PES Wind 3 2020

PES ESSENTIAL Figure 3: short test at 100% • H eat run test: the thermal behaviour of the Figure 4: Ingeteam climatic (Temp & RH) chamber converter is assessed under several operation points of the generator. These tests are used to confirm that no temperature is outside the expected limits as well as to characterize the thermal model of the components. This information is particularly useful in order to detect potential cost reductions based on different geographic areas of wind farms. The new-generation power converter has been tested this way under the worst operation conditions for GSC, MSC and stator circuit. • S pecial tests: the configuration used for combination tests also allows some additional tests that reduce integration and FRT behaviour uncertainty to be carried out. In this case, the power converter has been subjected to motor mode test and short circuit at stator, which is critical in case of DFIG application. As an example, the figure 3 above shows the behaviour of the converter during a short circuit test. On the left side, MSC currents, peak current up to 9kA, in case of a short circuit at stator of 100% of Voltage drop. On the right, the rapid increase of chopper resistor ambient temperature can be seen. Extreme climatic condition tests A critical point of a validation process is the climatic one. To be able to verify empirically the correct behaviour of a converter and its components along the whole climatic range is important in order to detect unexpected behaviours that cannot be predicted by means of calculations. Ingeteam is able to carry out a detailed validation thanks to its test benches which are able to control the temperature and the humidity over a very wide range, and where the converters can operate at rated conditions. Executing tests at the extreme limits of temperature and humidity allows the observation and understanding of the specific behaviour of components when they operate close to their limit, and to define the best options regarding functionality and WWW.PESWIND.COM 51

PES ESSENTIAL cost. Without this empirical analysis, the o D etection of the points where Figure 7: Vibration test selection of components would be based on condensation could occur by provoking theoretical calculations and datasheets, it by means of extreme variations of because any change on their frequencies making a conservative selection that would temperatures with high RH values. could lead to structural damage. imply overrun, more likely. With this validation the optimum design is obtained. o Verification of de-humidification time In addition, shock tests with extreme required by heating system once acceleration values are carried out. In addition, the performance in case of failure condensation has occurred under the can be assessed in detail. Without this kind of worst conditions. Following these tests, the converter must test infrastructure, it would be impossible to remain operational. No damage affecting know how the converter really reacts when a o Confirmation of anti-condensation safety can be accepted. component such as a fan or a cooler fails. The logics validation, where all the possible behaviour at a specific room temperature or scenarios are validated. Passing these tests guarantees that the humidity value could differ drastically from combination of converter and wind turbine is another value. This uncertainty is overcome • D amp heat tests: tests of several days correct and will withstand the lifetime of the by carrying out failure tests at several (>96h) are carried out at maximum turbine. The results are also correlated with climatic points to identify the real temperature and RH values. After that, the FEM models developed. performance at each point without dielectric properties are verified. depending on assumptions and calculations Electromagnetic compatibility tests that could provide erroneous conclusions Extreme mechanical condition tests and lead to designs that do not fulfil the The immunity of the converter against the requirements or could even be dangerous. Another critical part of the validation process emissions of the environment or generated of the converter for its final application is the by nearby devices is critical to guarantee the The climatic extreme conditions validation assessment of its behaviour and response to maximum availability of the turbine. includes the following type of tests: low frequency vibrations. Incorrect behaviour could cause severe damage to the Also, the converter itself can generate • Heat run tests: the thermal behaviour of the converter and the wind turbine. emissions that could affect the correct converter is assessed, setting maximum operation of nearby items, within or outside current values and the worst temperatures. Depending on the wind turbine, the location the turbine. The whole range for both operation of the converter and the fastening structure, temperatures and for external ambient and the response could change drastically. Thus, To confirm that the converter is able to external cooling system is covered. this is a process to be carried out for each operate in an environment within the See Figure 5. wind turbine-converter combination. expected emissions limits, compatibility • Cold climate tests: in this test, it is Prior to the test, Ingeteam develops detailed verified that the converter is operative in Finite Elements Models (FEM) to predict the the desired time under the lowest response of the converter and to assess the environmental temperatures and once different design options. operating starts the cooling/heating logics are valid. Thus, in addition to The main test consists in sinusoidal sweeps temperature, DI/DO are monitored. In using the specific ‘Frequency-Acceleration addition, the operation under variable profiles’. These profiles are defined based cycles of external temperature is on accelerated test processes with the aim assessed. See Figure 6. of simulating the whole accumulated damage along the life of the turbine in only a • C ondensation tests to cover the following couple of hours. processes: During the tests, the resonances are checked Figure 5: Heat run test Figure 6: Cold climate test temperatures evolution (peaks due to activation/deactivation logics) 52 PES WIND

PES ESSENTIAL Figure 8: Results for conducted emissions combined requirements of maximum design phase of the converter. Being durability and reliability with cost- proactive regarding regulatory demands Figure 9: Radiated emissions test optimization is essential, but Ingeteam leads to the improvement of new converter tests according IEC61800-3 standard are understands that different international designs and avoids late modifications that included in Ingeteam’s validation process. standards can present a barrier for wind could delay a project. Any new design within These tests are carried out in the turbine installation. the company integrates the strictest manufacturing plant, using the most standards for all the applicable marks and representative configuration, and by Therefore, Ingeteam considers the strictest labels including CE, UL or DNV-GL. certification bodies. international standards for all its designs. Passing them minimizes drastically the risk The participation in IEC committees such as and uncertainty regarding EMC. Ingeteam participates in the committees TC22 (Electronic Power Conversion) and Certification process that issue these requirements and thus it TC88 (Wind Energy Generation Systems), Another cornerstone of Ingeteam’s design stays up to date of the latest regulatory IECRE (IEC Renewable Energy), as well as in process is certification. Achieving the innovations and implements them from the specific working groups within IEC including WG05 (Hazardous Substance) or WG26 (SW testing), or STP UL groups for development of standards like UL508 (Industrial Control Equipment), proves the commitment of Ingeteam to the quality of its products. Moreover, this approach is not only applied to product design, but also the manufacture of the products in its plants. For that purpose, the plants are certified for the manufacture of any component and marked with the main wind mark labels. These certifications confirm international compliance and avoid project delays due to any marking regulations and barriers. In addition, they facilitate the certification process of the wind turbine. Ingeteam has already certified its plants for power converter within DNV-GL and UL scopes, and in addition has been trained for APQP4Wind. Conclusion Extended validation of Ingeteam’s new generation of power converters confirms their operational performance under the most severe conditions. The use of full-scale test benches for integration assessment and climatic behaviour evaluation are key to optimize the design and detect potential improvements at an early stage. The information obtained from the tests assures the optimization of the design and guarantees that the converter is going to operate properly in the field. The incorporation of the latest and most stringent regulatory requirements at the design phase and also in the certification of the manufacturing for plant, allows Ingeteam to facilitate the wind turbine certification process, wherever the geographical location, thereby reducing the project time-to-market and saving costs throughout the development and validation design processes. Clients can be confident that thanks to extended validation, Ingeteam’s new products deliver the best in-field value for money. www.ingeteam.com WWW.PESWIND.COM 53

ASK THE EXPERTS: EQUIPMENT A real unique selling point! Liftket‘s CEO Jürgen Dlugi, tells PES about the company’s expansion in the wind industry. In 1953 they started off by supplying electric chain hoists and are now able to offer a complete service crane globally, suitable for on and offshore work. Well aware of safety needs, they provide full training and tailor made packages to meet their clients’ needs on request. PES: A warm welcome to PES Wind, it’s good the company initially developed agricultural A uniquely high level of vertical integration to talk with you. Would you like to begin by equipment, before specializing in electric enables us to be flexible for our customers. In giving us an overview of LIFTKET? chain hoists from 1953. Hoffmann’s combination with our unique structure, we innovations, namely the horizontal assembly can offer a very comprehensive range of Jürgen Dlugi: We are one of the largest and of both motor and gearbox and the patented products, from series production to oldest manufacturers of electric chain hoists safety-brake/clutch system, set the custom-made products. worldwide, with loads ranging from 125 kg to standard for electric chain hoists. 25,000 kg. Founded in 1948 by D. Hoffmann, At our company headquarters in Wurzen, are 54 PES WIND

ASK THE EXPERTS: EQUIPMENT all departments, from administration to is that the product requirements are much Jürgen Dlugi production, under one roof, which brings higher. Special corrosion protection is many advantages, staffed currently by about required, other painting is needed, and in 250 employees. Fast decision-making general, other materials are sometimes processes and quick reactions to the used. In addition, the lifting heights and loads corresponding customer needs are what are usually much higher. characterize us. PES: Safety must be a preoccupation at PES: We know you are involved in various LIFTKET, we’d be interested to know about industries and would like to know how your training programs? important the wind sector is for you? JD: We deliver any kind of tailor-made JD: We were the first supplier of service service and training concepts for our cranes, to the wind industry and nowadays we customers. Therefore, we have established supply not only a lifting device, but a complete our own ‘training center’, called the service crane that meets the requirements of LIFTKADEMIE. our industry most effectively. Maintenance work for hoisting equipment PES: We are curious about the differences in has to be carried out by trained and working on and offshore? authorised professionals only. Authorised people must have theoretical training as well JD: The main difference in the offshore sector WWW.PESWIND.COM 55

ASK THE EXPERTS: EQUIPMENT Manufacturing process of LIFTKET chain hoists as experience in the field of cranes and In addition, we also offer training courses to make? How do you see this developing hoists. They must have excellent know-how especially tailored to our customers’ over the next 6-12 months? of the special regulations and must be able to requirements. Our training courses can be decide whether the lifting equipment is in held either in our in-house training centre or JD: The current situation around COVID-19 safe working order or not. at the customer’s premises worldwide. has of course affected the business Within the LIFTKADEMIE we aim to provide somehow. Demand has become weaker. our customers and their employees with the PES: Is research and development an Nevertheless, there were no negative necessary know-how to ensure safe integral part of your business, do you have effects on the supply chain for our working on and with our electric chain an active R&D department? customers. We believe that the bottom has hoists. On the one hand, 3 ‘standard been reached, as we see a slow but steady trainings’ can be booked: Repair & JD: Of course. Based on our core principle: upwards trend. Maintenance, this training can also be ‘designed, engineered and manufactured in booked online via our website www.liftket. Germany by ourselves’ we have our own www.liftket.de de, Train the Trainer and Sales Training. R&D department. As already mentioned before, the advantages of having everything About LIFTKET LIFTKET Service Crane Solution under one roof also apply here. The R&D department works closely together with our LIFTKET Hoffmann GmbH is an production and technical department, internationally renowned which brings short decision-making manufacturer of electric chain hoists processes. We also have special test with loads ranging from 125 kg to laboratories for wind turbines. 25,000 kg. At the company premises in Wurzen, Germany, currently about 250 PES: What makes your solutions stand out employees develop and manufacture from the competition, what are the benefits solutions for the three business to the end user? segments industry, custom, and stage. A strong network of service and JD: Every single electric chain hoist is sales partners ensure customer- designed, developed, produced and tested oriented stock-keeping, maintenance, by us under real load and overload conditions. and repair. A unique ID makes it possible to trace exactly when an electric chain hoist was built, by LIFTKET manufactures modular whom, with which raw materials, from which electric chain hoists for virtually every supplier, even after 10 years. A real USP application that involves the safe and (Unique Selling Point)! precise lifting of loads. Founded in 1948 by Dietrich Hoffmann, the PES: Can you tell us something about your company initially developed geographical reach? agricultural equipment before specializing and exclusively focusing JD: Numerous customers and partners in on electric chain hoists from 1953. over 65 countries rely on our LIFTKET quality Hoffmann’s innovations, namely the products. Safety, durability, ease of horizontal assembly of motor and maintenance, service and a fair price/ gearbox and the patented safety- performance ratio are particularly valued. brake/clutch system, still set the standard for electric chain hoists. PES: How has the current coronavirus situation impacted on your business and how you run it? What changes have you had 56 PES WIND



TALKING POINT How can we make the most out of wind energy with smarter grid and market integration? SGS Wind Turbines Words: G raham Ault, Executive Director at Smarter Grid Solutions As we move towards net zero carbon emissions targets, significant efforts to connect more clean energy resources to the grid are being made. Globally, the energy industry is welcoming expected that cumulative capacity of lockdowns and economic changes on innovations in renewable energy and distributed storage and solar in North electricity demand, there are many Distributed Energy Resource (DER) assets. As America, Europe and Oceania will double by variables which can impact the level of a result, correctly managing and distributing 2025. Similar predictions were made by The renewable penetration, the decarbonisation the energy from these DER assets to enable International Renewable Energy Agency of the grid and the operation of wind power the most efficient, clean and smart energy (IRENA) who project that the onshore wind on a daily basis. system is a big focus for system operators, capacity growth rate will quadruple to more utilities and asset owners alike. than 200 GW added annually by 2040. As it stands, the UK is the world leader in offshore wind, reaching the capability to Big strides have been made already in the Renewables by nature are intermittent. The power the equivalent of 4.5 million homes capabilities of energy storage and sun does not always shine and the wind does per year and is currently on track to generate distribution networks, with major projects not always blow. Add to that, the current more than 10% of UK electricity by the end testing long-term battery models. A recent uncertainty over the long-term implications of 2020. Whereas in the US, wind accounts study by Wood Mackenzie revealed that it is of the Covid-19 pandemic and subsequent for little more than 7% of the energy mix, but 58 PES WIND

TALKING POINT ‘DERMS provide scope for low carbon technology scalability and flexibility to decrease the dependence on fossil fuels and contribute towards a fully smart, decarbonised energy system.’ its share is growing. In the past couple of functions that harness the benefits of DER in 3. Economic optimisation and scheduled years, figures are showing a significant the grid while protecting against the dispatch increase and in 2019, it accounted for around potential downsides of supply continuity. 300 million MWh. This application can be seen in action in Increasingly, grid supporting services will be south-east England where a large additional provided by DER, which will require DSOs to To increase the roll-out of wind generated capacity from wind farms, along with solar perform the same economic optimisation power, it is essential that technologies are photovoltaics, has been added to the functions as performed by energy market used to combat the challenges faced. distribution grid, helping to overcome the operators today. DSOs will build portfolios Distributed Energy Resource Management cost and delay that would otherwise have of flexible DER service providers and Systems (DERMS) software can play a vital resulted from network capacity shortfalls. contract, maintain availability and utilise the role in balancing the grid’s ever-evolving required flexibility through optimal, supply and demand. DERMS technology It is clear that using this software can help market-based dispatch. In time, this will provides the necessary connections towards achieving net zero carbon emissions include the use of generation, demand, between clean energy producers and other targets but what should onshore wind customer and storage flexibility low carbon technologies such as electric developers, network operators and emerging orchestrated through the same DERMS and vehicles, wind and solar, the grid and the Distribution System Operators (DSOs) look associated market platform. This can wider system and markets. This provides the for to ensure they are getting the most out of provide cost-based and carbon-based necessary data and control infrastructure to their DERMS system? optimisation of all DER and support new manage the distribution and use of clean customer business models and objectives. energy where it is most needed, to meet the 1. Integration with other network 4. Forecasting demand of end users, curtail surplus management systems As DERs become more prevalent and load production when demand is low and grid patterns and technologies change, DSOs are constraints emerge, and make use of various In order to create a smarter and more flexible becoming more reliant on having reliable forms of energy storage where available. system, DERMS software must be able to forecast information in order to schedule integrate with other operational systems service provision by DERs, for example, Using DERMS to get the most out of already in place, for example, advanced demand response and flex services. Being wind power distribution management systems (ADMS). able to forecast for real time operations This means that control room operators can creates a more resilient set of network Properly implemented DERMS can enable operate the network through the ADMS while management processes which can help large scale roll-out of distributed wind the DERMS can monitor and control the DER DSOs adapt and plan at different timescales energy by creating an ecosystem of DER autonomously, providing visibility of DER and in advance. This will provide additional management which provides value to a range DERMS operation through the single opportunity to wind farms to deliver network of clean energy players of all sizes and types. operational window of the ADMS. This services as well as coordinate operations and It implements the three-pronged approach two-way integration unlocks much more the forecasts themselves with the DSO. to both digitalise and decarbonise a grid capability in both the DERMS and the ADMS. based on increasingly decentralised energy. Graham Ault This also allows network operators to scale DERMS come in different shapes and sizes. their flexible wind power integration and For example, Fleet DERMS manage the management solutions to the wider network operation, customer and commercial with ease and without the additional system exploitation of distributed energy or operational costs. opportunities by providing fleet wide visibility and controllability of diverse and 2. Real-time constraint management geographically distributed energy assets. In applications this case, DERMS provides the digital backbone on which to build Virtual Power A good DERMS allows the wind power Plant (VPP) solutions that build multiple DER hosting capacity of the network to be into grid and market significant assets. increased without diminishing network security because DER can be managed in While planning the development and grid real-time based on live network conditions connection of new wind power assets, the and with multiple layers of security and primary form of DERMS of interest to the fail-to-safes. This, in turn, can also add wind industry is called, Utility DERMS. This layers of network and supply security application of the technology enables faster through DSO flexibility service provision and less expensive grid interconnection and flexible network operation in the same providing benefits to DER developers and way that ancillary services, such as grid operators. frequency response, support the operation of the energy system today. Utility DERMS deliver grid management WWW.PESWIND.COM 59

TALKING POINT Darren, Johanna and Tom from Smarter Grid Solutions Managed Services team 5. Data analytics anticipate events and opportunities. Good The significance to system operation is DERMS provide support for data capture, growing fast. The connection between larger The DSO operating model is changing to sharing and analytics. Examples of such wind power (onshore and offshore), smaller have a more active interaction between open, or even collaborative, approaches to wind farms integrated directly into energy customers, energy asset operators, operational and planning data and advanced distribution systems and distribution and DSOs and other service providers. DERMS uses of it are emerging but much more is customer flexibility is also growing in users and stakeholders require greater now expected. significance. Some of the core infrastructure visibility of what the system is doing in to enable that whole system coordination and real-time and a better understanding of why Powering forward optimisation is already in place but the tools to these actions have been carried out. That utilise the distribution and storage of wind data can also be used by both DSOs and Many innovations and developments have power needs to be taken further to meet the network users to better respond and been made in both onshore and offshore wind. full requirements of a net zero system. David Smith, Senior Engineer working on an ANM Element By ensuring that network operators, and emerging DSOs are implementing the above checklist of crucial DERMS functionality, the road to net zero could be much smoother and faster. DERMS provide scope for low carbon technology scalability and flexibility to decrease the dependence on fossil fuels and contribute towards a fully smart, decarbonised energy system. Implementing DERMS properly lays the foundations for ongoing exploitation of DER and larger wind power flexibility. Doing that groundwork now means that DSOs will be in a stronger position to deliver multiple value streams to customers, gain more visibility and control over their systems, and deliver flexibility and further integration points into new markets with new value streams to DSOs and network users. www.smartergridsolutions.com 60 PES WIND





STEEL INSPECT® WIND Q7 worldwide quality consulting PLANT Steel Inspect provides Quality throughout all Project Execution Phases because quality matters 1 Design Check and Procurement Support 2 Manufacturing Control and Expediting steelinspect.com 3 Documentation Support 4 Inspections prior to Transport 5 Preparation for Erection & Installation 6 QC for Erection and Commissioning Stage 7 Final Acceptance and Handover

ASK THE EXPERTS: PROJECT MANAGEMENT Integrated quality control in offshore wind: part 2 Following on from our interview with Wim Keen in the last edition, PES had some questions for Maik Rienecker, founder of Steel Inspect and father of the unique Q7 concept for optimal quality management of offshore windfarm EPCI (Engineering, Procurement, Construction, Installation) projects. He was happy to explain the Q7 concept in more detail and share the benefits this brings to offshore wind farm construction projects. 64 PES WIND

ASK THE EXPERTS: PROJECT MANAGEMENT PES: Hi Maik, welcome back to PES Wind, for manufacturing, including site construction project management, quality assurance in the second part of the interview, following and commissioning for worldwide EPCI the field to transform into a global, lean on from the last issue. For the benefit of our power plant projects. holding structure. new readers, would you like to begin by telling us something about the history of Consequentially I capitalized on this PES: In our earlier discussion, Wim Keen Steel Inspect? experience I gathered from various kinds of explained that offshore wind makes up projects worldwide and founded the more than a third of Steel Inspect’s annual Maik Rienecker: Steel Inspect and especially company. From 2016 we consistently turnover. He also told us that your approach its predecessor Rienecker PM was founded in pursued the growth path, as a quality service towards quality is very unique, because of 2006. At this time, I had already gained wide provider for inspection and monitoring. the ‘Q7 concept’. Can you please explain experience over the years from 1990, in The establishment of Steel Inspect allowed what this is in general and how it was born? purchasing and quality management for us to pool the experience of 15 years WWW.PESWIND.COM 65

ASK THE EXPERTS: PROJECT MANAGEMENT MR: The main added value is the holistic construction projects? Maik Rienecker approach of integrated project quality control and time supervision, throughout all MR: The Q7 concept comprises the specific benefit does Steel Inspect bring in the project execution phases, in order to management of a complete offshore wind in this phase? efficiently reduce costs on quality and to farm construction project: from design, up to MR: I started by defining the main steps of a improve time awareness! and including handover. All managed by one project execution, the phase of a project and the same team, which, by overviewing where the points of return are difficult and This means know-how transfer from the every single phase, is able to prevent engineering phase onwards, starting with bottlenecks between single phases from quality control during procurement, happening. This is a huge advantage: by fabrication and delivery until the erection doing so we prevent time delays and quality and commissioning on site. This also setbacks in a very early stage. includes on-time delivery, as well as maintaining the right mindset of all involved It goes without saying that all of the parties. Finally, we also take responsibility documentation is also managed by us: for cost optimization for the duration the starting with a Project Quality Control Plan, project execution. which we set up and from it derive all quality documents, needed for the complete The idea itself was born out of my way of project, in all phases. looking at project execution, as an integrated process where the single phases are Furthermore: the specialists on projects connected to each other and consequences bring in experience from multiple former of action are very often obvious only in one of projects and are thus automatically acting the next phases. proactively to prevent any bottlenecks from happening. PES: Why is the Q7 concept so important for the success of offshore wind farm PES: Why 7 steps and can you explain what step 1 of the Q7 concept entails? What • Establishment of data Q7 Quality Doc Workflow interface Establishment of Data Interface Configuration > diverse Interfaces available Contractors/Fabricators for XLS/XML/Sharepoint/ Documentum/Open Text/ Ticket System Outlook/Primavera/MS Project/SAP/3D/2D and SQL Construction Site Database requests, new Interface via API or WEB Project Mgmt & Controls Suppliers Engineering Services • Scope data transfer Q7 or complete Project > Standard Transfer via Bulk DOKU automated upload of documents • Service and daily use / support > training days for the client (User/Power User) • As-built always up to date! 66 PES WIND

ASK THE EXPERTS: PROJECT MANAGEMENT expansive. Mainly during fabrication, to teach all project members the fact that MR: Currently we have only been involved in transport and installation. Q1 stands for only released and updated documents are one or more of the Q7 phases. Clients and design and procurement support, phases used, monitored and accessible for all partners are well aware of the advantages, in which the details for the further involved parties and departments. but it takes a lot of engagement and trust to implementation are defined and prepared. cooperate in all these phases with an external That’s why we start with quality PES: As in an offshore wind farm EPCI project partner, who will be looking at internal assurance and control during engineering after production of the components, the processes to optimize them. and procurement. installation and commissioning phases are also very important and where there is a high We have already proposed the whole concept, PES: Steel Inspect brings in a lot of potential for bottlenecks and delays. however, based on complexity and its scope experience in quality control for the So, how the Q7 concept manage these overlapping different phases and departments production of steel components. Since phases successfully? it will always need a careful study of the project when and for which components? and the needs of our clients. MR: The Project Quality Control Plan serves MR: We have especially been involved in as a tool to drive the project, with less costs We are also able to support a project during a foundation parts like monopiles, jackets and incurred by poor quality and is always specified phase. Based on this approach the transitions pieces, as well as tower parts and focussed on being on time. specific services necessary for a specific nacelle production. project must always be defined thoroughly, At the same time such a quality plan defines together with our clients as much as possible Additionally, we have already participated in the bottlenecks and problems known from in advance. the fabrication of offshore substations. former projects and contracts so as to avoid References are available for about 20 them and, very importantly, not only to know PES: For whom is the Q7 concept especially projects starting in 2011 with GlobalTech1. about them, but to keep them in mind at beneficial? Some of the latest projects we have been all times. involved are Moray East, Danish Kriegers Flak MR: It is especially made for project owners, and Kaskasi. Hollandse Kust Zued, one of our It needs proactive meetings and analysis investors, energy providers, EPCI next projects has just started. prior to the implementation of the single contractors and large steel workshops with phases. Unfortunately, very often there is no different subsidiaries and sub-suppliers. PES: What role does documentation play in time given for such analyses and project an offshore wind farm construction project preparation. So, this missing time will cost We also see the concept as a very and how does you manage this topic real money at later stages of the project. If appropriate supplement for engineering successfully to the benefit of its clients? this fact is taken in to account by all the offices to complete their offers. different involved departments and parties MR: Each industrial plant project depends on the project will run smoother and on time. It PES: How do you see this evolving in its documentation, especially on the quality is indeed so simple. the future? and the on-time delivery of documents, the data base structure and the change process. PES: Can you give an example of a specific MR: I’m convinced that the Q7 concept will be project you were involved in and where the fully understood by our clients and taken Another point is the accessibility for all application of the Q7 concept brought over in specific ways, because quality project members. Also, here it is important significant advantages to the project? matters right from the beginning and throughout. The holistic approach of quality and time will be the only way to improve the execution of projects, especially in complex developments such as wind farms. Reduction of non-budgeted costs will come along if our concept is used by adapting it specifically. PES: So, how do you see yourselves in 5 years’ time? MR: Steel Inspect will dive in deeper into the business of renewable energy, but not forgetting where we came from. We will always be linked to the entire range of power plants, supporting our clients as described in this article. I’m convinced that only a meaningful mix of energy sources will be the future for mankind, of course adapted to the environmental standards just being set up worldwide. Within this energy mix the offshore energy, both fixed and floating, will continue to play a very important role. It will grow further and we are ready and eager to grow with it. www.steelinspect.com WWW.PESWIND.COM 67

THINK TANK Continuous wave wind Lidars: all heights, all terrains, always available and for all turbine rotors 68 PES WIND

THINK TANK A wind Lidar is quite simply a remarkable piece of technology recently described by Avangrid as having ‘advanced the wind industry globally’. Generic Lidar benefits are summarised by Renewable Energy Systems (RES) as being ‘safer, cheaper, better, faster’ than traditional meteorological masts. An invisible, eye-safe beam of light interrogated i.e. availability is not major renewable energy power project. Istos interrogates the sky above at user defined height dependent. Renewables Ltd. is performing the wind heights and determines the characteristics of measurement programme using a ZX 300 the wind in order to advise and improve wind 3. A n unparalleled range of measurements Lidar together with very short 30-metre- and meteorological industry understanding can be taken from the installed location high wind data reference masts. Recording around the world, onshore and offshore, on (~1m Above Ground Level) from just 10 wind data across the full turbine rotor and fixed and floating structures. metres and up to 300 metres. beyond top tip height of even the largest wind turbines, the ZX 300 Lidar eliminates Continuous Wave (CW) Lidars are able to These unique features of CW Lidar are the need for a full scale conventional achieve something unique in addition; this is described and evidenced below, beginning meteorological mast approach. due to their on-board ruggedized focussing with vertical profiling use cases. system that allows for the following features: The combination of a roaming Lidar with only All heights a very short met mast as a fixed, long-term, 1. A ll the laser power is focussed at each secondary reference, this bankable specific measurement distance ensuring A novel approach to wind measurements can methodology cuts cost, reduces the need for very high sensitivity which in turn allows often provide the best approach when working at height and makes establishing the wind measurements to be rapidly project-specific factors such as cost, wind profile across the whole site far less integrated over short periods of times complexity of terrain or time are taken into time consuming. on moving platforms e.g. floating Lidar account. Continuous Wave Lidars deliver applications, or when the wind flow is flexibility in this regard by measuring across a With a low visual impact, the low height changing rapidly, such as in complex very broad range of heights, from ground- approach to measurement equipment helps flow, and equally over large areas when level up to 200 metres and beyond, up to 300 to curb potentially significant business risks scanning the larger wind field, for wind metres in certain applications. Two examples while simultaneously reducing project turbine performance measurements are discussed below. uncertainty. The flexibility afforded by a and control. mobile Lidar unit also gives developers an Very short met masts combined with opportunity to fully explore the wind 2. In all applications the focussing of the roaming CW Lidar potential of a site. laser also ensures maximum availability that is not subject to the range being A new wind measurement campaign is Recording at four locations, the latest underway in western Greece as part of a Figure 1: Low visual impact solution with ZX 300 sited in trailer next to short 30m Typical trailer installation met mast. WWW.PESWIND.COM 69

THINK TANK measurement campaign from Istos is to form Combined results from >500 ZX300 performance verifications - Data Availability a key part of the development of an approximately 160 MW wind power Height (m) Data Availability % installation that is planned for the location. (m) Mean Std Dev Data obtained during the analysis period will support the optimisation of the project 180 99.00% 0.8 both in terms of the final layout and the selection of the ideal wind turbine model, 160 99.10% 0.9 including the rotor diameter and its rated generation capacity. 140 99.30% 0.9 105 99.50% 0.9 In addition, while the complex and rocky terrain found in this part of Greece and 91 98.20% 1.4 mountainous regions elsewhere can be challenging for wind measurement, the 70 98.80% 1.1 advanced data capture from a 50Hz Continuous Wave scanning Lidar such as ZX 45 99.00% 1 300 ensures a high degree of accuracy is possible even in the most difficult scenarios. 20 99.10% 1.2 Very tall met mast validations with Figure 2: Statistical analysis of data availability of a batch of over 500 ZephIR / ZX 300 performance verifications CW Lidar from the UK Remote Sensing Test Site. In contrast with the previous case study, a Combined results from >500 ZephIR 300 performance verifications - Horizontal wind two-year measurement campaign of a speeds vertical profiling continuous-wave (CW) focusing wind Lidar has been carried out by Height (m) Gradient R2 the Royal Netherlands Meteorological Institute (KNMI) at Cabauw, the Netherlands. (m) Mean Std Dev Mean Std Dev Data availability and data quality of the wind 91 1.002 0.007 0.990 0.006 Lidar under various meteorological conditions was compared with in situ wind 70 1.001 0.005 0.992 0.006 measurements at several heights on the 213m tall meteorological mast. 45 1.000 0.005 0.993 0.006 An overall availability of quality controlled 20 0.998 0.005 0.993 0.006 wind Lidar data of 97% - 98% was achieved across the two-year period. Within the wind Figure 3: Statistical analysis of horizontal wind speed of a batch of over 500 ZephIR / ZX 300 performance energy industry wind Lidars are typically verifications from the UK Remote Sensing Test Site. validated between 4 m/s and 16 m/s and for this range of wind speeds the correlation As reported above, the constant high terrain and fixed objects, the assumption of gradient against the mast was between 0.99 sensitivity of CW Lidar ensures high levels of homogeneous flow conditions within the - 1.00, with 1 corresponding to theoretical data availability. ZephIR / ZX 300 provides measurement volume introduces differences perfect agreement. The ‘scatter’ of finance-grade wind measurements up to between Lidar and cup anemometer. In measurements observed was low, with R2 typical hub heights and have demonstrated situations like this a flow conversion values better than 0.996. These consistently reliable and available wind technique can be applied. measurements equate to a bias in the measurements to ranges from ground level horizontal wind speed of just 0.03 - up to an IEC compliant met mast at the UK CFARS compared the various techniques 0.13 m/s. The mean bias in the wind Remote Sensing Test Site. adopted when using a WindCube, Triton and direction is within 2°, which is on the same ZX 300 remote sensor and presented the order as the combined uncertainty in the All terrains following analysis of the accuracy of each alignment of the wind Lidars and the mast device pre- and post-conversion / correction wind vanes. In October 2020 the Consortium for the of data to account for the complex flow as Advancement of Remote Sensing (CFARS) shown in Figure 4. This combination of low and high released its literature review of Remote measurements, with proven performance Sensing Devices operating in complex flow. Across a broad range of cases previously throughout creates a very flexible approach These devices included the WindCube published by ZX Lidars and Meteodyn to projects that utilise CW Lidars. (Leosphere, a Vaisala company), Triton Sonic incorporating 13 different wind project Wind Profiler (Vaisala) and ZX 300 (ZX Lidars), locations, data presented confirmed that CFD Always available a Continuous Wave Lidar. conversion of ZX 300 data in non- homogeneous flow conditions produced Further to the above study performed by Ground-based Lidars and Sodars employ a excellent agreement with collocated KNMI, more than 500 individual performance variety of beam probing or scan patterns by anemometry. As a result, the data can be validations of Continuous Wave Lidars at the which the horizontal wind speed, vertical considered as finance-grade in such situations. UK Remote Sensing Test Site have been wind speed and wind direction are derived conducted that specifically investigate the - all assume homogeneous flow conditions ZX 300 performance in complex flow is performance across all measurement within the scan / beam volume. In contrast, achieved by its unique 50 Line of Sight heights with respect to data availability and traditional meteorological masts equipped measurements in just 1-second. From this accuracy (limited to a maximum of 91 metres with cup anemometers provide a single baseline performance, the use of additional due to the mast height) and the summary of measurement at the installation point of the Complex Flow tools available from a range of results is presented in Figures 2 and 3: sensor. In complex flow, often caused by service providers including WindSim, 70 PES WIND

THINK TANK Figure 4: Presented at AWEA Wind Resource Assessment 2020. Courtesy of CFARS, A. Black, M. Debnath, A. Lammers, P. Mazoyer, R. Schultz, T. Spaulding, S. Wylie Meteodyn and Natural Power are able to challenge has concluded in the successful These CW Lidar feature extend further optimize the performance of ZX 300 further, development and validation programme by with horizontal profiling use cases as delivering results that are traceable and computational wind engineering company discussed below. auditable with a published conversion process. ZephyScience and independent wind consultancy Deutsche WindGuard of a All rotors With regards to the range of terrain classes further data conversion technique ‘ZX CFR’ as defined by Bingöl et al., 20091. ZX 300 was (Complex Flow Resolver). This has now also Mounted horizontally, for example on wind also shown to perform to high levels of demonstrated results to known and turbines, Continuous Wave Lidars utilise the accuracy in all conditions including even acceptable uncertainties allowing ZX Lidar rapid data rate, which use a default highly complex sites as shown in Figure 5. systems to be deployed standalone in integration time of 20.48 milliseconds giving complex terrain and deliver wind speed and a nearly 50 Hz data rate, to interrogate the Continuing collaboration around this wind direction measurements that can be wind field over a wide area in real-time. included within Energy Yield Assessments 1 F . Bingöl Complex Terrain and Wind Lidars. Risø- (EYAs) and Site Suitability Assessments (SA). In October 2020, Siemens Gamesa PhD-52 (EN) August 2009 Renewable Energy (SGRE) released a Figure 5: Presented at AWEA Wind Resource Assessment 2020. Courtesy of CFARS, A. Black, M. Debnath, A. Lammers, P. Mazoyer, R. Schultz, T. Spaulding, S. Wylie WWW.PESWIND.COM 71

THINK TANK Figure 6: ZX TM measuring across the full rotor of large offshore turbine rotors and out to 2.5D statement of testing and approval of operational rotor equivalent power curves issues in the wind industry. Over this period, nacelle-based CW wind Lidar ‘ZX TM’ for the can also be measured with ZX TM’s unique 50 experience has been gained in many purpose of Power Performance Testing on points around the full rotor swept area, applications and the general understanding Siemens Gamesa wind turbines. This specific particularly important for turbines with of Lidars’ capability has improved. It has now Lidar allows the power curve of SGRE wind larger rotor diameters offshore and on sites become a mainstream technique, and there turbines to be measured and verified as a with complex veer or shear profiles onshore. is a much greater appreciation of the value it function of the Hub Height wind speed and can offer to wind power and meteorological may be, when agreed with the customer, Finally, the rapid data of rate of ZX TM further projects as demonstrated here. The decision used instead of the procedure described in permits investigation of turbulence in for ZX Lidars to adopt CW technology for the IEC61400-12-1:2017 (ed. 1/ed. 2) using a fluctuating flows at a sample rate wind Lidar many decades ago continues to meteorological mast and anemometry approaching that of a sonic anemometer. deliver benefits today and the wealth of data installation. This advance opens the door to collected only allows for further optimisation significant cost reductions in fully-approved Conclusion to specific use cases, or adoption within new turbine power performance testing. use cases. Continuous Wave Lidar has now been used Importantly and drawing on the CW benefits, for nearly two decades to analyse real-world www.zxlidars.com Figure 7: ZX TM measuring operational rotor equivalent power curves, increasing wind field knowledge when compared to traditional 2 and 4 beam modes 72 PES WIND

Part of Croda International Plc

THINK TANK Wind turbine energy generation: reliability problems and solutions Wind turbine reliability remains an issue Words: Vanessa Bill - Sales Coordinator, Petr Chizhik, Lead Applications Scientist Nick Weldon, Technical Marketing Manager at Croda International plc While wind is enjoying significant growth, studies confirm that wind turbines suffer from reliability issues: The EU’s RELIAWIND study found that electrical systems accounted for the highest failure rate, but gearbox failures accounted for the highest amount of downtime (14 days)1. The National Renewable Energy laboratory Figure 1: Annual failure rate and downtime per failure by component, adapted from3 found that the majority of wind turbine gearbox failures are caused by bearings (76.2%) and gears (17.3%)2. Figure 1 displays the annual failure rate and downtime per failure by component. The costs of maintenance Maintenance is essential to prevent failures but ongoing operation and maintenance is costly, representing around 25% of the total cost of the wind turbine over its lifetime4. These high costs cause some wind turbine owners to skip maintenance: Insurer G-Cube cited the top cause of a claim as poor maintenance, at 24.5% of total claim costs, with claims involving gearbox failure costing on average $380,000 to rectify5. Introducing REWITEC Here we present our technology, REWITEC, 74 PES WIND

THINK TANK Some common damage modes in wind turbines gearboxes and bearings Micropitting/ grey staining White etching areas/ cracks (WEAs) Degradation of gear tooth working surfaces Structural changes in the metal that form under lubrication conditions where the film is below the surface – subject to continuous too thin for the load. debate as to their source. Fretting corrosion False brinelling Surface damage caused by repeated small When a stationary component moves very movements of one contacting surface over slightly, it rocks against another, it pushes another with the formation of brown oxide out the grease and can create indentations in particles. the bearing. Macropitting Smearing and scuffing Visible pits which are formed when small cracks get larger to the point where material Caused by roller/ raceway sliding under is broken off. boundary/ mixed lubrication, localised heating due to poor lubrication. Chemical corrosion Surface degradation caused by chemical Electric arc damage - caused by poor attack. earthing or insulation allow electrical discharge through the bearing. Can create small craters or fluting, where the bearing can give a washboard appearance which causes vibration. a microparticle-based lubricant additive technology reduces friction and thus also surface roughness. Figure 2 shows a friction that has been proven to repair existing the temperature in gearboxes and bearings. measurement in Fuchs Pentosin EG FFL-7A damage and protect the system for the REWITEC is being used worldwide, oil with REWITEC added after 20 hours. The future, improving reliability in wind turbine especially in the wind energy sector and we measurement was performed at 60°C with a gears and bearings. are growing each year. load of 1 GPa and rotation speeds of 424 rpm / 339 rpm (20 % slip). A lifespan of 20 - 30 years is expected for Based on our more than a decade in the wind commercial wind turbines. During use, both industry and having supplied more than 3000 A friction reduction of 41 % was achieved by the gearbox and bearings are affected by wind turbine treatments, we provide adding REWITEC. The surface analysis of the wear, to the extent that these components assistance to our customers around the contact surfaces from the 2-disc tests also must be replaced over the life of the wind world to address such issues as pitting, run shows a protective and repairing effect of turbine. These replacement components are through marks, downtime damage and many REWITEC, so that the surface roughness is associated with downtime and loss of other risk factors that can cause wind turbine significantly reduced, and the surface generating capacity as well as significantly breakdowns. We offer bespoke solutions, topography is smoother, leading to a increasing operation and maintenance costs. on-site application, and pre- and post- reduction of local load, tribological stress application surface analyses. and temperature. Part of Croda International plc, REWITEC GmbH is a medium-sized German company. REWITEC in action: laboratory test results Surface protection in bearings We offer an efficient solution for the problems described above. REWITEC Here we focus on independent third-party Standstill damage is a common problem in develops innovative and patented tests which have been performed with wind turbines. This occurs in systems where technology consisting of phyllosilicates in conditions similar to the those found inside vibrations appear when stationary. Although the form of micro and nano particles with wind turbine bearings and gears. common lubricants help reduce the damage, several other additives that have a protective they cannot prevent it because of the very and repairing effect. Friction reduction in gears. poor lubrication due to lack of movement in the system. Adding REWITEC to the The particles use lubricant as a carrier to The friction process in gears can be lubrication system optimizes classic reach the rubbing metal surfaces and to simulated by the 2-disc assembly bench with lubricants: Our silicon-based nano- and coat damaged areas by adsorption. The rolling friction with a slip of 20 %. Therefore, micro-particles adsorb onto the steel new, modified surface is optimized and numerous tests with different gear oils in surface and remain there, even if the protected from a tribological point of view, combination with REWITEC were tested in lubrication is deficient. We have scientifically so that surface roughness, friction, wear, this configuration at the University of analyzed the behaviour of REWITEC- and temperature in the system are Mannheim, Germany. These include oils by particles through the false-brinelling-test. reduced. This leads to a significant Castrol, Mobilgear, Klüber, Fuchs, Amsoil and The experiment results show a significant improvement in efficiency and lifespan. In Shell and were analyzed with and without wear reduction of up to 76%. addition to surface protection, the REWITEC. Results show that REWITEC significantly reduces friction, wear, and WWW.PESWIND.COM 75

THINK TANK Figure 2: Friction measurement in gear oil Fuchs Pentosin EG FFL-7A with REWITEC® added after approx. 20 hours. Figure 3: An example of the typical surfaces treated on a 2-disc assembly bench without (left) and with REWITEC (right). Figure 4: Standstill damages generated through a so called false-brinelling-test without (left) and with (right) the addition of REWITEC. 76 PES WIND

THINK TANK Figure 5: Tooth flank imprints of the high-speed shaft in a wind turbine before (A) and 3 months after the application of REWITEC (B). REWITEC in action: field tests REWITEC application was successful and significant downtime and repairs can be achieved its aim: repairing and the protection extremely expensive. It is necessary to analyse and to compare the of surfaces. steel surfaces in the system before and after REWITEC technology repairs existing the treatment. We use replica set technology Main bearing damage damage in wind turbine gears and bearings by REWITEC to perform the surface analysis and protects the system for the future. of gears or bearings by making imprints of The main bearing from a 1.5 MW GE wind Through surface modification, roughness is areas of the surface with high precision and turbine was analysed (Figure 6). To analyse significantly reduced, which leads to lower reliability. The subsequent analysis of the the wear development over a period of one local loads and lower tribological stress. imprints with light microscopy provides year, we made several surface imprints. The These effects provide a longer lifetime, valuable tribological information about the roughness before treatment was Ra = 0.556 better reliability, and higher efficiency, thus surface condition. µm. Five months after the application, the making wind turbines last longer. roughness was reduced by 28 % to Ra = 0.403 Tooth flank surface damage on a high- µm. At the third measurement 12 months www.REWITEC.com speed shaft after application, roughness was reduced by 60 % to Ra = 0.225 µm. We show that the 1 F inal Publishable Summary of Results of Figure 5 displays the tooth flank surface of a structure and roughness of the surfaces are Project ReliaWind, ReliaWind Project Nr high-speed shaft in a 1.5MW wind turbine. significantly improved. That means less 212966 The first imprint (A) of the high-speed shaft stress on the mechanical components and a was taken before the application of substantial increase in the lifetime. 2 https://grd.nrel.gov/#/stats REWITEC. It shows running traces and notable micro pitting. The second imprint (B) Conclusion 3 N REL Gearbox Reliability Collaborative was taken three months after the product Update, Sheng, Keller & Glinsky, 2013 application. The same area of the tooth flank Wind turbines form a cornerstone of the is clearly visible: Micro pitting is repaired and world’s efforts to reduce carbon emissions 4 https://www.irena.org/document there are no running traces. There is a from electricity generation. Wind turbine downloads/publications/re_technologies_ significant improvement in the surface technology is maturing, and prices are cost_analysis-wind_power.pdf condition. This surface modification ensures reducing, but the technology still suffers more homogenous load distribution in the from reliability issues. Gears and bearings are 5 h ttp://www.gcube-insurance.com/news/ system and this protects the surfaces. The not the least reliable component in a wind gcube-top-5-us-wind-energy-insurance- turbine, but when they fail, they cause claims-report/ Figure 6: Main bearing imprints of wind turbine GE1.5 MW before (left), 5 months after the application of REWITEC (middle) and 12 months after the application of REWITEC (right). WWW.PESWIND.COM 77

TALKING POINT Ensuring wintertime profits with blade heating Words: Lasse Hietikko 78 PES WIND

TALKING POINT The anti-icing blade heating technology is the enabler for windfarm power production in extreme icy conditions in Quebec, Canada. The efficient use of heat keeps the turbines operating up in the mountains, in the most demanding, freezing conditions, such as Lac Alfred wind farm. It consists of 150 wind turbines, with total Lasse Hietikko capacity of 300MW and is located up in the mountains of Gaspe peninsula, Quebec. The retrofit!’ Today the total number of retrofitted wind farm is heavily influenced by the turbines has increased to 28 units. proximity of the Atlantic Ocean. It has vast wind resources, but the combination of Over the years the Wicetec heating moisture rising out of the sea that stays open technology has evolved from a stand-alone the whole wintertime, high altitudes and the to a system that is integrated into the wind cold weather means the environment is farm SCADA system. We have also developed prone to icing conditions. a monitoring tool which immediately shows the status of all anti-icing systems. This gives The winter is long and usually starts in real-time, online information on the October and ends in April. The turbines tend operating condition and for example icing to stop easily if any ice is detected by their conditions at the site. sensors. Many of the turbines here suffer heavy icing, which leads to long periods of Company complete standstill. This leads to losses of about 15% of the annual energy production, Wicetec Oy is a company with long history AEP. It was obvious that something needed despite the company’s rather short 5 year to be done in order to save the investment. existence. The research and development of the surface based electrothermal blade ‘Until the summer of 2016 we had only used heating technology started nearly 30 years our blade heating technology on new ago at the VTT Technical Research Centre of turbines,’ explains Tomas Wallenius, CTO and Finland from where Wicetec is a spinoff co-founder of Wicetec. He continues: ‘many company. It independently owns the patents, installation steps can be carried out more other IPR and technology know-how. easily at the blade factory, when installing such technology on new turbines during the Our founders and the key personnel were manufacturing process. Now we have had to previously in key position in the related accept the constraints for retrofitting the research work, as well as in piloting the blade installation on existing turbines. However, heating technology to different wind we have not compromised the blade heaters turbines. This means we have over 25 years performance, quality, or the safety of of experience of wind turbine icing onboard! the system.’ Today Wicetec is the leading independent The first two retrofit blade heating systems blade heating provider. The technology is were installed and commissioned in the end of year 2016, just before Christmas holidays. This was due to Wicetec’s ‘can do’ attitude, mutual efforts and co-operation with the local service company and the wind farm owner. The site installation teams and the supporting engineers together with the managers were celebrating the achievement in the darkening hours of that cold winter day in temperatures of -20°C. The two retrofit systems turned out to be a success. The results were analyzed by an independent third-party company. Based on the good results and operating experiences the technology was further rolled out to the turbines that were most affected by icing. As one of the site technicians said, ‘The least productive turbine became the most productive turbine after the blade heating WWW.PESWIND.COM 79

TALKING POINT These photos were taken on the same day. The turbine on the left is without any blade heating. The turbines on the right have retrofit blade heating and thus, aerodynamically critical areas are free of ice and snow. field proven and implemented in several wind heating elements are installed on the blade example for maintenance. turbine types, the oldest carbon fabric blade surface. The operating principle of our heaters have been in use for 22 year and are technology is anti-icing, which means that The WIPS prevents up to 90% losses due to still in operation. the blades are heated while the turbine is in icing. The WIPS significantly reduces the operation and prevents ice accumulating on Levelized Cost of Energy (LCOE) over the Currently 1000MW of wind power uses this the aerodynamically critical areas of the turbine lifetime, compared to a turbine patented technology. Everything in our blades. This leads to no standstills due icing without the technology in icing conditions. technology is based on scientific research and furthermore to no de-icing cycles, as and persistent development, which makes the turbine stays operational regardless of The turbines are designed to spin 24/7 and Wicetec the key player in the market. Our the icing conditions. The WIPS consists of when they are not spinning it is not good for core knowledge is in the heating element blade heating elements, automation control the bearings, nor for the whole drivetrain. design, manufacturing, blade integration and cabinets, ice detector, and intelligent control software algorithm. We are proud to control software. Based on bearing company experts’ input, say that we are the company with the most two hours of standstill is enough for the oil experience in the wind turbine icing and The intelligent control software enables film to disappear between the metal surfaces turbine blade heating worldwide! continuous automatic operation in the bearings under the pressure. This leads throughout the winter season. The software to micro pitting and corrosion and further to Our technology includes web based graphical user interface premature failure of the components. that visualizes the WIPS operational states. The Wicetec Ice Prevention System (WIPS) It also allows manual operation of the WIPS, In some cases, there is a risk of losing the is an automatic blade heating system where as well as shutting down the system, for corporate Power Purchase Agreement (PPA) the carbon fabric-based electrothermal if the turbines do not generate enough power throughout the year. Additionally, there is a In cold climate areas wintertime production is double compared to summertime. Modified from Suomen risk that this will also incur penalty payments. Kuvalehti (01/2019) This can all be avoided with our well-functioning and efficient electrothermal blade heating technology! Why wintertime production matters In the cold climate areas wintertime is indispensable for the wind farm owner. In fact, the turbines produce double compared to summer. This is explained by more wind, with the higher density of the air. Electricity prices tend to be higher as well. The size of the turbines is growing continuously and they are becoming taller and taller. The blades sweep higher, more often hitting the clouds and therefore are more affected by icing. Thus, the need for blade heating is also growing rapidly. www.wicetec.com 80 PES WIND

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ASK THE EXPERTS: COATINGS Combatting corrosion with traditional and new methods PES Wind caught up with Ed Hall, President of Oxifree, to discover the latest corrosion solutions. Our readers have always been interested in this sector, as it has a real impact on maintenance and life span of the wind turbines. Research and development are at the forefront. The core product encapsulates the part, rather than sticking to it, which lends itself to many different possibilities. Read on to find out more… 82 PES WIND

ASK THE EXPERTS: COATINGS technologies focused on corrosion prevention, fire and temperature protection, as well as cathodic protection. PES: We know you are involved in various industries and would like to know how important the wind sector is for you? EH: The offshore wind energy industry has seen enormous growth in KWH of energy produced and now needs to look to the role of preventative maintenance to secure its future in the energy sector. It is highly difficult to operate in due to logistics for both construction and maintenance, along with the aggressive and corrosive environment. Specifying the correct corrosion mitigation technology is vastly important for efficiency, in terms of both time and effectiveness. Without long term effective preservation, it could prove too inefficient and costly to be viable. Our experience in the wind sector to date has shown us that we absolutely have a role to play in asset integrity and providing a flexible solution that allows operators to keep things running whilst providing vital corrosion prevention. We really want to support this industry to keep things moving, as it becomes more integral to keeping our business and homes running. PES: Is research and development an integral part of your business? EH: Absolutely, without research and development a business simply stands still. We have always valued the role of R&D and it is integrated into our own testing in house, through the projects we perform under our Global Services division and through the relationships with our distributors and clients. We continually review how our products are performing and how we can develop new offerings to combat new, or changing requirements. For instance, right now our GenLab (laboratory oven) is running product PES: A warm welcome to PES Wind Ed, it’s preparation and can often be applied to live Ed Hall good to talk with you. Would you like to equipment since it does not depend on begin by giving us an overview of Oxifree? adhesion but instead encapsulates the asset. The built-in corrosion inhibitor actively Ed Hall: Thank you for having me! Well, in protects the metal structure preventing the short Oxifree offers anti corrosion solutions ingress of air and moisture. It is a versatile for complex metal assets. Our core product product and has potential to bring major is TM198, which is a thermoplastic coating savings to infrastructure spend. melted down from a solid resin, in the supply unit and applied using a heated hose and gun. In 2020 Oxifree became part of the Seal For Life Industries Group joining a long line of The coating requires minimal surface comprehensive protection products and WWW.PESWIND.COM 83

ASK THE EXPERTS: COATINGS Windmill Flange courtesy Robke De Windmill flange results courtesy Robke De testing, we like to be on the front foot. preservation product to inhibit corrosion needs to be dry; humidity or cold don’t with little to no surface preparation. It’s early impact application. PES: We were wondering about your days and we will share more when we can. geographical reach and if you have plans to This all makes for a speedier application expand into other areas? PES: What makes your solutions stand out process which in turn keeps manpower costs from the competition, what are the benefits down. It can often be applied to live EH: We have always worked on a global scale to the end user? equipment saving expensive shutdown with our distribution network. In 2017 we costs. The fact that our technologies are launched our Global Services Division, which EH: A major difference in TM198 is the fact it designed to maintain preservation whilst allowed us to take on projects within the UK doesn’t adhere but encapsulates. That remaining easily inspectable, i.e. NDT or and The Netherlands, as well as supporting makes us stand out because there are so visual, over the life of the product provides our partners projects worldwide through our many situations that require the ability to operators better efficiency. own in-house team. remove the protective coating for maintenance, e.g. structural bolting, or PES: How has the current coronavirus We see no limitations to our business and repair or simply for moving parts. The fact we situation impacted on your business and have been in talks with new representation can protect a working cat link and it can still how you run it? What changes have you had in recent weeks. The issue of corrosion is be utilised, or protecting hydraulic fittings to make? How do you see this developing global and with our own infrastructure and and actuators allowing them to move within over the next 6-12 months? that of SFL, we are keen to reach as far and the coating with use is a big benefit. wide as needed. EH: Well first and foremost it has impacted our A lot of other products also require extensive travel. Our business development team usually PES: Do you have any interesting projects in surface preparation which can involve travel up to around 20 countries a year. This the pipeline that you are able to share with us? blasting. This can produce dust and debris year that figure will be very low. So, we have and harmful pollutants. TM198 only requires gone virtual along with the rest of the world, EH: We are currently working with a major an ST2 surface which can be achieved using a using Zoom and Microsoft Teams to deliver our city utility company to combat corrosion in wire brush. It’s also not dependent on a meetings and perform presentations. their sector. perfect weather environment – the asset just The second major area is in our training. We We are also working on a new short-term usually conduct a 5 day in-person course at our facility in the UK. This has morphed into a 5-day online course through Microsoft Teams, with live demonstrations and auditing on both sides of the call. We have found it to be very successful and have been able to conduct audits across the globe for representatives who were due to have their skills evaluated. We have even supervised our first virtual project in the past few months. It’s amazing what can be achieved online, but I know myself and the team are looking forward to some face to face meetings again. For now, we continue to work remotely and support our customers with greater efficiency than ever before. Going forward I think travel will start to come back into our lives, and hopefully we can return to exhibitions next year. But my priority is to keep my team safe and we will follow the guidelines. 84 PES WIND

PROTECTING ONE THEFUTURE COMPANY With a growing portfolio of high performance products, Seal For Life offers innovative corrosion prevention and INNOVATIVE thermal protection technologies. TECHNOLOGIES A track record of more than 60 years, always pushing the boundaries to develop new solutions for the ULTIMATE challenges of tomorrow. PROTECTION We set our standards high and put our customers first. sealforlife.com

ASK THE EXPERTS: COATINGS Catlink Transverter Station courtesy PeperEnergy PES: What do you think will be the greatest efficiently now will save in the years to come. opportunities and the greatest challenges, for the wind industry in general and Oxifree We will continue to grow and expand our in particular, over the next few years, and product offerings and educate the market where do you see yourselves in 5 years’ time? on the benefits of our technologies, which will always be focused on performance as EH: I think the biggest changes we will see now well as effective integration into asset is cost. It’s been an incredibly tough year for all integrity programmes. businesses and I think this is going to linger for a while yet. We know maintenance managers We will also continue to reap the benefits of already run a tight budget when it comes to this forced adoption of technology making preventative maintenance spend, but I like to our working practices more efficient than think we can start to show that spending ever before. Alternative corrosion protection all it takes is a wire brush, a piece of the What does the future look like? Coating Repair Patch that is already pre In today’s changing markets new and coated, add to the substrate and the job is ‘The current situation the world is alternative corrosion protection methods done. It’s as simple as applying a structural experiencing has exposed the benefits of are welcomed. Introducing Easyqote: a band aid if you can call it that. simple and durable solutions. Limited brand developed by STOPAQ, an inventor amount of skilled personnel allowed in and manufacturer of Polyisobutene (PIB) Whilst the focus for EasyQote has been in workspaces has increased the demand of coatings, to expand the uses of such Europe, the ultimate aim to have a global our solutions where anyone with minimum technology beyond the Oil and Gas reach and support SFL clients worldwide. online training can become an expert in focused markets. The brand was born out Alongside that the teams continue to explore corrosion prevention. We see that in the of the idea that should corrosion solutions new ways for expanding their PIB coating future the minimum surface preparation be applied simply as a sticker, rather than technology to different industry sectors but and single coat systems will be in growing painting and spraying. also to work on solutions for the future demand,’ continues Dinko. developing alternative ways to solve the new The wind energy sector challenges industries face. ‘Fast forward a few more years and we believe we will see an increase in the The wind energy sector is a contributor to a acceptance of our ‘alternative’ ways of cleaner way in creating energy, with stopping corrosion, as the industry will be EasyQote the mission is equal. ‘We are here looking for products that are less labour to contribute to sustainability of wind intensive and with minimum operational or energy related assets by arresting corrosion environmental impact to apply’. and thus increasing the lifetime of the same. As the implementation of wind energy The world is changing, as the wind energy sector grows, we plan to be a part of it from market has proven, and SFL are no different new build to the days ahead reducing the in what they wish to achieve. ‘Patience for maintenance period to a minimum,’ Dinko any acceptance is detrimental and we will be Cudic, Business Line Director for STOPAQ, patient to get rewarded for our contribution Seal For Life Industries. to a safer and sustainable world’. The design life for EasyQote is a minimum For more information on EasyQote please 30 years in preventing corrosion, but it visit www.sealforlife.com comes with the added value in doing the job once and in the safest possible way. www.oxifree.com The product is 100% safe for the user and the environment. On the offshore towers, 86 PES WIND

WINDFIT® INNOVATIVE DECISION MAKING SOLUTION We combine digital expertise with IoT technology to boost your windfarm’s performance. WindFit detects issues with your turbine and recommends optimization actions that help you make money while saving time. Plug & Play Sensor Box • Windfit® smart sensors for independent real-time monitoring • 10 parameters checked up to 100 times/sec on each turbine • Third party data sources. Diagnoses Dashboard • Secured online data access via Windfit® portal • Data history and trends • From individual turbine data to multi-farm overview. Increase AEP Monitor Performance YAW MISALIGNMENT DAILY PERFORMANCE SOON Quickly detect and correct turbine Independently monitor wind alignment to boost AEP. turbines daily performance. MONTHLY PERFORMANCE ROTOR AERODYNAMIC IMBALANCE Easily identify turbine-related Remotely detect blade underperformance. pitch offset to increase AEP. Preserve Lifetime YAW DYNAMICS Optimize your yaw strategy ROTOR MASS IMBALANCE to local conditions. Remotely detect blade mass anomalies to protect the turbine. Ask for a demo: Read our White Papers [email protected] @SereemaContact FOUNDATION www.sereema.com Sereema Permanently track the structure +33 411 932 937 integrity. YAW OVERSPEEDS Receive immediate alerts of harmful yaw activity.

TALKING POINT 88 PES WIND

TALKING POINT Digital automated independent solutions: a necessity for asset managers and an opportunity for O&Ms Words: M us Rezzoug, MD, Sereema Wind industry business models are shifting their focus. They used to be mainly driven by financial aspects of the business plan and the debt used to finance it, while technical operations, often subcontracted, came in second place. The priority of the wind industry was to ensure robust turbines with a high degree of availability, with performance being considered secondary. This happened mainly for three reasons: industry, as it makes wind energy more One of the answers provided by competitive within the energy mix. The influx manufacturers today is the race towards 1. High electricity resale prices were of capital has been unstoppable, and has turbine sizes. Especially in the rapidly guaranteeing comfortable margins. even led to a sharp increase in the selling expanding offshore market where 10MW price of wind farms already in operation. turbines was the target a couple of years ago, 2. Technical skills were not always available whereas today we look at 14MW machines, or easy to acquire by the owners and Patrick Pouyanné, CEO of Total Group, a major and tomorrow 20MW ones. However, lower asset managers investor in renewables, advocated recently, buying price per MW at installation does not that producing 1 GW of electricity requires solve the problem of operational 3. D igital data was of poor quality, often USD 1 Billion investment. Such a heavy performance. In fact, every additional difficult to use because it was controlled investment is partially compensated by the percent of AEP gain has way more impact by the turbine manufacturers. low cost of money, but this dynamic could today than 4 years ago, 5% more production change if the capital cost rises as all return on yielding 10% in annual Cash Flow to Equity. The gradual disappearance of feed-in tariffs investments will need to increase as well. and the implementation of reverse auction Another answer lies in Data. Its quest even systems are giving the market a different So even if the wind industry is still boosted by becoming the new Eldorado. But many dynamic, with the main consequence being a a very cheap capital, the decline in wind farm challenges await the data diggers. significant drop in the resale price of yields cannot be forever compensated for by electricity. Average prices have decreased by the low cost of debt. Focusing on machine First, monitoring and improving the 50% in the last 8 years, directly impacting the performance is a gamechanger for major performance of wind farms require access to wind farms Return On Investment (ROI). players and a key power factor to go and look large volumes and quality of data, paired with for bigger production margins, more in line powerful data computing, in order to Nevertheless, this drop in the price of with the new business model. establish large-scale processing. Despite electricity is an excellent opportunity for the WWW.PESWIND.COM 89

TALKING POINT many announcements and marketing For them, data isn’t and should not be limited - t heir analysis is oriented both towards messages, the wind energy sector remains to the SCADA delivered by manufacturers. improving performance to increasing AEP, relatively less digitized compared to other The real performance lever also integrates and preserving the lifetime of the industries. Making the digital switch isn’t information from third party sources. machines, limiting maintenance costs, easy for big organizations and will be driven and improving the profitability of the by innovative, native digital companies. The reasons why: investment in the long term. Second, many players/owners are seeking to - independent data is more precise, A system like Sereema’s Windfit generates reach a critical mass in order to set up digital especially when acquired at very high up to 35,000 times more data than a classical systems that centralize their operational data, frequency with fully automated process SCADA system, acting like a magnifier whether in the form of raw or processed data. revealing details, aka underperformance - they provide deeper levels of information sources, that asset managers were not able to see before. Solutions today need to answer the need of wind farm owners and operators to be closer to their assets. 200% performance Assets are not considered just as a spur of the moment producing machine anymore, but more as a long-term investment generating higher and longer revenue. Wind farms are also reaching an age when maintenance contracts come to an end with turbine manufacturers, looming in on retrofit or repowering issues. Investors are thus now all the more focused on the lifetime cycle of the farm, from mid to long terms issues as well as short ones. Maintenance vs. Performance O&Ms have so far focused on optimizing maintenance costs while their clients, wind farm owners and operators, also need optimized performance and boosted 90 PES WIND

TALKING POINT production. In order for both maintenance performance corrective actions in their that are causing the wind turbine to costs and performance strategy to be maintenance procedures. underperform and even define how both the reconciled, a third-party referee is the only wind turbine and the wind farm should operate option to display a neutral, independent O&M strategies evolve today depending on in order to optimize their performance. vision, detached from what’s happening on the brand, and even within the same brand, both sides of the equation, but focused on the depending on the region. The switch has Two, they provide an external and machine performance vs maintenance ratio. been turned on and it’s very promising to independent view of the turbine. This allows see virtuous 3-party collaboration starting identifying issues that are not visible from Win-win situation to settle in, step by step. It bodes well for the turbine’s SCADA data. These systems the digital development of the whole wind are able to identify and quantify the most The emergence and development of power industry. frequent causes of underperformance on innovative digital solutions in the wind operating wind turbines such as pitch offsets energy industry is a strong and inevitable Windfit by Sereema, brings more than on the blades, yaw static and dynamic trend. Although, O&M’s first reflex was to independent expertise, and introduces misalignments, power curve degradation, see the risk of increasing their maintenance independent data. More than just yet another wrong implementation of curtailments, etc. costs, or having the quality of their source of expertise, independent solutions Correcting these otherwise non detectable maintenance questioned. We are proving, producing automated results answer fully issues mechanically improve assets AEP. with systems like Windfit, that it’s more the arising need for data control, fruitful to consider this new deal as an understanding, analysis and actionability. Based on 1.4 GW monitored, Windfit has opportunity of development for all parties. shown that: All these operations are biased if not drawn Far from blaming the O&M for from independent data. Almost 30% of turbines present a rotor underperformance, or to act as a preacher’s aerodynamic imbalance worth correcting son, digital newcomers like Sereema bring Independent data solutions (between 1 to 6% AEP gain) independent facts, and only facts, to the table helping all parties optimize assets’ These present 2 major advantages over the 1/3 of the machines revealed north deviation performance without harming O&M’s costs. standard available data sources: of at least 10°, particularly important when dealing with wind sector management issues A challenge for the clients coming down to an One, they are designed for performance: from or performance analysis per wind sector; opportunity for the O&Ms to improve their the sensors selection and high frequency data customer relationship by developing their acquisition to the full automated data Up to 20% reveal a yaw misalignment quality of service and integrating the processing, these systems can identify issues generating a minimum of 1 to 6% AEP loss. Those 3 features are only part of the global scope independently and autonomously monitored by Sereema’s product. Our clients today are building their user strategy according to their needs: Permanent and long-term performance monitoring: - being able, at each given time, to make sure the turbine is producing to its best possible in-situ ability, not just availability. In this strategy, the system becomes part of the turbine. - u nder-performance diagnosis: perform campaigns in order to identify all issues that are creating non-optimal conditions for WWW.PESWIND.COM 91

TALKING POINT How does Windfit® work? .. Data Stream Processing Windfit® Portal . Data visualization, Data storage and computing is done on Corrective Strategy Sensors Fusion, Data acquisition our cloud servers. Data calibration and results quality Results automatically available on Data acquired independently by control. Windfit portal, accessible in one Windfit at high frequency from its Fully-automated process converting click to our clients. embedded sensors. acquired data into actionable diagnoses. Monitoring system of equipped Single sensor box equipped on each wind turbines with alarms and turbine. suggestd actions to increase assets performance. Data transferred through the cellular network to our cloud serveurs. operation. In this strategy, the system is have been being problematic for a while, pushed through by the O&M teams. It’s not usually used at: either lower production than expected or an easy task when the only data available to frequent maintenance issues. compare and analyze is provided by the Commissioning and/or end of warranty: same manufacturer who sells the upgrades In conclusion, independent automated as well… - w here owners want to make sure their digital solutions allow for a real change on turbines operate at their best since the operation of wind farms making the Sereema’s strategy does not dwell on the beginning approach focused on performance and reigniting the fire between O&Ms vs changing the balance of power between Operators, but on acting as an independent Due diligence owners and manufacturers. 3rd-party expert reinforcing each actor’s skills and competence to have boosted - on the seller side to show the value of the Today the market is bursting with expert performance and life maintenance strategies assets; and on the buyer side to verify the alternative solutions but they’re all fit together in a realistic but optimized overall status of the asset maintenance or O&M oriented. There are no economic and environmental plan. solutions for example to challenge and Problematic wind farms prove the value of software upgrades www.sereema.com - e very owner has a set of wind farms that About Sereema Sereema is the future of Wind farm optimization through SAAS paired with IoT & Big Data processing. Our solution, Windfit® helps asset managers and wind farms operators define corrective actions to improve power production and preserve wind turbines lifetime. The solution acts as an autonomous automated expert, processing big data generated by our sensor box, to deliver accurate and actionable diagnostics to the end users. It is based on latest IoT technology, MEMS sensors embedded in a single box and big data cloud computing. Available as an automatically renewed subscription, the service is sold as an all-inclusive package and can be purchased all across the world, no matter the type and model of turbine, both on onshore and offshore windfarms. 92 PES WIND



THINK TANK High Voltage Test Laboratory Making a difference in windfarm transformers The electric energy industry has long been a conservative business taking very deliberate and measured steps in adopting new technologies. The renewable energy markets have forced companies to adapt to a fast-paced and rapid technology development cycle. The exponential growth and the demand for more power in a smaller envelope continue to drive rapid development. 94 PES WIND

THINK TANK H-J has accepted these challenges and we At H-J, we are dedicated to developing rigid. This may compromise the bushing’s are leading the renewable energy industry-leading bushing solutions by physical integrity and, most importantly, the transformer industry with material and listening to our customers. Solutions for high sealing integrity of the bushing. product development for both high and low voltage bushings include plug-in type voltage bushing applications. technology for 38 kV class with 150 and 200 kV H-J has developed a new high temperature BIL options. Bushings are available with 600, epoxy in order to help manufacturers match New, higher power solar inverters and wind 900 and 1200 A continuous current ratings. the transformer high temperature insulation turbines are being developed and released on Higher voltage and BIL versions are currently systems. This new high temperature epoxy is a regular basis. This is driving a series of under development to support industry suitable for continuous use at 155°C. This fundamental changes in transformers for needs. These are dry, solid, internally- greater range of temperature allows users to renewable applications: shielded epoxy resin bushings. The bushing pack more power into smaller footprints by interfaces are designed in accordance with running the systems hotter. The efficiency of • Solar inverter containers are open and relevant IEC or IEEE Standards to provide these liquid-filled high temperature exposed to elements, interchangeability with different molded transformers is still far superior to dry-type rubber elbow solutions in the market. transformer solutions, and provides • C onverting from dry-type to liquid-filled tremendous benefits in terms of size and transformers, The standard operating temperature for performance in space-limited applications bisphenol-A and cycloaliphatic epoxies are such as solar inverter containers and wind • U sing high-temperature insulation 105°C and 120°C. However, an important turbine nacelles. systems and operating temperatures, consideration with epoxies is that the and maximum temperature must not be exceeded Solutions for low voltage bushings are in operation. Above these temperatures the equally important and present a more • Increasing current ratings and the high epoxy nears or enters the glass transition customized and diverse range of product voltages to 35 kV, 200 kV BIL class and range (Tg) where the material is no longer needs. The need for matching the generator beyond. connection and internal transformer winding connection optimization requires a high level of customization. We embrace this at H-J and provide solutions which work for each individual customer project, big or small. H-J’s low voltage bushing offering includes voltages from 1,2 kV, 30 kV BIL to 5 kV, 75 kV BIL with current ratings up to 12.000 A. These are dry, solid, one-piece epoxy resin bushings which may be exposed to UV rays with no deterioration in life expectancy. H-J offers our proprietary epoxy blend options for 105, 120 and 155°C maximum operating temperatures. In wind farm applications, turbine designs are continually evolving, growing in power size, while optimizing structural dimensions. The result is a further reduction in the space provided for the transformer in the nacelle area which presents additional challenges in bushings designs: current ratings are increasing and a precise level of customization is required to meet the available space. Different bushing bodies, terminations, hole patterns, and mounting clamp styles are developed to fulfill such requirements. At the same time, since the transformer is enclosed, the ambient temperature will increase considerably requiring the use of high temperature components. H-J’s high temperature 155°C epoxy is ideal for this environment. The conductors are typically aluminum or copper with plating options such as tin, silver and nickel. The entire bushing can be WWW.PESWIND.COM 95

THINK TANK 3.6KV 60KV BIL 5000A epoxy bushing 1.2KV 30KV BIL 6000A epoxy bushing 5KV 75KV BIL 5000A epoxy bushing customized, from the insulator to the internal transformers. Here’s why: strenuous usage. terminal to the external terminal. • High level of customization: dimensions • Hydrophobicity: water molecules Our low voltage bushings are single-piece and features can be easily changed to accumulated on sheds are better repelled design which provides several advantages: match the specific needs for internal and and thus use less space than porcelain, external connections. resulting in fewer chances for creating an • No need for assembly at OEM site electric path. • A bility to offer high current options: • F ewer gaskets mean fewer possibilities epoxy resin is molded directly onto the • Flexible installation: bushings can be for leaks conductor, allowing for significant mounted in vertical or horizontal cross-sectional areas of copper to carry orientation since there is no oil inside. • B ushing leak tested as a complete system large amounts of current safely. at H-J • Compact Design: distances are reduced • A bility to withstand cantilever and short while meeting voltage and creep distance The epoxy resin is directly molded into the circuit forces: epoxy resin is more requirements due to fewer components conductor, making it a single unit. There are forgiving than porcelain insulators while needed for construction. only three components required for a still maintaining strength and complete bushing assembly: a bushing, a performance integrity. • Fewer chances for oil leakage: single- mounting clamp and a mounting gasket all piece bushing design mitigates potential provided direct from H-J. • L ess fragile than porcelain: epoxy resin leak points and provides for better sealing can better withstand rough handling and between epoxy and conductor. Epoxy resin bushings are ideal for windfarm • Quick development process: the design Engineering and QA working together and production of an epoxy resin mold are quicker than porcelain, thus shortening lead times. Why choose H-J bushings? H-J is constantly innovating to meet the market’s needs, positioning ourselves to provide value without sacrificing quality to our customers. Vertical integration is one of our strengths to develop the product from raw materials to final solution. With our proprietary, in-house formulations and production H-J maintains control over the components that go into the bushing design, streamlining the flow of production. H-J has established manufacturing, engineering and commercial facilities around the world to stay closer to our customers and better support each market: High Ridge, Missouri, USA Toronto, Canada Leon, Mexico Bogota, Colombia Pereira, Colombia Blumenau, Brazil 96 PES WIND

THINK TANK 38KV 200KV BIL 600A plugin epoxy bushing 155C rated operating temperature Epoxy resin customized mold press Belo Horizonte, Brazil About our company: voltage test laboratory. Barcelona, Spain The H-J Family of Companies celebrated Quality, R&D and production process our 50th anniversary in 2019 - a major capabilities have been at the forefront of Frankfurt, Germany milestone for our family-owned company the company’s values, but our people are located outside of St. Louis, Missouri, USA. what make the difference. Our bushings Mysore, India We offer a broad range of products for the have been used for many decades in electrical transformer and switchgear various applications such as pole-mounted Manila, Philippines industry from bushings to connectors, transformers, pad-mounted transformers, fuses, tap changers, valves, and even compact substation transformers, Tianjin, China transformer manufacturing machinery. submersible transformers, completely H-J’s global manufacturing facilities include self-protected transformers, and more. Xi’an, China an epoxy resin casting facility, chemical The bushing technology used in each engineering and development laboratory, transformer design can be customized, and Busan, South Korea state-of-the-art tool and die machine we offer multiple insulation types such as center, non-ferrous foundry, porcelain porcelain, silicone, thermoplastic, and five Taipei, Taiwan manufacturing, multiple machining and different proprietary epoxy resins. plating centers, and a state-of-the-art high The H-J Family of Companies has www.h-j.com continuously developed new designs since 1969, helping shape and improve our industry through innovation and reliability in good times as well as in times of need. We will continue to do so moving forward. WWW.PESWIND.COM 97

TALKING POINT Global growth for offshore wind must lead to zero emissions goal Words: L eo Hambro, Director at Tidal Transit Limited Tidal Transit’s Eden Rose at Sheringham Shoal Offshore Windfarm 98 PES WIND

TALKING POINT The 2nd offshore wind boom is upon us and this time it is going global. During 2021 project installation will be underway in UK, Denmark, Germany, Netherlands, Belgium, France, Norway, Spain, Portugal along with US, Vietnam, Taiwan and China. By 2025 many more countries will join this rush to install the cheapest form of largescale renewable power available. The last 10 years of this sector has been per day is only a small part of the overall Leo Hambro about major efficiency gains. This has been picture. But what about the gigawatts of brought about by giant leaps in generating power that these vessels help produce. Why energy density even greater than diesel. But capacity, huge economies of scale and use diesel when electricity is even more no… If we are to seek efficiencies while also general efficiency throughout the supply plentifully and readily available. moving away from fossil fuels, then we chain. Turbines can now be erected and cannot allow 10 MW of electricity to be used commence operation within 24hrs or less. Well it doesn’t take a naval architect to tell Installed redundancy has reduced the need you that it is harder to walk in water than it is for regular intervention. Key failure points on land. Therefore, we must accept the fact have been removed. All of these and many that the energy requirements to move more have helped offshore wind find its place people and their cargo by water is going to be as the keystone within the generation mix for high. Also, sadly the energy density of diesel decades to come. (45MJ/KG) is still over 20 times greater than an efficient Lithium battery (2MJ/KG), With this in mind, and looking to further despite Elon Musk’s efforts. enhance the efficiency of this green industry, one must note that the means of access to This might lead many to conclude that it is these offshore farms heavily relies upon a simply not worth doing due to the cost of marine logistics fleet which currently has a batteries and the huge tonnages that would hefty carbon footprint. be required to replace like for like capabilities. Or one might think that the only reasonable Whether it be the installation vessels, survey step would be to make a headline grabbing boats, cable layers, jack-ups, SOVs, CTVs or symbolic gesture in adopting a hybrid helicopters, the amount of fossil fuel used to solution to at least allow some of the fuel to get to an installed turbine and to service it for be offset by battery power. I hear you saying, its 25-year life would scare many green ‘but what about hydrogen?’, due to the fact lobbyists. 370+ CTVs using up to 2,000 litres that it can be green sourced and has an Karoline Electric Fishing Boat WWW.PESWIND.COM 99

TALKING POINT 1890 Electric Boat of the oceans but for near coastal and for such as 2014’s first electric car ferry small vessels the future is electric. (Ampere), 2015’s first electric commercial to make hydrogen to then turn it back into fishing boat (Karoline), 2018’s first electric electricity and only be left with about 1MW of So how is it that other sectors of the marine container carrier (Yara Birkeland) and 2020’s electricity to put through a motor. That can’t industry have already made the switch First Fully Electric tug (TBN – hopefully E.T. be a sensible solution unless electricity is without the plentiful supply of electricity that ‘Electric Tug’ and not Tuggy McTugface). free and we are not there yet! This is the offshore wind industry has. Electric Following several firsts there have been especially true when considering that boats were being used on the Adirondack many more similar crafts delivered thanks to currently 98% of the commercially available lakes of Upper New York State as early as innovative battery manufacturers such as hydrogen originates from non-renewable 1880. Over 130 years later, the last decade Corvus Energy and EST-Floattech with sources. Hydrogen clearly has its benefits has brought commercially viable solutions energy density increasing dramatically too. due to its ability to store energy and for long haul marine transport it could be the saviour Following the first of class vessel type, there have been several major ferry conversions. Regulations in the Netherlands will soon ban diesel powered commercial crafts from the canals of Amsterdam. Other cities will follow suit and this will lead to many more conversions and new builds. These types of transits can easily be done without considering a change in operating profile due to the energy usage being low. However if you look at the battery capacity required to take a 70 ton CTV to a windfarm at 20+ knots in 1.5m Hs seas 20 miles from the coast, before spending up to 2 hours pushing on to turbines (deploying and collecting technicians) and then another hour in transit back, you could easily exceed the capacity of 50 tons/6MWh of batteries rather than 2 tons of diesel. It is feasible but a tough challenge for a vessel designer and there are limitations around displacement and impact forces that need innovative solutions to handle. Additionally, there is very limited Tidal Transit’s E-CTV Electra 100 PES WIND