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] 888.502.WORX torkworx.com FROM PROTECTING YOUR ASSETS TO POWERING OUR CITIES TOGETHER IT’S POSSIBLE Innovative lubrication that enhances performance. Wind turbines are a vital part of the electricity network, the world’s largest and most complex machine. Often operating in extreme environments, the effective lubrication of gearboxes and bearings are vital for wind turbines to deliver optimum performance. As well as offering a range of lubricants and greases, our experts are ready to share the knowledge and practices that will help ensure maximum performance, no matter what the conditions. To fi nd out how we can help you power tomorrow, go to shell.us/power © SOPUS Products 2018. All rights reserved. CS13771-01 CONTENTS 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 CONVERSATION turbine manufacturers. 32 Uptake’s managing director of global energy solutions Sonny Garg talks about how sharing data is crucial to performance. 38 2 AUGUST 2018 THE COVER CCWYED THIS IS DARYL WILSON, CEO OF HYDROGENICS. AND HE’d LIKE TO INTRODUCE YOU TO OUR ADVANCED HYDROGEN TECHNOLOGY MANUFACTURING FACILITY. Today Daryl is feeling inspired. After all, he’s leading reliably and safely transform how we consume energy. a shift to a cleaner, global energy future through While our leadership comes from our technology, hydrogen technology. With growing production our success is the result of one essential ingredient facilities in Canada, the U.S., Belgium and Germany, – the human one. Our experts, our engineers, our we’re designing and engineering innovative solu- researchers and our day-to-day people are focused tions for hydrogen generation, power storage and on advancing hydrogen technology for a better, transportation. OEMs, cities, and other partners are earth-friendly energy source. Learn how the human looking to Hydrogenics for carbon-free solutions that factor is changing the world at Hydrogenics.com The human factor. The most advanced part of our technology. 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 Bearing failures are the most important issue in wind turbine gearbox maintenance, accounting for 70% of gearbox failures*. Castrol® Optigear® Synthetic CT 320 retains half the water PPM on average than our nearest competitor using similar types of chemistry**. By choosing Castrol Optigear you can increase your bearing life by 50% and win the bearing life battle. If you want to get the lowest water content in the field opt for Castrol Optigear Synthetic CT 320. For more information go to castrol.com/windenergy or call 1-877-461-1600 WATER vs. BEARING LIFE (R.E. Cantley Formula, Timken Corp: Circa 1977) 2.5 2 1.5 70 ppm avg. (Castrol CT 320 in-service data) 92 ppm avg. (nearest competitor published data) 1 Relative Bearing Life 198 ppm (nearest competitor in-service data) 0.5 0 25 50 100 200 300 400 500 600 700 *WEU Operations and Maintenance Report 2016. Water (ppm) **Based on sample data available to Castrol. 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.