made tralised drive shaft. It also wouldn’t have been only has there been a clear increase in capacity wind power one of the most attractive sources possible to easily scale a REDUREX gearbox to factors, i.e. the percentage of full-load hours at a of power generation on our planet today. Engineering 4 MW, not to mention the final weight if this wind farm – the costs of generating energy are were actually achieved. also continually falling year after year. As an aside, with every new Winergy gearbox we deliver each day, we make a contribution Crane technology also still had a long way to go. Strength In the 1980s and 1990s, onshore wind turbines to reducing carbon emissions and thus to pro- calculation Only with the systematic development of drive achieved capacity factors of between 10 and tecting the environment. Some things may well technology for wind turbines and the progres- 20%. Today’s turbines achieve 30% and more. In have been better in the good old days, but cer- sive geopolitical evolution in favour of alterna- the offshore sector, the difference is even more tainly not everything. Load test on Nm Nm tive energy sources did the impossible quickly striking. Whereas the first offshore wind farms the test bench become possible. had yields of up to 25%, the yield figures are now upward of 50%. The cost of using onshore wind energy to generate one MWh has fallen * Energy generation costs according to How has gearbox construction changed? from around 107 euros in 1985 to 52 euros in MAKE Consulting; 2014. A comparison of 1984 and 2014.

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Offshore wind farms with Winergy gearboxes

Park Land Turbine 01 Vindeby Denmark Bonus 450 kW offshore 02 Middelgrunden Denmark Bonus B76 2 MW 03 Nysted (Rødsand I) Denmark Siemens SWT-2.3-82 04 Samsø Denmark Siemens SWT-2.3-82 The wind is up 05 Avedøre Holme Denmark Siemens SWT-3.6-120 VS 06 Horns Rev II Denmark Siemens SWT-2.3-93 increased from 4.5 MW in the early days to some Planetary gearboxes were already in use in the 07 Rødsand II Denmark Siemens SWT-2.3-93 600 MW a year today. Our offshore market share first offshore wind farm in Vindeby. Back then, a 08 Anholt Denmark Siemens SWT-3.6-120 China of 60% speaks for itself. turbine had a rotor diameter of 35 metres and 09 Frederikshavn Denmark Siemens SWT-2.3-93 capacity of 450 kW, and required a gearbox 10 Hooksiel Germany Bard 5.0 “Just” another car weighing 3,200 kilogrammes. Today, a 4 MW offshore 11 Riffgat Germany Siemens SWT-3.6-120 Every generation of cars comes with new, and offshore wind turbine with a 130-metre rotor The long journey of often spectacular, innovations – including ABS, diameter is fitted with a planetary gearbox 12 DEWI Wilhelmshaven Germany BARD VM 5 MW air conditioning and the current move towards weighing 30,000 kilogrammes. 13 Alpha Ventus Germany Multibrid M5000/REpower 5M the offshore pioneers self-driving cars. Yet hidden away beneath the 14 EnBW Baltic 1 Germany Siemens SWT-2.3-93 bonnet, the vehicle’s heart is still the same – and Based on the aerodynamic characteristics of 15 BARD Offshore 1 Germany BARD 5.0 the rotor, a modern turbine can only be oper- For more than 20 years now, the cost-effective- that’s its drive system. It has been continuous- 16 Utgrunden Sweden Enron Wind 70 1.5 MW 35 ness and feasibility of offshore wind farms have ly improved in countless ways, yet this fact is ated at a greatly reduced speed. As a result, oft- 17 Lillgrund Sweden Siemens SWT-2.3-93 been a matter of intense debate. While we do often overshadowed by the more spectacular cited gearbox comparisons based on turbine 34 not intend to continue this debate here, we be- external changes. capacity are not meaningful. 18 Thorntonbank Phase 1 Belgium REpower 5M-126 lieve it is worth noting that 6.9 GW of turbine 19 Thorntonbank Phase 2 Belgium REpower 6.15M-126 capacity had been installed around the world While advertising focuses on xenon lights and If, for example, a 4 MW turbine were operated 20 Thorntonbank Phase 3 Belgium REpower 6.15M-126 by the end of 2013. intelligent voice recognition, the power density at the same speed, the gearbox would be able 21 Blyth Offshore UK V66 of a two-litre engine in a typical series produc- to achieve rated power output of approximate- 22 North Hoyle UK Vestas V80 2 MW Winergy has been a pioneer in this field too, tion car has more than doubled, while its fuel ly 10.6 MW. This means that a modern gearbox 23 Scroby Sands UK Vestas V90 2 MW and has been involved since 1991 with the consumption and emissions have been sharply has a power density which is more than twice as 24 Kentish Flats UK Vestas V90 2 MW first offshore wind farm in Vindeby, Denmark. reduced. high too in comparison, coupled with improved Winergy’s product range has changed signif- vibration behaviour and greater reliability. 25 Barrow UK Vestas V90 2 MW icantly since then. Whereas gearbox capacity If we take a look at wind energy in recent years, 26 Burbo Bank UK Siemens SWT-3.6-107 back then was 450 kW, it has now increased well it is not only the capacities of the wind tur- In the case of car engines and our wind tur- 27 Beatrice UK REpower 5M-126 over tenfold to 6 MW and more. The London bines but also the technologies used that have bine gearboxes, these advances could only be 28 Rhyl Flats UK Siemens SWT-3.6-107 Array – currently the world’s largest offshore changed in a similarly visible and dramatic fash- achieved by means of countless minor improve- 29 Ormonde UK REpower 5M-126 wind farm with a power capacity of 630 MW – ion to the features on offer in the automotive ments that aren’t evident when you look at a 30 Greater Gabbard UK Siemens SWT-3.6-107 went online in 2013, and all 175 turbines have industry. And the drivetrain, which is tucked modern gearbox or engine. Seen from the out- been equipped with a 3.6 MW gearbox made by away out of sight in the , has developed side, it’s just a gearbox, even though it houses a 31 Sheringham Shoal UK Siemens SWT-3.6-107 33 Winergy. This means that the capacity pro- just as stealthily and continuously into the high- highly complex torque converter on the inside ... 32 London Array Phase 1 UK Siemens SWT-3.6-120 duced by Winergy for offshore generation has ly efficient heart of every wind turbine. 33 Pori 1 Finland Siemens SWT-2.3-101 34 Longyuan Rudong Intertidal Phase I China Siemens SWT-2.3-93 35 Weifang Intertidal China GUP 6 MW

40 000 MW Historic Forecast 41 457

Installed capacity of 27 33 897 offshore wind farms 30 000 MW 09

27 144 08 16 04 02 20 000 MW 20 973 06 05 17 21 01 16 502 15 07 03 14 29 13 12 983 25 12 11 10 10 000 MW 28 22 26 9 501 31 6 932 23 5 469 30 3 085 3 501 32 19 1 277 1 816 18 620 710 803 1 012 24 46 96 256 364 Winergy’s market share: 60% 20

2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 Source: BNEF

Page 6 Page 7 “For me, the most important “Winergy is a part of my life. If thing is the sense of belonging Winergy is the engine, I’m one of that Winergy has given me – it’s the molecules in the fuel that keeps not a brand or a department, but the engine ticking over nicely.” a family!” Yunfeng Gao, Customer Project Management, Voerde Deng Qian Yi, Warehouse, Tianjin

“The whole package is just right “I have personally had the liberty for me: I have a fantastic team, and freedom to explore new initia- good working conditions and an tives to make the Winergy brand area of work that I enjoy. There’s stronger in the Indian market. also the satisfaction you get from I really feel proud to be associ- working in the wind energy sector ated with the brand name and therefore from doing your Winergy and, of course, with the bit to make the world perhaps whole Winergy family the world just a little bit better.” over.”

Elke Schneider, Sales, Voerde M. T. Rao, CEO, Chennai

“I am extremely proud and hon- oured to be a part of Winergy. “It’s about making a difference Let’s work together to make while you’re making a living!”

greater progress in the future.” John Hayden, Production, Elgin Xing Bin, Production and Assembly, Tianjin

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What are you up Winergy to these days, ...

... Gerhard Reisse? stands

A real wind pioneer! are given the freedom to work independently plenty of opportunities to see the world, the and in an enterprising way.” 76-year-old still enjoys travelling. He has already Like Don Quixote, he fought windmills on be- been to Ethiopia this year, and was in Kenya half of windmills – and he did it for years. In fact, Reisse: “Control is good, but trust is better.” before that, and one of the places he still hopes Winergy probably wouldn’t exist in its present to visit is Iran. form if it weren’t for Gerhard Reisse and his com- Two of his long-term colleagues confirm that mitment to Flender’s wind energy business. He these aren’t just empty words. Paul Bollwerk, He keeps mentally and physically fit for these served as head of Flender’s sales activities in now head of sales at Winergy, and Jürgen many activities by spending time with his for ... Europe from 1982 to 2000. Niestegge worked with Gerhard Reisse in pro- grandchildren and by playing a weekly round moting the wind energy business during a time of golf with his former Flender management Under his supervision, the wind turbine gear- when wind turbines were often being built in colleagues, Werner Tappertzhofen and Werner box business developed into its own division customers’ converted cowsheds. Both are grate- Inderfurth. “Flender really had an impact on me. and later became Winergy. Despite the many ful to him for the chance they were given to And perhaps I also had something of an impact sceptics and reservations in the business, he develop into experienced salespeople in such a on Flender. But it’s now just as nice to enjoy my and his sales team backed this new technology promising new industry. retirement,” says Reisse. Maximum experience in wind energy and believed in the future of wind energy. In the early years, it was Gerhard Reisse who personally Bollwerk: “I wouldn’t be where I am today approached Flender’s Management Board with without the trust and guidance I received Market and technology leadership every new wind project, to seek its approval. from Gerhard Reisse.” At the time, the wind turbine gearbox business was often a risky undertaking. “But it was always Reisse now enjoys catching up on the things he clear to me that a salesman has to keep up with didn’t have the time for during his busy career. Reliable partnership the latest technology,” Reisse explains. This includes going to concerts and the theatre with his wife – and also the simpler things, like Today, 14 years after his retirement, it is still clear working around the house and in his garden Investment security to him that it was always a team effort. “It was or simply reading a good book. “I’m currently always a ‘we’ thing, never a ‘me’ thing. We never reading My Song by Harry Belafonte. It’s quite operated on the basis of a hierarchy. Employees powerful,” says Reisse, who lives in Bocholt. Al- are at their best when they experience trust and though his years in the sales business gave him Top quality

Reliability

... Karl Brun? Loyalty A great example, with his heart in the right cluded his period of pre-retirement part-time place. employment and entered full retirement. He nevertheless maintains regular contact with his Fairness Karl Brun always took a hands-on approach to long-time colleagues and can still be seen in the his role as global Vice-President of Production. production halls in Voerde from time to time. No single person has left such a distinct mark on Winergy’s production sites as he did over the Udo Holdschlag succeeded Brun as the Vice- Zero defect tolerance years. From 2001 when Winergy was founded, President of Production at Winergy. He worked he was in charge of production at the plant in with Brun for many years and considers him a Voerde and later assumed responsibility for great example of a person with his heart in the A clear sense of identification the overseas plants in India, the USA and China right place. “Karl was always a model of com- too. His down-to-earth manner of rolling up his mitment and dedication, and he expected the sleeves and handling matters quickly and sim- same of others. This really helped me in my own A global service network ply left a very positive impression on everyone development,” says Holdschlag. he worked with. Holdschlag: “For me, Karl Brun is one of the homes too, and tends their gardens in addition His winsome attempt at establishing the Ger- fathers of Winergy.” to his own. He also lends a hand at the local 4 assembly plants on 3 continents man language in the world of production at children’s playgroup, seeing to minor repairs. Winergy has also made a lasting impression. In his personal life too, Brun remains down to But apart from all this work, he still has time He casually translated the German term “Takt- earth and hard-working. “I was finally able to to go on holidays with his wife and to take im- Skilled and motivated employees montage” as “Tact-Montaaage” in English, thus tackle some repairs and expansions around promptu trips to explore the various sights in creating a new expression that quickly took hold the house that I had kept putting off. And I did the Ruhr region. And all the strains of work are, and is recognised throughout the worldwide all the work myself,” shares Brun. And as if that of course, long forgotten when he sees the right Winergy family to this day. In 2012, Brun con- wasn’t enough, he helps out around his sons’ eyes of his three grandchildren.

Page 10 Page 11 THE 100-GIGAWATT MAGAZINE

Unimaginable today!

There were times when a simple handshake was 80 a month. I don’t know whether the procure- my customer deemed important, and bearing enough. But that’s now little more than a short ment head was especially perceptive, but he im- his signature in ink. After a meeting of just two – almost wistful – memory: in 1998, I received a mediately noticed my amazement at the size of hours, I was holding in my hand the largest wind call from the head of procurement of one of our the order and quickly sat down at his computer turbine gearbox order that had ever been placed long-time customers. He wanted to arrange a to draft a contract for 500 gearboxes (with the at the time. Now, whenever I see the many tur- meeting at short notice regarding some import- option of 1,000), corresponding to their desired bines operating on the hills surrounding Sara- ant projects in Spain for their wind turbines. budget and time frame. The delivery period for gossa, it’s this unexpected business transaction the first, most urgently needed gearboxes was that always springs to mind. During the meeting with the customer, it quickly a full twelve weeks. When the contract came 100,000,000,000 WATTS became apparent that the project involved sup- off the printer, we were sitting in front of a sin- Paul Bollwerk, Vice-President of Sales plying up to 1,000 gearboxes at a rate of 60 to gle sheet of paper containing everything that Photo: Wikipedia provide power for an average of ...

How we define partnership

True partnership is always a relationship on equal terms, and this is critical for proper understanding in all technical and financial matters. Partnership is also a commitment that you don’t enter into every day. Such a commitment is based on real trust – and this doesn’t come for free. Such trust has to be earned, and the partnership has to prove itself viable, time and time again. That’s why we don’t define partnership based on investment security or global positioning; above all, we base it on reliability – particularly in terms of quality, on-time delivery and price.

But there is also a human element to partnership: we associate it with good conversa- tions, controversial discussions, economic successes and technological depth, honesty, responsibility and a great understanding of the other partner’s interests. To put it simply, a partnership on equal terms. Perhaps we could even call it a friendship.

67,000,000 VACUUM CLEANERS

100,000,000 WASHING MACHINES

200,000,000 BLENDERS

The customer advocate 50,000,000 HAIRDRYERS

The editorial team asked me to write an artic- you might say we had a good understanding of challenges that our customers present us with – le entitled “The customer advocate”. Maybe self-interest. But we wouldn’t be Winergy if our assigning them the right levels of priority at all that’s what we sometimes are, but I would say customers didn’t know that there is a whole lot times. We are therefore delighted if this means it only reluctantly and would be even less in- more to it than that. We have ties with some of we are seen as a strong team. clined to put it in writing. We are happy to do our customers that go back decades, and these the things we do, and we do them as a mat- excellent business relations are characterised Approximately 74,000 gearboxes with total ter of course, frequently, and again and again. by straightforwardness and openness, mutual power output of 100 GW – we can’t deny that And if that involves our occasionally having to liking and a willingness to help, reliability and this figure makes us, the sales department for explain incredibly short-notice changes in the expertise. In other words, our customers are the Winergy family, just a little bit proud of delivery schedule and adopting a position of made up of many great individuals who all do the part we have played in this success. At the defence for our customers because the wind a good job. same time, we have to thank our customers for market is still so difficult to plan in, due to the having made this possible in the first place by involvement of politicians, that hardly makes We ourselves try to cater to our customers as choosing our products and a partnership with 110,000,000 TOASTERS 140,000,000 MICROWAVES us an advocate – I would hope that at best it broadly as possible and maintain direct lines us. And we won’t let up in our efforts to make serves to strengthen our partnerships. We all of communication at the technical level. Our sure they continue to do so. know that we don’t have many customers, but key account sales force therefore sees itself the ones we do have are near and dear to us. So as a team whose job it is to solve the various Paul Bollwerk, Vice-President of Sales

Page 12 Page 13 THE 100-GIGAWATT MAGAZINE

Our plants Voerde, Germany Elgin, Illinois, USA

Extract from the company magazine ment by all concerned. The market for wind More than just a job 2001 Start of gearbox manufacturing MOVE, 2/2001 turbine gearboxes will continue to enjoy strong under the Winergy brand growth in the next few years. The Friedrichsfeld Jay Johnson witnessed Winergy’s first steps Even without a huge production facility, years In 2009, the Elgin team’s wish finally came true. Inauguration of the new Flender assembly assembly plant gives us a stable basis for further in the US market. He is one of the eleven of significant growth followed. Boosted by the Winergy commissioned a new production facil- 2005 1,000th unit shipped and installa- plant in Friedrichsfeld growth, in wind turbine gearboxes as well as in people who were the starting crew of Winergy production tax credit (PTC) reinstated in 2005, ity at Madeline Lane, which meant another huge tion of 3.5 MW test bench conventional drive technology. Drive Systems Corp. in Elgin, Illinois. “We were Winergy and its customer General Electric en- milestone was achieved. This new facility in- On 11 May 2001, the Chairman of the Board of such a small group and so close. Everyone did larged their output by 50% every year from 2006 cluded a 2.8-megawatt test bench, and another 2006 to Ramp-up due to PTC; Management of A. Friedr. Flender AG, Dr Winfried everything, everyone pitched in to help any- to 2008. The team in Elgin grew from 40 to 80 5-megawatt test bench was added in 2011. To- 2008 120% growth Walzer, officially inaugurated the new assem- That was 14 years ago ... body,” he says about “the old days”. “The old people in one year. A 3.5-megawatt test bench gether with the 3.5-megawatt test bench from bly plant in Voerde-Friedrichsfeld in an opening ... and now the Voerde site is one of the most days” – those are his words for the time around was added to support the growth. As GE was Tollgate Road, the total test capacity is now 2009 Inauguration of new gearbox ceremony. A look back at Flender’s situation in state-of-the-art wind turbine gearbox pro- 2001 when it all began for Winergy in Elgin. Only the only customer at that time, Winergy’s suc- 14 megawatts. Jay Johnson is proud of all the assembly plant mid-1999 explains the importance of the new power stations were installed to create a new high- duction facilities in the world. Significant new one hour outside of the city of Chicago, Flender cess story in the US market is intrinsically linked achievements the team has made: “We helped Friedrichsfeld facility. voltage power supply, with walk-through cable investments were made just three years after had been producing industrial gearboxes since with GE. Doris Klein-Hessling has also been Winergy to grow worldwide.” For him, it is the 2010 Launch of customer service Flender’s former key visual, which ducts to the assembly hall and the test benches. the 2000 move, as the wind energy boom 1982 and Johnson was the production super- with Winergy for many years now. The sales passion of the people and the feeling of be- programme for the Americas, was in use when the construction Back then, there was a need for the assembly pro- In total, 1.5 kilometres of new cable ducts were necessitated the addition of 6 MW, 7.5 MW, visor. “In the year 2000, Dan Weilandt, Winergy’s manager and GE key account manager is more longing together that make the difference: “This including authorised service work started in Voerde. cesses to be reorganised, and the approximately excavated and about 8 MW of electric test power 8.3 MW and 14 MW test benches. The additional first CEO in Elgin, came to me and said: ‘Jay, we familiar with the relationship than anyone else: is my 29th year with this company and we feel providers 7,000 square metres in Bocholt were no longer were installed. And to move the heavy gearbox halls J, K, L and M were renovated and rebuilt. are starting a new company just for wind tur- “It was GE that drove us to establish production like a part of something. We have always been sufficient – the assembly and test bench equip- components, all the cranes and crane runways Today, crane lift capacity totals 150 tonnes; this bine gearboxes. Do you want to join us?’ And I lines and optimise our production processes in ‘get it done’ people. And at Winergy, we have 2011 Introduction of 3 MW gearbox ment and their operators had to be relocated. were replaced; a total of 48 indoor cranes with lift alone necessitated investments of close to a said: ‘OK,’” says Johnson. When he talks, you can the times of huge growth in 2007 and 2008,” the feeling that we create something that lasts, manufacturing and 5 MW test Flender had two options – it could either build a capacity of up to 40 tonnes were installed. hundred million euros. imagine that in the early days things were as says Klein-Hessling. something which is our responsibility. It’s more bench new factory in the Mussum part of the town at simple and clear as they sound. than just a job!” a cost of DM 65–70 million or it could accept the The new assembly plant, which currently has 516 The Voerde site remains the heart and the nerve It is the trustful, fair and open communication 2012 Exclusive gearbox and coupling offer of then majority shareholder Babcock Borsig employees, can produce about 5,000 to 6,000 centre of Winergy. It is home to all the com- It all started with $900,000. That was the invest- from both sides that continues to impress her to supplier for America’s largest AG to use its industrial site in Friedrichsfeld, with gearboxes a year, which corresponds to revenue pany’s important functions, and the directives ment Flender made to set up Winergy in Elgin. this day. “In uncertain times regarding the PTC, onshore wind farm, Shepherds Flat over 46,000 square metres of enclosed produc- of around DM 500 million. In particular, the new for the foreign sites go out from here. The com- Part of this investment was the first 800-kilowatt GE asked whether we were willing to adopt their Wind Farm, Arlington, Oregon tion space. At the time, more than 30,000 square plant boasts test benches with installed test pany has achieved a solid market position by test bench. It consisted of a size 22 Flender H3SH expectation that the PTC would be extended metres of it were being used as warehouse space. power totalling 8 MW and the largest test bench means of centralised leadership and use of the gearbox, a 1,000-horsepower traction motor and jointly take the risk that the PTC might ex- 2014 8,000 gearboxes manufactured for mass-produced gearboxes with up to 4 MW Winergy brand. We now need to maintain and from a locomotive and a handmade lubrication pire. So we planned the units with the risk that in Elgin On 23 November 1999, a multi-year lease was test power, giving Flender cutting-edge test ca- extend this, so that Voerde together with Elgin, system, and was built up by the Winergy staff on we would have to allocate them to different GE signed between Babcock Borsig AG and A. Friedr. pabilities unequalled anywhere in the world. Chennai, Tianjin and Winergy’s worldwide ser- their own. “In the early years, it was more like: projects all over the world.” Flender AG for the Friedrichsfeld site. In the very The move to Friedrichsfeld started in April 2000 vice organisations can lay the foundations for get your hands dirty and get things done,” re- short space of just 14 months, the existing build- with about 150 employees. The first wind turbine the next 100 GW. members Johnson. With this spirit, Winergy had ings and grounds were renovated, refurbished gearboxes underwent testing on the new 2 MW a successful start and grew steadily in its first and rebuilt where necessary at a total cost of test bench in July 2000. And in October 2000, the years. Soon the facilities at Tollgate Road in Elgin DM 43 million. The existing three-part assem- first 100 assembly workers followed from Bocholt reached their limits. When Winergy’s CEO at the 8 GW Forecast for newly installed wind bly hall measuring 420 metres in length and to Friedrichsfeld. The entire relocation took place headquarters, Stefan Tenbrock, visited Elgin one 7 energy capacity in USA 75 metres wide was thoroughly renovated on the while production was under way, without any day, he asked whether the colleagues needed 6 inside, and partially on the outside as well. Four downturn in revenue – an outstanding achieve- anything to keep on performing. Jay Johnson’s 5 + 17.1 % immediate response: “We want a building like 4 the one in Voerde.” “Stefan Tenbrock looked at 3 me and just said: ‘Be careful what you wish for. You could get it,’” says Johnson. 2 1 0 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023

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Nine years at Winergy Tianjin

I have worked at Winergy for almost nine years and have witnessed Winergy’s entrance into the wind power industry, as well as the market’s peaks and troughs, and its stabilisa- tion. In the course of these nine years, Winergy has developed from being a rented workshop with one assembly line, a small office building and three travelling cranes to become today’s modern plant comprising three production lines and individual departments for engineering, application engin- eering, purchasing, warehousing, production, quality and customer service. In time, the team has increased greatly in size, from over ten people to more than one hundred people today. The steady development stands as a testament to the Winergy employees’ hard-working approach and to the strong support provided by the Winergy headquarters.

During these nine years, I have had a strongly held belief that we can get along with each other like a Tianjin, China Chennai, India family and can strive towards our common goals, regardless of our position, age, gender, race, region, language or culture. Every colleague, be they at Is China really so important? A mango plantation becomes a modern tur- the headquarters or right beside me in my division, bine gearbox production facility offers me sincere greetings, sincere support, sincere For years, we have been reading in credible conducted by MAKE Consulting forecasts cap- stipulated guideline. Quality awareness and suggestions and sincere advice. I feel at home and studies about China breaking one installation acity of about 26 GW or more for 2020. This process reliability are improving at almost the The driver of the modest trailer pulled by an gearbox requirements guaranteed full capacity of a football pitch. “When we were finished, the have been able to develop myself well here. I feel record after another. This is hardly surprising, makes China the largest single market in the same rate as turbine installation is increasing. even smaller tractor which has seen better days utilisation of the new plant for the first few years. outline looked too narrow for my liking. So we very proud to be a member of this excellent team. considering that in its twelfth Five-Year Plan, world. As China realises its offshore plans in the com- had never moved so much earth before. At one When Manfred Egelwisse, a member of the simply moved the line a couple of metres to the the Chinese government called for 107 GW of ing years, local turbine makers will increasingly end of the site, which had been a mango plan- Winergy AG Supervisory Board at the time, right.” Surveyors and planning permission? “We As a part of the assembly team at Winergy Tianjin, I new wind energy capacity. The downside, as we can see daily in the news depend on experienced gearbox suppliers. tation until a few days ago, a digger heaped one asked Dirk Bernsmann whether he would con- did submit all the necessary applications, but also take pride in being able to produce top-quality and as we know from our own experience, is load of earth after the other onto his trailer. He sider being in charge of building the plant, it we didn’t wait until we had formal approval,” wind turbine gearboxes! As the assembly manager About 36% of this has been installed in the past that China is a regulated market. We have found then tipped it back out again a few hundred didn’t take long for Bernsmann to make up his says Bernsmann, laughing. The situation was at Winergy Tianjin, I firmly believe the following: few years, meaning that 69 GW are still to come. that the Chinese government and Chinese tur- metres away at the other end of the site. He did mind. similar when it came to outfitting the produc- put the customer first and make quality your prior- We currently project an annual wind turbine in- bine manufacturers prefer to use local suppliers. this every day from sunrise until sunset, until the tion floor. Everything needed to be bought, ity; satisfying the highest customer demands results stallation volume in China of between 15 and And then there is the fact that some 6–8 GW of flaw was eradicated and the ground was flat. Be- “I remember sitting in the plane on the flight from screwdrivers to test bench components. in greater demand from more customers. Only by 18 GW, possibly up to 20 GW. By comparison, the installed turbine capacity in China is not cur- cause the three-man delegation that had come back from our first visit to India and thinking But how to know what exactly would be need- guaranteeing high assembly quality can we reduce US and Europe didn’t even manage to get up to rently connected to the grid, so the turbines from Germany some months previously to look ‘This is going to be really tough!’ But chances ed? There was no shopping list for a new wind the frequency of after-sales service and thus reduce 14 GW per annum in their boom years. The fore- turn only to supply themselves. for a suitable piece of land for a planned fac- like this only come around once in a lifetime,” turbine gearbox assembly plant. So employees unnecessary costs; only in this way can we reduce cast is still for coal-fired power plants and other tory had not been able to tell at the time that the he recalls. Even just lining up the land purchase went through the various parts of the plant in the pressure on our sales colleagues; and only in energy sources to decline in China starting in China is extremely important for the wind in- mango plantation was on a slope. brought some of the cultural differences be- Voerde and simply jotted down all the things this way and in shortening the lead time can we 2030, meaning that renewable energies such dustry – probably just as important as the en- tween Germany and India home to him. “The they saw being used for production. win more recognition from internal and external as solar power and wind energy will have to ergy transition in Germany. If Germany is the What would someday be the entrance to the estate agent wasn’t going to sell the plot to just customers. take up the slack. We can therefore assume that role model for achieving independence from grounds of Winergy Drive Systems India in anyone. He first wanted to know who he was “I put on a boiler suit and helped to build China’s annual wind turbine installation will fossil fuels, China is the model for moving Chennai was over three metres higher than the dealing with and wanted to get to know the gearboxes in Voerde to find out what we Shen Qi, Head of Assembly, Winergy Tianjin, China continue to increase. The most recent study ahead with a good approach on the basis of a far wall of the future building. “When we first people who were looking to buy his land.” So needed. That was like a second appren- visited the plot, it was covered in mango trees, he invited Bernsmann to breakfast at his home. ticeship for me,” says Bernsmann. Just a few so nobody suspected that there was so much of That would be unthinkable in Germany. Eventu- months later in June 2005, the building shell a slope,” says Dirk Bernsmann, the project man- ally, the land went to Winergy for less than ten was finished. The first test run was then con- ager in charge of building the plant. Together euros per square metre. “Three years later, with ducted in September. And the first gearboxes Approved wind capacity Chinese electricity generation with Flender AG’s civil engineer at that time globalisation and the boom in markets like manufactured in Chennai were sold in October, Bernhard Giese and Karl Brun, Winergy’s head India, we would have had to pay three times that a mere ten months after the construction work in acc. with the twelfth Five-Year Plan (2011–2015) by technology of production in Germany, he embarked in May amount,” says Bernsmann. started. The key to this achievement was the 2004 on the adventure of building a plant from fact that the responsible people on site quickly % 27 GW 19 GW 6 GW 29 GW 28 GW 107 GW 120 GW Historical Projected 100 the ground up in a completely new environment In spite of his being a qualified mechanical en- came together as a smooth-running team. “V. C. 100 – a plant that was scheduled to be producing gineer with experience in construction projects S. Velumani was a huge help as the deputy man- Building a production plant from 36% 80 installed 80 wind turbine gearboxes for the Indian market under his belt from his previous jobs, building ager, as was the current managing director M. T. scratch in a strange country – a huge under cutting-edge conditions just 18 months this new plant was like being thrown in at the Rao, who came on board during the construc- feat for all involved. 60 60 later. “We’ll fly to India to look at five pieces of deep end. “My approach is always not to over- tion phase,” notes Bernsmann. He’s still proud of 40 land, and we’ll buy one of them.” This casually think things, and simply to get on with it. That the team: “It was a great achievement by all con- 40 stated goal was the beginning of the story of the was worth its weight in gold in India,” says Berns- cerned. Everyone always knew what they had to 20 Chennai plant for Dirk Bernsmann and Winergy. mann, looking back. An example? Before the lit- do – that was the only way we could build the 20 0 tle tractor could begin its patient earthmoving, plant in such a short time.”

69 GW capacity but approved, installed not yet Tulsi Tanti, owner of the Indian wind turbine the dimensions of the new building had to be 0 –20 manufacturer , recommended Chennai laid out. After the plantation had been cleared Batch 1 Batch 2 A 2 B Batch 3 Batch 4 Total 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2020 2030 –40 (2011) (2011) (2012) (2013) (2014) 4 batches as a location. He was also in large part respon- of trees in January 2005, Bernsmann and his sible for Winergy’s decision to set up operations team took a chalk liner and drew the build- Solar Oil/gas Biomass and waste Coal in India in the first place, as his sizeable turbine ing’s walls on the sandy ground, like the lines Source: MAKE/NEA Nuclear Wind Oil Source: BNEF

Page 16 Page 17 THE 100-GIGAWATT MAGAZINE

è2040 è2040 è2040 Megatrends ä ä ä 35% greater 2 billion more 90 % growth and outlook demand for energy people on the planet in demand for electricity

Drivetrain technology for wind turbines The drivetrain architecture is a critical design speed geared drivetrain architecture. Onshore, Global electricity supply Global electricity demand choice faced by wind turbine manufacturers, as growing demand for 3 MW+ turbines favours by fuel, in thousands of terawatt hours by sector, in thousands of terawatt hours will develop differently around the world the drivetrain represents a significant portion the adoption of hybrid medium-speed systems. of the turbine cost and weight. Furthermore, MAKE anticipates that medium-speed and 40 40 design choices made in the powertrain have direct-drive systems will continue to increase lasting impacts on life cycle reliability and op- their penetration levels in Europe, but that the erating costs. majority of installations up to 2020 will continue We anticipate that by 2040 ... to be geared systems. 30 30 MAKE expects that both geared and direct-drive ... non- OECD countries like China and India turbines will coexist for the foreseeable future, China has become an incubator of drivetrain in- as each technology possesses inherent advan- novation, with many OEMs offering direct-drive will lead growth in energy demand. tages. The level of revolutionary innovation in or hybrid drivetrains. This is fuelled primarily by 20 20 the drivetrain is highly dependent on the target competitive pressure and ’s presence ... about 60% of demand will be market and the associated risk profile, as the fig- as a technically differentiated market leader. ure below shows. MAKE anticipates that this technology trend will 10 10 covered by oil and natural gas. continue, and direct-drive or medium-speed The US market has been slow to adopt radical- systems will constitute nearly 50% of China’s in- ly different drivetrains featuring direct drives or stallations by 2016. ... natural gas will surpass coal medium-speed geared systems, as financiers 0 0 as the second-largest fuel source. place a premium on track record, established For more insights into other emerging technology 2000 2020 2040 2000 2020 2040 supply chains and proven aftermarket solutions. trends, visit the MAKE website: MAKE expects that geared drivetrains will con- www.consultmake.com ... energy-related CO2 emissions tinue to dominate the Americas market for the Gas Nuclear Other renewables Other industries Commercial Transportation will plateau and gradually decline. foreseeable future. Coal Wind and solar Oil Heavy industry Residential

Alternatively, the European offshore market is an intrinsically risky environment, and experi- mentation with revolutionary drivetrains has Source: ExxonMobil flourished. Newly announced offshore prod- ucts are all departures from the classical high-

Regional drivetrain segmentation Global population in billions of people Economic output (GDP) in trillions of dollars

9 120 AMER EMEA APAC AMER EMEA APAC 6% 1% 18% 23% 28% 31% 0% 36% 90 0% 6 1% 2% 11% 60

93% 82% 76% 3 71% 62% 59% 30

2012 installations 2016 installations (forecast) 0 0 15.0 GW 13.3 GW 15.8 GW 9.1 GW 13.6 GW 26.3 GW 2000 2020 2040 2000 2020 2040

Direct drive High speed AMER = Americas EMEA = Europe, Middle East and Africa Rest of world China OECD (Mexico and Turkey included in key growth) Medium speed APAC = Asia Pacific GW = gigawatts connected to the grid India Key growth

Source of texts and diagrams: MAKE Source of diagrams: ExxonMobil Page 18 Page 19 For me, Winergy means:

Sister and Brother “With approximately 300 GW of wind turbine installations worldwide, Winergy means all the friendships created over the years 100 GW of gearboxes delivered by We have had lots of victories and, yes, have shed some tears Winergy means that we are really We must respect each other, my sister and brother making a major contribution to renew- able wind energy. Winergy is therefore We sometimes have problems in our travels, but somehow we never unravel not just an employer for me, but also We will work through the night and never ever give up this fight a brand which I’m really proud of!” We trust each other, my sister and brother Lu Yong Yao, Application Engineering, Tianjin We created jobs and worldwide brands, something to be proud of in all the lands For Winergy is more than a job, a pay cheque, or a position; it is our heart, our soul, and our mission We lift up each other, my sister and brother “A service department usually only We went from small kW to mighty MW test benches, from looking for a hammer to standardised wrenches receives feedback regarding product From the days of no parts and bad heat lots, to the days of full production and no stomach knots performance. It’s only in the case of Think of each other, my sister and brother Winergy that I am given a warm wel- come in the field simply when I mention Some will say we are crazy, but none can say we are lazy the organisation’s name – that’s how It is this man’s opinion that we are one in a million satisfied our customers are with the Give thanks to each other, my sister and brother performance of our product.” It is a company and family we made together, through all kinds of weather Sv. Gowrisankar, Service, Chennai I could not think of doing something different or anything better Mentor each other, my sister and brother

It is all the help and support that you are giving, to keep Elgin healthy and living “In a nutshell, Winergy is a milestone in We all owe each other our thanks and gratitude, for without any of us we would be subdued the world of wind energy.” Hug each other, my sister and brother M. Sathiesh Kumar, Sales, Chennai imes we may not have been on track, but I always knew you had my back Why is it we do what we do? It is all because of and for you Remember each other, my sister and brother “For me, Winergy means that my phone is often already ringing when I arrive at Here’s to the wind and let’s hope it blows, we need to be clear so everyone knows the office in the morning. With my coat Work at what we cherish and these times shall never perish still on and my bag over my shoulder, I Some of us shall row and some of us shall steer speak to a co-worker on the phone who For all of our sakes, please bring us a beer has a problem at the test bench. … Celebrate each other, my sister and brother After I have solved his problem, he Jay Johnson, Technical Service, Elgin thanks me for helping so quickly. I go back to my office and see my bag still on my desk. I then switch my computer “Winergy is a place where teamwork “Winergy is an attractive employer in “What Winergy means to me: excel- on, sit down and check the time. It’s and collaboration are the key to suc- a sector that’s constantly evolving. lence, community and freedom. Excel- nearly 10 a.m. already and I have loads cess and where hard work does not Every day is exciting and presents new lence in technology. Excellence in de- of e-mails to read. I decide it doesn’t go unnoticed. It is a place where em- challenges! And the focus is on the in- sign. And excellence in manufacturing. matter too much, because having ployees are empowered to suggest and terests of our customers.” Community in the workplace. Commu- solved the problem, that test bench is drive improvements. It is a place where nity in the city of Elgin. And community now generating a lot of turnover again. Kai Föcking, Sales, Voerde people have passion for their work.” on the international stage. Freedom What’s more important is that I have from fossil fuels. Freedom from nu- co-workers who know what time I get to Tina Wilcoxen, Planning, Elgin clear power. And freedom from global work and who call me when they need W – WORLD-CLASS QUALITY warming.” my help because they appreciate what I – INNOVATION I do. That’s invaluable and it speaks for “Small things accumulate and amount N – neW TECHNOLOGY Ryan Warner, Production, Elgin the employees. In the mornings, I’m to considerable results: drips become E – enerGETIC PEOPLE cursing under my breath as I reach for an ocean and individuals become part R – robust DESIGN the phone, wondering what somebody of a team. We treat our plants like our G – GLOBAL MARKET “Even though we are working in differ- wants from me this time. But by the homes – we encourage them to grow Y – YEARN FOR CUSTOMER ent parts of the world within Winergy, end of the call at the latest, my bad and therefore generate value.” it feels like we are one big family to- S. Michael Daniel, Quality, Chennai mood is gone and I get down to work.” gether.” Li Ting Xing, Logistics – Warehouse Marc Bruckmann, Production, Voerde Indirakumar Munusamy, Engineering, Chennai

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