Power & Energy Solutions

The premier renewable energy publication

Synergies are better than my way or your way. It is an efficient combination and results in our way. The last years in the offshore wind industry, which is similar to oil and gas, have shown that each project and/or location has its own, individual logistic concept and needs an exclusively chartered vessel or even vessels. To reduce cost and increase efficiency this concept has to be questioned. Alternative solutions such as vessel pooling or shared logistic runs might be an alternative option to establish. First concepts are on the trial and wind park owners are willing to forward responsibilities to their suppliers having more clients and therefore the possibility to share vessel cost over a few projects. Looking back to the beginning of offshore wind, specialised vessels were rare and mostly found in the oil and gas industry. The high priced tonnage made it difficult for the wind farm owner to find an economical business plan in other words - the whole industry was pioneering its way through the tangle of the offshore wind jungle. Subsidised parks were developed and soon became the test areas for all kind of trials. Starting with simple environmental experiments, on site as well as onshore and with

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Six years ago, ZF Wind Power took the challenge to set the benchmark in the industry pioneering wind gearboxes to power the new giants of the sea. The project started with an early cooperation between the customer and ZF with one main focus: reliability. Dr. Dirk Strasser, Manager Wind Gearbox Design at ZF Wind Power, Witten, shares his reflections with PES, on the project from an engineering perspective and points out the resultant benefit for the customer.. Development projects for the wind industry usually are characterised by short development times and gearboxes developed to specification. The 8 MW development started with a different focus. A reliable drivetrain at competitive costs was the objective, with reliability being recognised as one of the most important contributors to the turbine’s competitiveness. Before starting detail design, ZF cooperated closely with the customer in order to cover all gearbox requirements in the interface specifications. This means, on the one hand, a sound mechanical design on the rotor side, delivering a mechanical torque of minimum 8,000 kNm whilst keeping parasitic loads small, and on the other hand, meeting mechanical and electrical requirements on the generator side prescribed by the integrated drivetrain layout.

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WAB is the leading business network for the wind industry in Germany’s northwest region and the nationwide contact partner for politics, media and industry for offshore wind power in the country. Projects such as “Inn2POWER” clearly show that WAB is also active in Europe, on behalf of its 350 members, in the wind energy sector. “We have a very heterogeneous membership structure. It covers every aspect of the wind industry, ranging from very small start-up businesses to research institutes and major energy suppliers,” said Andreas Wellbrock, managing director of WAB. WAB’s members are involved in project development, financing, insurance, manufacturing - foundation structures, towers, nacelles and rotor blades - logistics and installation, grid connection, service and operation as well as dismantling and repowering. WAB therefore is always able make up-to-date and first-hand information available to its members on current issues. A recent example of this is the network’s interest in wind-to-gas technology, the exploration of opportunities for its development and research on its market potential for the wind industry. The 5th WINDFORCE Baltic Sea conference was held in February this year in Tallinn, Estonia and proved a resounding success. “WAB is also present where exciting new markets are emerging. At its

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While German wind turbine manufacturers have become active in nearly all markets in the world, in Germany it is facing a profound upheaval. Now that renewable, decentralised energy transition technology has become a major pillar for power generation in this industrial nation. Matthias Zelinger, Managing Director of the Power Systems trade association and VDMA (German Mechanical Engineering Industry Association) gives PES the benefit of his insight. Since the beginning of the year the federal government has started organising the expansion of new installations by implementing a tendering system, following a major, international trend. This increases competition and cost pressure, along the process chain. At the same time, they are striving to achieve fair conditions on the world market and develop a new integrated energy system in Germany. The expansion of wind energy in Germany was very successful over the last three years. 2016 saw a capacity increase of approximately 4,600 megawatts onshore and 800 megawatts offshore. With more than two gigawatts going online, 2015 was a record year for offshore wind energy. The reason for this great leap was in fact due to a delay: the completion of a number of offshore grid connection points in 2015 meant that an unusually large

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At PES we know that maximising uptime and reducing costs are essential to the offshore wind power business. Semco Maritime helps offshore wind farm operators do exactly this by offering full service and maintenance concepts for offshore substations and wind turbine foundations - the so-called transition pieces. Semco Maritime helps offshore wind farm operators maximise uptime and drive down operational costs by offering full service and maintenance concepts for offshore substations and wind turbine foundations, the so-called transition pieces. It is simply good business to have a pro-active approach to maintenance because it prevents break-downs which cause costly downtime during repair. ‘After building and commissioning more than 20 offshore substations in the North Sea area we discovered a gap in the market. We found that offshore wind farm operators spend much time and energy on coordinating the work of a large number of service providers. Therefore, we are now offering a full scope service concept whereby we release time and resources for the operator enabling him to concentrate on the operation of the wind farm,’ says Bjarne Christensen, Director of service operations at Semco Maritime.

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Words: Al Maiorino It seems the US is finally being blown away with the idea of wind power. At last traditional forms of energy are being reviewed and clean, sustainable wind energy is being taken seriously. There is to be a 200 turbine windfarm off the coast of Long Island. “Today is a big day for clean energy in New York and our nation. Governor Cuomo has set a bold vision for a clean energy future, and this project is a significant step toward making that a reality. The South Fork Wind Farm will be the second offshore wind farm in America, and it’s largest. There is a huge clean energy resource blowing off our coastline just over the horizon, and it is time to tap into this unlimited resource to power our communities.” said Deepwater Wind CEO, Jeffrey Grybowski, in an empowering speech following the approval of a revolutionary project. In light of much discussion over climate change, it has become imperative to reassess conventional forms of energy sources such as fossil fuels and make changes. There is a need to provide energy that is replenished naturally, offers climate change mitigation, and adds economic benefits on various levels. In response

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PES invited award-winning Scottish technology company PhotoSynergy Ltd (PSL) to give us an insight in to their suite of new products, produced in response to industry led requests to find practicable, cost-effective solutions in a variety of sectors where safety of life is paramount. The company, in collaboration with a number of key technology partners, continues its focus on increased safety and productivity through innovative forms of illumination based broadly on its ground-breaking LIGHTPATH™ technology, a fibre lighting system offering an innovative technical solution. In January this year, PSL and Livingston-based WFS Technologies launched the Seatooth LIGHTPATH™, an on-demand wireless ribbon lighting system designed to revolutionise diver safety and efficiency in remote subsea locations. The system is a combination of two advanced technologies – WFS’s Seatooth, a subsea wireless communication system that can download and log information gathered on subsea installations remotely and PSL’s LIGHTPATH™, a side-emitting flexible fibre that projects a continuous line of light that carries no electrical power – and works for both diver and ROV operators, working either near surface, or at depths of up to 3,000m. The light is engaged automatically when the diver or the ROV comes within 5m of a structure, and provides

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Words: Gerry Lalonde, CEO, Orenda Energy Solutions. Planning consent is still grey area for the small/medium wind turbine market and it is about time we had consistency and predictability rather than disparate decision making that often blights and inhibits progress across the UK. It has been known for years that planning authorities decision making varies depending on location and geography which might make anyone but the most determined user look at other renewable schemes that offer an easier pathway to energy self-sufficiency, when wind energy ticks many boxes in terms of its appeal – grid friendly with no grid structure required, unobtrusive, as well as offering revenue and investment opportunities. In my view, that’s why we need to shake off the planning shackles because, as the energy industry in the UK continues to evolve, small/medium wind can be pivotal as the ‘driver’ as the scheme of choice particularly for farmers and private landowners. Turbines at this level, around the sub-50kW mark, are vital to maintain this continuous drive to underpin the UK’s small-scale renewable needs. Even the Chief Executive of the National Grid, Steve Holliday, was on record in a recent interview stating that ‘’by 2020 small-scale, distributed generation will represent a third

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What is torqueing and why is it important to be able to record it? PES finds out from Norbar, the torque tool specialists. In this context, torqueing is principally the measured application of rotational force to a threaded fastener. When the torque is either under or over the manufacturer’s specification, it can cause considerable damage to the turbine structure. Protecting against this risk should be of primary importance so the health and safety of operatives and the life expectancy of the turbine are safeguarded. The extent of the damage from inaccurately applied torque can vary substantially. The potential for vibrations occurring in the turbine is perhaps the most crucial technical implication of over or under torque. Any vibration presents a real risk of calamitous failure. Maintenance operatives across many windfarms need to use an assortment of tools to finish the job. In the turbine tower for example, an operative may need one tool to run down the bolts plus a hydraulic wrench to achieve final torque. Using these two tools present a number of potential complications, particularly regarding ease of operation and manoeuvrability. Subsequently health and safety is a significant concern. Therefore having the ability to record the torque data from tightened joints

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During October 2015 Moventas Gears, the wind turbine gearbox specialist headquartered in Finland, made an investment decision, which now supports customers all around the UK and central Europe. The 3.6MW Full Load Test Bench & Final Assembly workshop was commissioned in Huddersfield, in August 2016. Supported by the UK government, the Huddersfield upgrade was part of a Regional Growth Fund initiative. All gearboxes serviced at Moventas go through a proven test run process regardless off the gear type or size. This is a Moventas internal and essential quality standard and usually also a customer requirement. Refurbished gearboxes that have gone through partial load or spin test can also have the option to be full load tested; if there has been major component change or modifications in the design, the full load test is a must. Moventas has a range of test benches dedicated to the serial production and service workshop requirements covering kW and MW drive trains. The difference between full load test and partial load or spin test The main purpose for the traditional full load test run is to guarantee successful component manufacturing, refurbishment and assembly process. The test run itself is not to improve quality – it is a

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