windpower engineering & development october 2015

Foundations readied for Lake EriePAGE 9

ATTACK?

Turbine of the month: GE’s 3.2, 130PAGE 28

October 2015www.windpowerengineering.com

CYBERAre you ready for your

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ATTACK?A T T A C K ?

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2014

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HERE’S WHAT I THINK

2014

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The nature of warfare changes constantly. Static trench warfare played a big role in WWI, but improved air power and a more mobile battle tank brought much greater

fluidity to WWII, making trenches obsolete. Later wars erased the idea of a front line altogether. WWII more importantly, became the information war.

For example, the German Enigma machine, a cypher, let the German High Command communicate with its far-flung resources without fear of the Allies reading its communiques. Simultaneously, a small army of code breakers in the UK, Alan Turing among them, worked feverishly to decipher the Wehrmacht’s orders. For that process, the code breakers invented several digital programmable computers. They worked so well that after the war, timid and short sighted leaders disassembled the computers deeming them too dangerous should they fall into the wrong hands.

Fast forward 70 years and the 1945 authorities actually appear quite prescient. Their worst fear about information technology and security seemed to come true. As engagements in hot wars subside, other forms of information warfare are being waged almost anywhere a significant installation has an Internet connection. A speaker at a technical conference recently remarked that to see something scary, try monitoring the controls of a significant facility while hackers attempt to gain access. When they pose as authorized workers, hackers could reset controls to increase power outputs, turn them off altogether, or make selections that could damage equipment.

One documentary on YouTube.com (See why Obama fears China’s hackers, probably so titled to capture U.S. attention) interviews several Australian

government officials and business leaders dealing with the problem. The image the producers present is one of pervasive and relentless intrusions.

On the business side for instance, Codan Ltd, an Australian manufacturer of metal detectors and military radios, discusses how its design for a metal detector was stolen, copied, reproduced, and sold on the open market. The company discovered the theft when one of the copies came back to the company for warranty work and its sloppy circuit boards and other clues gave the fake away. Suspecting industrial espionage, a close inspection of company computers found malware had infected many of them. Investigators surmise that a salesman in a hotel room could have picked on click bait (such as a fake Viagra ad). The action told intruders an unprotected computer of interest was online. With the malware downloaded, the unwitting salesperson took the infection back to his company. There, it likely enabled the theft of more critical secrets, such as those that let once-secure military radios manufactured by the company perform with no more security than a trucker’s CB radio. Almost invariably, intruders are traced back to China.

The feature article in this issue just scratches the surface of the problem of cyber intrusions and security for utilities. The internet has brought bad guys right to the front door of control rooms. If they can pick the lock, they can appear as authorized users with unfriendly intentions.

Cyber experts don’t guess that an attack might come to the grid. It already has and will come again. Forewarned is forearmed. W

OCTOBER 2015 windpowerengineering.com WINDPOWER ENGINEERING & DEVELOPMENT 1

Are you ready for your cyber attack?

E d i t o r | W i n d p o w e r E n g i n e e r i n g & D e v e l o p m e n t |p d v o r a k @ w t w h m e d i a . c o m

Editorial OCT 2015_Vs3.indd 1 10/12/15 3:48 PM

2 WINDPOWER ENGINEERING & DEVELOPMENT www.windpowerengineering.com OCTOBER 2015

C O N T R I B U T O R S

CATTANACH

GUARIGLIA

HILDERBRANDHALL

KARP

PENROSE

KREUSEL

ALNES

HAMMER

HUGHES

TARR

UGLAND

TOTARO

LEE ALNES is a global key account manager at Vaisala. He has been in the wind industry for nearly 15 years and has extensive expertise in project assessment.

BOB CATTANACH, a Partner at Dorsey & Whitney, helps clients navigate the complexities of regulatory law, especially in the area of cybersecurity and compliance. With decades of experience as a trial lawyer, Cattanach technical background enables him to understand the complex business challenges associated with today’s cyber world, providing the strategic acumen to achieve success.

JOHN W. GUARIGLIA, RLA, is an Associate Principal with Saratoga Associates and has worked on a variety of site development, planning, and aesthetic projects throughout the Northeast and the mid-Atlantic. He has experience with all levels of site development from concept drawings and master plans to the preparation of construction documents.

BRAD HAMMER, an associate in the Regulatory Affairs Department at Dorsey & Whitney, represents energy clients before various state and federal regulators. He also counsels clients on data privacy compliance matters for state, domestic, and foreign regulators, including the Federal Trade Commission, U.S. Department of Commerce, and the European Union Data Protection Authorities.

JOE HALL, Co-Chair of Dorsey & Whitney’s Energy Industry Group, is responsible for developing, implementing, and managing the firm’s strategic initiatives in the power, clean tech, oil, and natural gas industries. Joe has extensive experience representing electric utilities, independent power producers, power marketers, industrial customers, private equity firms, and others before federal and state regulatory agencies and reviewing courts.

VAN P. HILDERBRAND JR., an Associate in the Energy Group and the Environment & Natural Resources Group in the firm’s Washington, D.C. office, represents a diverse set of clients across energy sectors with project development and project finance transactions. He also represents clients in resolving regulatory compliance issues, litigating disputes under federal and state environmental laws, assisting with permitting issues, and advising on the environmental aspects of business and real-estate transactions.

MICHAEL HUGHES, CIH, CSP is the Global Head of EHS for Onshore Wind at Siemens Wind Power.

JEFFREY M. KARP is a partner in Sullivan & Worcester’s Washington, D.C. office where he heads the firm’s Environment & Natural Resources Group. The Group includes the following fields of practice: environmental compliance and litigation; climate-related business and technology; renewable energy and energy efficiency; water resources and conservation; and energy, infrastructure, and finance.

JOCHEN KREUSEL is the Group Senior Vice President and head of the Smart Grids Segment Initiative at ABB Group, Zurich, Switzerland. Kreusel studied electrical engineering at Aachen University of Technology in Germany. He joined ABB in 1994 and has held managerial positions of increasing responsibility in the areas of marketing and technology, and was appointed to his current position in early 2011. HOWARD W. PENROSE, PH.D., CMRP, is the President of MotorDoc LLC (formerly Success by Design), Web Editor-in-Chief of the IEEE Dielectrics and Electrical Insulation Society, and Secretary of the Society for Maintenance and Reliability Professionals. He is the author of the Foreword Book of the Year,

“Electrical Motor Diagnostics: 2nd Edition.”

JESSE TARR has a Bachelors Degree in Construction Management from Northern Michigan University, and has been professionally involved in Wind for 10 years. He started Wind Secure in 2007 with a focus on improving corrosion protection methods on wind turbine foundations. In 2013 he was granted utility patent US8584430 B2 for his process for extrapolating “As Found” anchor bolt tension.

PHILIP TOTARO, founder and CEO of Totaro & Associates, has a Bachelor’s Degree in Aerospace Engineering and over 10 years of experience in strategic planning as well as creating and protecting intellectual capital. Mr. Totaro has previously worked for General Electric Co., United Technologies Corp., and most recently was head of intellectual property and competitive assessment for Clipper Windpower LLC.

JOHN UGLAND, a wind industry engineer, specializes in asset management and optimization of wind turbines through the application of technology to improve performance, prolong life, or mitigate cost. John began his career in the wind industry quite literally at the bottom rung of the tower ladder

– as a traveling wind tech. John has had the unique opportunity to experience O&M from many sides: as a technician, site manager and engineering manager.

Contributors 10-15_Vs6.indd 2 10/8/15 10:14 AM

Follow the whole team on twitter @Windpower_Eng

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Cyber security and wind farm penetrations

Want to see scary stuff? Monitor hackers trying to get into the controls of an electrical substation looking for weak spots for later exploitation. At some time, say experts, the attack will come. Fortunately, there are cyber cops with suggestions for preventive measures that may thwart the intruders.

A few ideas for an improved 21st century grid

A couple decades ago, wind power slowly began to make its way into the mainstream electric power-supply system. At the time, it was assumed this source of renewable energy could easily connect to the existing grid without fundamental changes. As wind power has grown over the years, this assumption hasn’t proven exactly true.

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Editorial: Are you ready for your cyber attack?

Wind Watch: Icebreaker foundation, Unique pitch drive, News from New Orleans

Siting: Assessing cumulative visual impacts

Reliability: Evaluating generators through electrical signature analysis

Software: Harvesting technology intelligence and mitigating IP risks

Condition monitoring: Making it easy to read

Turbine of the Month: GE’s 3.2, 130

Bolting: Getting all bolts to the same load

Safety: Designing turbines for a global marketplace

Remote sensing: How sodar stacks up to met masts

Policy: Who owns your energy-use data?

Equipment world: Ultrasonic wind sensor, mobile wind meters, hazardous vapor protection, Bearing replacement made easy

Downwind: Storm surge barrier also serves up tidal power

D E PA R T M E N T S

F E AT U R E S


48ON THE COVERCyber security requires constant vigilance, say experts.

Contents_10-15_Vs2.indd 4 10/7/15 2:07 PM

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IF WIND TURBINES ARE TO BE BUILT LARGER, their designers will have to think differently about building larger components. An inventor in Dallas wants to assist with a recent design for a pitch drive could take weight off a rotor and a turbine’s main bearing.

The clever cam-activated mechanism turns a ring gear by “walking” or pulling on four geared pads engaged with the gear. “Torque transmits from a center cam to the pads, while the pads that are stationary for a moment support the output ring by surface contact,” says inventor and designer Carlos Hoefken, founder and CEO of MacroLever Inc. “The pads move in pairs, triplets, or more, so the design generates pure torque. You can think of each pad as a drive.”

The significant feature of the design is that it combines the function of bearing and drive into a single package. Only two pads are lifted and repositioned at a time so the driven gear is supported by the other pads.

The gear pads hold several mating gear teeth providing a large area of contact unlike a conventional drive which has less than two gear teeth in contact at any one time. Hoefken says his design would weigh only 10% of the gearbox usually selected for a pitch application and would also work without teeth, just a

plain surface. “The design could have a ratio a low as 50:1 or as high as 1,000:1 and more,” he says. Other pluses, he says include low maintenance costs, simple lubrication, and a reduced need for costly alloys.

A substitute mechanism of the type describe here could be made of cast and machined

gear segments, which would be much less expensive than a conventional design,

COULD TAKE WEIGHT AND COST OFF A TURBINE

NON-CONVENTIONAL SPEED REDUCER

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“The main purpose of this invention is to create an electrical alternative to hydraulic drives. For that, the gearboxes must be light and deliver high torques at low rpm and with zero backlash,” says Hoefken.

“I believe this solution will be so economical that it will be possible to add an extra degree of freedom, say elevation angle to a turbine,” says Hoefken. “The elevation angle could deal with wind flows that are not parallel to the horizon which would add a little extra production to wind turbines.”

He also sees an application in yaw drives. (See the sketechs on the previous pages.) Designers for large turbines, 3 MW and up, often use up to eight yaw motors and drives to keep the turbine properly oriented. With the new technology, says Hoefken, one drive would be enough to actuate the yaw function.

“I think we could get rid of several yaw drives in a turbine and use as few as one of these designs,” he says. Yaw functions would be further simplified by omitting the large

and expensive three and four-meter diameter yaw bearings. “A substitute mechanism of the type describe here could be made of cast and machined gear segments, which would be much less expensive than a conventional design,” he says.

Hoefken developed the cam operated speed reducer after solving many other motion control issues in industial automation and custom machinery.

Two prototypes of a first and second generation design are working in Hoefken’s Dallas lab. The inventor adds that there are other applications most are which are to replace hydraulic actuators with simpler electric drives. Hoefken says he is already working on a third generation of the drive. W

W I N D W A T C H


WHAT DO YOU THINK?Connect and discuss this and other wind issues with thousands of professionals online

The CAD illustration is from an animation of Hoefken’s mechanism. To view the animation, dial into www.tinyurl.com/macrolever.

The main purpose of this invention is to create an electrical alternative to hydraulic drives. For that, the gearboxes must be light and deliver high torques at low rpm and with zero backlash


W I N D W A T C H

Clever foundation selected for Lake Erie Icebreaker offshore wind project

TO HANDLE THE WIDE VARIETY OF SEABED CONDITIONS for offshore wind farms, engineers in Europe have devised a range of foundations. So when engineers at the Lake Erie Energy Development Corp. (LeedCo) began considering what would work best in the soil of the lake bed for the planned six-turbine Icebreaker offshore wind project, a modified version of the ubiquitous monopile seemed a front runner. However, it had no track record so investors gave it a thumbs-down. But a little more looking produced an unusual design with clever features that geotechnical studies now say will work well.

LeedCo is a not-for-profit organization created to break the ice, so to speak, and get the offshore wind industry going in the region.

The company’s job is to marshal the plans, permits, ports, and manufacturing capability of lakefront cities in Lorain, Cuyahoga, Lake, and Ashtabula counties.

LeedCo VP of Operations David Karpinski recently provided an update on the project and introduced a clever foundation that could be the first of many in the Great Lakes. “We considered a monopole three years ago and found a challenge in Lake Erie soils. The soil depth reaches down only 80 ft. and then bedrock. Eighty feet sounds like a lot, but it is not. Below the surface layer, at the mudline, the soil is soft for several meters. There is not enough lateral stability there for a monopile,” says Karpinski. It would be possible to drill into the bedrock but that is expensive.

Another concept takes a monopile and modifies it with what is call a friction wheel. But this design has no track record and that makes it too risky.

“Then, we started to hear more about this monobucket. It is based on a suction-bucket technology that has been used for 20 years in oil and gas industries, mostly for anchor points. It works like this: The underside of the bucket is open and initially sits on the lake bed. After it settles a little under its own weight to establish a seal, water is pumped out to lets differential pressure drive the bucket into the lakebed,” says Karpinski.

It’s also critical to mount the turbines on a nearly vertical pile, so the bucket must be installed no more than 0.5° from vertical. “To keep it vertical during insertion, water jets are fixed to the bottom of the skirt in three zones. Should it begin to tip, the installers can activate water jets to displace soil and straighten it. What’s more, chambers on the inside of the bucket provide sections that can be pressurized separately for additional corrections,” he says.

To build confidence in its methods, Karpinski says the bucket’s design firm Universal Foundation (UF) conducted a series of installation trials. Over 28 days, a crew installed and removed a bucket 16 times at 16 different sites in the North

Sea and was able to achieve 0.1° verticality in each case. UF says this accuracy negates the need for a separate transition piece with its problematic grouting, thereby reducing steel, offshore operations, and exposure to delays, which results in significant cost reductions.

Karpinski adds that his team was attracted to the one-piece structure because there is no need for excavation and no pile driving. Also, it weighs about 25% to 30% less than the monopole friction wheel, although the fabrication costs will be about the same. “What’s more, we can optimize the design, and with history, its cost can come down.”

UF has been working on the device for 15 years and at least three of the foundations are in the wind industry’s service. One installed in Denmark in 2002 holds a Vestas 2.3-MW turbine, and two others support met masts in the North Sea.

Another part of the project is to Americanize the European monobucket. The design will be re-specified to U.S. materials and welding standards. Manufacturing consultant Patrick Fullencamp at GLWN will assist with a redesign to reduce the number of welds and include automation.

A local welding fabricator, AT&F in Cleveland, will be able to build the structure. Ultimately, the bucket will have to be fabricated closer to the water, but there are shipyards around for that operation. “There are also dry-docks and barges along the lake. Turbine-tower manufacturer Ventower is another possible fabricator, and it is possible to get different components from different shipyards. The goal is a competitive design,” says Karpinski. W

The monopile with a friction wheel was an early contender for foundations in the Icebreaker wind project. However, without a track record it was nixed in favor of the monobucket.

The monobucket has been installed several times by developer Universal Foundation with vertical accuracy of 0.1°.



A RECENT INVENTION OUT OF SPAIN promises to eliminate lightning hits to structures such as wind turbines and stadiums. Cloud-to-ground lightning strikes when electric charges on earth and opposite charges in a storm cloud overcome the resistance provided by the air that separates them. “Rather than provide just a low-resistance path to ground, as existing grounding systems do, the HALO Lightning Suppressor

grounds out earth-based charges thereby creating a deionized space that prevents the meeting of lightning streamers from ground and cloud,” says Jay Kothari president of EMP Solutions, the

sole distributor in North America. Upward streamers are eliminated by grounding out positive and negative charges at a high rate, up to 640,000 V/microsecond.

Effective lightning protection has eluded turbine engineers. For instance, Ben Franklin’s still-used lightning rod, like HALO, relies on a strong and reliable grounding system that creates a low-resistance pathway for ions to earth. DAS, another system, looks like an umbrella without its covering. “You see them most in Florida. It works as a dissipater by drawing charges up from the positive ground charges and dispersing them through its many points. But the DAS is a large bulky system not viable for wind turbines.”

A Halo for wind turbines protects them from lightning strikes

And the ESE, or Early Streamer Emitter, collects charges, “like our system but instead of grounding them, it produces its own upward streamer and attempts to send it away from the structure under protection. However, it has been banned in Europe because it was causing damage to adjacent structures. ESE is not banned in the U.S.,” he says.

What’s more, a wind turbine has two issues, says Kothari. “The first issue is the problem caused by atmospheric lightning, and second, because the turbine is spinning, it generates its own electrical field. So you have the static from the turbine as well. The solution is to deionize the air passing overhead and dissipate the static charge generated by the spinning blades. For that, we install a unit inside the tower to pull some the static electricity off the blades and send it to ground. And we install a unit on top of the turbine to dissipate the charges generated by the storm cloud. The two devices provide a huge area of protection.

A single device can protect a 100-m radius or about 337,000 ft2 of space,” he says.

“Those areas prone to lightning, such as in Florida, may need a beefier grounding system. So each application is custom engineered,” says Kothari. He adds that for the last 10 years, the device has had a 100% success rate in Europe protecting any structure or area from the threat of lightning including towers, antennas, marinas, oil and gas storage, and more. In fact, the manufacturer offers a $500,000 liability policy

towards any damage or injury that occurs from a lightning strike while the unit is properly installed. W

Ben Franklin’s still-used lightning rod, like HALO, relies on a strong and reliable grounding system that creates a low-resistance pathway for ions to earth.

The Halo deionizing device works like a capacitor. The top and bottom of the aluminum domed portions are separated by a disk of insulating PVC. Positive and negative charges collect on opposite sides of the disc. Draining one charge to ground prevents ground originating streamers from reaching those coming from the clouds (shown).

W I N D W A T C H

1 0 WINDPOWER ENGINEERING & DEVELOPMENT www.windpowerengineering.com OCTOBER 2015


NREL program investigates the impact of wind flow on wind farmsATMOSPHERE TO ELECTRONS (A2E) IS A MULTI-YEAR, U.S. Department of Energy research initiative with the goal of reducing wind-power project costs through an improved, physics-based understanding of the wind plant operating environment through advanced modeling and simulation capability.

According to the research initiative, better insight into flow physics has the potential to reduce energy losses by up to 20% at a wind farm, lower project operating costs, and improve project financing terms to more closely resemble traditional capital projects.

At a recent AWEA Wind Resource Seminar, National Renewable Energy Laboratory’s Senior R&D Engineer Jason Fields discussed the A2e research goals in light of the ongoing industry changes over the next five to ten years. This was part of a session that focused on the future of wind power and wind resource assessment over the next five to ten years.

W I N D W A T C H

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“We need a model that represents the full structure of the atmosphere at many different scales and that includes wake modeling, control of the complete wind plant –not just individual turbines – and a better understanding of wind-plant performance uncertainty.”

To help get there, A2E is a seven-year (2014 to 2021), multi-partner collaboration that has six main focus areas:1. Performance risk, uncertainty, and

finance (how uncertainty in wind energy is represented financially),

2. High-fidelity modeling (includes simulations, high-performance computing and validation measurements),

3. Data archive and portal (ensuring a long lived, secure place to store and access relevant data),

4. Integrated wind-plant control (a look at the total wind plant and not just individual turbine control),

5. Aeroacoustics and propagation (a look at noise generation)

6. Integrated system and design analysis (finding the best designs for full wind-plant control).

“We’re essentially trying to tie in all these disciplines into a single package that accurately represents and measures an entire wind farm,” said Fields. However, one challenge in doing so is keeping up with today’s push for growth and technology evolution, which lends to ongoing design and manufacturing changes.

“Technology is evolving at a rapid pace. We’re moving toward an ability to modularly deliver wind plants with multiple rotors, multiple hub heights, and multiple nacelle-nameplate capacities in the same project,” explained Fields. “So, we need measurement and modeling tools that adapt to these new manufacturing capabilities.”

As an example, Fields displayed the Wind Plant Scales graph from the Department of Energy’s 2014 Wind Technologies Market Report . *Suggest oinserting chart here* The black line shows the average rotor diameter over time and

W I N D W A T C H

Technology is evolving at a rapid pace. We’re moving toward an ability to modularly deliver wind plants with multiple rotors, multiple hub heights, and multiple nacelle-enabling capabilities – and in the same project,

Fields began by asking the audience to imagine the next generation of “smart wind turbines” and to consider how the industry might design them. It’s not difficult to envision taller turbines with longer, more aerodynamic blades, and improved controls that seamlessly capture more wind while integrating power into the grid. For Fields, however, the answer

is mainly found not just by focusing on a single wind turbine design but by looking at the total wind plant.

“We think the answers lie in a few different areas, but fundamentally in a better understanding of the atmosphere,” he said. Fields maintained that significant challenges still exist that relate to fully understanding a turbine’s response to the wind flow in and around wind plants.



the bars are histograms of the average rotor size by project. “This graph serves as one example of those changes. Before 2009, there were virtually no projects with rotors larger than 100 meters,” Fields pointed out. “But now that figure represents 80% of the market. Wind plants are also increasing in size.”

The trend toward larger wind farms likely won’t change anytime soon. According to Fields, if wind manufacturers have the ability to deliver varying components, brands, and sizes for the same project, it reshapes the traditional wind farm design landscape. It also begs an important question.

“We have a clear theme for the future: larger rotors, larger plants, higher hub heights. So we have to ask the question, ‘Are point measurements sufficient to describe the atmosphere at a wind farm – and to the level of detail necessary – to accurately predict loads, predict power, and predict the total resources across the site?’”

This change in landscape and turbine size, ultimately, has to drive advances in wind measurements and the science behind those measurements. One area of interest to Fields is in wind-plant optimization. This means effectively increasing power generation, but to do so it’s necessary to start with highly accurate data. “For plant optimization to make any sense, we need to ensure we’re relying on high accuracy inputs and wind-flow data,” he said.

This drives additional reliance on remote-sensing devices along with accurate wind-flow and wake models. It also means models will need to incorporate full wind-plant control data for accurate energy estimations. “The future of wind-plant control doesn’t look at how turbines operate individually, but rather as a collective to maximize generation of an entire wind farm.”

To provide an example, Fields showed a video that demonstrated the negative wind-flow effect that upstream wind turbines can have on downstream units, leading to sub-optimal plant performance. One

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solution is to integrate an optimized yaw-based wind-farm control system, which can “steer” wakes from greater overall power production.

For an optimized wind plant approach to work effectively, the underlying inputs must be accurate. “Right now we have successfully demonstrated those individual turbine control capabilities , but if we’re looking at total wind-plant control, that changes the game, so our tools must adapt to this change. That is what we’re working on, an advanced wind-plant optimization approach based on highly accurate wind-flow data full wind plant controls.”

Other changes to consider for the future of the wind industry include energy storage. “The ability to arbitrage energy and sell it at different times can mitigate some of the variable supply challenges we have. This has implications for transmission systems, wholesale prices, retails prices and consumer choice,” he concluded.

*suggest including Navigant chart here*The ultimate goal of A2e is to

ensure future plants are sited, built, and operated in a way that produces the most cost effective electrons. A2e researchers certainly have their work cut out for them to keep up with demand and the changes in the industry. “Ultimately, there’s significant room for improvement in understanding wind flow, optimizing wind design, wind-plant controls, and storing energy, and this is shaping the R&D work we do for the future of wind-power production,” said Fields. W


W I N D W A T C H

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According to the “Wind Technologies Market Report” recently released by the Department of Energy

and its Lawrence Berkeley National Laboratory, the total installed wind-power capacity in the United

States now stands at nearly 66 GW, which currently ranks second in the world. The report notes

that wind energy prices are at an all-time low, and are competitive with wholesale power prices and

traditional power sources across many areas of the country. The findings also suggest that the success

of the U.S. wind industry has had a ripple effect on the American economy and currently supports

about 73,000 jobs related to development, siting, manufacturing, transportation, and more.Sweet winds in TexasThrough a joint partnership, Duke Energy Renewables has acquired a 50% stake in Mesquite Creek Wind, a 211-MW wind-power project near Lamesa, Texas. What makes this deal extra sweet is global food manufacturer, Mars Inc. (best know for its candy products), will purchase the power and associated renewable energy credits from the wind farm for a 20-year period. Mesquite Creek Wind consists of 118 1.7-MW GE wind turbines, enough to provide electricity for Mars’ entire U.S. operation.

Joining forces The first U.S.-Mexico cross-border wind farm was recently inaugurated in Tecate, Baja California. Comprising of 13,100 acres of leased land near the city of Tecate, the Energía Sierra Juárez 1 project consists of 47, 3.3-MW wind turbines and a newly constructed 4.8-mile trans-boundary transmission line. The project has an installed capacity of 155.1 MW and will displace more than 125,809 metric tons of carbon dioxide a year.

Banking on OklahomaSouthern Power announced an agreement to acquire the company’s second wind project from Apex Clean Energy, a 151-MW Grant Wind facility in Oklahoma. Located in Grant County, the project plans to use 66 Siemens wind turbines capable of generating enough electricity to help meet the energy needs of about 50,000 average U.S. homes. The acquisition is expected to close in March 2016 upon successful completion of the project.

New winds for CanadaThe 270-MW K2 Wind Facility, one of Canada’s largest wind-power projects, has officially opened in southwestern Ontario. The project consists of 140 Siemens 2.3-MW wind turbines and is expected to generate clean energy for approximately 100,000 Ontario homes each year. K2 Wind has also created a Community Benefits Fund Agreement with the local Township of Ashfield-Colborne-Wawanosh to deliver about $15 million in funding for community initiatives over the next 20 years.

8 Ohio’s new foundations The Icebreaker offshore wind project, planned for the waters of Lake Erie near Cleveland, will incorporate a new foundation design developed in Europe. The Mono Bucket foundations are expected to significantly reduce installation costs for the pilot project compared to the modified monopile concept originally developed by LEEDCo in 2013. The Mono Bucket foundation is an all-in-one steel structure consisting of a monopile shaft attached to a large-diameter bucket. It is installed with a unique suction system that requires no pile driving or dredging, eliminating noise and soil disturbance.

Wind work around North America

Gaining more groundEDF Renewable Energy (EDF RE) has officially closed the acquisition of OwnEnergy, a national developer of mid-sized wind projects. The transaction encompasses 100% of OwnEnergy’s assets, including its pipeline of future wind projects. To date, this entails eight wind projects either in a construction or operating phases, which represent 329 MW of developed wind-power assets sold to third parties. EDF RE is currently one of the largest energy developers in North America with 6 GW of developed renewable projects and an installed capacity of 3.2 GW.

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Managing assets in Tehachapi Vestas has secured a service agreement with Renewable Energy Trust Capital (RET Capital) to cover the 102-MW Coram Wind Project in the Tehachapi region of California. As part of the agreement, Vestas will serve as RET Capital’s onsite asset manager, providing 24/7 surveillance and site management. The contract also includes reporting to power purchaser PG&E, responding to curtailment requests, maintaining electrical and meteorological equipment, managing wildlife and vegetation, and more.

Two is better than oneMidAmerican Energy Company plans to begin construction on two new Iowa wind farms in the spring of 2016. Plans call for approximately 134 turbines and up to 301 MW of generation capacity at what will become the Ida Grove Wind Farm, and another 104 turbines with 250 MW of generation capacity at the new O’Brien Wind Farm. With the addition of these two facilities, MidAmerican will operate over 2,000 turbines with wind projects in 23 Iowa counties.

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Assessing cumulative visual impacts for wind projects

S I T I N G


The potential effect utility-scale wind energy projects have on the aesthetic quality of regional landscapes is a common concern for regulators and

stakeholders. Failure to address this concern early in the public review process can lead to misinterpretation, diminished public confidence, and delays in project permitting.

In areas that have a rich wind resource, it’s not uncommon for different developers to propose two or more projects within a single viewshed. With little to distinguish one project from another, there’s the potential for dozens or even hundreds of turbines across one landscape.

Although one of a developer’s primary responsibilities is to identify and mitigate the potential visual impact associated with its specific project application, this role is becoming increasingly complicated. Regulators are now often requiring consideration of the cumulative visual impact of adjacent existing or proposed projects on the scenic resources of a host community.

However, most regulatory agencies don’t have specific rules, regulations, or standards for completing a cumulative visual assessment, nor do they offer meaningful guidance concerning appropriate assessment methods. Therefore, the developer must find a way to determine the best way to evaluate the projects.

Making the assessmentsAn assessment of potential visual impacts takes advantage of the inventory and analysis efforts completed for the proposed project subject to the investigation. A cumulative visual impact assessment, which is typically prepared by a licensed landscape architect, is completed to provide a direct comparison of the existing visual condition with or without a wind project, to the first proposed project, the second project, and so forth.

By using viewshed mapping (also known as zone of visibility mapping) and photo-simulation data sets developed for the primary project, it’s simple to add a second or third project for cumulative assessment and at low cost to the developer.

J o h n W. G u a r i g l i a , R L AA s s o c i a t e P r i n c i p a l

S a r a t o g a A s s o c i a t e sw w w. s a r a t o g a a s s o c i a t e s . c o m

The viewshed maps here were created to illustrate the visibility of a proposed 11-turbine project located immediately adjacent to an existing 14-turbine wind farm. The study area of each map extends to an outside radius of two-miles from both projects, and includes the screening effect of topography and existing forest vegetation. The maps were calculated for blade tip height of each existing and proposed turbine. GIS analysis was also used to determine the degree of heightened impact and the areas of new impact.

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S I T I N G

From here, your wind farm will look like this. The photo simulations illustrate a proposed-project view from a selected location.

In addition to written documentation discussing the potential cumulative impact, two tools – viewshed mapping and photographic simulation – are typically used by visual analysts assessing visibility and potential impact.

1. Viewshed mapping is a GIS-based tool that identifies the geographic area within which there’s a relatively high probability that some portion of the project(s) are visible. The maps identify areas where further investigation is appropriate, and determine sensitive viewing areas and locations of affected viewer groups. The two types of maps commonly used in identifying visibility are:• Topography only viewshed maps

account for the screening effect of existing topography (e.g., bare earth conditions). This worst-case treeless condition analysis is used to eliminate unaffected areas from further consideration.

• Vegetated viewshed maps incorporate existing forest vegetation into the topographic analysis to identify areas of probable screening based on existing mature forest cover. This mapping type acceptably identifies the geographic area within which one would expect to be substantially screened by intervening forest vegetation. Vegetated viewshed maps provide a more realistic representation of project visibility than the bare earth assessment and enables focused inventory of impacted resources.

Data from the cumulative viewshed maps is generally used to illustrate areas impacted by one project, compared to areas impacted by multiple projects (referred to as “new visibility”). This information can help determine the net increase in the number of turbines visible from any given place (referred to as “heightened visibility”). However, these maps don’t help illustrate the amount of each turbine that’s visible, the effect that distance and atmospheric conditions have on potential project visibility, or the aesthetic character of what is visible.

2. Photographic simulations are an effective and highly used tool to illustrate the degree and character of project visibility of the wind energy project(s) from a specific location. Simulations are developed

by super-imposing a rendering of a three-dimensional computer model of a project into a high-resolution existing conditions photograph. Simulations, although they represent the view from a specific vantage point, are used to illustrate what the project will look like within the landscape (“visual character”). They also disclose how much of each turbine is visible above intervening landform and vegetation (“degree of visibility”). Simulations provide clear interpretation of the effect of atmospheric and linear perspective.

Although viewshed mapping and photographic simulation provide usable information about the potential cumulative impact of multiple projects, they offer one method of analysis. Alone they do not adequately communicate the new and heightened impact associated with adjacent wind energy projects.

Ideally, mapping and simulation must take place in tandem, along with proper documentation (e.g., cumulative visual impact assessment report) to fully convey cumulative project visibility. W

WINDPOWER ENGINEERING & DEVELOPMENT 1 7

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Evaluating wind-turbine generators through electrical signature analysis

R E L I A B I L I T Y


Properly assessing an operating turbine’s electrical and mechanical systems is no easy task. An electrical signature analysis or ESA is independent of load or speed, so the test is often applied to analyze generators and electric equipment. Still, a challenge is to

ensure loading stays constant during each test and at the same speed for variable-speed generators.

During an ESA test, rotational speed multiplied by the number of individual components provides useful information. The amplitude of the peaks on FFT spectra (an analysis that transforms a waveform into the components of its frequency spectrum) is also analyzed in relation to the peak voltage and current line frequency. The peak voltage and current changes depending on loading or output and all associated peaks remain relative to the voltage and current peaks. There are few exceptions to this

H o w a rd W P e n ro s e , P h . D . , C M R P P r e s i d e n t

M o t o r D o c L L Cw w w. m o t o r d o c . c o m

Examples of low-frequency data

The graphs represent low-frequency data. The top graph is RMS data, the middle graph is the low frequency FFT, and the bottom graph is the demodulated FFT.

rule and the conditions remain the same even when the amplitude of the peaks change slightly.

An ESA also provides information such as power factor, efficiency, phase balance, harmonics, and other important power-quality data that is valuable when performing an analysis. This is significant because a single test or data set alone cannot provide an accurate view of the complete system.

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WINDPOWER ENGINEERING & DEVELOPMENT 1 9

The best approach is a holistic one with an examination of multiple measurements. For instance, information about the machine tested and its controls, such as variable-frequency drives (VFDs) are just as important as voltage and current data. For a wind turbine, useful pretest information includes a:• Complete machine nameplate,

especially the horsepower or kilowatt, base rpm, voltage, and current

• Number of rotor bars (or slots) and stator slots

• Bearing information• Type of couplings• Gearbox data, such as:

• Gear teeth or ratios for each shaft• Bearings and their shafts and locations

• Number of blades for direct-drive pumps and vanes

• Belt-application data, such as:• Sheave sizes• Belt information• Shaft center-to-center distance

• Control information, and• All other components attached

electrically or mechanically to the system.

This list of components is important for an accurate analysis. The data collected are then related to the speed of the machine, and multiplied by an appropriate and pre-determined number. For example, stator (the stationary part of an electric generator) issues are related to the number of stator slots times the rotational speed in rpm.

How this data is finally presented is up to the analyst. Some prefer to use Hertz and others prefer rpm or cpm (cycles per minute). Either method is valid and, ultimately, the more information that’s available, the better.

Basic analysisData collection for a generator is either performed using voltage probes and current clamps, or by connecting a pre-installed plug that can jack into a data collector. Because exposed energy is probable and hazardous, it’s imperative

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The upper left data is the 0.05 second current, the upper right is the high-frequency current FFT, the lower left is the 0.05 second voltage, and the lower right is the high-frequency voltage FFT. Data such as this is often used for tracking harmonic conditions and higher frequency faults.

to follow safe methods of data collection. Collecting data from current transformers or potential transformers is acceptable but frequency and amplitude are often dampened.

The first step in a generator analysis reviews the applied voltage and current, so ensure both are collected. The RMS (root mean square) and waveform of just the voltage and current will say a lot about how the equipment is operating. It will become apparent if there are problems, such as cyclical loads, VFD issues, or other concerns.

Higher resolution spectra around the line-frequency voltage and current will relate directly to conditions effecting the rotor and driven equipment. Some bearing, fan, impellor, and gear issues also show up in this range. Normally the data is viewed in decibels (dB) measuring from the peak voltage and current (0 to -100 dB). This provides a relationship in the relative force that’s associated with the evaluated frequency. These peaks mirror each other on either side of the line frequency. De-

modulated voltage and current are related to the mirrored peaks.

This data is often presented in voltage and current frequencies without the actual line frequency peak. It can help determine the rotational speed and the peaks to look for in the low-frequency spectra. It is not, however, used for determining alarm conditions. Higher frequency data is used for looking at harmonic conditions and higher frequency faults, such as stator conditions, rotor conditions, and eccentricity.

At higher frequencies, points of analysis are formed as twice, line-frequency pairs.

Waterfall analysisDepending on the system, a waterfall analysis – a visual representation of the cumulative effect of data – can provide further insight. This is especially true when frequency peaks have broad bases, which can indicate looseness in a variety of system components, changes in speed, or torsional issues. The waterfall analysis

provides a “Z-axis view” such that an analyst can review changes over time.

The front or X-Y axis view provides a layered or average view across the time span when data was collected. When cyclical issues exist, often there’s a rise and fall across the Z-axis. Looseness of powertrain components is indicated with a fluttering across time.

Torsional analysisTorsional vibration is a concern in power transmission systems that use rotating shafts or couplings because it can cause failures when not properly controlled. Torque ripple, an increase or decrease in output torque when the shaft rotates, is measured by calculating the difference in maximum and minimum torque over one complete revolution.

This is often difficult to detect with vibration analysis and requires expensive strain gauges mounted on the rotating components. Fortunately, an ESA lends itself to the direct detection of torque ripple. Such ripple can then detect the

Examples of high-frequency data


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Waterfall data of this sort with a rise and fall across the Z-axis indicates cyclical issues.

associated frequency and the dB down from the peak voltage or current. The frequency, if significant, will also show as peaks in the low-frequency and de-modulated spectra.

Torque ripple will reveal data on the driven equipment, couplings, and even the controls. For instance, a variable frequency drive will have an amplitude of ripple, and with greater severity, can result in coupling faults, shaft failure, or equipment failure.

Evaluating the generatorJust as with induction machines, the transducer for the generator is the air-gap between the rotor and stator. This air gap increases the reluctance between the stator and rotor, which enhances the magnetizing current. Small variations or changes in the magnetic field stem from the rotor vibration and are detectable by ESA. The data rides on the voltage and current waveform, which is an amplitude-modulated signal.

When collecting data on a generator, it’s important to read information from the stator before transformers or other devices are in the circuit because they will block the signature intended for inspection. All existing ESA devices have a 600 Vac limit with the exception of the ALL-TEST Pro OL that has a 1,000 Vac limit. The ALL-TEST Pro OL is a power quality and ESA data collector that has been used on motors, generators, and wind turbines since 2002.

For a system with voltage higher than the limit of the instrument, data is collected using current transformers (CTs) or partial transformers (PTs).

However, CTs and PTs will cause some damping and possibly even a small phase

shift unless they are specifically selected for ESA testing. For proper analysis, it’s critical that data for all three phases are recorded in voltage and current. When using CTs or more than one conductor, enter a CT ratio to ensure a proper loading evaluation.

Bearing signatures, when present, are a significant find regardless of their amplitude. It takes a significant amount of damage to the bearing races or balls to cause the rotor to vibrate enough for detection. An ESA provides a secondary method for bearing fault detection.

Details of the method for analysis are beyond the scope of this article, but data collection is still worth the time and effort to ensure an optimally performing machine. Proper analysis requires significant data for an accurate reading. Overall, an ESA can detect conditions through the entire generator power train, from the prime mover to generator load. W


Harvesting technology intelligence and mitigating IP risks with IP Analyzer

S O F T W A R E


Companies seeking to differentiate their products and services often seek patents to secure the revenue

streams generated by their innovations. The patents these companies obtain can serve as a proxy for their R&D expenditure, so the impact of thorough and comprehensive analysis of the patent landscape can be profound.

Multiple independent studies from the U.S. Patent & Trademark Office, the European Patent Office, and research companies in multiple industries have determined that anywhere from 70 to 95% of all relevant and independently verifiable information regarding the function of a particular technology comes from the patents and applications covering that technology.

The remainder of such technology intelligence is comprised of other sources such as conference proceedings, technical papers, and journal publications. In order to get the complete picture, it is important to combine all relevant information sources when analyzing the evolution of technology and predicting future trends.

The relevance of a particular patented innovation to the industry can be measured by the degree to which that technology has been duplicated, so a relevance assessment determines the extent to which particular technologies have been copied. This assessment also serves to identify potential patent infringement risks and commercial liabilities in the form of royalties which might be owed by one company to a competitor who holds those patent rights.

Using this analysis method, IP Analyzer software lets users quickly visualize the

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Analysis methodology

Relevance assessment used by IP Analyzer

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S O F T W A R E


The heatmap indicates that blade manufacturing, controls for frequency and voltage regulation, aero performance, and

generator efficiency have been some of the most heavily patented areas historically.

Heatmap for the patent landscape shows the concentration of patent filings in a given component and technology cluster. It is clear that blade manufacturing, controls for frequency and voltage regulation, aero performance, and generator efficiency have been some of the most heavily patented areas. This correlates to the historical cost of energy reductions seen in the industry.

IP Analyzer also allows for industry and competitor benchmarking with an array of metrics delivered through information dashboards. Comparison of the innovation efforts of the top 10 IP holders in the industry reveals important trends. Over half of the patents on technologies developed and used in the industry are held by the top 10 companies, but they also control over 75% of the patents on widely used technologies identified by the orange and red coding. This increases the potential liability exposure for competitors to those in the top 10.

The software analyzes the total landscape to reveal industry and competitor benchmarking shown in easy-to-read charts. This provides comprehensive information

Heatmap for the patent landscape

Ranking companies by the quality of their patents

component and technology trends which have emerged in the industry by comprehensively evaluating the patent landscape of over 40,000 global patent filings in the wind industry. While there are well over 100,000 patent filings on wind technology generally, IP Analyzer has been able to weed out the false positives and focus on the core set of innovations which are relevant to horizontal axis, utility-scale technology.

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Technology maturity based assessment

Technology benchmarking


S O F T W A R E

and immediate visualization of important factors which differentiate one company’s technology capabilities from another. For example, in Ranking the companies by the quality of their patents, of the top 10, Chinese manufacturer Guodian United Power holds no high value patents (red column) but is still fourth in wind patent asset ownership.

Through tracking of a Technology Readiness Level, IP Analyzer determines the extent to which a competitor is using its own patented innovations. Many companies have cultivated a patent portfolio full of ideas they never intend to use, as well as many innovations which are impractical to use.

IP Analyzer can determine the extent to which the commercialization of a specific technology has taken place, what was the non-recurring engineering cost associated with technology development, as well as predict the CapEx, OpEx and performance benefit which the individual technology brings to bear.

Patents also serve to codify a commercial risk associated with the potential infringement of a competitor’s intellectual property rights. Having determined the usage of patent protected technologies from the relevance assessment, IP Analyzer also serves to inform a company about the commercial liability due to the design similarity of their product or service offering to the IP rights of their top competition.

A composite risk score identifies the extent to which a company might have to undertake risk mitigation such as in-license of IP rights or potentially change its design to avoid a competitor patent.

The composite risk score quantifies the extent to which a specific product architecture might have infringement risk exposure compared to the breadth of the patent claims for each one of the 40,000 plus patent filings worldwide.

IP Analyzer also shows a detailed breakdown of the potential patent liability exposure of a specific turbine design to each competitor based upon the relevance assessment. This identifies the extent to which risk mitigation might be required or royalties might have to be paid based upon the usage. Because the status of patents changes over time, as does the usage of those patented technologies by competing companies, IP Analyzer adjusts the composite risk score in real-time.

This process, conventionally known as product claim mapping, results in a total number of

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patents which might have infringement risk exposure for a specific product architecture. IP Analyzer also identifies the companies that hold those patent rights, which helps a product manager or risk manager identify potential hot spots.

This independent IP risk review, by IP Analyzer, is similar to the process of getting a type certificate on a wind turbine or sub-component. This IP risk evaluation and certification has already become part of the project finance due-diligence process. So far, IP Analyzer has been instrumental in cost avoidance totaling $210 million by mitigating IP risks which would have otherwise resulted in royalties. W

Product claim map

S O F T W A R E

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global meeting point for onshore and offshore experts.

Make WindEnergy Hamburg your gateway to the world

of wind energy. Exhibitors are invited to register now.

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J o h n U g l a n dTe c h n i c a l A c c o u n t M a n a g e r

R N R G

C O N D I T I O N M O N I T O R I N G


Condition monitoring made easy to read

What makes a good condition-monitoring system for the wind industry? One that lets users derive operational value.

We could argue that hardware, sensor placement, and storage servers all play a critical role in the value chain of CMS, but what is really important in a condition monitoring system today? The information it delivers and how a CMS delivers this information to a user is critical.

Understanding the user The adoption of vibration-based condition monitoring has grown rapidly in the wind industry. In fact, it has outpaced the highly skilled labor necessary to interpret traditional vibration data. Effective maintenance programs require multiple stakeholders. At the wind farm, there are technicians and site managers. In the back office, there are asset managers and reliability engineers.

Renewable NRG Systems recognized the skill shortage as an opportunity to redesign the CMS user interface. The company has launched

a new, easy-to-use UI this summer with the intent that anyone involved in the maintenance of a wind turbine could easily access, use, and understand the information provided by the CMS. We focused on making turbine health information accessible to all levels of an organization; it’s not just a tool for a select group of vibration analysts.

Fleet management Most companies operate in a lean mode these days, so an effective CMS must let users get to the information they need as quickly as possible. A top level, Fleet View screen, shows all monitored turbines in one view and immediately lets a user focus their resources where they are needed most.

Beyond automated email alerts, users can check the UI to see if there are alerts that have not been acknowledged. Acknowledging an alert means it has been seen, validated, and an action plan may be in place. This feature is especially important with multiple stakeholders

The TurbinePhD condition monitoring system provides a Fleet View for high-level information for many wind farms. For instance, Wind Farm C has only 2 components in alert. But things are not so good at Wind Farm G, with 38 components in alert.

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C O N D I T I O N M O N I T O R I N G


The spectrum analysis identifies significant vibrations and the rotating components responsible for the peaks.

In the previous illustration, the health indicator or HI for the downwind generator bearing indicated an ailing component. Are other generator bearings reaching a particular point in their life? The CMS can pull that information from across the wind farm and display it for evaluation.

The Turbine overview provides an easy to read evaluation of a particular turbine. For this unit, the easy-to-recognize red bars are calls-for-attention for the Main upwind bearing, a planet gear, and the downwind generator bearing.

involved in the wind turbine’s maintenance. For example, a site manager could view and acknowledge all the alerts for their wind farm, while a reliability engineer (responsible for multiple windfarms) could verify that action has been taken.

Accessible and actionable information, at the right level. Traditional vibration data historically involved a lot of squiggly lines. To the trained individual, those can tell a complete story. The Spectrum analysis graph offers an example of a classic bearing inner-race fault, complete with shaft-rate sidebands.

But is such information actionable? Is it accessible? Yes, for the vibration analyst, but probably not for the site manager or even a reliability engineer. In a well-structured maintenance program, those are the people that need that actionable information.

Using graphical icons and automatically calculated, statically-based Health Indicators (HIs), such as those in the illustration Turbine overview, site managers without vibration experience can review the health of a turbine’s drivetrain (from their desktop, phone, or tablet) and determine whether or not they need to take corrective action.

Or perhaps a reliability engineer may need to investigate whether or not there is a serial problem: is the bearing defect contained to only one turbine or does it affect more of the population?

A vibration-based CMS doesn’t have to be exclusive territory. Empowering all stakeholders responsible for wind turbine maintenance yields the most effective maintenance program. TurbinePhD provides these features, and more, to end users at all levels in a wind turbine’s maintenance cycle. W

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GE’s 3.2-130 wind turbine

T U R B I N E O F T H E M O N T H


There is a lot to be said for small companies because they are often considered quick and nimble when presented with

actionable information. Large companies, on the other hand, are often considered a little slow on the uptake.

GE, however, is big company with a big wind division that acts like a small, nimble firm. Since 2002, the company says it has invested more than $2 billion in next-generation wind turbines. The company’s 1.5-MW turbine has benefited from the investment by possibly being the most manufactured worldwide. The company quickly improved the design to produce 1.6 and then 1.7-MW versions. The company has done the same for other lines. For instance, it recently took the wraps off its 3.2-MW 130 at the Husum trade fair in Germany. It is the latest on the company’s 3-MW platform, which initially offered up to 20% more annual energy output than GE’s 2.5-120, on which the 3.xs are based. For the upgrade, we tap the new 3.2-130 as our Turbine of the Month.

The new design combines a larger rotor, improved load management systems, and more efficient drivetrain over predecessor models. With four hub-height options from 85 to 155 meters, the 130-meter rotor turbine can be tailored to different site conditions.

“With its high-capacity factor, the turbine can offer efficient power supply in locations with low and medium wind speeds,” said Andreas von Bobart, GE’s general manager for its renewable energy business in Germany.

GE engineers are now thinking beyond individual turbines to entire wind farms, and so say the 3-MW platform represents a technology developed for the Industrial Internet. The company says all turbines in

its brilliant line (yes, small b) will feature a network of sensors, which allow analyzing many data points to evaluate the performance and efficiency of wind farms.

By combining “big data” analytics with the industrial internet, the company says it is helping manage the variability of wind to provide smooth, predictable power. The company’s wind portfolio includes turbines with rated capacities from 1.7 MW to 3.2 MW and support services ranging from development assistance to site optimization, operations, and maintenance.

Taking advantage of energy storage along with advanced forecasting algorithms let the turbines communicate with neighboring turbines, service technicians, and operators.

It’s no secret that gearboxes have been a sore spot for the wind industry, failing well before their 20-year expected life is up. The

GE’s recent 3.2-130 turbine boasts 28% more AEP over 2.5-MW turbine on which it is based. The company says it has more than 26,000 wind turbines worldwide representing more than 43 GW of installed capacity, and they operate with 98%+ availability.

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T U R B I N E O F T H E M O N T H


industry is slowly getting a handle on the problem. One of GE’s handles is a patented loads control system that proactively measures stress during operation. In addition, the turbine runs with individually adjustable blade pitch for greater energy production. A power converter adjusts output voltage and frequency for the grid, further enhancing the annual energy production.

The optional battery storage is a significant option. For instance, by pairing a company-designed battery at the turbine level with forecasting algorithms, GE says owners can drive higher output and a deeper revenue stream. Company engineers have

developed three battery-focused software applications that work with the wind turbine to improve the availability of wind power. Owners and operators can select the application or a combination of them to best suits their site needs. The controls apps are intended for:• Ramp control. In conventional setups,

when wind speed increases quickly, the grid cannot always absorb the extra power produced. The Ramp Control App lets a brilliant turbine capture power what would ordinarily be lost and store it in the battery.

• Predictable power. Power producers must provide consistent and predictable power to the grid. The

variability of wind, however, makes smooth grid integration challenging. The Predictable Power App lets a brilliant turbine smooth out short-term peaks and valleys in wind power and makes it predictable over periods of 15 to 60 minutes.

• Frequency regulation. Power demand changes throughout the day requiring grid operators to keep up with its constant fluctuation. Grid operators look to power producers to respond rapidly to keep the grid balanced. The Frequency Regulation App lets wind farms store energy in the battery and respond immediately and with precision to load changes. W

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J e s s e Ta r rP r e s i d e n t

W i n d s e c u r e

B O L T I N G


A better way to tension anchor bolts gets them all to the same load

Anchor bolts secure a variety of structures to foundations. Wind turbines are just one such structure. Loose anchor bolts

will allow excessive fatigue the foundation’s reinforcing steel, grout, and concrete. This fatigue eventually leads to larger, more expensive problems such a grout and concrete failures, all of which jeopardize the foundations functional longevity.

Consider a circle of anchor bolts, such as those that hold a turbine tower to its foundation. A deviation in tension from one

bolt transfers uneven loading to surrounding bolts, leading to non-uniform pressure on the structure’s foundation. As more bolts loosen the problem propagates and when left unchecked, can lead to a catastrophic structural failure.

Anchor bolts come loose for many reasons. A few include failure of the supporting grout, improperly tensioned anchor bolts, and failure of the supporting foundation, such as fracturing or uneven settling. It is important to establish precise records of bolt tension to better determine if there are issues, and the possible root cause of changes in bolt tension.

With regard to a wind turbine, a base section out of level by fractions of an inch will lead to several inches or feet out-of-level at the top of the tower. The generator, gearbox, and other components at the tower’s top must be precisely balanced for the wind turbine to operate properly. When such components are out of balance, it leads to the failure to one or more of them and the costs to fix such issues are extradinary.

We have devised a process for improving a structure’s integrity that includes

measuring anchor bolt stretch, correlating that to an exact “as found” tension, and re-tensioning several anchor bolts on the structure to a final load P. In a nutshell, bolt stretch, B is measured for each bolt in a set. The integrity of the structure is found by solving the equation for each anchor bolt:

F=kP−(BAE)/L

where F = the calculated load on a bolt; P = a bolt load found from test; B = a measured bolt stretch from the load F to final load P; A = the cross sectional area of the bolt; E = bolt material’s modulus of elasticity,

The graph plots anchor-bolt stretch in millimeters as a function of bolt number around a structure.

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B O L T I N G


Six of the 70 anchor bolts

Bolt number Bolt stretch, (B) mm

As-found tension,(F) kips

Final tension, (P) kips

48 2 39.25 62

49 4.28 13.31 62

50 1.48 45.16 62

51 0.85 52.33 62

52 1 50.62 62

53 2.48 33.79 62

L = a length of bolt under tension, and k is a unit specific constant.

By monitoring a set of anchor bolts after about a year for changes in F, and at least for one bolt, anchor-bolts changes in the structure can be detected and repaired before further damage occurs. A failing structure is assessed in several ways including evaluating the F values as a function of the bolt position in the bolt circle.

The corrective process requires a tension gauge and micrometer that measures an applied tension and bolt length, and a way to correlate these to the equation. This allows quickly determining bolt tension, adjusting it to a required value, and then identifying potential sources of the tension change.

The method here puts a known tension on an anchor bolt and measures a bolt’s axial length change. It is a simple way to find bolt tension prior to the test. Its tension is determined by solving the equation.

Because the equation is linear, it applies to a recommended load range and for a given bolt. However, it does not apply when a bolt is overloaded, beyond a maximum loading because its elasticity is lost and the bolt suffers irreversible deformation.

Consider this example to apply the equation. Let:P = 62,000 lb or 62 kips B = 0.0433 in. A = 1.25 in.2 E = 29,000,000 (#10 grade 75) and L = 124 in. k = 1

Therefore:F = 62,000 − [0.0433×1.25×29,000,000]/124F = 49,342 lb, or 49.34 kips, the actual load on the bolt.

Knowing A, E, and L, and by measuring values for P and B as part of servicing a structure, the equation provides F, the as-found bolt tension prior to retensioning to a required value P. The accompanying illustrations show the variation in values generated by solving the equation to map bolt length and tensioning profiles for the structure. The structure is then evaluated based on these values for potential integrity problems.

Problems readily identified by this method include non-uniform foundation settling, defective anchor bolts, and anchoring system failures. There are others, and all can be investigated by

conventional means and corrected before further damage.

To further illustrate, the following example came from a working turbine secured to its foundation by 70 anchor bolts. The anchor bolts are tested by the method described with the values of bolt elongation, as found, and final tension for each of the bolts being measured and recorded. Final tension is determined by a calibrating device of our invention.

In the example, bolts of particular interest are numbers 48 to 53 because they are under-tensioned. An investigation determined the area of loose anchor bolts had failing grout, which required repaire. Upon completion of an approved process for repairing the grout, the bolts are tested again and found to be holding their required load, thus ensuring operational reliability of that structures foundation anchoring system. W

The plot is for as-found (F value in the equation and denoted by diamonds) and after tensioning (P value in the equation and denoted by squares) for the bolts of the previous illustration.

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M i c h a e l H u g h e s , C I H , C S PG l o b a l H e a d o f E H S f o r O n s h o r e W i n d

S i e m e n s E n e r g y, I n c .w w w. s i e m e n s . c o m / w i n d


S A F E T Y

Designing wind turbines for safety and compliance in a global marketplace

Acommitment to safety underpins the design of a wind turbine, while designers focus on

transportation, practicability, cost, and functionality. Balancing these design goals must occur in a manner that does not compromise the safety of those who manufacture, install, or service the turbine over its lifecycle.

The best way to control operational risk is to eliminate hazards during a turbine’s design or planning stage. Safe

design integrates hazard identification, risk assessment, and control methods early in development to eliminate or minimize risks to the long-term integrity of the turbine.

The first challenge is to ensure a turbine design meets or exceeds all Environmental, Health, and Safety (EHS) requirements applicable to all countries where installation is planned. This is often an issue because turbine designers aren’t always familiar with all locations their turbines may be installed. The design team’s location determines the baseline design criteria of the turbine. For example, when a team is located in Denmark, the EN standards serve as the baseline design reference. When teams are in the United States, OSHA or ANSI standards provide the reference.

Wind-farm construction begins after a long turbine design process that should guarantee a safe machine, regardless of the site country.

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ISO CODES. RIGHT ON TARGET.

hyprofiltration.com/

S A F E T Y

If these baseline references are not adjusted to the countries where the turbine is eventually installed, it may be out of compliance with regulatory requirements in those locations.

Hundreds of EHS regulations may add to the challenge, depending on the country. Therefore, it’s important to identify all EHS regulations applicable to the design before development begins. Ideally, the regulations and internal requirements should be compiled in a manual, much like the one displayed, called Engineering EHS Turbine Design Manual.

This manual can include supporting information, such as pictures of best practices, mistakes that have led to retrofits, and other safety issues. Clarity and consistency are also keys to the success of this manual. It’s important the EHS regulations are filtered for the applicable requirements based on where the turbines will be installed, and that this information is presented in a manner that’s easily understood by the design team. Consistent updates and ongoing reviews are necessary to ensure the manual incorporates new regulatory changes and that the changes are properly communicated to the design team.

Once a team has a firm understanding of the EHS regulations, then turbine designing can begin for the target market. After completing a design model, it’s important to perform a virtual or 3D Concept Design Risk Assessment. This is where the Engineering EHS organization, and either an EHS representative from the target market country or an EHS consultant, validates that the turbine design meets the regulatory requirements. This person also ensures there’s sufficient clearance to perform the many installation and maintenance tasks necessary at a wind site.

To ensure a wind turbine is designed to meet each country’s safety codes,

regulations should be compiled in a safety design manual, much like this example, called

Engineering EHS Turbine Design Manual.

OCTOBER 2015 WINDPOWER ENGINEERING & DEVELOPMENT 3 3

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S A F E T Y


The Engineering EHS Design Manual: Good and bad design practicesA good design practice is to have a minimum of 140mm of clearance on both sides of an anchor point to allow attaching snap hooks.

A bad design practice is not having enough clearance on either side of an anchor point preventing a snap hook from being installed.

A good design practice is to ensure equipment does not obstruct the walking or working surface or create tripping hazards by elevating the diamond-plate walking surface so it’s flush with equipment.

An example of bad design practice is having the motor housing elevated above the walking or working surface, thereby creating a tripping hazard.

Country EHS regulation comparisons

Europe United States Difference

EN 50308:2004 4.5 Climbing Facilities

A ladder shall:• Be safeguarded by an anti-fall device

comprising an anchorage line and a fall-protection mechanism, or a climbing cage if the vertical height exceeds 3.0 m.

1926.1053(a)(19)

• Where the total length of a climb equals or exceeds 7.3 m (24 ft.), fixed ladders must be equipped with a ladder device system.

In Europe, the EN standards require that a fall-protection system is installed on fixed ladders that are 3.0 m (9.84 ft.) in climbing height.

In the U.S., OSHA standards require that a fall-protection system is installed on fixed ladders that are 7.3 m (24 ft.) in climbing height.

EN 50308:2004 4.5 Climbing Facilities

Anchorage points for safety lines shall:• All be colored uniformly “yellow” to

contract with the background.

• OSHA does not have a requirement for the color of anchorage points for personal fall-arrest systems.

In Europe, the EN standard requires fall-arrest anchorage points to clearly stand out against the backdrop.

In the U.S., OSHA does not currently require anchorage points to be painted.

For instance, the design of an electrical panel may meet the regulatory requirements for work clearances, but its position in the nacelle might obstruct a technician’s ability to complete routine component changes. A virtual walkthrough of the turbine can simulate actual work positions and limitations where alternatives may prove effective and can be modeled. This ensures selecting the most effective solution and provides for a reliable turbine design that meets all EHS regulations.

After completing the Concept Design Risk Assessment and it is deemed sufficient, follow up with a Detailed Design Risk Assessment. This assessment is completed

during the prototype phase and provides an opportunity for the design team, including representatives from the EHS organization, to physically validate that all EHS risks are accounted for and are not an issue. The team should also assess the effectiveness of the controls and mitigations, and make necessary adjustments before a turbine goes into serial production.

This final risk assessment ensures the production of a fully compliant turbine with the least likelihood of risk throughout its lifecycle. The goal is to remain committed to safety in the design and production of turbines, while delivering a machine that provides maximum output with the latest advances in design expertise and technology. W

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Comparing remote sensing to met towers

R E M O T E S E N S I N G

If you ask to borrow money to develop a wind farm, the lender will ask: How much energy will it generate? Your answer, of course, depends on the wind, a variable resource

and one that will significantly affect the cash flow of a wind farm. Measuring and assessing the wind provides investors with valuable information about a project’s risk and potential success.

For over 30 years, meteorological masts – met towers – have served as the primary wind-measurement tool. It’s usually equipped with anemometers, vanes, and data loggers that record wind speed and direction. Nearly every modern wind-power project, collectively worth billions of

dollars, has received cost-justification based on one of these devices.

But times are changing. Ground based, remote-sensing technology often supplements today’s towers because remote-sensing technology can measure winds at much greater heights. LiDAR (light detection and ranging) or SoDAR (sound detection and ranging) are remote-sensing methods that use either light in the form of a pulsed laser or sound to measure ranges. The measurements are needed because the industry is building ever-taller turbines (80 to 100 m) to capture the stronger winds higher up.

But met towers don’t usually top 80 meters. They’re also costly to build and complex to install

L e e A l n e sG l o b a l K e y A c c o u n t M a n a g e r

Va i s a l a I n c .

The Vaisala Triton Wind Profiler is a remote-sensing system that measures wind speed and direction as much as 200-m up. It’s been compared to towers in individual validation studies and in a new global study done in conjunction with Vaisala’s customers.


An overview of measurement validation in the wind energy marketplace

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A typical 60-m met tower• Towerconfiguration. Perfect measurements

would require mounting a device on an invisible tower that couldn’t alter or divert the wind. But reality shows that a tower affects the wind and impacts related measurement data. This is because wind flows around the tower and can bounce off and over it before hitting the sensor or anemometer.

• Measurementdevice.By design, a cup anemometer (aptly named because of the cup-like shape of the device that “captures” and measures the wind) reacts more easily to increases in wind speed than it does to decreases, often putting out disproportionately higher readings at higher wind speeds due to gusts. An anemometer can also over-speed in reaction to vertical currents and is affected by the sway of a tower in the wind. In fact, in some wind directions, data from two anemometers at the same height on the same tower can differ by as much as 10%.

Taking these issues into account, the wind industry generally stipulates that most cup anemometers are accurate to within 1 to 2% of actual wind speeds.

After data collection comes the tricky process of sorting though or “cleaning and screening” the met-tower information. This is labor-intensive and somewhat subjective. A meteorologist has a variety of choices to make in filtering out data, and must bear in mind that extrapolating data from lower heights to turbine height causes errors. Even the seemingly simple task of averaging wind speeds over time is open for interpretation.

Chances are that no two meteorologists will come up with exactly the same results from the same set of tower data. So it’s important to document all potential physical factors that might affect the outcome. Fully understanding and accounting for the challenges in comparing measurement devices is critical for conducting good studies that produce a scientifically supportable result.

The most important metrics reported by a correlation study are as follows:

• Correlation. Wind speed or direction measurements are compared using the correlation coefficient, r, and the coefficient

A typical 60-m met tower holds a range of instrument at several levels. However, the tower and guy wires cause some wind-flow disruption.

at any height. Most lenders are aware of this. Those holding the purse strings also know that wind measurements taken at lower heights are not ideal and lead to financial uncertainty. So as turbine heights reach beyond the 100-m mark, wind measurements are becoming an increasingly relevant factor in wind-farm financing.

Comparing measurement devicesAt some point, nearly every new remote-sensing user asks: “Is this device as accurate as my met tower?” The short and sweet answer is “yes.” In fact, remote sensors are often more accurate than met towers. A number of validation and correlation studies have proven this.

These studies, often conducted at a wind-turbine test facility, tend to go like this: A remote-sensing system

is placed near a met tower for at least four weeks. Afterwards, researchers compare the measurement data from the two systems.

This seems straightforward, but comparing information from wind-measurement devices has its challenges. When comparing remote sensors to tower-based wind measurements, it’s important to first understand the sources of possible error. The following conditions represent some of those potential sources. • Location. Because it’s physically

impossible for a remote sensor to secure the exact location as a tower at the same time, the data collected will already be skewed. This alone will cause the two measurements to differ at least somewhat.



of determination, r2. A correlation coefficient is a number between +1 and -1 describing the relationship of one variable (for example, the met-tower measured wind-speed data) to another (the remote-sensor measured wind-speed data). A coefficient of +1 indicates a perfect positive correlation (both devices recorded exactly the same thing), and a coefficient of 0 means there was no correlation whatsoever. The coefficient of determination, r2, is the square of the correlation coefficient and describes how much of the variation in one variable is predictable from the other variable. Sometimes manufacturers will maintain that their system is “99% accurate.” What this actually means is that r2 was 0.99 in at least one correlation study. Because of anemometer uncertainty, one could argue that it’s hardly possible for a system to be 99% accurate.

• Reliability. Even a perfectly accurate instrument is not practical or useful to the wind industry if it’s unreliable or requires constant attention. Reliability is reported as the percentage of time a machine is operational during a test period. Typical met tower reliability targets for the industry range from 75 to 95%. If a system is operational less than 85% of the time during a wind measurement campaign, its results are not trustworthy.

• Data recovery. Tower data recovery is either 0 or 100% within a given time period. The data recovery of a remote-sensing system will vary because of its signal strength, atmospheric conditions, and other factors. Data recovery is usually reported as a performance metric in correlation studies.

The growing number of validation studies has given the wind industry a lot more confidence in remote-sensing data. LiDAR and SoDAR sensors are becoming the routine choice for wind project developers, especially for large-scale wind farms.

Industry experts and researchers have done an impressive job conducting comparisons between remote sensors and traditional measurement technologies. The goal now is to continue this work to help the industry further reduce financial uncertainty and ensure a favorable return-on-investment for wind energy projects. W


Vaisala recently released a global study using significant data from remote-sensing units in commercial-field use. The study compared more than 50,000 hours of wind data from 30 Triton and met-tower pairs deployed in various locations globally and over an extended period. The Triton Wind Profiler is an advanced remote-sensing system that provides wind measurement data across an entire blade sweep of a turbine. On average, the Triton’s measurements correlated extremely well with the tower’s measurements. It is considered just as accurate as a met tower. To download a copy of the study’s Executive Summary, visit http://forms.vaisala.com/triton-comparison-study.

As turbine heights grow, remote sensing plays an increasingly important role in wind measurement.

Why met towers come up short



J o e H a l l , B o b C a t t a n a c h , a n d B r a d H a m m e rD o r s e y & W h i t n e y L L P ’s E n e r g y, C y b e r S e c u r i t y a n d P r i v a c y P r a c t i c e

P O L I C Y

So, who owns your energy-use data?

The integration of renewable energy and environmental policy has meant the power industry has had to rethink core assumptions

about fuel sources, costs, reliability, and centralized planning. It has also had to reconsider the traditional utility-customer relationship. As distributed generation has grown around the country, energy monitoring and smart metering has increased to better meet power demands. But there is a fine line between monitoring and privacy.

One important conversation has far-reaching implications: the legal and regulatory treatment of customer energy usage data or CEUD. The ownership and treatment of CEUD touches legal issues

that include customer privacy rights and a business’s ability to protect potential trade-secret operations. Is it fair game that your neighbors, local businesses, or even

The traditional electric meter tells how much a house or company uses each month. But, whose data is that?

the government have access to data on how and when you use electricity or, in some case, even where it comes from, such as natural gas, fossil fuels, or wind power?

In the absence of significant regulatory clarity in the near future, the current lack of guidance in this area may create significant and sometimes unforeseen risks for the industry. Utilities, regulators, and many consumers are strongly invested in discussions over what may become the next-generation utility model at the federal and state level.

Understanding CEUDRecent advances in metering technology have allowed a detailed exchange of data between a utility and its customers. Through the use of smart meters, this data can serve as an effective tool for more efficient energy pricing and billing by helping utilities better regulate and measure electricity use over time.

However, one concern is that the exchange of CEUD is not necessarily just between utilities and customers. A variety of stakeholders may seek this information for various business, political, and policy objectives such as:

• Target marketing. Businesses selling products and services aimed at increasing home or building efficiency could benefit from customer power-usage data.

• Regulatory enforcement. Local governments may need CEUD to support and enforce local ordinances that mandate energy use reduction in buildings within their borders.

• Conservation compliance. State agencies may seek to verify compliance with conservation, energy efficiency, and emissions reduction efforts (most state agencies may already have access to such data through mandated reporting, but may seek more granular and precise information).

• Efficiency mandates. Owners of apartments or large buildings could request tenant-specific power usage to monitor and encourage energy efficiency, or to ensure compliance with local ordinances.

• Environmental watchdogs. Energy or environmental “watchdog” groups may want power-usage data to enforce conservation, efficiency, or emission reduction requirements on utilities, or customers, or both.

Based on the steady trend over the last decade, the demand for CEUD is almost certain to increase. Privacy law is a relatively


Utility_10-15_Vs4.indd 39 10/7/15 2:31 PM


P O L I C Y

have at least 15 customers, and no one customer can account for more than 15% of energy use in a set. Although the individual energy-use data remains accessible, it’s non-specific to any one customer. Aggregation, however, is not without its limits and critics.

Some – especially large commercial or industrial customers – challenge the efficacy of aggregation. Why? Because certain characteristics of their energy-use patterns are so unique that they’re impossible to securely mask without risk of exposure. The failure of the ability to effectively secure data may potentially expose such commercial and industrial customers to “corporate espionage” by those attempting to gain competitive intelligence about a particular entity’s commercial operations (such as the cost of production at a facility).

Inadvertent disclosure The challenges of protecting usage data extend beyond affirmative corporate espionage. For example, utilities sometimes struggle with competing obligations when disclosure of CEUD is

or the power to promote efficiency and conservation.

• In those states addressing usage data, the trend has been to treat the CEUD as belonging to the customer even though it’s the utility that creates and collects the data. That means customers have the ultimate say over its disclosure, and the utility may only use the data to perform its regulated utility functions (e.g. providing service, billing, dispatching for repairs).

This balancing act between protecting data and the utility’s use of that data for legitimate purposes may shift if the information becomes “de-identified” through aggregation. Through the process of aggregation, information that could identify a specific customer is removed, and a larger set of customers is grouped into a set of CEUD (often based on geography).

For example, Colorado uses the fairly common “15/15” standard. In it, an aggregated set of CEUD must

Smarter devices could report data to identify specific consuming household appliances over the course of a day.

Source: National Institute of Standards and Technology, Guidelines for Smart Grid Cybersecurity: Volume 2 – Privacy and the Smart Grid (Sept. 2014).

new consideration in the power industry, and few regulations exist to define the obligations and protections that apply to power-usage information. Most significantly, under current law, it’s not at all clear who actually owns CEUD – the utility or the customer. In most jurisdictions, it’s also unclear whether there is any legal obligation to disclose or protect CEUD.

This places utilities and their customers in a challenging position and raises a number of fundamental questions:

• Without a set legal mandate, does a utility have a duty to protect CEUD?

• In the absence of any specific formal requirements, can a utility’s customers (retail or industrial) seek redress if they are harmed by the disclosure, intentional or inadvertent, of CEUD?

• Is power-usage data sufficiently important to the “public interest” to warrant regulatory protection and provide regulators with the authority to act on CEUD?

• If protection is warranted, should it occur at the state or federal level?

In the absence of regulatory guidance, the rights and liabilities associated with the ownership and protection of CEUD and commercial information will default to bilateral agreements between negotiating parties (typically with a leverage imbalance), and potentially to common law through precedent-setting litigation. Current regulationsWhile the National Institute for Standards and Technology has issued standards that provide specific guidance with regard to smart-grid cyber security, those standards provide an imprecise discussion with respect to power-usage and data privacy concerns. To date, only a limited number of states have provided direction concerning ownership, protection, and disclosure of CEUD.

• In some states, such as California, the Legislature addressed the treatment of CEUD by statute.

• In other states, including Colorado and Minnesota, public-utility commissions are beginning to address CEUD based on their regulatory jurisdiction over the retail customer and utility relationship,

BACHMANN SUPPORTS ALL ASPECTS OF CONDITION MONITORING• Integration of condition monitoring to existing Bachmann controllers• Stand-alone condition monitoring for non-Bachmann controllers• Remote monitoring and analysis• End of warranty vibration inspection

Bachmann electronic Corp. | 34121 North Route 45, Suite 203 | Grayslake, IL 60030, USAT: +1 (847) 249 30 03 | [email protected] | www.bachmann.info

Condition Monitoring

More Profi t, Greater Production

Produktanzeige_CMS_h5xb9.indd 1 26.04.2012 08:20:11Utility_10-15_Vs4.indd 40 10/7/15 2:31 PM

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P O L I C Y

BACHMANN SUPPORTS ALL ASPECTS OF CONDITION MONITORING• Integration of condition monitoring to existing Bachmann controllers• Stand-alone condition monitoring for non-Bachmann controllers• Remote monitoring and analysis• End of warranty vibration inspection

Bachmann electronic Corp. | 34121 North Route 45, Suite 203 | Grayslake, IL 60030, USAT: +1 (847) 249 30 03 | [email protected] | www.bachmann.info

Condition Monitoring

More Profi t, Greater Production

Produktanzeige_CMS_h5xb9.indd 1 26.04.2012 08:20:11

required under federal or state laws addressing generator interconnections. Competing objectives can create conflicting mandates from state PUCs where a utility is required to provide certain interconnection data through interconnection studies, but doing so could expose the CEUD that the PUC would otherwise treat as trade secret or propriety information.

With increased interest in distributed generation or large remote generators, utilities are conducting studies for and providing interconnections to an expanding number of entities wishing to interconnect to sparsely populated areas of electric distribution systems. Even if this data is anonymized or aggregated, these studies may inadvertently result in an information release on large commercial or industrial customers.

The path forwardWithout a federal standard, the appropriate treatment of CEUD in the power industry will likely find resolution on a state-by-state basis. Unfortunately, on some level this correlates

to an inconsistent and potentially conflicting patchwork quilt of regulatory obligations. It also means regulatory guidance is not likely to happen anytime soon.

In the meantime, consumers and businesses will have to continue to try to find ways to protect their privacy and trade secret information. The proliferation of distributed generation may also force utilities to reconsider their CEUD policies and may even prompt tariff revisions as disparate stakeholders seek state PUC guidance.

Even the potential solution of aggregation has its limits, and the rapid evolution of metering technology is sure to complicate the challenge. While a few states have made efforts to formulate policies for CEUD, not enough time has passed to evaluate the best processes to date.

For now, one thing is certain: the inexorability and complexity of CEUD-related questions will not wait for the law to catch up, and industry participants will have to make decisions based on a variety of predictive indicators unique to their situation and jurisdiction. W

Utility_10-15_Vs3.indd 41 10/7/15 11:20 AM

Today, wind is one of the least expensive energy sources worldwide and has become one of the largest generation subsectors in some regions. Further growth and acceleration is expected, especially in light of its significant cost reductions over the past few years. To meet demand, electric power-supply systems must find ways to integrate renewable energy on a larger scale.

How exactly this is going to happen is still open for debate, particularly in the United States where an ageing grid and differing state regulations are a challenge. Ideally, what’s needed is a comprehensive analysis of grid codes and utility practices in use globally to provide an in-depth evaluation and understanding of renewable power generation and its effect on transmission systems.

Since the end of the 20th century, an increasing number of countries have promoted and incorporated the use of wind and solar energy. Denmark is a pioneer in this field. By 2011, it was supplying more than 40% of its electric demand with renewable sources – three quarters of which came from wind power. Germany is also watched closely as the first large industrial country attempting to transform its electricity supply with a strict focus on new renewable sources. Renewables accounted for nearly 28% of Germany’s power consumption in 2014.

For a comparison, the U.S. gets about 13% of its energy from renewable sources. But times are changing. California, for example, recently passed legislation that increases the state’s Renewable Portfolio Standard to 50% renewable-generated electricity by 2030. The power plants

J o c h e n K re u s e l Head of Smart Gr ids , Global A B B , I n c .

A couple decades ago, wind power slowly began to make its way into the

mainstream electric power-supply system. At the time, it was assumed this

source of renewable energy could easily connect to the existing grid without

fundamental changes. As wind power has grown over the years, this assumption

hasn’t proven exactly true.

century grid

A few ideas for an improved

21st


Transmission_10-15_Vs5.indd 42 10/7/15 2:33 PM

of tomorrow will need to keep up with demands. They will have to operate seamlessly and economically even at low loads and in fast-changing situations.

System integrationRenewable energies have three main characteristics that fundamentally change the electric power-supply system:

1. Remote generation. This characteristic is mainly driven by location. Winds are often strongest in more remote regions. This is an issue for power plants that tend to reside closer to the urban areas they serve.

2. Distributed generation. On a unit basis, distributed wind installations (those 10-kW or less) account for more than 67% of all turbines installed in the


Transmission_10-15_Vs4.indd 43 10/7/15 11:33 AM

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U.S. since 2003 and more than 33% of all turbines installed in 2014, according to the Department of Energy. Distributed wind systems can offer reliable electricity generation and back-up energy in a wide variety of settings, including for schools, farms, towns and communities, and more.

3. Volatility. This characteristic is introduced to the electric power-supply system because wind flows vary in intensity and over time.

Changing power needsThe rising share of wind and renewables are influencing the operation of conventional power plants. The increased use of plants for steep power-output gradients (and originally only intended for base loads) is taking its toll and poses a significant technical challenge. Cost is also an issue. Not just in terms of plant maintenance but also in terms of the market.

Wind and solar power have no variable costs so they will always rank at the lower end of the merit order in an energy-only market. This means that when renewables reduce or displace conventional generation, it becomes more difficult to provide a fixed cost coverage for energy.

These economic effects mean that building and operating conventional power plants is no longer as attractive as it once was in the past. While this poses a challenge, it also provokes change. As it stands today, conventional generating capacity is still indispensable as backup during periods of low renewable power output and for power system control.

Therefore, new plant designs are up for discussion and these designs are helping shape the electric power-supply systems and the energy market of the future. Here’s at a few potential changes.

• TransmissionThe transmission systems required for upgraded power plants that handle multiple sources of energy generation will look different from those of the past. In transmission networks, remote generation leads to increased capacity requirements. Also, the volatility of the generation – particularly in combination with the low number of full-load hours of the renewable energies – increases transmission requirements.

Expanding the interconnected power system represents the most cost-efficient option to match volatile generation and consumption. One likely scenario is the addition of

With a fundamental redesign of power systems, a significant change in system management will have to include the integration of many distributed units on the generation and consumption sides.



This table represents the effects of the main drivers for change on different parts of the electric energy supply and utilization value chain. The growing number of operating conditions in the distribution networks increases the information requirements.

a super-imposed transmission level or an overlay grid that’s based on high-voltage direct-current (HVDC) transmission lines. An overlay refers to a grid (most often envisioned as HVDC) that essentially “sits on top” of the existing one to bring power from renewable sources over long distances. HDVC serves as a highly efficient alternative for transmitting large amounts of electricity over long distances and for variable loads.

• Distribution Resolving challenges isn’t a new a task for electric power suppliers.


One of the most significant changes in system management will be the combination of a large number of distributed units on the generation and consumption side. Here’s a comparison of some of the traditional solutions commonly seen today and future options for a more balanced grid.

Expanding the interconnected power system represents the most cost-efficient option to match volatile generation and consumption. Here you see the costs for renewables are reduced by integrating power supply systems in Europe, North Africa, and the Middle East.

Currently, when the grid is unable to offer sufficient capacity, it’s imperative that congestion or other problems are proactively detected and resolved. In many cases, an increase in distributed generation requires a reinforcement of the grids.

Mitigating problems and finding solutions are already a common practice in the coordination between large-scale power plants and system operators. But these solutions have yet to be largely standardized and automated – an important goal for the future.

• ConsumptionBecause of the volatile power output associated with renewables, the short-term demand response is a potential issue and one garnering attention in the domain of energy storage. Storage can make a difference, especially in the first 15 minutes of a cycle. This is an important period because it’s sufficiently long enough to ramp-up power plants with fast startup capabilities. Storage capabilities could serve as a less costly alternative in the long run. Depending on the application, their capacity for demand response can help in short timeframes and provide a stabilizing effect for power plants.

Besides the proven, but landscape profile-dependent pumped storage plants, battery storage facilities can contribute in the short term for frequency stabilization and peak shaving. In the long term, and for the compensation of seasonal variations, extending grid-interconnected systems or interconnecting hybrid systems (such as natural gas supply) might be the answer.

century grid

Generation costs and savings from MENA

Future options for a more balanced grid



The road ahead Future conventional generation will require plants that operate economically even at low loads and in frequently and fast-changing load situations. The transmission networks will have to take over long-distance transmission tasks with varying load flows. To compensate for the volatility of the new renewable sources, wide-area interconnected systems are a possibility.

With a fundamental redesign of power systems, a significant change in system management will have to include the integration of many distributed units on the generation and consumption sides. Frequency control will prove a challenge, especially with a decreasing number of rotating masses acting as stabilizing elements. Balancing loads and generation will become more difficult in systems with varying primary energy supplies and without power storage.

But change is possible and necessary if renewable energy is to reach its full potential. With its determination and a commitment to innovation, the North American wind industry can help pave the way for a new and improved electric power-supply system for the 21st century. W

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CYBER SECURITY

CYBER SECURITY

Cyber Security 10-15_Vs3.indd 48 10/7/15 12:14 PM

EDITOR

Want to see sc

ary stuff? Moni

tor hackers tr

ying to get in

to the

controls for a

n electrical s

ubstation look

ing for weak s

pots

for later expl

oitation. At s

ome time, say

experts, the a

ttack

will come. For

tunately, ther

e are cyber co

ps with sugges

tions

for preventive

measures that

may thwart th

e intruders.

CYBER SECURITY

& wind farm pe

netrations

& wind farm pe

netrations

Paul Dvorak EDITOR

CYBER SECURITY

SHORTLY after midnight

on a near moonless morning in April 2013, several gunmen opened fire with AK-47s on the transformers at the Metcalf Transmission Substation in California. More than 100 rounds punched holes in 17 transformers, spilling over 50,000 gallons of transformer oil and shutting the station down. In 19 minutes, the gunmen caused over $15 million in damages. But rest easy because the FBI does not think the attack was the work of terrorists. The gunfire was just one volley in a battle that has already commenced. Later attacks will be more subtle than those with Russian assault rifles. They will come over the Internet.

This article can only scratch the surface of the cybersecurity problem because of its fluidity. However, a few of the big successful hacks have made headlines, such as the hack at department store Target stealing credit card numbers, and into the Federal Government computers, pilfering sensitive personal information from four-million government employees that can easily be used for blackmail. More intrusions go unreported by the news. Fortunately, wind farms do not seem on the receiving end of




concerted attention, although experts say that anything on the web is a target.

A lot of bad people are anxious to make bad things happen to this country and its infrastructure. Foreign agents have been poking around at least several western wind farms and other unacknowledged utilities as well. It’s difficult to tell where they come from because they use many ways to mask that information, but most indications are Russia and China. The intruders are probably looking for weak spots in an overall system, ideally a way to hobble a large part of the U.S. economy, and all without firing a shot.

The problem at largeHackers, as good a name as any for these intruders, are looking for anything they can disrupt, but specifically information on the electric grid, how to collect that information, and how to use it. “The concern is that systems on the grid are interconnected so even a small wind farm can be an entry point to systems that controls larger portions of the grid,” says Joseph Doetzl, head of cyber security for the Product Group Enterprise software within ABB in the U.S.

Doetzl says he is not aware of any success by hackers or first-hand accounts of widespread disruptions in the U.S.

“Taking a single 100-MW wind farm offline is probably not something that would disrupt a grid or damage equipment, although there would be a financial impact. The grid, at large, does a good job of handling loads that come on and off line. Protection mechanisms are built in. The concern is that the control systems for a single generating facility are communicating with control systems for larger areas. A control system at a generating facility improperly secured could serve as an access point for another facility that has

a larger impact,” says Doetzl. In security parlance, the bad guys could swim upstream.

One scenario is that hackers would simultaneously hit several plants to take as much off line as possible. “Large portions of

the grid in North America would go off line along with physical

In Fiscal Year 2014, ICS-CERT received and responded to 245 incidents reported by asset owners and industry partners. The Energy Sector led all others again in 2014 with

the most reported incidents. ICS-CERT says its continuing partnership with the Energy Sector provides opportunities to share information and collaborate

on incident response efforts. Also noteworthy in 2014, says ICS-CERT, were the incidents reported by the Critical Manufacturing Sector, some of which were from control systems equipment manufacturers. The ICS vendor community may be a target for sophisticated threat actors for a variety of reasons, including economic espionage and reconnaissance. Of the total number of incidents reported to ICS-CERT, roughly 55% percent involved advanced persistent threats (APT) or sophisticated actors. Other actor

types included hacktivists, insider threats, and criminals. In many cases, the threat actors were unknown due to a lack of attributional data.

Known threats from 2014

Source: ICS-CERT

Turbine OEM suggests security modules to protect wind turbines

Siemens says its security concept for wind-turbines offers reliable protection against cyber criminality, a real threat for networked wind-power plants. The security modules of its Scalance S family are said to be easy to use and provide protection in a flexible, reaction-free, and protocol-independent manner. This allows securing existing networks without need to reconfigure network stations or to change the network topology.

The modules are for use in automation technology and are said to seamlessly connect to the security structures of office and IT environments. Through a combination of security measures, such as firewalls and VPN via IPsec tunnels, Scalance S protects individual wind turbines and entire wind farms against threats such as data espionage and manipulation, unauthorized access, and automated break-in attempts.


OCTOBER 2015 5 1

CYBER SECURITYCYBER SECURITY

& wind farm penetrat

ions

damage to equipment that takes a long time to replace. A series of cascading catastrophic effects would follow, such as no electricity, clean water, or transportation,” says Doetzl.

To consider the consequences of an attack, just look back to several quite unintentional blackouts that have occurred since 9/11. The most significant one in August 2003 left northern Ohio and parts of Michigan, Pennsylvania, and New York, even parts of Canada in the dark for several hours to two days. That was an accident. Imagine someone trying to make mischief.

Fortunately, says Doetzl, Federal Energy Regulatory Commission (FERC) through North American Energy Reliability Corp. (NERC) has created mandatory and enforceable site security standards for the electric grid. “All of those have come

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Radiflow SCADA IDS (Intrusion Detection System) is server-based software that is said to analyze the OT network traffic to protect against cyber threats. The IDS system combines two distinct competences: SCADA/ICS modeling and Anomaly detection. The IDS receives a parallel (mirrored) stream of all network traffic and analyzes it to generate and display a network topology model, and serve as a baseline for detecting exceptions indicating unauthorized traffic. The IDS has six detection engines to cover network visibility, maintenance management, signature-based detections, virtual firewall, anomaly detection, and measuring operational behavior.


into existence with the Energy Policy Act of 2005, with the first standards effective in 2008. New standards next year will include greater portions of the bulk electric system to address cyber and physical security for electric system facilities. The Departments of Energy and Homeland security are also publishing guidance to assist with securing critical infrastructure,” he adds.

Generally speaking, there are two aspects to the topic of cyber security. “As an owner operator, you are concerned with system availability, and that it is not damaged. So a risk analysis is involved in making sure you are taking prudent steps.

For instance, it is possible to secure the perimeter of a nuclear facility and everyone that can access the critical operations within the plant. A typical wind farm, however, has many fewer employees on site and it’s typically remotely operated. But it can be secured with a proper deployment of all the remote operations using protocols, which would include robust cyber security. Shortcutting cybersecurity measures puts a facility at risk,” says Doetzl.

For wind-farm owners and operators, he suggests that: “A lot of guidance is available from the Department of Energy, National Institute of Standards and Technology (NIST), and NERC regarding properly securing systems. So start with basics. Ask: Is all remote access secured? Use encryption and secure authentication so that anyone accessing these systems must do so in a secure manner. Include security monitoring and incident response. So if something does happen, it is possible to respond quickly and prevent the incident from spreading,” he says.

Compliance to cyber security standards can be difficult. “I’d say, pick the most appropriate guidance and implement it. If you are subject to NERC compliance, then do that. If not, pick some of the more general guidance around the NIST framework. A lot sounds like eat right and exercise. It’s easy to say but difficult to do. But somebody has to manage these things and keep on top of them,” says Doetzl.

More Doetzl advice: Make sure you have patch management in place to minimize security vulnerability on a regular basis.

As head of cyber security for ABB Enterprise Software, Doetzl says his company’s interest is in making sure it offers secure products,solutions, and services.

“We must have secure development practices that ensure our products and services are as free of defects as possible when they get to the customer environment. We make sure our products are secure when delivered and then maintain the security over the lifecycle of the product through services and support.

ICS-CERT, cyber copThe Industrial Control Systems Cyber Emergency Response Team (ICS-CERT), a section of the Department of Homeland Security, is tasked with providing a controls-systems-security focus as


German security analyst and hacker Maxim Rupp, as reported by ICS-CERT, was able to penetrate several poorly designed turbine controls. The Grid Tie screen-grab he captured, from a RLE Nova 6-kW wind turbine, shows that just one selection could cause trouble for the owner. The wind-farm hazard may seem low because ICS-CERT lists only two other turbines as security risks: the U.S. made Xzeres 442SR, a 12.2 kW unit for residential applications, and the Nordex NC (Nordex Control) 2. The ICS-CERT Alert from 2013 is here: http://goo.gl/2VyjYQ





ions

COPA-DATA provides holistic cyber security and SCADA solutions for industry

4.0 and the Internet of Things.

A security engineer turned hacker and cyber-vigilante is one of the most unlikely heroes of this year’s TV summer season. “Mr. Robot” depicts the hacker lifestyle as more than just a parallel universe of today’s society. It has long since become a recurring theme in mainstream culture – no matter how different these depictions happen to be – as well as a steady threat, a constant headline fixture. Just consider the Sony hack in connection with the motion picture “The Interview”, which might or might not have been

sponsored by North Korean authorities. More recently, affair-promoting dating portal AshleyMadison.com experienced a massive data breach, releasing gigabytes worth of personal information.

There is, however, a more serious threat that gets insufficient media attention and it pertains to renewable energy systems. The risk of hacked power lines, as experts and recent studies have concluded, could be another danger with unforeseen – and unprecedented – consequences.

The threat for wind farmsIn mid-June, reports of Trojan malware spreading through the German Parliament (Bundestag) surfaced with an invitation for a conference containing phishing software, leading to stolen data from at least five computers. If the Bundestag, with its high-grade security system, is subject to data breach, what about other entities, such as energy suppliers?

German security researcher, Maxim Rupp, found several potentially critical flaws in current security systems of solar lighting systems and wind turbines that could be maliciously exploited. In one case, a hacker could have gained complete administrative access of the turbine and possibly “change the wind vane direction, or change the network settings to access the web interface that would make it inaccessible.” This security issue was given the highest vulnerability score due to the mere ease of exploitation.

Lloyd’s of London evaluates the threat of power-plant sabotage by hacking as “improbable, but not impossible.” Yet there is an energy doomsday scenario mentioning years of work implanting malware into power plant control systems all across the U.S. In case of activation, this could lead to the overload and burn-out of several

SCADA security for the power gridBernhard Schuiki Industry Specialist Energy COPA-DATAwww.copadata.com

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part of the national Cybersecurity and Communications Integration Center (NCCIC). The Team’s literature says it provides analyses of vulnerabilities and malware threats to control system environments and it offers asset owners onsite assistance and remote analysis to support discovery, forensics analysis, and recovery effort.

If there is good news, ISC-CERT reports that it and German security researcher Maxim Roop found only three wind turbines vulnerable to cyber-attack and those were small (6 to 12-kW) non-commercial units. Still, ICS-CERT makes these basic recommendations:

• Connect no industrial control system directly to the Internet.

• Place all control-system assets behind firewalls, separated from the business network

• Deploy secure remote access methods, such as Virtual Private Networks (VPNs) for remote access

• Remove, disable, or rename any default system accounts (where possible)

• Implement account lockout policies to reduce the risk of brute forcing attempts

• Implementing policies requiring the use of strong passwords.

• Baseline the organizations control networks to understand what the

“normal” communication patterns are within their environment.

• Monitor the creation of administrator-level accounts by third-party vendors (ICSA-10-228-01).

For more on what the ICS-CERT has to say, go here: https://goo.gl/r9zZRR. Or, to report intrusions call (877) 776-7585 W

Shodan finds computersThat’s not just a headline. It’s the tagline for a search engine that finds Internet facing devices, according to U.S. cyber cop ICS-CERT. The Department of Homeland Security cyber security says, almost writing ad copy for Shodan, that its “database contain devices identified by scanning the Internet for the port typically associated with HTTP, FTP, SSH, and Telent. Searches can be filtered by port, hostname, and/or country. FTP and Telnet service banner and client or server messages exchanged during long attempts, and SSH banners (including sever versions).”

One function of the site, says developer Patrick Stave, (@patstave on Twitter) is to pinpoint shoddy industrial controls. Others, however, say it lowers the technical bar needed to canvas the internet, and it is the Google for hackers.

Shodan finds computers, says the Shodan website (shodanhq.com), to expose online devices such as webcams, routers, power plants, and….wind turbines. Even ICS-CERT recognizes the capability of the website and cautions that if Shodan can find your computers, bad guys can too.





ions

plants across the country, with a potential cost ranging from approximately $250 billion to nearly $1 trillion.

How big a target are wind farms?In a recent AWEA blog, David Ward showed that American wind plants use up-to-date, sophisticated security methods. As in most other power plants, wind plants use SCADA (supervisory control and data acquisition) systems. Power conversion in turbines provides an additional buffer or firewall between the generator and the power system. As an additional incentive, wind and power plants have commercial reasons for protecting their systems: nobody wants to see their strategies fall into the competitor’s hands. Ward believes that hackers consider wind plants too small to target, but with renewable energy constantly increasing its market share and therefore gaining importance, isn’t this bound to change soon?

Security software developer Klockwork Inc. provides a different outlook and has found a common, remotely exploitable flaw in a certain wind-turbine software. Software development information is publicly searchable and, technically, open to everyone. Having a solution developed and in place can take a lot of time, and it might not even be the permanent answer – a problem certainly not exclusive to the software in question. There are also reports of system updates targeted by hackers in various branches of business. Why not in wind farms, too?

Red Tiger Security conducts penetrating testing and vulnerability assessments on production control systems. The company’s Jonathan Pollet believes that SCADA security matters greatly and perceives its users as the main risk. He believes that, more often than not, engineers and system integrators lack sufficient skills to implement and maintain security in their SCADA systems. This makes the bridge between the company network and HMI network extremely vulnerable. According to a Red Tiger SCADA vulnerability study, it comes as no surprise that the average time from discovering to publicizing flaws and security breaches is a much-too-long 331 days, with the worst case exceeding three years. Certainly, cyber security warnings and issues are everything but a one-and-done issue.

Areas most at risk Which areas are particularly at risk of hacking threats? With renewable energy continuously on the rise, HVDC (High Voltage Direct Current) power lines could become the “umbilical cords” of energy transfer. With a loss of only 3% per 1,000 kilometers, HVDC lines, in the future, could bring solar energy from the Sahara desert to Europe, but are also becoming more widely used for power plants all around the world, including wind farms. Naturally, they must be extremely well-monitored. SCADA systems are currently employed to ensure the safety of these near-lossless power lines, but they aren’t enough.

Directly hacking these power lines might not really be the issue, yet the danger lies in software bugs and flaws left wide open with little to no security measures.

Attacks could bring HVDC lines down, leading to one of Lloyd’s of London’s energy doomsday scenarios, namely severe loss of power to large metropolitan areas. These attacks could also go in another even more punishing direction. Hackers might be able to reconfigure the entire energy gain system and program turbine reversals. Doing so would not just harm the system, but it could even damage or destroy the wind farms by merely changing the direction in which the turbines revolve. The result: weeks and months of power cuts, plus millions and billions of dollars in repair costs.

Increasing and maintaining security SCADA security matters greatly, even though it might not always be enough and must be supported by additional security measures and security experts. In addition, SCADA engineers should regularly monitor, update, and re-protect the system from potential threats. Furthermore, it is key to run regular checks to find, identify, and eliminate potential flaws. A Department of Energy report assessed the weaknesses of current industrial control systems for cyber-security and found a great number of devastating bugs and grave errors throughout countless different industry branches. The DOE concluded with a number of basic security recommendations.

Among the most basic recommendations was the creation of a security culture. Reports from Red Tiger Security’s Pollet have shown that a shockingly great number of “regular” SCADA administrators everyday use default, generic, and surprisingly easy passwords to protect increasingly flawed systems. Network protocols must be redesigned for security criterion before it is possible to implement and test further measures, such as highly advanced encryption mechanisms and strong authentications. Storing data in binary code and eliminating SQL servers while the program is running are equally vital, as is the separation of application from engineering.

It’s time to act If the preventive measures seem impossible to implement, consider assistance from skilled security officers familiar with such measure and other methods. The time to act – and to hire

– is now. While some experts believe that wind energy has yet to become an important enough target for cyber-terrorists, you cannot be sure whether or not the seed for an even bigger threat has already been planted and should be removed, ideally three weeks ago. Even if hacking threats are yet to reach wind farms, it is better to be safe than sorry. As your mother so rightfully advised: a stitch in time saves nine.

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E Q U I P M E N T

Wind-flow modeling Cancalia Engineering & Consulting, LLCwww.cancalia.com

Software developer, Cancalia, has updated its wind-flow modeling software. Continuum 2.0 arms wind-

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Ultrasonic wind sensorNor-Cal Controls Energy Solutionshttp://norcalcontrols.net

Traditional wind sensors can accumulate rust, scale, or other substances, and they are subject to

mechanical breakdown and periodic repairs or replacement. Nor-Cal Controls Energy Solutions has

responded with a product that reduces related maintenance costs for wind-project owners and operators.

The WindBridge signal converter is configured to let newer technology sensors seamlessly integrate into

an existing wind-turbine control platform, no matter the age, type, or communication characteristics of

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combines the intelligence of a specially configured device with the reliability of the VENTUS wind sensor.

Bearing replacement made easyWinergy www.winergy-group.com

Until now, when a bearing of the

planet carrier in a gearbox needed

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service company, Winergy, has developed a new, more

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new fixtures helps cut repair expenses for operators and

shorten a wind turbine’s downtime.

WPE_Equipment World_10-15_Vs1.indd 56 10/7/15 12:18 PM

E Q U I P M E N T

Hazardous vapor protection3Mwww.3M.com/servicelifeindicator

Using a respirator cartridge beyond its service life can endanger workers and

lead to regulatory violations. 3M has launched a new line of organic vapor

respirator cartridges with a Service Life Indicator. It serves as an end-of-service

life warning that visually signals users when a cartridge has expired. To check if

a cartridge needs changing, workers can simply peel back a removable sensor

protector and view the indicator bar when in the appropriate environment.

The indicator can also help optimize cartridge change schedules because it

indicates service life based on individual exposure and breathing patterns.

The 3M Service Life Indicator can complement a company’s current respirator-

cartridge-change schedule or, in some cases, replace it.

WPE_Equipment World_10-15_Vs1.indd 57 10/7/15 12:18 PM

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Acradyne ......................................................................................45AeroTorque .................................................................................... 5AMSOIL Inc. ............................................................................... IBCAWEA .............................................................................................59Aztec Bolting Services, Inc. ......................................... Cover, 19 Bachmann Electronic GmbH ................................................... 41Campbell Scientific, Inc. ...........................................................29Castrol Ltd. .................................................................................. 15Dexmet Corp. .............................................................................. 17EDF Renewable Energy, Inc. .................................................... 51Gradient Lens Corp. ...................................................................47Hamburg Messe ........................................................................25Hy-Pro Filtration ........................................................................33HYTORC .......................................................................................35Indji Systems, Inc. .........................................................................8Mattracks, Inc. .............................................................................. 3Moog, Inc., Components Group ........................................... IFCRenewable NRG Systems ........................................................BCVaisala Inc. ....................................................................................11Women of Wind Energy ............................................................ 57

A D I N D E X

5 8 WINDPOWER ENGINEERING & DEVELOPMENT OCTOBER 2015

Ad Index_10-15_Statement of Ownership_Vs1.indd 58 10/7/15 5:08 PM

THE AWEA WIND ENERGY FALL SYMPOSIUM SETS THE STAGE

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Storm-surge barrier also serves up tidal powerIN EARLY 1953, high tides and a major storm caused the North Sea to flood. The Netherlands, Belgium, and even parts of England and Scotland were affected. Recovery efforts eventually included the construction of an impressive nine-kilometer-long dam to prevent future flooding in the region.

Oosterscheldekering, or the Eastern Scheldt storm-surge barrier stands as the largest of the world-renowned Delta Works series of dams and storm barriers. It was initially designed as a closed dam but, after much debate, massive gate-like doors were installed in the last four kilometers of the barrier to let fish and sea life pass through much as before. When necessary, such as in the case of severe weather, these gates can close to prevent water from overflowing or surging on land.

Today, the Eastern Scheldt is doing more than giving sea life visitation privileges and protecting the Netherlands from potential flooding threats of the North Sea. The fast-flowing waters of the Eastern Scheldt estuary are proving an ideal source of clean tidal energy. As of late September of this year, five tidal turbines have been installed in the barrier, representing the largest tidal energy project in the Netherlands and the largest tidal array in the world.

“With our turbines in the Eastern Scheldt storm-surge barrier, we can now show the world what tidal energy is all about: providing a clean and reliable source of energy that could fulfill 10 to 20% of the world’s electricity needs,” said Tocardo Tidal Turbines’ CEO Hans van Breugel in a recent press release on the project. Tocardo designed and produced the free-flow water turbines for the dam. The array of five turbines has a total capacity of 1.2 MW.

Beyond making a global clean-energy mark, the five-turbine array is also expected to provide a significant source of Dutch export business, with a potential worldwide generation of more than 200 GW.

This is good news considering construction of the project was no easy feat and did not come cheap at a reported $12.4 million. But Tocardo and the designer, builder, and financial supporter of the turbine’s suspension structure, Huisman, didn’t miss a beat. Together, the two companies along with a host of Dutch businesses completed the project in a record time of nine months.


Before installation, the pre-engineered 50-meter long and 20-meter wide tidal structure had to be transported over water to the work island of Neeltje Jans. Using the slides of the storm-surge barrier, the tidal-power plant was placed on a floating pontoon with makeshift lifters installed between the pillars and under the surge barrier. Weather, water levels, and the ebb and flow of the tides each required continual monitoring to ensure safety.

Once weather conditions proved just right, engineers had an installation window of just two hours to carefully mount and connect the tidal power plant.

“This project marks an important step in the development of tidal energy,” said van Breugel, who noted that Tocardo has plans to eventually increase the number of turbines on the site.

The project was the result of many efforts, which included funding from the European Regional Development Fund, the Dutch government, and the province of Zeeland as part of the Operational Program for Zuid-Nederland.

The province of Zeeland, surrounded by water, provided significant expertise. “The knowledge that we’re building here can be used in other delta regions across the globe,” said provincial representative Ben de Reu. “Tidal energy is the future…of that I am convinced.” W

The array of tidal turbine is mounted behind a storm gate. The

barrier is operational at all times.

The array of five Tocardo Tidal turbines is rated for 1,200 kW. The units operate with water flow in either direction

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windpower engineering & development october 2015

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