PES Wind Issue 1 2017

Ingeteam Daniel Perkowski Daniël Dubbelhuis Matthias Zelinger Excited about the prospects for CEO at Wind Audit sp. z o.o. Account Manager Netherlands, Managing Director of the wind energy in India at Lagerwey Power Systems trade association and VDMAWIND Tools are getting smarter, new floating cranes are appearing in the industry, plus is chartering possibly a better option? As always, we preview the AWEA WINDPOWER 2017 event and the WINDFORCE 2017 conference in Bremerhaven. PLUS other exclusive articles and our ever popular interviews with industry leaders...POWER AND ENERGY SOLUTIONS • ISSUE 1, 2017INDUSTRY ONTHE MOVEIn the United States a 200 turbine offshore wind farmis being built and Germany is heading for new planningapplication legislation … we delve deeper to bring youfurther insight …

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EDITOR’S NOTE Ingeteam Daniel Perkowski Daniël Dubbelhuis Matthias Zelinger Excited about the prospects for CEO at Wind Audit sp. z o.o. Account Manager Netherlands, Managing Director of the wind energy in India at Lagerwey Power Systems trade association and VDMA WIND Tools are getting smarter, new floating cranes are appearing in the industry, plus is chartering possibly a better option? As always, we preview the AWEA WINDPOWER 2017 event and the WINDFORCE 2017 conference in Bremerhaven. PLUS other exclusive articles and our ever popular interviews with industry leaders... POWER AND ENERGY SOLUTIONS • ISSUE 1, 2017 INDUSTRY ON THE MOVEEditor’s note In the United States a 200 turbine offshore wind farm is being built and Germany is heading for new planningCan you believe it is already 2017? application legislation … we delve deeper to bring you further insight …The year has kicked off to a good start, despite the political uncertainty andwith BREXIT a reality. In fact at the time of going to print the Prime Minister, POWER & ENERGYTheresa May has just triggered article 50, so we will be following the changes SOLUTIONSover the next 2 years. It’s sure to be a bumpy ride. Europe, at the momentdoesn’t seem too keen on free trade with the UK – the wait and see continues. Directors Stuart GilliesSo an industry on the move seemed an apt title in these fast changing times. Mark SmithEfficiency is improving; prices are at an all-time low, new and bigger Stefann Perrigottransport possibilities, enhanced technology and more, all form the backdrop of this edition. Client Liaison Manager Vikki BirchThe AWEA WINDPOWER will be back in Anaheim, California, this year fromthe 22nd to 25th May. This is the event of the year for the US wind industry – a Editorplace to network, learn and do business. We hope to see you there. Elaine Perrigot [email protected] WINDFORCE event in Bremerhaven from the 9th to 11th May, will focus onthe tendering system for offshore wind power in Germany. This is very Associate Editorscontroversial and we will be hearing more about this as time goes. Stephen Pearson Zachary GeorgeAs usual we bring you a variety of topics from the importance of torqueing andrecording, power ascenders and their use in reaching difficult spaces and Designhelping in rescue operations, thoughts on the state of the industry from GWEC Andrew Jenkinsand many other advances and innovations. [email protected] have yet to see the effects of a possible new energy policy coming out of Productionthe US. However our feeling is that currently, our industry is ready to deal with Paul Lawsonanything. The leaders in the sector that we have spoken to are confident about [email protected] future. Sales EnquiriesTake a seat, grab a coffee, relax and enjoy the read. [email protected] Perrigot General EnquiriesEditor [email protected] Media Partnership Enquiries [email protected] Advertising Opportunities [email protected] PES is published by P&G Media Ltd P&G Media Ltd PO Box 310, Bristol, BS10 5WT, United Kingdom This publication is copyright © 2017 P&G Media Ltd and may not be reproduced or transmitted in any form in whole or in part without the prior permission of P&G Media Ltd. While every care has been taken during the preparation of this publication, P&G Media cannot be held responsible for the accuracy of the information published herein or any consequence arising from it. From sustainably managed forests. For more information visit: www.pefc.org www.peswind.com www.peswind.com 3

CONTENTS40 Ingeteam 104 Wind Audit Sp. z o.o. 8 Lagerwey Clean Energy on Daniel Perkowski Making wind farms India’s horizon explains how to best community friendly, we reduce O & M Costs… welcome Daniël Dubbelhuis Ingeteam Daniel Perkowski Daniël Dubbelhuis Matthias Zelinger 96 VDMA… Excited about the prospects for CEO at Wind Audit sp. z o.o. Account Manager Netherlands, Managing Director of the A glimpse into the future wind energy in India at Lagerwey Power Systems trade association and VDMAWIND Tools are getting smarter, new floating cranes are of German wind, with appearing in the industry, plus is chartering possibly a better option? As always, we preview the AWEA Matthias Zelinger WINDPOWER 2017 event and the WINDFORCE 2017 conference in Bremerhaven. PLUS other exclusive articles and our ever popular interviews with industry leaders...POWER AND ENERGY SOLUTIONS • ISSUE 1, 2017INDUSTRY ONTHE MOVE 18 In this issue’s lead feature, we hear from Al Maiorino, the President of Public Strategy Group, Inc, as he talks all matters US wind.In the United States a 200 turbine offshore wind farmis being built and Germany is heading for new planningapplication legislation … we delve deeper to bring youfurther insight …Comment 60 PES hears from Holmatro regarding Corporate focus6 Looking at the problems of red tape hydraulic solutions for the offshore 13 PES heads to Germany to learn more wind market within the wind planning sector about WAB, the leading business 70 PES invited award-winning Scottish network for the wind industry inConference Call Germany’s North West region technology company PhotoSynergy10 As usual, we are excited to look Ltd (PSL) to give us an insight into 32 PES is pleased to be joined by Peter offshore safety ahead and preview the Annual AWEA Hearn, Operations manager at Windpower 2017 event in Anaheim Ask the experts ActSafe, as he discusses making wind energy maintenance more efficientPES Essential 22 We are pleased to welcome back 49 We hear from Acotec regarding a36 We hear from ALE, who are developing Raymond Fisch, SVP at BBC Chartering, a regular contributor with revolutionary coating repair system smarter solutions for the challenges PES, read his latest interview here created with the increasing size of 57 We are delighted to welcome back turbines and components 78 H arald Hohlen, Senior Wind Moventas with their regular feature on44 Z F Windpower explains powering the Measurement Specialist at ROMO gearbox testing Wind, caught up with PES to talk about new giants of the sea improvements in iSpin technology and the Performance Transparency Project4 PES Wind

CONTENTS3244 8464 We look at the growing importance of 82 From competitor to partner – a must 100 We are delighted to welcome Geoffrey offshore accommodation – courtesy of in the quest for survival & success – a Taunton-Collins, weather risk analyst, ELA Container GmbH viewpoint from the Climate Academy GCube underwriting Ltd.93 S emco Maritime discuss the value of 84 R ay Faulkner of iRed tells us about continuous preventive maintenance the role of UAVs within the renewable energy sectorTalking Point 88 PES welcomes back Steve Sawyer,27 Conquest Offshore discusses surge Secretary General at the GWEC, for his towards large floating cranes outlook on the Industry39 AIMCO gives us the lowdown 108 Offshore wind turbines and the regarding some of their latest bolting technology that powers them – learn technology advancements more courtesy of HUBER + SUHNER.74 PES brings you the latest from widely Think Tank respected industry pioneer Kurt E. 54 SeaRenergy looks at logistic synergies Thomsen – a must read! in offshore wind projects www.peswind.com 5

COMMENT: PLANNINGUK wind red tapeplanning headacheWords: Gerry Lalonde, CEO, Orenda Energy SolutionsPlanning consent is still a grey area for the small/mediumwind turbine market and it is about time we had consistencyand predictability rather than disparate decision making thatoften blights and inhibits progress across the UK.Gerry Lalonde unobtrusive, as well as offering revenue and hybrid/micro-grid solutions. investment opportunities.It has been known for years that planning Moreover, recent ‘State of the Industry’authorities decision making varies In my view, that’s why we need to shake off figures from the same source revealed thatdepending on location and geography the planning shackles because, as the the small and medium wind industry alonewhich might make anyone but the most energy industry in the UK continues to delivered 391GWh and saved 168,257determined user look at other renewable evolve, small/medium wind can be pivotal tonnes of CO2. This is a hugely significantschemes that offer an easier pathway to as the ‘driver’ as the scheme of choice figure for a sector that employsenergy self-sufficiency, when wind energy particularly for farmers and private approximately 3500 people in the UK.ticks many boxes in terms of its appeal – landowners. Turbines at this level, around (source: RenewableUK)grid friendly with no grid structure required, the sub-50kW mark, are vital to maintain this continuous drive to underpin the UK’s There is clearly potential to unlock and small-scale renewable needs. exploit great opportunities within the sector, but ask any farmer or private Even the Chief Executive of the National landowner looking to utilise their own land Grid, Steve Holliday, was on record in a for the purposes of self-sufficiency in wind recent interview stating that ‘’by 2020 power generation, if the planning and siting small-scale, distributed generation will of the turbine was straight-forward and you represent a third of total capacity in the UK, will often be regaled with tales of planning a quadrupling in just a few years. It red tape and bureaucracy. It clearly represents a massive increase from the old frustrates and often hampers progress days of centrally dispatched generation…..’ when the land is privately owned and doesn’t impinge on anyone outside the The case for small/medium distributed wind farmer or landowner’s perimeter fence. is a compelling one. A recent Scottish Renewables report suggested that small It remains unfair, that someone wishing to and medium wind turbines help businesses install a solitary small wind turbine, on his hedge against future electricity costs and land for electricity self-generation, should help communities generate their own be hampered by a cumbersome and energy. The sector provides significant protracted planning application system. numbers of jobs in the UK including There should be a point at which small wind manufacturing and assembly and most and big wind planning applications are importantly, the sector is incredibly treated differently, but largely, they are not. innovative – with new technology, new Currently both small wind and large wind behind-the-meter business models and planning applications are tossed into the6 PES Wind

same basket and whilst the former is for private use, the latter has COMMENT: PLANNINGsignificant commercial benefits to an energy utility company. www.peswind.com 7Planning authorities should be distinguishing between planninglaws for small wind turbine applications – those below the 50kWbandwidth – and their much larger megawatt cousins that clustermuch of our landscape, but this isn’t a uniformly accepted doctrine.Planning regulations vary too much. The approach is too disparate.There are differences depending on which environmental planningoffice you speak with, so isn’t it about time a concerted effort waschannelled into making this system easier especially for farmers andprivate landowners who wish to erect small/medium turbines fortheir power generation?It is easy to understand why farmers and private landowners maydecide that installation isn’t worth the bureaucratic hassle,especially when “small” units of distributed generation don’trequire major infrastructure upgrades to any road network or thegrid, like many large installations.Small/medium turbines can simply plug into the grid as soon as theyare sited. What’s more, these largely singular, solitary, small/mediumwind turbines are usually located in areas that don’t have thecumulative visual or environmental impact of the big wind farms.Look across Europe and you’ll see a robust, yet unburdenedapproach. Planning for small/medium wind turbines in Italy isgoverned by tight regulation, but their process is far quicker and isnot weighed down by a sluggish and tiered administrative process.For turbines up to 60kW, the Italian Ministry for the Environmentand Territory requires GPDO – General Purpose DevelopmentOrder documentation to enable a small/medium turbine to be sitedand installed. It’s a relatively straight forward process, carried outwithin a set timeframe.Moreover, we run the risk of lagging behind the rest of Europe inthese matters. And, if we are to be on target and in line with thegovernment’s renewable strategy over the next few years, we needto do more to align our thinking on planning applications acrossthe country. In other words, we need consensus.Even stringent matters in the UK such as certification forEnvironmental Impact Assessment could well be valid for a solitarysmall wind turbine, as it would for a much larger scale wind farm!I think a great opportunity is being missed here. Those wanting toinstall small and medium wind turbines can create hybridrenewable energy systems with solar or biofuel, creating even morepossibilities for self-sustainment.The price of conventional energy sources, especially fossil fuels, isconstantly rising, whereas the costs of small wind, in particular, areshowing a gradual decline, emphasising the attractiveness of thesetechnologies, however, local planning consent needs to beadjusted, so more landowners and farmers can an option to adoptthese initiatives.Let’s hope a standardised approach in planning consent lawshappens. We need to accelerate specification changes toencompass small/medium wind turbine applications and not have auniform – ‘one size fits all’ approach to wind turbine applications,as is currently the case.Gerry Lalonde is Chief Executive Officer for Orenda Energy Solutions. www.orendaenergy.com

COMMENT: CO-OPERATIONThe co-operativewind turbineA new innovative approach to windfarms could, at last, makethem more popular and community friendly. Bringing thebenefits and the profits home to local communities. DaniëlDubbelhuis, Account Manager Netherlands at Lagerwey tellsus how. Daniël Dubbelhuis Large multi megawatt parks in The future is in locally rooted wind farms. concentrated areas developed by Of course it is still necessary to explore a8 PES Wind anonymous big developers - ensure further municipality or region fully, to find the best anonymization of wind turbines. Local place, but in my view we have to develop residents feel that they get saddled with a wind turbines with and in local problem that they have not asked for, communities, who consequently will receive resulting in a growing resistance to on land the benefits. Wind development has an wind turbines. often forgotten social aspect and historically that is nothing new. Centuries The last 10-20 years have shown how not to ago, there was the community mill. The mill develop wind projects. The parties in a village or town ground the flour for the ultimately end up in court, each trying to community, sawed wood and kept our land get their own way. In the meantime dry by pumping water. Everyone benefited sustainable energy becomes a conflict from this mill. This aspect should return and between developers and local residents. the wind turbine becoming a connecting element within the community. Not Why do we develop both large and small wind something that divides it. farms in this way? Why with each project achieved do we create more resistance to We see more and more local initiatives. wind power? Shouldn’t the sustainability People are enthusiastic and motivated to aspect also be reflected in the relationship take energy production into their own hands between all the actors in a project? and they understand the benefits of being a turbine owner. All citizens, including farmers From these thoughts a new concept is being and locally based companies, pick up the designed by us at Lagerwey. It is the gauntlet, often in close co-operation with co-operative wind turbine, where the each other. But with that enthusiasm alone, manufacturer not only ensures a perfectly no wind project will get off the ground. A working wind turbine, but also takes a role in wind project development has several strengthening relationships and involvement phases. Especially in the early stages, even in the development area. Additionally, the now, many projects do not make it. There intention is to help the people in the vicinity, will be serious legal, financial and technical both as a client and as the ultimate owner of issues in the process. Smaller initiatives are its own wind turbines. not always able or willing to do this alone.

COMMENT: CO-OPERATION ‘We want to focus on supporting local initiatives - that’s a win-win situation for all parties. We believe more local projects will come off the ground. We hope to be the supplier of these projects and the communities will benefit, not only from producing its own renewable energy, but also gain an economic advantage’At Lagerwey, as a turbine manufacturer, as a guide, without taking over the project.we have ourselves struggled for some time The ownership and benefits have to remainover how we can contribute to this with the co-operation or local initiative.movement from the bottom up. We do notown parks. But we are involved in all The financing of wind projects deservesprojects, throughout the entire process. special attention. The needed financials runThere’s a lot of experience and more quickly in to the millions and as the costimportantly, a rich network. We want to mounts, a smart and reliable construction isfocus on supporting local initiatives - that’s needed to deliver the benefits. Lagerweya win-win situation for all parties. We has contacts with parties that develop andbelieve more local projects will come off offer innovative solutions for this, such asthe ground. We hope to be the supplier of crowdfunding, participation projects andthese projects and the communities will low interest loan schemes. In addition,benefit, not only from producing its own there are private investors (including windrenewable energy, but also gain an mill owners) who want to invest their moneyeconomic advantage. in green, sustainable, new wind projects.We also want to bring wind turbines So Lagerwey itself remains involved inliterally closer to the people. For example setting up a project, providing advice andwe do this through guided tours in our expertise. We cannot develop the project,factory in Barneveld, making wind turbines but will advise and bring the necessaryless detached and anonymous. expertise needed to create a socially and economically successful project.How does it work exactly? Lagerwey bringsso-called ‘kitchen table developers’ and For now the concept will be tested in thelocal stakeholders together and gives Netherlands and strengthened further,advice during the first phases of the wind tailored to fit the needs that exist withinproject. Kitchen table developers, meaning co-operations and local initiatives. Afterwind professionals, who have years of that the concept will be examined and beexperience in the implementation of smaller rolled out in other countries wherewind projects and often locally supported. Lagerwey operates.They also believe in the power of theprojects supported by the bottom up drive, Lagerwey will launch the initiative thisincluding finance and managing. They work spring. More information will soon be available on www.lagerwey.com www.peswind.com 9

CONFERENCE CALLPhoto credit: GreenVenueReport.comAWEA WINDPOWER 2017The American Wind Energy Association is heading back to growing small businesses, andCalifornia for the biggest wind energy event in North participating in forward-thinking sessions,America, WINDPOWER®. PES brings you the latest you will find anyhting you need at theinformation on this unmissable event. largest annual conference for the U.S. wind energy industry.If you are invested in U.S. wind energy or Attendlooking to enter the market, AWEA Join over 7,000 wind industry professionalsWINDPOWER 2017 Conference & Exhibition WINDPOWER is mainstream. WINDPOWER May 22-25 in Anaheim, California at theis the place you need to be. It is where is big league, and AWEA WINDPOWER largest annual wind energy conference inprofessionals from across the globe find Conference & Exhibition is where new North America. Given the industry’s growth intop-tier speakers, world-class education, opportunities are waiting to be discovered. 2016, AWEA expects this year’s event to becutting edge technology, and premium another significant opportunity for garneringnetworking. This complete conference By meeting face-to-face with thousands of relationships and developing business.experience cannot be found anywhere else. industry professionals, developing relationships with leading wind energy Network companies, exploring potential with new or WINDPOWER brings a variety of networking events to help you foster positive business relationships in engaging environments.10 PES Wind

REGDIOSN’TT DEELRAY. WISIBNIDGPLOEAWGEURE TODAY! WIND is an American resource creating American jobs. WINDPOWER contributed more new electric generating capacity in 2015 than any other source. WINDPOWER is on a path to generate 10% of American electricity by 2020. WINDPOWER is the choice of iconic brands like Google, Microsoft, Amazon, Walmart, General Motors, IKEA, and Yahoo! to name just a few. WINDPOWER has a Brand New Attitude. And AWEA WINDPOWER – the largest North American wind energy trade show -- will introduce our Brand New Attitude in Anaheim, California this May. Don’t miss it!www.windpowerexpo.org

CONFERENCE CALLShow floor at WINDPOWER 2016 in New Orleans, Louisiana, USAShow floor at WINDPOWER 2016 in New Orleans, Louisiana, USA energy industry, it’s essential to know what’s on the horizon for the U.S. windWhether during a reception, on the golf by over 100 expert speakers and panelists, energy market, how to influence it, and howcourse, or at a special luncheon, you’ll have including top CEOs and Presidents. to ensure success across the industry.an opportunity to take full advantage of That’s why the education program atwhat WINDPOWER in Anaheim has to offer You’ll meet new members of the industry; WINDPOWER 2017 is vital to any seriousby joining premium networking events over 33% of attendees are WINDPOWER professional in wind energy.available to all attendees. first-timers. Every registrant has access to all exhibitors and session panels, which are AWEA has planned sessions on forecastingExpand your business by connecting with available in one location. for the U.S. wind energy market,over 400 exhibiting companies and transmission infrastructure, the futureorganizations. Take part in premier Learn workforce, project financing, internationaleducational and informational sessions led market updates, offshore wind Regardless of your expertise in the wind development, and much more. Tailor your experience through five separate Education Stations, while engaging in face-to-face networking with industry decision-makers through a variety of special events designed to help you build those essential connections. Join us WINDPOWER is where business gets done and connections are made. Make this year the year you expand your business, network, and education. More information on the exhibition, conference, Discover Anaheim fundraiser, and networking events is listed on www.windpowerexpo.org. WINDPOWER® May 22-25, 2017 | Anaheim, California12 PES Wind

CORPORATE FOCUSWind networking in Germany PES heads to Germany to learn more about WAB, 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.Andreas Wellbrock development and research on its market able to add to the highly stimulating potential for the wind industry. discussions that are sure to arise.Projects such as “Inn2POWER” clearlyshow that WAB is also active in Europe, on The 5th WINDFORCE Baltic Sea conference The revised Renewable Energies Act camebehalf of its 350 members, in the wind was held in February this year in Tallinn, into force on 1 January 2017. As in Denmarkenergy sector. Estonia and proved a resounding success. and the Netherlands, the level of subsidies “WAB is also present where exciting new for offshore wind farms will be determined“We have a very heterogeneous membership markets are emerging. At its annual in auction proceedings from the start of thestructure. It covers every aspect of the wind three-day WINDFORCE conference, held year. The most recent tendering results inindustry, ranging from very small start-up this year for the thirteenth time, WAB will Denmark and the Netherlands show thatbusinesses to research institutes and major host a specialist conference that has long costs clearly go down in line with projectenergy suppliers,” said Andreas Wellbrock, held its own at the international level. volumes. Unlike in Germany, operators inmanaging director of WAB. Up-to-date and high-calibre contributions those countries do not have to bear the from member businesses have always costs for a wind farm’s transformerWAB’s members are involved in project attracted representatives of industry from platform. Moreover, these projects aredevelopment, financing, insurance, across Europe to our event in the northwest located much closer to the coast and inmanufacturing - foundation structures, region,” confirms Andreas Wellbrock. shallower waters, which reduces costs.towers, nacelles and rotor blades - logisticsand installation, grid connection, service On 9 May, state secretary and maritime The end of January marked the Federaland operation as well as dismantling and coordinator Uwe Beckmeyer and state Network Agency’s official launch of the firstrepowering. WAB therefore is always able secretary Rainer Baake, from the Federal tendering round for offshore wind power.make up-to-date and first-hand information Ministry for Economics and Energy and “We’ll see hammer prices showing thatavailable to its members on current issues. CEO of Division Wind Power at Siemens Dr. generating one kilowatt-hour of offshore Markus Tacke, will open this year’s wind power is comparable with theA recent example of this is the network’s WINDFORCE conference in Bremerhaven. generation of power in new gas or coalinterest in wind-to-gas technology, the “Thanks to funding for Fraunhofer IWES power plants,” explained WAB’s managingexploration of opportunities for its from the Federal Ministry for Economics director. Industry experts assume that and Energy, we have our very own onshore successful bids could be well below ten test site here in Bremerhaven. Its core euro-cents per kilowatt-hour. component is Adwen’s 8-MW prototype, the world’s largest turbine, with a rotor The other side of the coin, however, is the diameter of 180 metres. It is already under limited volume of expansion foreseen in construction,” Andreas Wellbrock explains. Germany until 2030 and an associated shortfall in orders for some WAB member The focus of the thirteenth WINDFORCE businesses. “If offshore wind power is to event, from the 9th to 11th May, will be on the meet its industrial potential, which is tendering system for offshore wind power in undoubtedly there, we simply need to have Germany. The outcome of the first round of more new offshore wind farms in the North tendering is expected to be published before and Baltic seas.” New construction will be the conference opens and the 500 necessary due to the pressure on prices participants attending the conference will be forced by tendering in order to maintain and www.peswind.com 13

CORPORATE FOCUS14 PES Wind

CORPORATE FOCUSexpand the diversity of the industry and According to the Global Wind Energy 30 MW in the United States. “We areassociated added value, as well as many Council (GWEC), offshore wind farms always providing opportunities forhighly qualified jobs. around the world with a total capacity of members to participate in a delegation 2,219 MW were newly connected to the and see for themselves the developmentsFor the first time, the conference will broach grid in 2016. In China, 592 MW went taking place elsewhere to gain insightsthe topic of how important offshore wind online, as did 30 MW in South Korea and into new markets,” affirmed Andreaspower is for North Rhine-Westphalia andsouthern Germany.Offshore wind energy is a national industrybut has long been gaining importanceacross the globe and WAB has been awareof this for some time. “At the WINDFORCEevent we like to think outside the box, ofcourse. Developments in wind powertechnology in the United States andchanges that may come about throughBrexit will be up for discussion amongst theexperts gathered there. The expansionfigure for wind in Europe of 1,558megawatts (MW) recorded in 2016 and theEUR 18.2 billion invested last year, in elevenoffshore wind projects, underline thegrowing importance of offshore wind powerfor Europe,” said Wellbrock.A total of over 12.6 gigawatts of offshorewind capacity has now been connected tothe grid. A total figure of some 24.6gigawatts is expected by 2020. Marketconcentration amongst manufacturers wasalready very clear in 2016, and sectorconsolidation was noticed at every level.YOUr KeY TO Bremerhaven 2017OFFShOre WInD InDUSTrY! 60 international speakersWInDFOrce 2017, 9 – 11 maY over 400 delegates Maritime Wind Dinner13th Conference simultaneous translationVisit us at: www.windforce.infoOffshore Wind Energy 2017: 6 – 8 June in LondonHUSUM Wind 2017: 12 – 15 September in Husum

CORPORATE FOCUSWellbrock, describing one of the reason. The basis for this is good, trusting support. The focus of activity for WAB liesadvantages of WAB membership for partnerships with members, rapid and in Germany northwest region, but from thebusinesses. “The WINDFORCE straightforward contacts with other outset it has been open to businesses,programme continues to include specialist members and the attractive perks that institutes and institutions operating on thepresentations on regulatory issues, members get when participating in WAB international stage. Since 2002, the windservice and maintenance, recurring events”, said Wellbrock. energy network has continually grown toinspections, corrosion protection, and become a leading voice for the Germanstorage and grid connection.” WAB also promotes cooperative ventures, offshore industry. creates networking opportunities within theAt the end of 2016 there were 4.1 GW context of delegation visits, initiates training The Offshore Wind Industry Allianceconnected to the grid in Germany. These and education projects, supports R&D (OWIA) was set up jointly by WAB andoffshore wind farms need to be maintained. projects and provides opportunities for other associations in 2012. The OWIA jointThe new Renewable Energies Act licences member businesses to take part in trade office in Berlin makes it easier for politicalan operating period of 25 years. The key to fairs and congresses. communication about offshore windcost reduction is experience and the energy to take place with betteroptimisation of operation and service plans WAB therefore facilitates exchange at the networking and in direct proximity tothat come with it. Businesses that have international level. It regularly provides professional and political discussion inbeen members from the outset will provide members with information on current topics Berlin. This has further optimised the flowinsight into optimised logistical solutions with studies, position statements, press of information to and from Berlin for WABand innovative maintenance plans. Experts releases, newsletters and advocacy and its members.in corrosion protection and rotor blades willshare their knowledge. The increasingimportance of submarine cables andseabed cabling will also be featured, withWAB member businesses providing expertknowledge on this topic.The topic of grids and storage is relativelynew in the WINDFORCE programme. WABsupports a more rapid expansion oftransmission grids and storage technologyas part of an integrated system. “We’re verymuch looking forward to welcoming manyinterested participants to the thirteenthWINDFORCE in Bremerhaven from 9 May”,WAB’s managing director said.WAB was the first wind energy associationto be included in the “go-cluster” action, inwhich Germany’s Ministry for Economicsand Technology brings together the “mostinnovative and best performing” networksin Germany. “Our strength here transcendsnational borders. Many internationallyoriented wind industry businesses havebecome WAB members for this veryAndreas Wellbrock gives his view on making offshore wind, as a provider of baseload the diversity of players and expertisea success of Germany’s energy turnaround. power, as well as onshore wind, is needed. Wanted now are reliable policy growing. Success is always being framework conditions and substantialTo begin with, the concept of the measured by the cost of change. That is expansion volumes.Energiewende is described internationally why the competitiveness of wind power isas the “energy turnaround”, a notable very important. This presupposes rapid grid expansion onsuccess in itself. Initially, those who land and correspondingly at sea. Thedoubted the idea of an energy turnaround Next to the growth required in the industry is making every effort inand smiled condescendingly at Germany proportion of renewable energies in the supporting the federal government, stateshave to a certain extent now become system, a reduction in individual energy and grid operators. Some 150,000 jobs inenthusiastic advocates and given the consumption, an increase in energy the wind industry on land and at sea anddevelopment good press. efficiency, and adjustments in the the value creation associated with the wind transport sector are crucial for a industry are, next to the target of reducingThe energy turnaround has long since successful energy turnaround. It has greenhouse gas emissions by 40 percentbecome a global issue that can help in already been mentioned that national grid by 2020, an important criteria for publicmitigating climate change. The Paris infrastructure, storage technologies and acceptance of the energy turnaround.Climate Agreement came into force in future networking across Europe are2016 and, as a consequence, many significant factors. Synchronising the expansion of renewablesnational climate plans have been and transmission lines, and defining goalsdesigned to comply with it. By 2022 all of The wind industry has shown the way for the sector for 2030, are essential for theGermany’s nuclear power plants are to be and is bringing down costs. It has come success of the energy turnaround.taken off the grid and the importance of up with innovative and competitiverenewable energies, and particularly of solutions and developed an industry with www.wab.net/16 PES Wind

JOIN THE WORLD’S LARGEST OFFSHORE WIND ENERGY GATHERING EXHIBITION CONFERENCE NETWORKING Over 10,000 professionals More than 400 exhibitors REGISTRATION IS OPEN Contact us: [email protected] Find out more at: offshorewind2017.comCo-organised by: Event ambassadors:

PES ESSENTIAL INDUSTRY ON THE MOVE Words: Al Maiorino18 PES Wind

PES ESSENTIALIt seems the US is finally being blown away with the idea ofwind power. At last traditional forms of energy are beingreviewed and clean, sustainable wind energy is being takenseriously. There is to be a 200 turbine windfarm off thecoast of Long Island.Al Maiorino that is replenished naturally, offers climate change mitigation, and adds economic“Today is a big day for clean energy in New benefits on various levels. In response to thisYork and our nation. Governor Cuomo has effort, the Long Island Power Authorityset a bold vision for a clean energy future, Board has just recently granted approval forand this project is a significant step toward the construction of what will be one of themaking that a reality. The South Fork Wind United States’ largest renewable projectsFarm will be the second offshore wind farm yet. This is a project that will re-invent thein America, and it’s largest. There is a huge way that renewable energy is utilized;clean energy resource blowing off our opening doors for more just like it to come.coastline just over the horizon, and it is timeto tap into this unlimited resource to power In accordance with a recent articleour communities.” said Deepwater Wind published by the New York Times titled,CEO, Jeffrey Grybowski, in an empowering “Nation’s Largest Offshore Windfarm Willspeech following the approval of a Be Built off Long Island,” the officialrevolutionary project. project, developed by Deepwater Wind, will be lodged between the eastern tip of LongIn light of much discussion over climate Island and Martha’s Vineyard, spanningchange, it has become imperative to about 256-square-miles. Consisting ofreassess conventional forms of energy approximately 200 turbines, the productionsources such as fossil fuels and make of this wind farm will allow for the fueling ofchanges. There is a need to provide energy 50,000 homes. How will the landscape look? These turbines are anticipated to be about 600 feet tall, and will be connected to a substation in East Hampton by a 50-mile undersea cable. Though talk of opposition has occurred regarding visibility of the wind farm, Deepwater has reassured individuals that it will be extremely minimal, if noticeable at all, from the coasts of both Long Island and Martha’s Vineyard. As stated on their company website, Deepwater claims that traditional power plants burn fossil fuels and produce harmful pollutants that are associated with several negative impacts on our environment and public health. However, they assure readers that offshore wind is a clean and plentiful energy source that will help displace fossil fuels, while improving the cleanliness of the air that we breathe. www.peswind.com 19

PES ESSENTIALDeepwater reveals that this project will make such pride in protecting the environment. hundreds of thousands of individuals with afor a great number of high paying jobs, Deepwater has demonstrated this by cost effective and clean source of energy.benefitting local companies tremendously. partnering up with several environmentalThis is because the number of individuals advocates, conservationists and scientists, Though Deepwater has been grantedneeded to build and operate this project to protect endangered whales and other approval for the construction of thisincludes the expertise of environmental marine-mammals during pre-construction breakthrough project, which will in factservices’ companies, scientists, marine and construction of the project. open doors for more like it to come, thatbiologists, engineers and tradespeople. doesn’t mean that the opposition toUltimately, when the project generates Within the last decade, the company has offshore wind will come to a halt. In fact,power locally, it will provide jobs locally. experienced an exceeding number of future wind proposals, whether on-shore or technological advances, including hugely off, will most likely continue to moveAnother aspect of Deepwater’s proposal is a lowering the costs of building and servicing. steadily until acted upon by an externalkeen awareness and protectiveness of Because offshore wind is strongest in the force. Public comment, regulatory hearings,wildlife. Often, public opposition regarding middle of the day and early evening, when or stakeholder input could exemplify this.renewable projects is focused on potential electricity is utilized the most, the clean However, to ultimately gain the approvalharm to wildlife, which is why it is so energy plants will help stabilize electric rates. that Deepwater was able to secure, thererefreshing to see a renewable company take The new development will ultimately provide are many convincing tactics a company can20 PES Wind

PES ESSENTIAL‘Ultimately, when the project generates powerlocally, it will provide jobs locally.’use to conduct public outreach and ask through daily news. Web ads can link to the Al Maiorino, the President of Publicmembers of the community to voice their website, with measurable click through Strategy Group, Inc. is a public affairssupport for other renewable projects. rates, while ads on social media platforms executive with over two decades of can have objectives that increase page success in his field.Maintain a Consistent Image likes, engagement and more. Mr. Maiorino is a NIMBY expert, writerProjects can be negatively affected due to Additionally, ads on social media outlets and public affairs consultant who hasconflicting information on a development, can target, by interest in environmentally made Public Strategy Group, Inc. aor just an overall lack of consistency in friendly causes or groups, within a unique firm that goes beyond themessaging. The voice should be geographic region, for wider awareness traditional public affairs role of manyunchanging throughout communications, and online engagement of support. Key firms. He has successfully run andacross all platforms, to create the feeling performance indicators of social media ads won corporate campaigns involvingthat all audiences are listening to the same include cost per video view, cost per page land use difficulties, legislativecompany representative. By nailing down a like and more to ensure the best use of an advocacy issues for large and smalluniform voice, companies can more easily advertising budget. When calls to action companies ranging from Fortune 100approach negative feedback, as an are placed on the website or social media clients to smaller firms, and voteropportunity to educate individuals, on the platform to which members of the audience referendum campaigns.merits of the wind project, without elevating are driven, a flood of conversions will occuropponents’ positions. from those who take the next step to He began his career as a political complete the requested action. party operative and took theDevelop a Project-Specific Presence knowledge gained from a diversity ofOnline Leverage Stakeholder Support political campaigns to the corporate level over 20 years ago and formedThe Internet has become an asset in Stakeholder involvement from groups or Public Strategy Group, Inc. He haspromoting projects, ideas and virtually organizations with missions or platforms that made PSG one of the few firms in theanything facing opposition. It is critical that align with the project is key in gaining project nation that specializes in buildingwhen trying to gain approval for a project, a approval. In many cases, finding these public support for development typewebsite (or at the very least a landing sponsors can involve making a presentation projects, while also offeringwebpage) devoted to the proposal, is to the membership or just a simple one-on- grassroots public affairs for corporatecreated. This will allow companies to one meeting with the leadership to discuss clients on legislative and regulatorypresent the facts and offer resources to the benefits of the proposal. Renewable issues. Throughout the years, he haseducate community members and to learn proposals come with incredible managed hundreds of corporatemore about the proposed project. opportunities to gain third-party support, to public affairs campaigns in a variety of help validate benefits in the media, on the industries such as energy, gaming,On this website or webpage, companies internet and at public hearings. shipping, tourism, cable television,should include a place where local retail development, auto racing, andresidents can sign up as advocates for the The Long Island Wind Farm project housing/residential projects. Hiswind proposal, as well as a place where approval brings hope for a more amenable company has worked in twenty states,supporters can take action instantly. With a response from citizens and public officials one U.S. Territory and three countriesform letter that viewers can sign onto by to help new wind proposals gain and for over 20 years has helpedfilling out their name, email address and zip momentum. By utilizing some of the tools companies gain approval oncode, your website can become an listed above throughout the United States development projects totaling billionsepicenter of support. These letters can then and beyond, more efficient approvals could of dollars in investment.be emailed straight from the user’s own indeed be possible, saving companies’ timeemail address directly to public officials and money. As a field or sea of wind He has written many articles and is aautomatically, allowing supporters to voice turbines gains a more positive image in the regular contributor to numerous tradetheir support with a single click whether in a eyes of the public, it will become a widely journals and business periodicals.line at the grocery store or on the go. recognized symbol of clean, affordable and sustainable energy with which to provide www.peswind.com 21Social Media/Digital electricity for buildings and transportation.Using web ads is a cost-effective way to http://publicstrategygroup.com/gain attention on a company’s projectwebsite. Web ads on local news websitesallow for companies to geo-locate targetaudiences and produce ads that will reachonly potential voters while people scroll

ASK THE EXPERTS A job that never ends Raymond Fisch, Senior Vice President, at BBC Chartering, talks to PES about the changes in the shipping market, the importance of training and the strong ethos which runs throughout the company.22 PES Wind

ASK THE EXPERTSRaymond Fisch PES: Welcome back to PES Wind PES: We are interested to know if your magazine. It’s been two years or so since apac service – any port any cargo – has we last spoke. Thanks for talking with us. impacted directly on your work in the For our new readers would you like to offshore wind industry. begin by explaining a little about the background of BBC Chartering and how RF: Our apac service is highly appreciated you currently serve the wind industry? by our customers delivering transport solutions for any port, any cargo and for Raymond Fisch: Thank you PES. BBC any sector. It also offers great shipping Chartering continues to be the leading solutions for all long haul transports in the force for industrial ocean transport services off-shore wind sector, and there is much and also to the wind power industry. We interest in it. Where we say that ‘no port is have continued to operate the world’s no problem’ either, we stay out of the largest fleet of project carriers, the leading business which is usually covered by project chartering network and with 33 dedicated offshore wind installation assets. offices around the world the leading global service for integrated transports of any PES: What are the benefits of BBC’s cargo. In 2016 we operated more than 180 apac service for the customer? vessels and a peak fleet capacity of more than 2.1mln. DWT. RF: With apac service customers find the world’s largest and highest performing Although the shipping markets are generally project shipping network. Already in the slow, we have seen an unprecedented planning phase they know they can bank on growth of the wind power sector over the the experience and know-how of a highly past few years. Our share of bookings for accomplished partner for their project. the sector increased significantly by over There is no spot in the world which is not 60% alone in 2016. This is strongly driven covered through our sailing network. by US wind power developments, especially from the Far East. But also South Wind power shippers benefit from our America and Europe could strengthen their flexibility, i.e. if booked at short notice, we exports in the industry. Meanwhile we also can arrange inducements along trade lanes, observed significant increase in their import anywhere on over 30 global high frequency bookings. A clear sign of how global wind lanes; they benefit from the least power supply chains have become. commercial risk through our market-leading shipping performance, and with that they PES: How has the wind sector business benefit from the lowest damage risk, with changed during this time? our quality operations and integrated transport services. RF: Global sourcing strategies in wind power are the rule these days. The industry If booked on a strategic volume contract is looking for efficient, reliable and high basis they benefit from the most performing transport solutions. In general economical shipping solutions and the we are noticing that more responsibility highest service value that the market gets transferred to us, as a strategic partner currently has to offer. to the industry. This trend is not entirely new but, we also observe an increasing PES: Could you explain the advantages spot orientation for wind power projects of chartering to the user? Are any extra these days. costs incurred? Unfortunately price levels today are RF: Either a strategic volume contract devastating and do not reflect the forms the basis of an apac service trade, or service value our customers receive. This a spot engagement benefits from existing has to change so that service quality can trades in apac service. be sustained. In the first case, the charterers book their There are many large developments under strategic capacity and while securing it as way and principally BBC Chartering serves part cargo, this would allow other project the sector through three different types of charterers to use the shipping capacity as chartering services. One is on a standby well. The charterer’s advantage is to book basis, second is on a dedicated project a reliable and economic service. With a basis and third is as a strategic volume future oriented view on larger volumes, partner to industrial customers. also covering latest global sourcing and supply chain strategies, this service is a www.peswind.com 23

ASK THE EXPERTSgreat tool to minimise risk, streamline cost, performance for any existing wind power RF: It’s our mission to build the higheststay highly flexible and secure cargo requirement. With that today, BBC performing and most trusted shippingperformance for charterers. Chartering operates the world’s largest company for project-, breakbulk-, heavy lift fleet of premium project carriers. and general cargo transports in the world.In the second case, charterers focus on At BBC Chartering we set out to further aflexibility and apply short term capacity Whereas lifting capability is of increasing company culture where improving ourdecision making. Apac service then still importance, it’s equally important to business, looking after each other and theprovides them a high performance; optimise cargo handling and intake for environment is a natural way of thinking. Allhowever the desired contracting flexibility large, long and voluminous cargo, e.g. rotor our values are important guiding principles,usually comes at a higher price tag. In the blades. Especially for new buildings this but two are of highest importance for this.current market, the medium term shipping becomes a major criteria, i.e. demandingrates are very volatile and difficult to faster traversing hatch cover systems, First-off it’s about professionalism: for uspredict, which means charterers risk better crane layouts, etc... Our current this is the value behind skill, judgment andincreasing their cost basis though this. newbuilding program of an “EcoTrader 500” behaviour of trained people; and second- addresses such factors, not limited to, but off integrity: for us this is the value behindPES: As the turbines get bigger what especially for wind power cargo an unimpaired condition, honesty andspecific challenges do you have to requirements. The vessel is already fairness. Both are most importantovercome in their transportation? recognised as the “next generation work preconditions in project shipping and we horse” in the industry. could not do our job without taking this toRF: Our fleet currently provides a heart with regards to our training efforts.maximum lifting capacity of up to 900mt. PES: How important is training to you asMore than 80% of our fleet can lift 240mt a company in view of the stringent We ensure a high level of quality throughoutand above and this gives our charterers health and safety regulations? our activities; we continuously identify andunparalleled possibilities, flexibility and24 PES Wind

Revolutionaries wantedThe worlds ‘green revolution’ leaders rely on BBC Chartering‘sability to deliver quality transport solutions for any small or largescale undertaking. As unlimited as renewable power so is our passionto deliver the required shipping performance for any volume at anytime and port. www.bbc-chartering.com

ASK THE EXPERTSaddress the training needs of our coverage. Also with regards to industrial many reasons, subject to further demandemployees so they can develop, shipping segments, we go where the dampers as we move on.understand and apply the relevant skills, market asks us to go; this also includes themethods, or tools. For projects specifically, development of regional niche services. Of PES: Lastly, what singles you out fromwe do safety inductions, debriefings, course we are always open to discuss on other heavy lift shipping specialists?deliver toolbox talks and ask for feedback. any type of collaboration.We work every day to create awareness for RF: In a nutshell what singles us out are ourour HSEQ policy. PES: There have been significant brand values: trust and performance. They changes in the political landscape, with are the basis of our unique global set-up,PES: We know that you operate in many BREXIT and Donald Trump in the both with regards to the chartering networkcountries worldwide and wondered Whitehouse, how do you think these will and the fleet. We have a great global team,where the key markets are for BBC affect the current trade agreements? with the largest aggregated experience inChartering and if there are any areas project shipping, and this extends to theyou would like to break in to? RF: We have to see what comes our way. many indispensable working relationships We believe in the future of project shipping around the world. Our experience, knowRF: As I said before we are global and and that there will always be a demand for how and network are unparalleled and wegeographically speaking there is hardly high quality transport solutions. We also are on a mission: to build the highestone port which we have not visited over believe in globalisation and free trading as performing and most trusted shippingthe years. Alone in 2016, we had close to important economic policies to create company for project, breakbulk, heavy lift6,000 port calls in more than 700 ports welfare on a global scale. But we cannot and general cargo transports in the world; aaround the world. There is probably no deny that there are many challenges which job that never ends.second operator in project shipping who we have to deal with. We may get used tocan claim the same kind of global slow global economic growth, which is for www.bbc-chartering.com26 PES Wind

TALKING POINTA surge towardslarge floating cranesSuddenly the news is spreading. The installation market is setups increase in size. But what if thedeveloping so fast that large floating cranes seem to be the foundations become even bigger than theanswer to the ever-increasing turbine size in the wind industry. 1500 ton for an XXL monopile, what if weJack-ups have long been the installation vessel of choice in have a 12 megawatt or an even biggerthe offshore wind industry; however we are now seeing turbine? As offshore wind farms move tovarious contractors using large offshore floating cranes. deeper waters and foundations grow exponentially, floating installation vesselsWill Conquest Offshore 1400 crane barge jack-ups probably won’t be able to provide could become the more efficient and costfollow them into the deep waters or stay the solution. At least that seems to be the effective solution in the future.within the very shallow waters? idea. It looks like the installation market will move from jack-ups to floating assets and Conquest MB1Offshore Wind DEME’s Orion and Boskalis F-3000 new builds are well underway. What is Conquest MB1’s part in this future?Renewable energy is becoming more and It has a reliable 136 x 36 x 8 m crane bargemore important to the global energy Crane size and capacity with a 1400 ton crane, 60 pob, 8 anchormarket. Within this renewable market, the mooring spread, 20 ton per m2 and a hugeoffshore wind industry is turning into a Who would have thought that it would get 3500m2 deck space. Conquest is a provensignificant factor and has been this big, this fast? What seemed tool in the offshore industry. Derrick bargesexperiencing a rapid growth spurt over the impossible a few years ago has exceeded or crane barges have been around forlast few years. all expectations. At the moment the decades and were developed in the foundations are installed mostly by mid-20th century. Then came Heerema andAs turbines get bigger and heavier and jack-ups or floating vessels. The jack-ups its competitors created large semi-foundations get wider and wider, the have been challenging each other as the submersibles with massive cranes, which have dominated the scene ever since. However these have not yet been used extensively for offshore wind. www.peswind.com 27

TALKING POINT‘As offshore wind farms move to deeper waters Conquest Offshore’s track recordand foundations grow exponentially, floatinginstallation vessels can become the more efficient Conquest has a track record in civiland cost effective solution in the future.’ construction, salvage and wreck-removal. It gained international exposure by successfully playing a key role in the salvage operation of the Italian cruise ship, Costa Concordia, off the Tuscany coast, near the island of Giglio, Italy. Large containers or sponsons, approximately 45m high and 800 tons, were installed on the side of the Costa Concordia for re-floating operations. The key factor in the installation was the shallow draft of less than 3m, the large deck space and the lifting capacity. Conquest Offshore’s MB-1 heavy lift barge was also the key asset in the largest wreck removal recorded in 2016. The Troll Solution jack-up, weighing approximately 7,000 tons, experienced a28 PES Wind

TALKING POINTdebilitating accident while carrying outmaintenance work on the wellheadplatform, CAAN-A in 2015, Mexico. TheTroll Solution collapsed and sank into theseabed, where the water depth wasapproximately 30m. After sinking, the TrollSolution came to rest within two meters ofthe active platform.The operation used a guided guillotine todismember the jack-up, instead of cutting,which is a more conventional method. The6 pieces that made up the deck house andthe 31 pieces from the vessel’s hull werelifted from the seabed with a non-traditionalhoisting technology: a 1000 ton hydraulicsalvage grab.Conquest and Offshore windCan the barge follow into the deeperwaters, with the larger structures andincreasing capacity, or must it stay in theshallower water niche, with smallerstructures and just enough capacity, or canit service in both deep and shallow waters.Each of these needs a specific approachand dedicated engineering.Monopile and transition pieceinstallationIn 2015 Conquest Offshore presented anadvanced system for monopile andtransition piece installation for offshorewind. The barge is capable of working with3 monopiles, and 3 transition Pieces, or upto 16 transition Pieces in each shipment.Upending can be done on deck, with anupending tool or the monopiles could betransported and upended floating duringthese operations.The challenge is working with wave andswell motion during the floating installationof the MP’s, as you work from a floatingbarge. The specially designed motioncompensated pile gripper (MCPG) is the keyto the success. While hammering the pile,the gripper’s hydraulic cylinders activelycompensate the surge, sway and heavemotions of the barge to ensure the verticalinstallation of the MP’s within set limits.However, monopile sizes are growing fastand exceed the 1000 tons capacity windowof Conquest, especially when adding theDynamic Amplification Factors (DAF). Thefuture for Conquest’s MB1 monopile andtransition piece installation points towardsvery shallow water. There are a few offshorewind locations, either in the planning earlydevelopment, where water depth is very www.peswind.com 29

TALKING POINTlimited. Conquest MB1 is the perfect tool Pre-piling • Seabed levellingfor this line of work and can become themost efficient and cost effective solution for The Conquest barge is similar to Boskalis’ Cost effective solutionvery shallow water. new Giant 7 barge, which was involved in pre-piling operations on the Wikinger The Conquest barge can be the ideal costDeeper waters offshore windfarm in the Baltic waters of effective solution for floating piling Germany during 2016. Of course there are operations. And while the offshore windA large part of the foundations of offshore a few differences: the crane is 1000 ton, industry is screaming for cost effective andwind turbines are monopiles, which are with a 600t hook and is placed mid innovative solutions for optimising thelarge diameter steel pipes and the jackets, starboard side, in contrast to Conquest’s installation process, this floating installationwhich are smaller. Both jackets and XXL portside aft location. But in general, the concept is ready to launch. Additionally, themonopiles compete with each other in Conquest barge can perform similar floating installation concept is completelydeeper waters. pre-piling operations to those performed independent of the soil conditions and by Giant 7 in Wikinger. water depth. Conquest MB1, a provenWhich one will win? Each have their own method, added with the right innovativebenefits, both can bear the amount of During pre-piling, subsea templates are solutions, could be the ultimate costweight and stress exerted upon them. The used to ensure the correct positions of the effective tool.other solutions loom in their slipstream: piles, including the angle. Both weights ofsuch as gravity base foundations or floating the template and the pin piles are well Close cooperation and serviceturbines in the deeper water. within the main crane’s 1400 ton capacity. Once the piles are inserted into the As the offshore wind sector is expanding atDeeper water jackets (30-60m) and seabed, the jacket is lowered and fitted a fast pace and wind farms of increasingpre-piling into the piles. proportions will be installed over the coming decades, Conquest OffshoreThe maximum depth for a finished project There are a few advantages to pre-piling as supports the growth of its customers byis about 45m. Beatrice is an example of (source: 4COffshore): delivering a combination of reliablethis. Other projects in the planning pipeline equipment and innovative solutions,that use jackets are going towards water • Pile sleeves and mud mats are eliminated together with the ‘can do’ mentality of adepths of up to 60-70m, but we have to wait on the jacket dedicated workforce.and see when this will materialise. • Piles can be installed well in advance of Through the integrated and pro-activeA jacket might be the answer for the deeper the jacket and wind turbine generator approach, Conquest provides an efficientoffshore wind farm locations. installation and cost-effective service based on a proven track record. Added value and maximumJackets are able to cover water depths up • Fabrication of jacket can be conducted in utilisation of the equipment is ensured, byto 60m or more, in most cases. Great, parallel with piling operations working closely together with customers andthough who will be providing the service of all others involved, while controlling riskpre-piling? Jack-ups aren’t able to cover • Seabed variations can be levelled by during the project and beyond.these areas and the large installation varying pile stick-upvessels are too expensive for the piling job. www.conquestoffshore.com30 PES Wind

Offshore WindHydraulic SolutionsTP-levelling & fixation | Seafastening | Jacket fixation | Lifting, levelling & weighing solutions | Cutting tools | SkiddingChallenge us!Allow us to inspire you and challenge us to come up with a solution for your specific problem. Contact ouroffice, visit us at Offshore Wind Energy in London, booth S-M60 or at Offshore Energy in Amsterdam,booth 1.055. We look forward to hearing from you!Holmatro | Industrial Solutionswww.holmatro.com

CORPORATE FOCUS Making wind energy maintenance more efficient Words: Peter Hearn, Operations Manager, ActSafe In this, the first of four articles, we look at how ActSafe Powered Ascenders are making wind turbine maintenance quicker and more efficient.32 PES Wind

CORPORATE FOCUSWe are all familiar with the adage “time is available weather windows. ascenders augment traditional ropemoney”, and in offshore wind energy access techniques, to allow workers tonothing could be more true. Getting people Although many tasks can be performed reach difficult areas of the wind turbine, forand material onsite quicker and allowing from existing access platforms, there are inspection, repair and cleaning tasks.work tasks to be completed more efficiently still some areas of a wind turbine that are Once ropes are established, it is equallycan save thousands of euros per annum. difficult to reach. These include; viable to work from ‘bottom up’ as ‘topActSafe Powered Ascenders are helping to down’ which doubles the efficiency andmake wind turbine construction and 1. The interior of the transition piece speed of inspection.maintenance cheaper by enablingpersonnel to get themselves in difficult to 2. The exterior of the nacelle Even where blade repair platforms arereach places and manage tools and being used, ActSafe Powered Ascenderscomponents more easily, saving both time 3. The exterior of the spinner can be used to allow workers access to theand material costs. suspended platform for meal and toilet 4. Wind turbine blades breaks, massively reducing down-time andPersonnel access and work positioning improving operations. 5. The exterior of the towerIn wind energy, it is imperative that For operations, down into the transitionmaintenance and construction personnel 6. Some areas of the interior of the tower. piece, some of which may be consideredcan reach their place of work. The confined spaces, Powered Ascenders allowtechnicians need to be able to perform ActSafe Powered Ascenders allow easy, access to be performed quickly, reducingtasks, as efficiently as possible, to reduce quick and efficient access to all areas of a exposure to potentially hazardouswork time and get tasks completed during wind turbine that have previously proven environments. Rescue planning is built into difficult to access. For access to the exterior of the wind turbine, Powered www.peswind.com 33

CORPORATE FOCUSthe access methodology. Rescue and evacuation winching deck on the outside of the turbine, can all be achieved easily andPowered Ascenders can also be used for a In onshore wind energy applications, efficiently by all personnel with a minimumwide range of work positioning tasks in the rescue and evacuation has always been level of training.interior of the turbine to reach areas where planned using gravity to assist people toexisting platforms don’t allow, such as; the ground, however, in the offshore If ActSafe Powered Ascenders are beingtower cabling; elevator cabling, light fixtures environment the best egress may in fact be used for personnel and load lifting; theyand transformers. ActSafe Powered up towards a helicopter winching deck. are immediately available for anAscenders can even be rigged as a climb ActSafe Powered Ascenders make these emergency. Personnel are better equippedassist system on the access ladder way. tasks easy, allowing Health & Safety to deal with an emergency as they are Managers to plan and risk assess around more practiced with the equipment,Load lifting rescue up scenarios and deal with a range rigging is easier and a single person can of complex rescue tasks. easily manage a 200kg rescue load. UsingActSafe Powered Ascenders are already a the equipment daily for a range of liftingmainstay in the offshore wind energy Rescue scenarios such as: navigating a and work positioning tasks, reduces theenvironment for enabling personnel to lift stretchered patient within complex internal need for constant refresher training. Theytools and components. They are able to spaces, negotiating a 200kg rescue load are able to cope with the specificprovide a temporary solution for lifting tools up several decks, or lifting a stretchered emergency procedures and this alsoand components from vessel to transition patient 100m from the transition piece to a reduces the need to supply and maintainpiece, an auxiliary lifting capacity. If for specialist rescue equipment onsite.some reason the primary chain hoist orcrane is not functioning Powered ConclusionAscenders ensure that work can continueand personnel are not left idle. Here is a single tool which enables a wide range of load lifting and personnel accessPowered Ascenders can also be used for tasks to be completed quickly andmany tasks within a wind turbine, where the efficiently. Rescue planning is built in andweight of tools must be managed and training costs are lowered, as being a dailypositioned, within restricted spaces and use working tool, personnel are familiar andmultiple decks. Adding an optional AC practiced in handling the machine and thepower source ActSafe Powered Ascenders various ways of rigging it to do lifting tasks.could potentially replace other liftingequipment on the wind turbine. They are In future articles, we will examine specificextremely portable and so are stored case studies in which Actsafe Poweredoffsite, which greatly improves line Ascenders are solving access problemsmaintenance, ensuring the equipment and making wind turbine maintenancealways performs when it is needed most. quicker and more efficient.Some specific examples of maintenance For more information on how ActSafe cantasks that can be performed by ActSafe improve your Wind Energy MaintenancePowered Ascenders; program, please contact: [email protected]. L ifting tools and components from www.Actsafe.se transfer vessels to the transition piece.2. L ifting tools and components inside the tower, especially where work is being carried out on intermediate platforms.3. P ositioning and replacing electric and hydraulic motors, particularly those in restricted spaces such as pitch motors.34 PES Wind

ActSafe Power Ascenders are an ingeniouscombination of a high-capacity rope winch in acompact, lightweight and user-friendly design.It simply redefines the possibilities for workingin vertical work environments.Get in touch with us today to findyour nearest ActSafe distributorActSafe Systems AB T: +46 31 65 56 60Sagbäcksvägen 13 E: [email protected] Lindome, Sweden W: www.actsafe.se

PES ESSENTIALSkilled manoeuversThe renewables market, particularly wind, is a key sector for “We own a fleet of specialised equipmentALE. Building on experience in the power sector, they have that is specifically used for projects in thisused their knowledge and expertise to develop smarter sector, such as ` blade trailers and lowsolutions to the challenges created by the increasing heights profile wind tower adapters. Our qualifiedof wind turbines and associated components. electrical and mechanical installation teams have the knowledge and experience to In relation to the on-shore wind energy provide the most efficient solution, on a market, ALE offers a bespoke Transport, project by project basis.” Crane and Installation (TCI) package for the wind energy sector. The transportation “We can also provide our clients with port phases of projects include route handling services. This includes equipment assessments, liaising with local authorities, inspection, damage assessment, storage providing specialist transportation facilities and loading or reloading of equipment and facilitating the removal and equipment to specialist transport.” replacement of any street furniture or structures that may obstruct the route. “We offer different types of cranes for the erection of wind turbine components. The LG1750 combines the benefits of a crawler crane, it is high capacity and has the possibility to change configurations, and36 PES Wind

PES ESSENTIAL‘The wind energy sector is a major industry forALE and our priority is to invest in training toensure our technicians are always developingand regularly trained to best serve our clients’those of a truck mounted crane. This crane generation of wind turbines. Executioncan lift heavy nacelles on top of tall towers, time is also a critical issue in any projectbut with a reduced relocation time, as the and, besides the pure technical challenge,superstructure and back mast (when there is a project management challengepresent) don’t need to be disassembled,” where all the pieces have to fit to deliver asaid Fabio Garcia, Business Development good performance.Manager – Renewable Energy. “The increasing sizes have affected the way“We also use the LR11350, a large crawler we perform projects, from the road surveyscrane with 1,350t capacity, which can to the calculation of lifting activities, thecomfortably lift any kind of Wind Turbine way we do it is more professional andGenerator (WTG) component at any height specialised. On the other hand, we are(73t /190m lifting height). The LR11350 can seeing an increase of new wind developingbe relocated fully erected straight to the markets/countries, where the sector is notnext hardstand, provided that the site roads mature at all and the challenge is thereforeare wide enough and compacted. For the even higher,” Fabio continued.transportation of different WTGcomponents, we mainly use a 4 axle “As one of the leading companies in ourextendable trailer for blades, an 8 axle sector, ALE is always looking for newextendable trailer for tower sections and a 6 solutions and equipment that can help usaxle Goldhofer for nacelles. For other and our customers to fulfil the marketcomponents we use normally Step Deck requirements. ALE is well known in thetrailers. This combination gives us flexibility industry for our Innovation Series, in manyand a very good performance ratio.” different sectors. Specifically, for wind, we are updating our main craneALE operates wind projects across the equipment to be in line with the newworld. “During the recent months, our team challenges in the market.”has been performing mainly in Thailand andSouth Africa. In Thailand, we mainly used Recently, ALE announced that their windan LG1750 crane, lifting 30 WTG up to turbine electromechanical installation120m hub height. Our scope included technicians have been trained according toreceiving the components in Laem the standards of the Global WindChabang Port, transport to site (450km) and Organisation (GWO), an institution thatlifting major components including tower develops training standards in the windsections (65t), nacelles (85t) and blades industry. ALE’s dedicated wind technicians(13.5t / 59m). The job lasted six months,” attended a specific training course includingsaid Fabio Garcia. “In South Africa, our different training modules, as provided by ascope was mainly related to works in certified GWO Training institution.Harbour (Couga Port) and transport tosites. One of the jobs involved a distance of “The wind energy sector is a major1,300km. This was a big challenge in terms industry for ALE and our priority is toof project management and organisation of invest in training to ensure our techniciansthe different deliveries.” are always developing and regularly trained to best serve our clients,” saidAs the industry changes and the clients’ Carlos Moreno, Commercial Manager –need develop, ALE needs to react to this: Wind Energy Installation.“The increasing sizes of WTG is obviouslya challenge for the whole heavy transport “As clients increasingly expect higherand heavy lifting industry. Components are quality and safer standards across windgetting heavier and towers higher, so we projects worldwide, we wanted all of ourneed to adapt ourselves to the new technicians to be fully trained and certified to the GWO training standards so they www.peswind.com 37

PES ESSENTIALhave the assurance that the same blade export or pre-assembly at Siemens’ 3.5 miles away, through winding city streetsstandards will be applied globally. By new facilities in Hull. to Queen Victoria Square.achieving this qualification, itdemonstrates our technicians’ capabilities ALE equipment and staff are undertaking Once in position, it was mounted onand consistency when working on all wind the handling and pre-assembly of imported specially-constructed supports. At theinstallation projects.” towers, nacelles, weighing up to 360t, and highest point it is 5.5m from the ground - blades, measuring up to 75m long, to be allowing double-decker buses to pass underSimilarly, ALE are also involved in offshore used on the Dudgeon offshore wind park, the tip of the blade. It is believed to be thewind projects. In the UK, ALE secured a which will comprise of 67 Siemens’ 6 MW first time such a huge industrial structurefour-year Crane Framework Agreement with offshore wind turbines and an overall has been manoeuvred into a city centre, toSiemens for the supply and deployment of capacity of 402 MW of power to supply be displayed as a temporary art installation.cranes, specialised transport equipment more than 410,000 UK households.and personnel. The installation is part of its contribution to In January 2017, ALE transported a Siemens the cultural and artistic programme. ThisThe project covers Siemens’ harbour-based wind turbine blade, measuring 75m long, as was instrumental for the artwork, ‘Blade’ byoffshore wind sites in the UK and Germany part of the Hull UK City of Culture multi-media artist Nayan Kulkarni, whoand the heavy lifting, transport and programme. ALE transported the wind blade reinterpreted the 75m long wind turbinepre-assembly operations will take place under the cover of darkness on SPMTs and blade as a monumental sculpture installedbetween 2016-19. The operations involve bolsters from Siemens’ production facility, across the historic Queen Victoria Square. This jaw-dropping contemporary art installation is the first artwork in Look Up, a year-long series of artist interventions in public spaces, commissioned by Hull UK City of Culture 2017, which aim to make people look at and experience the city in new ways. Moving and installing the blade has involved over a year of planning, also involving Hull City Council, project consulting engineers Arup and the Police. Dave Smith, ALE Projects Operational Manager, said: “This was a unique challenge. We have never before moved a structure of this size into a city centre along such narrow streets. We’re delighted to have been entrusted by Siemens to take the blade on its journey into the city centre and to have lifted it into position where it took pride of place during the City of Culture celebrations.” www.ale-heavylift.com/38 PES Wind

TALKING POINTBolting technologyadvancements transducerizedvs current controlWords: Paul Bundy, AIMCO Energy Services ManagerWhy is using a transducerized tooling systemimportant to me and my customers? Tounderstand the importance you mustunderstand the accuracy difference betweenTransducerized and Current Controlled tooling.Current Controlled (Open Loop) tools are a dedicated system The AcraDyne HT system also records date, time and rundownconsisting of a tool, cable and controller. They are pre-calibrated in information of up to 32 different pre-set torque jobs stored in thea lab using an external transducer on a rundown fixture. The tool is controller. All the recorded torque data is easily exported to Exceloperated on the external transducer at set torque points. The with the touch of a finger. Modular design unlike current controlledamount of current supplied by the system is matched up to the systems, which are a dedicated system. The calibration of atorque reading of the external transducer. transducerized tool is in the tool itself not the system. Tools, cables and controllers are all interchangeable. When the annual calibrationThe lab will input these torque readings, which the system is due you only need to send in the tool not the whole system.translates into the amount of current it needs to supply, to achievethe amount of torque required. Unfortunately current controlled If your customer relies on you for accurately applied torque. Taketooling is an open loop design. Once the tool is removed from the the Guess Work Out and use a closed loop transducerized systemexternal transducer there isn’t any true torque feed back into the for unparalleled accuracy.system. The system simply supplies the per-set current and theoperator has to accept the torque was properly applied. www.aimco-global.comHowever a number of things affect the torque output but not thetorque readings of the system. Things like temperature, gear wear,voltage and motor performance all affect the torque output but thesystem is unable to adapt and compensate for these changes. It’ssimply all guess work…! It’s also a dedicated system. Somethingas simple as changing out the cable voids the calibration.Transducer Controlled (closed Loop) tools like the AcraDyne HTsystem from AIMCO have the transducer built into the tool itself atthe output shaft. The transducer is constantly measuring the torquein real time and feeding that back into the system. Variations oftemperature, gear ware, voltage and motor performance do notaffect the accuracy of the transducerized system because they allhappen before the transducer. The system will simply keepapplying power until the transducer reads the requested toquebefore shutting off. www.peswind.com 39

PES ESSENTIALKutch, Gujarat, India ©Wind Power WorksClean energy onIndia’s horizonIn February 2015, the Indian government announced its and the US on top. According to EY, this isplans to almost quadruple its renewable power capacity to primarily due to the strong focus of the Indian175 GW by 2022 as part of the plan to supply electricity to Government on renewable energy coupledevery household in the country. This includes 60 GW from with the actual timely implementation ofwind energy. Further, India made a commitment at COP21 renewable energy projects. The report alsoto raise the share of non-fossil-fuel power capacity in the suggests that renewable energy iscountry’s power mix to 40% by 2030. increasingly proving its mettle against conventional energy generation.Consequently, these plans and targets consolidating its 4th position in themake the Indian market a unique fast cumulative global rankings, according to Additionally, after a historic solar powermoving and growing market where the Ministry of New and Renewable Energy tariff, India’s first reverse bidding windcompetitive companies can have great (MNRE) of India. auction last February, allocating 1 GW ofbusiness opportunities. But, they also come wind projects, defied all expectations andwith a complex and unstable legal India was among the top 10 countries in will make the wind market more efficient.framework where manufacturers find many terms of renewable energy investment, The auction witnessed aggressive biddingobstacles on the way. according to UNEP & Bloomberg New Energy despite an advisory issued by industry Finance. Also, India’s renewable energy body to avoid bold bids. As per recentMarket developments sector held its position at the third spot for reports, the Indian government is expected the second year in a row in the Renewable to tender out 4 GW of additional windIn 2016, India set a national record with Energy Country Attractiveness Index (RECAI) capacity next year and following this3,612 MW of new installations, bringing the released by EY globally, with China at second record-breaking success, the sector iscountry’s total to 28,700 MW and likely to shift entirely towards auction- based allocation. But, economic growth, increasing prosperity, a growing rate of urbanisation and rising per40 PES Wind

PES ESSENTIAL©Catalano Conzaga/GWECcapita energy consumption has increased repowering over life extension, but this trend, a peak volume of 1,268 MW in 2016,the energy demand of the country and this however, may change in the near future due ending the year with more than 35% of theincrease must be accompanied by a suitable to a lack of policy guidelines and incentives wind power capacity installed in theconditioning in the transmission systems. for repowering. Consequently, limited country. To date, 9% of all wind powerOtherwise, the electric system stability could progress has been achieved in the absence capacity in India is equipped withbe compromised. In this regards, due to its of national or state level policy guidelines for Ingeteam’s technology. Overall, 2016 was arapid growth, the Indian electricity system repowering. Life extension, on the other record-breaking year for the company withfaces many challenges in terms of grid hand, generates much less regulatory and nearly 5 GW of new capacity added instability. In order to achieve this grid stability permitting hurdles than repowering and can 2016 alone, a total of 36,414 MW of windand the controllability required to operate in be achieved at a fraction of the cost the full turbines have been equipped withweak grids, Ingeteam has successfully repowering demands. Ingeteam’s technology since 1995, makingdeveloped, designed, manufactured and the Spanish company the world’s numbercommissioned its INGECON® WIND DFIG A few months ago, Ingeteam generated one supplier of wind power converters.2000LV power converter in India. Not only broad market attention with the introductionensuring the fulfilment of one of the most of INGECON® WIND FIX2VAR SPEED, a Regulatory frameworkrestrictive and demanding grid codes, but ground-breaking autonomous poweralso minimising the wind turbine’s Levelised conversion system that increases the Annual Expert opinion by Iñaki Soto, ManagingCost of Energy (LCoE). Energy Production (AEP), lifetime and Director of Indversis Management grid-performance of fixed-speed wind Consulting, S.L., a specialist consultingRepowering vs Life Extension turbines by enabling them to transform to company dedicated to enterprise promotion variable-speed machines to best match wind and business project development in India.Wind turbines are typically designed for a conditions without the need to recondition20 year life service and commercial wind both the original generator and wind turbine More information: http://www.indversis.power generation in India began in 1986. programmable logic controller (PLC). com/en/Many of the older low capacity windturbines installed more than 15 to 17 years Leadership positions In order to encourage investment andago and occupy some of the best wind sites development of the renewable energy sector,in India will soon need to be replaced with The leading top 5 turbine suppliers in India the Indian government has created amore efficient, larger capacity machines – are Gamesa, Suzlon, INOX, Regen and favourable regulatory framework enablingrepowering - or remain operational beyond WWI, according to MAKE Consulting. fiscal and financial policies, under thethis age. The decision what to do with the Gamesa continues to reinforce its position umbrella of the Make in India project,end-of-life assets must be carefully in India, where the company has ranked as availing of incentives such as generation-weighted: dismantling and disposing of the leading OEM for the third year running, based incentives (GBIs), capital and interestfunctional turbines or extending wind farm further increasing the gap with respect to subsidies, viability gap funding (VGF),life-time by increasing assets value, the number-two OEM and lifting its market concessional finance, fiscal exemptions etc.maximising revenue and reducing LCoE. share from 25% in 2014 to 34% in 2015. While recognising that the MNRE hasUntil recently, the market seemed to favour Strengthening its footprint in the Indian actively contributed to RE usage, power converter market, Ingeteam reached regulations require a similar dose of clarity www.peswind.com 41

PES ESSENTIALIngeteam Power Technology Headquarters – Energy in Spain ‘To date, 9% of all wind power capacity in India is equipped with Ingeteam’s technology.’and stability in order to create the desired national offshore wind energy policy in About Ingeteameffect. Government does not only have the October 2015. The National Institute forresponsibility to promulgate laws and Wind Energy (NIWE) is the nodal agency for Ingeteam, an independent supplier ofpolicies, but also to enforce them. implementing the policy and creating the electrical conversion equipment, offers necessary ecosystem for the sector. power converters, generators, turbineHere is where most of the foreign Facilitating Offshore Wind in India controllers, CMS, SCADA managementcompanies have faced their biggest hurdle. (FOWIND) is a European Union supported systems and O&M services for windEven though regulators have provided four-year project; led by the Global Wind turbines up to 12 MW for onshore andExcise Duty or Special Additional Duty Energy Council (GWEC) consortium to offshore applications.exemptions to “Wind operated electricity implement. In close consultation with thegenerator, its component and parts thereof Ministry of New and Renewable Energy The company is committed toincluding rotor and wind turbine controller”, (MNRE) and State governments, this project investing in technology and innovationthe reality has been far more complex and will facilitate offshore wind power as the drivers of future growth.ambiguous. Procedures or structures were development in India.not the obstacle, whereas the practical Since 1995, almost 24,000 windapplication of the benefits was, since they Offshore wind planning activities are power converters have beenare subject to the correct understanding of expected to be expedited in the next few commissioned with Ingeteam’sthe norms by the local officers. A large years and both onshore and offshore wind technology, accounting for 36 GW ofnumber of memorandums, circulars and energy are anticipated to contribute to installed wind power capacityamendments have been published seeking India’s transition towards use of clean worldwide and a 7.5% market share.to enlighten companies and officials about technologies in the power sector.the correct application of the rules, and The company’s global footprintexplain what a wind turbine consists of, or Challenges, hurdles or any other obstacle includes manufacturing facilities inwho are supposed to be the beneficiaries of aside, the Indian market is one of the most Europe, North and South America,the exemptions. attractive markets for any foreign company and sales and service centres in the business. Skilled English speaking strategically located all over theIn such a dynamic environment, manpower is well available in the principal world. In 2016, 5% of net sales werechallenges many times run faster than metro locations and well trained engineers invested in R&D, the backbone ofsolutions. Today, the Indian wind industry are approaching a fast moving emerging Ingeteam’s business activity.may have overcome their teething sector. Land is yet available at reasonableproblems, but they are yet to face other cost and construction cost is far from other renewable energy, it will be essential toand bigger ones. India is about to embark emerging countries. continue introducing comprehensive,on the largest tax reform ever faced in the stable and long-term support policies,country. The Goods and Services Tax India seems to be convinced that renewable carefully designed to ensure that they(GST) implementation will undo most of energy is the correct way to overcome operate in harmony with existing statethe existing tax benefits for the wind power generation deficit and ensure future level mechanisms so as to avoid reducingindustry. Additionally, the sector will demands; India’s energy security has their effectiveness.observe how some other privileges like become a key driving force of its economicincome tax holidays, accelerated policy. With substantial expansion required The 60 GW target from wind energy willdepreciation or generation based in energy infrastructure, India now has the require duplicating the existing capacity inincentives, will become history as well. opportunity to create a clean energy the next six years. Policy makers, wind industry to increase installed capacities turbine manufacturers and the entire supplyMarket outlook while reducing the deleterious impact on chain will face an endless number of human health, environment and the climate. challenges in the time to come.India already has a strong track record inonshore wind and its intention to enter the Although for India to reach its full potential www.ingeteam.comoffshore wind sector was outlined in a and to boost the necessary investment in42 PES Wind

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PES ESSENTIAL Pioneering reliable offshore giants in serial production 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, shares his reflections with PES, on the project from an engineering perspective and points out the resultant benefit for the customer. MHI Vestas-Burbo Bank. Courtesy of MHI Vestas Offshore Wind.44 PES Wind

PES ESSENTIALDr. Dirk StrasserDevelopment projects for the wind industryusually are characterised by shortdevelopment times and gearboxesdeveloped to specification. The 8 MWdevelopment started with a different focus. Areliable drivetrain at competitive costs wasthe objective, with reliability beingrecognised as one of the most importantcontributors to the turbine’s competitiveness.Before starting detail design, ZF cooperatedclosely with the customer in order to coverall gearbox requirements in the interfacespecifications. This means, on the one hand,a sound mechanical design on the rotorside, delivering a mechanical torque ofminimum 8,000 kNm whilst keeping parasiticloads small, and on the other hand, meetingmechanical and electrical requirements onthe generator side prescribed by theintegrated drivetrain layout.The turbine layout led to some majorgearbox characteristics like a maximumdiameter of 3,000 mm and a weight of 72metric tons, providing a total ratio ofapproximately 1:38. ZF selected thedifferential design as the mostadvantageous concept for this purpose. As www.peswind.com 45

PES ESSENTIAL8MW Gearbox Failure Mode Effect Analysis supports a least the same reliability level as systematic and structured development. conventional gearbox designs. Afterdescribed below, the design turned out to analysing the calculations and reflectingbe very reliable from a theoretical and Commercially available calculation methods on the design details, one observes thatpractical standpoint. and state of the art industry standards do complexity is not defined by the number of not incorporate reliability calculations. utilised parts. Instead, complexity isFor ZF, ensuring reliability means covering Traditional concepts supply safety factors as determined by an uncertain load flow,all relevant failure risks, including those a calculation result that does not even allow particularly during unexpected drivetrainalready seen in wind applications, but also for design comparison. Thus, ZF decided to events. ZF reduces complexity bynew ones that might emerge. The latter set up a parallel project with a team of five respecting classical design axioms.were identified as the challenges involved experts to develop a calculation method forin entering such a high power class. Thus, accurate reliability determination. A major axiom, for example, is safeguardingthe engineering effort was increased by a proper load sharing on gears and bearingsfactor of four compared to earlier projects. The target was to cover all gearbox by avoiding over constraining. The ZFNot only the classical calculation and components in a systematic manner, not differential gearbox provides such a loadsimulation methods, but also effective only gears and bearings but also structural sharing principle by splitting up the highstatic and dynamic simulation tools components and “C-parts”. The results of input torque into two planetary stages, eachneeded to be used. more than a thousand gear material of them designed with lowest complexity. investigations were incorporated in theContinually, the engineering team had to algorithm. Also, a formulation of heat To further safeguard the OPEX and enableattend to details like gear mesh treatment expertise from ZF’s central a planned service strategy, the productmodifications in the range of 20 to 30 research and other ZF-owned research were incorporates an innovative internal sensormicrons to safeguard proper load introduced into the tool. After two years of system. The system consists of vibration,distribution on the gear mesh caused by intensive work, the method was finalised. In temperature and pressure sensors andstructure deflections. conclusion, the team compared the therefore makes it possible to monitor the computed results to existing field experience health of all relevant components.At the same time, they still had to keep the with wind gearboxes and adjusted individualbig picture in mind and consider the algorithms when necessary. The validation process was aligned inimportant interaction of the major drivetrain accordance with the strong reliability focus.components, where deflections in the Computing reliability accurately reveals Examining many individual componentsmagnitude of some millimeters occur. ZF that the ZF differential gearbox provides at and four prototype gearboxes, ZF testedapplies modern, systematic engineering the product for more than three yearstools to keep the team on track. Basically, a before going into serial production. Since each component exceeded the range of experience in size and weight for wind application, the component tests were used as an early safeguard for major processes. For instance, the 900 kg planet’s heat treatment and the milling and grinding processes of the 60 mm high teeth, required proper validation. Several tests with sub-assemblies were performed in order to check major assembly processes such as applying pre-load on bearings. The gearbox validation comprises functional testing to verify assembly processes of the gearbox and drivetrain, to measure deflections and load distributions on gears and bearings, and to check efficiency, temperature and noise behavior. During this procedure, the simulation models were verified and optimisations were performed in the two robustness-tests and field-test prototypes. On the customer system test rig, which simulates all drivetrain loads including wind forces and moments, two gearboxes were tested, under severe conditions, for more than 1,500 hours. In addition, a two-year field test on a near shore prototype turbine was performed.46 PES Wind

ZF TECHNOLOGY IN WIND TURBINESPOWERING A WORLD IN MOTIONAs a leading worldwide automotive supplier for driveline and chassis technology, ZF can look back over100 years of experience in developing and building transmissions. Add to this more than 70 years of jointexperience in wind energy (along with the former Hansen and Bosch Rexroth) and ZF Wind Power is acompetent partner, supplying major manufacturers of gear-driven wind turbines with gearboxes rangingfrom 0.8 to 8 MW power capacity and serving all key wind power segments. ZF is determined to be theleading supplier in geared solutions for wind turbines and is committed to succeed in making wind powerthe most attractive energy source in the future – to power a world in motion. www.zf.com/windpower Visit us and discover our broad portfolio at: ▪ AWEA, Anaheim, May 22-25, 2017, Hall C, Stand 2742 ▪ Windergy India, The Ashok, New Delhi, April 25-27, 2017, Hall 1, Stand A115-A116

PES ESSENTIAL‘ZF is currently preparing for the nextgeneration of wind gearboxes andsolutions further improving energyefficiency and reduce costs.’ ZF Wind Power 8MW Design ZF’s advanced technology solutions After all tests were passed successfully, and each reliability-relevant bolt, the applied contribute to the transformation of the after several optimisations were performed, torque is traceable down to component global energy system, in which reliable, ZF started the 0-series production with a level and stored in the ERP system. robust and efficient products and highly mature product in 2015. systems conserve precious resources. Technology optimisations have made it Having successfully tested the product, ZF possible to further uprate the gearbox. The With combined expertise in then focused on a stable serial production. gearbox concept allows either a torque automotive and industrial technology, For this purpose, tolerance chain analysis, increase by more than 40% within ZF is determined to support its combined with statistical evaluation of the restricted outer dimensions or an increase customers in making wind power the 0-series components, was executed. of the total ratio by approximately 30%. ZF leading renewable energy source for Through ZF technology expertise, in therefore provides solutions for future the future. Sustainability lies at the cooperation with the customer and the drivetrain layouts. heart of our endeavors. component suppliers, an adjustment of cost driving tolerances was possible while The reduction of Cost of Energy for wind is With state-of-the-art manufacturing keeping reliability at the existing high level. crucial to make wind energy the preferred plants and worldwide service locations, energy source of the future. ZF is currently ZF is dedicated to delivering custom- Process optimisations, by introducing preparing for the next generation of wind built solutions and services on a global appropriate measurement tools to gearboxes and solutions further improving scale, meeting the individual needs of compensate for temperature variations in energy efficiency and reduce costs. Part of the global wind energy market. production, contribute to a stable and cost these innovation programs will focus on optimised process, keeping in mind for modular and integrated platform designs, Optimised service strategies - avoiding instance that tempering a 15 metric ton increased torque density and advanced unnecessary downtime - are the key to planet carrier requires several days. bearing technology. Gearbox sensor reduce operational costs. As a technology and data analytics will increase continuous innovator, ZF anticipates The assembly processes focused on cost the efficiency and reliability of wind the trend towards intelligent systems reduction and therefore speed increase as turbines. ZF expects a significant cost by enabling performance optimisation well. At the same time, extraordinary reduction potential within the wind industry, of the overall wind turbine. We are now attention was paid to keeping the process and is committed to develop this path. moving forward with “Intelligent under control. Following the Industry 4.0 Mechanical Systems”. mind-set, all bolt assembly tools are www.zf.com/windpower equipped with computer interfaces. For48 PES Wind

CORPORATE FOCUSA revolutionary coatingrepair systemOffshore wind turbines suffer from severe the remainder of the service life and can releases tons of heavy metals into the sea.corrosion and with limited access to them, easily be applied in the extreme conditionsthe choice of the right corrosion protection is encountered offshore. Solvent-based coatings, on the other hand,crucial. The most widely used protection emit VOC’s which have toxic effects onmethods are anti-corrosion coatings, often in The high repair costs should be reduced by organisms. Moreover, VOC’s contribute tocombination with cathodic protection (in the selecting a system which saves on surface photochemical reactions introducingsubmerged zone). However, these coatings preparation and application costs. This ground-level ozone. The introduction ofoften suffer from premature failure due to translates directly in a coating that is surface VOC’s into the environment can be avoidedmechanical damage, application errors or tolerant and reduces the amount of layers. by applying 100% solvent-free coatings.the wrong choice of coating system. Another concern is the environmental The Humidur coatings address all theThese failures need to be addressed during impact of offshore wind farms. Wind challenges mentioned above and isservice life to ensure the integrity of the turbines are known to create disturbances therefore the coating of choice for thestructure. The lack of accessibility results in (e.g. increased noise levels) that affect maintenance of the wind mills on thehigh repair costs up to €2000 per m². marine life. The environmental impact of the Thanet Wind Farm and Kentish FlatsTherefore it is important to choose a high corrosion protection should be considered Offshore Wind farm. The repairs are doneperformance repair system that will last for as well. For example, the use of zinc by rope-access. anodes has been under recent scrutiny as it www.peswind.com 49

CORPORATE FOCUS50 PES Wind