Windpower Engineering & Development February 2020

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WINDPOWER ENGINEERING & D E V E LO P M E N T / / V O L . 1 2 N O. 1

COVER STORY

Offshore wind has reached an opportunity moment in its public affairs

21 12 Offshore wind would do well to look for applicable lessons in the experiences of other clean energy sectors. Rough public affairs waters are just beginning.

8 IN EVERY ISSUE 04

CONTRIBUTORS

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WIND WORK AROUND THE UNITED STATES

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WINDWATCH

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FEATURES 08

Some interesting product and policy news from our website.

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LEADERSHIP 2020 The 2020 class of leadership nomineees is out! Be sure to vote for your favorites online.

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FEBRUARY 2020

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Connected drones: The next technology advance for turbine inspections

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The evolution of wind turbine gearbox design has resulted in the use of an increased number of tapered roller bearings throughout the parallel shaft section.

On- and off-shore wind project announcements from across the country.

SPECIAL SECTION:

Setting two-row tapered roller bearings in wind turbine gearboxes

Drone inspections play a vital role in preventive maintenance of a number of structures.

Improved maintenance could lead to more reliable wind power generation and improved ROI by extending the life of turbine blades.

www.windpowerengineering.com

Extending wind turbine life with pitch bearing upgrades

Upgrades can increase pitch bearing life by up to 10 years, improving turbine life and efficiency while reducing downtime — all at a fraction of the cost of a new turbine.

Optimize asset performance by understanding wind resource, not relying on it

Asset owners must focus on increasing their understanding of each asset and how they relate to the surrounding environment.

Taking an AI-driven, contextual approach to asset optimization will maximize and secure project returns.

WINDPOWER ENGINEERING & DEVELOPMENT

3

WINDPOWER ENGINEERING & DEVELOPMENT

C O R E Y B AY L E S

GARETH BROWN

MIKE CASEY

DONAVON GRAVES

KYLE SMITH

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COREY BAYLES is currently a senior product engineer for renewable energy applications for SKF USA. Corey graduated from the United States Military Academy at West Point in 2005 and was commissioned as a Second Lieutenant (Armor) in the U.S. Army.

After two tours in Iraq, he left active duty and joined SKF (Kaydon Bearings) as a semiconductor market product engineer. Corey has nine years of experience in application and product design, and personally investigated dozens of failed pitch and yaw bearings.

He frequently collaborates with owner/ operators to improve pitch and yaw function and prevent unexpected turbine downtime. Corey and his family live in the Muskegon, Michigan, area.

GARETH BROWN is CEO and cofounder of Clir Renewables, a renewable energy AI software company. He is an entrepreneur and a chartered engineer with the IMechE. Gareth has over a decade of experience in the industry which spans the life-cycle of renewable energy projects from identification, development and construction to financing and operation. In 2005 Gareth started with Scottish renewable energy technical consultancy SgurrEnergy (now Wood) in Glasgow. He brought their operation to Canada, setting up the Vancouver office and leading the expansion across the Americas. Gareth began to notice a trend in the wind industry. Most, if not all, wind energy asset owners and operators do not have an accurate view of asset performance.

WINDPOWER ENGINEERING & DEVELOPMENT

MIKE CASEY is president and founder of Tigercomm. For 30 years, Mike has focused on the design and staffing strategies for winning communications programs. As Tigercomm’s founder, he counsels cleantech executives, investors and philanthropists on strategies for meeting their business objectives. Mike is a top U.S. innovator and strategist on cleantech marketing and communications. He has presented at more than a dozen major conferences, and he writes frequently on clean economy topics.

DONAVON GRAVES is director of business development and strategic planning at Skyward, a Verizon company. He works with companies to empower successful drone adoption and management, drawing from extensive expertise garnered through his work in transportation, logistics, utilities, construction and oil and gas.

KYLE SMITH is a principal application engineer for The Timken Company with a current focus on wind gearbox applications solutions and upgrades. He is based out of the company’s world headquarters in North Canton, Ohio. Kyle has held past engineering roles in support of various industrial markets, including power transmission equipment, aggregate and crushing equipment, paper production equipment and heavy moveable structures. He has been with Timken for 14 years. Kyle earned an associate degree in mechanical engineering technology from Stark State College and a bachelor’s degree in manufacturing engineering technology from the University of Akron.

www.windpowerengineering.com

FEBRUARY 2020

Wind work around the

united states 5

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nebraska

Infrastructure and Energy Alternatives started construction of Nebraska’s 300-MW Thunderhead Wind Project in November 2019 and is expected to finish it this September.

Chicago renewables company Invenergy developed the 108-turbine Thunderhead system, which is located in Antelope and Wheeler counties.

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IEA’s 300-MW Nebraska wind project will come online in September

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Enel Green Power breaks ground on 299-MW North Dakota wind farm North Dakota

Enel Green Power North America broke ground on the 299-MW Aurora wind farm in November 2019. The North Dakota wind project, which will be operational by the end of 2020, will sell power to Basic Electric Power Cooperative and clothing company Gap.

image Credit: Enel

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Vineyard Wind wins bid for 804-MW offshore wind project

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Connecticut

EDP Renewables will build 302-MW wind farm in Indiana indiana

Electrical utility NIPSCO and EDP Renewables North America are bringing a 302-MW wind farm to White County, Indiana. The Indiana Crossroads Wind Farm was announced in October 2019 and is expected to come online in 2021.

The project is expected to power 83,000 average Indiana homes.

FEBRUARY 2020

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Texas

Vineyard Wind has won a bid for the 804MW Park City Wind Project off the coast of Connecticut. The system will account for 14% of the state’s electric supply. Connecticut is adding offshore wind power to its electrical grid after Governor Ned Lamont signed an act in 2019 calling specifically for addition of the maritime renewable energy.

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Enel Green Power completes 450-MW Texas wind project

south Dakota

Enel Green Power North America completed the 450-MW High Lonesome wind farm, which spans across both Upton and Crockett counties, Texas, in 2019. The company is adding another 50 MW to the project to make it Enel’s largest wind farm in the world once fully completed in Q1 2020.

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Mortenson, Rocky Mountain Power partner on 750 MW wyoming

Mortenson and Rocky Mountain Power have teamed up to develop and construct two Wyoming wind projects that will total 750 MW. The first project, TB Flats I & II, will be 132 Vestas turbines built on 44 square miles; and Ekola Flats will be 53 turbines on 29 square miles. They’re slated for completion in October 2020.

200-MW Crocker Wind Farm begins commercial operations Geronimo Energy’s 200-MW wind farm in Clark County, South Dakota, began commercial operations in December 2019. The Crocker Wind Farm, built by Wanzek Construction, uses GE 2.7-116 turbines, and corporations Walmart and Cargill signed virtual power purchase agreements on the project. Walmart wants to use 50% renewable energy by 2025.

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Duke Energy 200-MW Texas wind project texas

Duke Energy Renewables’ 200-MW Mesteño Windpower project came online the last day of 2019. Based in Starr County, Texas, Mesteño Windpower’s output is being sold to the utility territory of the Electric Reliability Council of Texas. The wind project, built by Wanzek Construction, is Duke’s fourth in Starr County and eleventh in the state.

WINDPOWER ENGINEERING & DEVELOPMENT

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d n i w h c t Wa ’

GE tests blade for 12-MW wind turbine

The Massachusetts Clean Energy Center is testing a 107m blade that will be part of the industry’s largest and most powerful offshore wind turbine, a 12-MW unit designed by GE Renewable Energy. The blade arrived at MassCEC’s Wind Technology Testing Center in Boston in November 2019. GE is planning to commercialize its Haliade-X 12-MW turbine by 2021.

The blade is undergoing fatigue tests to determine whether it’s fit for over 25 years of use in offshore applications.

The Haliade-X 12-MW is a multi-million dollar investment that will help reduce offshore wind’s cost of energy in order to make it a more competitive source of clean and renewable energy, with each Haliade-X turbine being capable of powering over 5,000 U.S. homes. The global offshore wind market is projected to grow to 120 GW by 2030 by the Global Wind Energy Council.

Numerous U.S. states, including Massachusetts, have set ambitious offshore wind targets totaling nearly 20 GW, leading the research groups to estimate that there is a $70 billion supply chain opportunity associated with the new industry.

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WINDPOWER ENGINEERING & DEVELOPMENT

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FEBRUARY 2020

Dellne

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WIND WATCH

New jersey forms offshore wind group to boost adoption

Offshore wind companies send a proposal to U.S. Coast Guard

Dept. of Energy gives NREL more money for offshore wind testing

Wind will account for 30% of global electricity production

New Jersey set a goal to reach 7,500 MW of offshore wind production by 2035, so the state’s Dept. of Environment Protection established the New Jersey Environmental Resources Offshore Wind Working Group.

The organization will have representation from fishing and maritime industries and conservation groups that will inform offshore wind strategy and implementation.

Five companies involved in New England offshore wind development submitted a joint “uniform layout proposal” to the U.S. Coast Guard to establish guidelines related to offshore wind. The letter lays out turbine spacing and arrangements and requests established transit routes and emergency rescue services. A submittal like this is a common practice among maritime industries.

The Dept. of Energy’s Advanced Research Projects Agency-Energy (ARPA-E) awarded the National Renewable Energy Laboratory (NREL) $5.7 million to increase the efficiency of offshore wind turbines. The organizations hope to develop new monitoring and open source controller technology to collect data that will facilitate further offshore wind farm design.

DNV GL has predicted that wind will account for 30% of the world’s electricity production by 2050 in the report “Offshore wind: The power to progress.” Further splitting that amount, 18% of the world’s power will be from onshore wind and 12% from offshore. As wind technology progresses, the report also outlines the increased use of robotics and artificial intelligence.

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BY KY L E S MI T H P R I N C I PA L A P P LI C AT I O N EN GI N EER T HE T I M K EN C O M PA N Y

WHAT TO KNOW WHEN SETTING

TWO-ROW TAPERED

ROLLER BEARINGS IN WIND TURBINE GEARBOXES

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FEBRUARY 2020

TWO-ROW TAPERED ROLLER BEARINGS

The

evolution of wind turbine gearbox design has resulted in the use of an increased number of tapered roller bearings throughout the parallel shaft section to effectively manage both the radial and axial loads produced by helical gearing during operation.

This arrangement includes a cylindrical roller bearing in the float position coupled with a two-row tapered roller bearing in the fixed position, typically in a direct-mount configuration (also referred to as a face-to-face, DF or X arrangement). Compared to conventional arrangements that commonly use various cylindrical, spherical, ball and thrust roller bearing configurations, this stronger approach can better support varying loads experienced during gearbox operation, helping wind farm owners and operators avoid costly repairs and downtime.

For service technicians and rebuilders, this trend toward two-row tapered roller bearings requires that close attention is paid to controlling the assembly’s associated mounted setting. Unlike many conventional bearing types, two-row tapered roller bearing designs are composed of separable components with an unlimited range of axial locations relative to one another based on the installation method used.

These separable components require an external means of controlling the final relative axial location and resulting mounted setting, which is most commonly done by introducing a component spacer into the assembly. This spacer is then specifically machined to a controlled width by the installer or by the bearing supplier during the assembly production. However, many MRO professionals with limited tapered roller bearing experience have questions about how to achieve the best mounted setting results. And without proper mounted setting control, the resulting stresses can become excessive or may even result in unloaded conditions inside the bearing, leading to roller and cage damage.

This article reviews three common approaches for obtaining a final axial setting for a two-row tapered roller bearing assembly using a controlled spacer width.

Green spacer assemblies

A green (or unground) spacer assembly is intentionally supplied with a spacer that has extra width to allow the user to tailor various settings based on specific application requirements. Note that in some instances, bearings may be supplied without a spacer (typically when the user intends to produce or purchase one

FEBRUARY 2020

separately), in which case the combination of bearing components and spacer would be treated similarly when obtaining the target nominal mounted setting. Two common methods of obtaining the target mounted setting for a green spacer assembly are the measurement-and-calculation method and the manual push-pull method.

Measurement-and-calculation method

The measurement-and-calculation method requires the user to obtain measurements of the shaft, housing, bearing bore and bearing outside diameter (O.D.) to determine the actual mating component fitting practice. Secondly, the user must obtain the correct lateral loss factor(s) for the bearing assembly part number to support an accurate lateral loss calculation due to any resulting interference fits. Finally, the spacer gap between the bearing components at zero bench setting must be calculated using assembly component physical measurements (also known as drop measurements) or measurements obtained from the bearing supplier, thus allowing the user to determine the final spacer width to reach the target nominal mounted setting.

Push-pull method

Alternatively, the manual push-pull method requires the user to mount the bearing components and the unground spacer using the actual mating shaft and housing components to determine a baseline mounted setting value. This baseline setting can then be compared to the target nominal mounted setting to determine the spacer width that must be ground to achieve the target setting.

The push-pull method requires all rollers to be seated completely and uniformly against the adjacent large rib and requires that no external components or loads interfere with the ability to obtain an accurate measurement of the axial shaft movement in both the push and pull steps of the process. To ensure that rollers are seated and an accurate axial setting is measured, an axial load must be applied to the shaft in one direction while the shaft is oscillated a minimum of 20 times before applying an axial load to the shaft in the opposite direction while oscillating the shaft as before. The total axial movement of the shaft is the bearing assembly mounted setting.

Assuming proper procedures, a green spacer makes it possible to achieve an optimal final mounted setting, given that the actual dimensions from the mating bearing components, shaft and housing are accounted for, thus eliminating (most) tolerances from the equation and resulting in a very small possible mounted setting range. However, inaccurate measurements, incorrect calculations, imprecise spacer grinding, mismatched mating components or the inability to obtain an accurate push-pull measurement due to component size or adjacent component interference will directly impact the ability to achieve a high level of precision and consistency, leading to an unpredictable possible mounted setting range that can lead to a range of problems.

WINDPOWER ENGINEERING & DEVELOPMENT

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TWO-ROW TAPERED ROLLER BEARINGS

A floating cylindrical roller bearing (left) paired with a fixed two-row tapered roller bearing (right) is becoming the preferred method for managing loading conditions seen in wind turbine gearboxes.

Matched spacer assemblies

A matched spacer assembly (also referred to as a single bench setting assembly) is supplied with a fixed width spacer that has been ground by the bearing supplier to a specific width based on an assumed set of component fitting practice values and a target nominal mounted setting value for the application.

For this type of assembly, the bearing production facility completes the bearing physical measurements to understand the spacer gap between components at zero bench setting and to determine the final spacer width necessary to reach the specified nominal mounted setting. Both the assumed fitting practice range and the calculated lateral loss would be considered by the bearing supplier to determine the bench setting for the matched bearing assembly.

A matched spacer could be considered the least accurate approach to obtaining a target nominal mounted setting given that the shaft, housing, bearing bore and bearing O.D. tolerances all have a direct effect on the possible final mounted setting and are not accounted for on an individual combination of mating components, thus resulting in a relatively large possible mounted setting range.

different bench setting value can be selected based on the actual component bore dimension (rather than using a single bench setting for the entire interference fit range). This results in a more tightly controlled selection of the final spacer width and a reduced target mounted setting range.

Typically, the target mounted setting and shaft tolerance are obtained from the user or from application engineering review.

Engineering then performs calculations that cover the known inner ring fitting practice range to develop a table of bench setting values. This table allows the bearing supplier to select a single bench setting based on the actual bearing bore measurement and associated shaft tolerance combination. The bearing supplier then completes the measurement process to understand the dimension of the spacer gap at zero bench setting to thus determine the final spacer width necessary to achieve the target nominal mounted setting.

Bore-compensated assemblies are considered more accurate than matched assemblies, given that the bore tolerance variable and associated lateral loss are already accounted for in the fitting practice; however, this method cannot achieve the extreme accuracy of a properly controlled and processed green spacer assembly.

Bore-compensated spacer assemblies

A bore-compensated assembly (also referred to as a variable bench setting assembly) is supplied with a fixed-width spacer that has been preground to a specific width based on an assumed set of component-fitting practice values and a target nominal mounted setting for the application.

To begin, the bearing supplier again completes drop measurements to determine the spacer gap between the components at zero bench setting and final spacer width to reach the target nominal mounted setting. The difference between this assembly type and a matched spacer, however, is that the potential interference fit range between the shaft and inner ring bore is broken down into multiple groups, such that a

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WINDPOWER ENGINEERING & DEVELOPMENT

Roller angles, among other variables, can be customized, allowing two-row tapered roller bearings to better handle combined loads compared to traditional cylindrical, spherical and ball bearing designs.

www.windpowerengineering.com

FEBRUARY 2020

TWO-ROW TAPERED ROLLER BEARINGS

Note that this assembly type typically assumes a loose fit or a very light interference fit between the bearing outer ring and housing. In other cases, special compensation matrices may be necessary to accommodate interference fits at both the bore and O.D. of the bearing assembly.

The following table can help you understand the relative advantages of different assembly types (on a four-point scale, one star is acceptable and four stars is optimal): Preparation & Installation Efficiency Green Spacer (Measurementand-Calculation) Green Spacer (Push-Pull) Matched BoreCompensated

★★

Preparation and Installation Risk/ Variable Opportunity

★ ★★★ ★★★

★★

★ ★★★ ★★★

Possible Mounted Setting Range

Ease of Field Preparation and Installation

★★★★

★

★★★ ★ ★ ★★★★ ★★ ★★★★

Avoid these costly mistakes

Bearings that use a spacer to control the final mounted setting may be unfamiliar to many service techs. Keep the following advice in mind when maintaining or upgrading gearboxes: • Do not use an old spacer in a new bearing assembly.

• Do not swap spacers between old and new assemblies.

• Do not install an assembly without a spacer unless another axial setting mechanism is present (e.g., spring-loaded system or component end-cap).

• Never install a green spacer that has not been ground to proper width.

• Never assume a supplied spacer is the correct finished width.

• Always take time to measure and verify.

Where to turn

It is wise to consult a qualified expert to review the described measurement, calculation and assembly procedures when installing bearings that rely on a finished spacer width to control the mounted setting. Your trusted adviser can provide the support and clarity needed to ensure a successful outcome that avoids major corrective work. As the use of tworow tapered roller bearing assemblies in wind turbine gearboxes becomes more The manual prevalent, it is only a matter of time until push-pull such questions arise. Be sure to ask method measures your bearing supplier about training and total shaft axial movement education that can put your team ahead using a dial of the curve. WPE indicator.

FEBRUARY 2020

WINDPOWER ENGINEERING & DEVELOPMENT

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CONNECTED

DRONES: THE NEXT TECHNOLOGY ADVANCE FOR WIND TURBINE INSPECTIONS

BY DONAVON GRAVES • DIRECTOR OF BUSINESS DEVELOPMENT AND STRATEGIC PLANNING • SKYWARD

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WINDPOWER ENGINEERING & DEVELOPMENT

www.windpowerengineering.com

FEBRUARY 2020

Drone

inspections play a vital role in preventive maintenance of vertical structures, ships, worksites and horizontal infrastructure like railroad tracks and power lines. Therefore, connected drones are the next phase of this technology. In the near future, the main mode of operations for unmanned aerial vehicles (UAVs) will be autonomous flights, beyond sight line of any pilot. Automation plus emerging 5G cellular networks can make the work of inspecting wind turbines far faster and also yield better insights at much less cost.

Improved maintenance could lead to more reliable wind power generation and improved ROI by extending the life of turbine blades. Let’s look at how this is unfolding with the latest advances in uncrewed aerial systems (UAS).

The present: Current wind turbine inspections with drones Today, a field team heads to a wind farm with a drone equipped with high-resolution photography, LiDAR (light detection and ranging) and thermal detection instruments.

During the inspection flight, the drone captures high-resolution images that can measure erosion on blade edges. The infrared camera and LiDAR sensor look for hidden damage inside the equipment, seeing up to 15-cm deep. The data collected is most likely saved onto a secure digital (SD) card, uploaded to a laptop and emailed back to the office for analysis. This entire inspection takes about 45 minutes.

Back at headquarters, the images are analyzed by an AI program and compared with previous inspection findings. A technician evaluates any changes that could cause concern, and servicing is scheduled for needed repairs, heading off expensive, bigger problems at a later date.

The future: Connected drones for inspections Now let’s take it a step further. Imagine dozens of UAVs staged near a wind farm. They’ll be programmed to do routine inspections on a frequent schedule and also be at the ready for any unscheduled flights needed after weather events, helping to identify equipment damage.

These aerial robots will be equipped with computer vision to understand the surrounding aviation environment and detect other aircraft to avoid collisions. They’ll be registered with remote identification capabilities, allowing them to avoid conflicts with crewed aircraft and be tracked by authorities.

They’ll fly autonomously in airspace governed by a universal traffic management system (UTM) for drones, similar to what the Federal Aviation Administration (FAA) runs for commercial aircraft.

FEBRUARY 2020

The drones will be connected to the high speed, ultra-low latency 5G wireless network through small communication nodes placed right on structures in the field. AI software will guide the UAVs as they look for potential damage, guiding the drones to problem areas. Technicians could view the drone video in near real time.

While technicians onsite can view the drone video essentially in real time, the data being collected — terabytes of high-definition video, infrared sensor data, LiDAR measurements — could be livestreamed back to the office where more AI-powered software instantly evaluates it. Edge computing will allow much of this data to be processed without it having to travel between distant servers far away from the office, resulting in a quicker process and allowing dozens of towers to be inspected simultaneously.

When a problem is found, wind turbine service technicians will be instantly notified, along with the precise location of the equipment. As a result, units will be kept in better repair, reducing the time they’re offline and maximizing energy generation.

This is not the stuff of science fiction. Many pieces are already in place to deliver on this vision.

The role of 5G Three attributes of next-generation wireless networks are especially relevant for connected drones: very low latency, energy efficiency and reliability.

1. Very low latency: Latency is described as how fast a piece of data moves from one part of a network to another.

When there’s a delay between the visuals and the audio of a movie you’re streaming, you’re experiencing latency.

5G will cut data transit speed to many times less than the blink of an eye — eventually less than a 10-millisecond end-to-end response time. This reduced latency will create a near real-time experience for drone and sensor operators in terms of sensor response, drone control and delivery of the media and data collected. Lower latency should allow remote UAV crews to fine-tune sensor movements and drone position to get the perfect angle for a shot or analysis without experiencing meaningful control lag.

2. Energy efficiency: 5G is expected to have up to 90% lower energy requirements than 4G. With 5G, complex functions can take place within the network near the end user.

Devices shouldn’t need as much processing capability and should consume less energy. This is an appealing benefit for any organization with a big stake in reducing carbon emissions, like the energy industry.

WINDPOWER ENGINEERING & DEVELOPMENT

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CONNECTED DRONES

3.

Reliability: Drone aviation requires very high levels of reliability. New 5G networks are being built with a focus on reliability (among other attributes), which should provide the confidence necessary for drones to operate over the network.

Progress on a unified airspace system for drones The commercial drone industry and the FAA are working toward a system of low-altitude traffic management to help keep the skies safe as this new era arrives. The vision is for an automated, unified traffic management system for flight approvals, coordination with FAA air traffic control and low-altitude airspace compliance. The system would

integrate weather service and other data. Every drone in the air will be instantly identifiable and equipped with collision-avoidance technology.

Skyward advanced airspace intelligence offers critical safety data to mitigate environmentrelated risk and improve drone flight safety for drone pilots, including 3D views of key structures, transmission lines and more.

Improving insights and analytics with connected drones Connected drone technology will also be a big advance in maintaining energy, transportation, water and other infrastructure systems. It will enable faster visibility into areas affected by disasters. 5G technology is designed to enable devices that are traveling up to 310 mph, such as a

Because it’s a long way down.

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CONNECTED DRONES

drone, to stay connected to the network.

UAVs already provide aerial views to repair people assessing damage after a wind event, flood or lightning storm. With 5G, massive stretches of power lines could be examined in minutes, with insights on conditions fed instantly to responders. Wind farm managers could see what’s going on with turbines even when ground conditions are still dangerous or impractical.

New 5G networks are being designed to allow up to 1 million devices per square kilometer to be connected wirelessly. Coupled with AI, devices operating on 5G wireless should be able to more quickly produce actionable information out of raw data. Dronegenerated videos, LiDAR readings, photos and thermal data could be processed near the site of collection and transferred to decision makers in near real-time. In addition, wind power generators will get better analytics on supply and demand or system waste.

Added reliability and ROI for wind power Total global wind power capacity is expected to grow 62% by 2024. With the cost of a new wind turbine blade running about $1 million, it is imperative to keep turbines functioning at peak capacity and maximize their lifespans.

UAS has already dramatically improved the pace, quality and frequency of wind turbine inspections. Autonomous, connected drones operating on a 5G network should present more possibilities.

Intelligent video, remote diagnostics and near real-time analytics will help technicians see what may be on the brink of failing sooner. Managers will be better able to assess damage, prioritize repairs and predict maintenance. And as a result, the fleet of hundreds of thousands of turbines humanity relies on to deliver clean energy will become more efficient and reliable. WPE

WINDPOWER ENGINEERING & DEVELOPMENT

11:39 AM

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EXTENDING WIND TURBINE LIFE WITH

PITCH ING BEARING UPGRADES

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WINDPOWER ENGINEERING & DEVELOPMENT

www.windpowerengineering.com

FEBRUARY 2020

BY COREY BAYLES • Senior Product Engineer Renewable Energy Applications • SKF USA

Extreme

weather, unpredictable heavy loads, remote locations and designs for higher output are just a few of the operational challenges affecting wind turbines that can lead to unexpected bearing failures. Fortunately, wind turbine service life can be increased by upgrading design, components and technology. Upgrades can increase pitch bearing life by up to 10 years, improve turbine life and efficiency while reducing downtime — all at a fraction of the cost of a new turbine.

What makes pitch bearings unique Slewing ring bearings connect the rotor hub (spinner) with the blade so it can be adjusted to the optimal angle for wind conditions. The blade is typically rotated by an internal/external spur gear or hydraulic actuator.

Designed for a lifespan of 20 years (approximately 175,000 hours), pitch bearings typically feature deep groove gothic arch raceways and maximized ball complement. Balls are evenly distributed by puck-like spacers or caged separators. A single-row four-point, or double-row eight-point, contact design provides exceptional load capacities, with bearing raceways that allow the balls to carry load from any direction simultaneously.

However, certain characteristics can pose challenges with bearing longevity.

A typical pitch bearing might never rotate more than 90° its entire life, and heavy loads, combined with very fine (<5°) oscillation angles, can put a great deal of stress on pitch bearing components. They are also held stationary for long periods of time and constantly subjected to vibration, which rapidly degrades the lubricant and leads to adhesive wear.

The isolated location of many wind turbines, exposure to a wide range of weather conditions and the pitch bearing’s position atop the tower limit regular access and observation. Usually, pitch bearings are directly observed every six to 12 months during periodic maintenance, making it difficult to detect problems early. Additionally, the hollow cast-iron hub and composite blade are quite flexible and provide the bearings little support.

FEBRUARY 2020

WINDPOWER ENGINEERING & DEVELOPMENT

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PITCH BEARING UPGRADES

Why pitch bearings fail: lubrication Unfortunately, the classic failure modes predicted by standard bearing calculation models (i.e., fatigue spalling and brinelling) are actually uncommon causes for pitch bearing failures. The main culprit is usually bad lubrication. Lubrication-induced failures include vibratory wear (false brinelling), corrosion, debris denting and surface-initiated fatigue. Separator damage, raceway flaking, split balls and bearing lockup can all be signs of a poorly lubricated pitch bearing. Many failures categorized as load-based might actually be the result of an issue that started with grease degradation.

In addition, more sophisticated pitch-control techniques designed to increase power production density result in heavier stress on the lubricant and bearing components. Dithering is a good term to describe the motion of bearings on turbines with active pitch control â&#x20AC;&#x201D; continuous, rapid oscillations at extremely fine pitch angles. This type of operation is not only a foundation for recent turbine efficiency gains, but is also a catalyst for lubricant degradation and component wear.

Wind turbines are subjected to harsh weather environments, so lubrication practices must be designed to ensure maximum machine uptime with minimal maintenance.

Proper grease selection is the first and most important step.

Pitch bearing grease must resist water washout and contain a durable additive package that protects against high load and vibrations. Use of continuous-feed lubrication systems also enable sites to add or adjust grease-fill as necessary, without requiring technicians to climb.

Why pitch bearings fail: load and operation While lubrication is the primary challenge, load failures are also an area of concern. Overloading usually happens because the bearing lacks rigid support from the hub assembly, leading to an imbalance where a fraction of the raceway carries most of the load. Load- and operation-induced failures include component fracture (rolling ball elements, ball separators, races), separator lockup and raceway core crushing. As noted above, these failures might also be exacerbated by lubrication conditions.

In a pitch bearing, the contact area between the ball and the raceway forms an elliptical shape that is centered over the race contact angle. Under heavy thrust or overturning loads, the contact ellipse can spill out of the physical limits of the raceway (truncation). The probability of contact truncation increases with the ratio of bearing diameter to thickness, or as external support decreases. Severe contact truncation produces stress

A pitch bearing upgrade can increase turbine life and efficiency while reducing costly downtime, all at a fraction of the cost of investing in a new turbine.

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WINDPOWER ENGINEERING & DEVELOPMENT

www.windpowerengineering.com

FEBRUARY 2020

PITCH BEARING UPGRADES

risers that cause the path edges to break off or the balls to split in fragments.

Finally, calculations rely on a set of conditional assumptions that sometimes bear little resemblance to real life. A bearing in a clean room with new seals, fresh grease and mounted on a rigid, perfectly flat surface might last dozens of years. Unfortunately, real life is seldom neat, and industrial equipment (like a wind turbine) must perform where it is needed.

Bearing upgrade: increasing path surface area and strengthening rings Although most pitch bearings fail in similar ways, the underlying causes can vary, and improvements must start with an understanding of that bearing’s unique issues.

With the potential cost of downtime and bearing changeouts ranging into hundreds of thousands of dollars, it’s beneficial to work directly with a manufacturer that can offer a bearing replacement solution that will improve productivity and extend turbine life cycle. The most effective bearing upgrades mitigate edge loading, strengthen the races, address separator wear and prevent contamination — ultimately, this results in a more efficient bearing.

Recommended case depth shown in blue; actual case depth of failed bearing shown in red (left). The failed bearing features rubber seals, which are replaced with an ‘H’ seal crosssection profile in the bearing upgrade (right).

Bearing upgrade: separator rings and raceway geometry Despite some theoretical advantages, the compromises necessary to account for manufacturing variation in continuous ring separators more than outweighs any of their benefits. With diameters regularly exceeding 2 m, it is virtually impossible to hold good shape and tolerance on a ring 5-mm thick. Gaps between the races must be enlarged to accommodate the ring, thereby reducing path contact area and increasing truncation. Rings also must be fabricated from mild steel, as high-strength alloys are not typically weldable. On the other hand, segment-style cages suffer none of these drawbacks and provide limited freedom of movement that can relieve loads that might rip apart single-piece rings.

For the paths, strict geometric dimensioning and tolerancing (GD&T) controls on the form, finish and spacing improves load sharing and balance. Nearer to perfect form means less friction, skidding and tight spots, thereby reducing internal wear and improving pitch system response and efficiency.

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Bearing upgrade: upgrading seals Pitch bearing seals play a dual role: protecting internal components from contamination and stopping lubricants from escaping into the environment. Unfortunately, seals

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w w w. a u r o r a b e a r i n g . c o m

PITCH BEARING UPGRADES

Contact truncation

Proper packaging

False brinelling and corrosion

Fractured balls

are not completely effective; after all, a bearing cannot rotate if it is hermetically sealed. Common pitch bearing seals are hydrogenated nitrile butadiene rubber (HNBR), installed on a groove in one race with two seal lips that drag along the opposite race. This seal style wears quickly, rapidly degrades when exposed to UV and ozone, responds poorly to distortion and provides contaminants with a direct path to the bearing internals.

An “H-profile” seal design made from thermoplastic polyurethane (TPU) and installed on a labyrinth retention groove significantly improves seal effectiveness. This free-floating design is highly responsive and provides seal pressure even when deformed.

It is less sensitive to ring deformation during operation, reducing grease leakage and water ingress to help improve robustness and reduce maintenance costs. In addition, TPU wear rate is a fraction of conventional rubber, extending effectiveness and replacement intervals.

Raceway durability Shear stress from heavy contact loads can penetrate beneath the surface and cause the softer core to yield, leading the hardened path to detach from the race (core crushing).

To prevent this, the induction-hardened layer must penetrate deeply enough that steel strength exceeds the contact shear stress.

In pitch bearings, structural deformations and heavy overturning loads mean that peak shear stress could occur at any point along the path surface. Therefore, it is imperative that the hardened layer be a uniform pattern and not diminish as it moves further from the design contact angle. A deep, uniform heat treatment greatly mitigates the effects of contact truncation.

Bearing upgrade: proper storage, packaging and handling Since most bearings may have an extended shelf-life before installation, it is important to ensure they are stored and packaged to prevent degradation prior to use. Proper

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WINDPOWER ENGINEERING & DEVELOPMENT

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packaging can prevent corrosion and damage from shock, vibration and other hazards during transport. Packaging should include the application of a corrosion-preventative coating to mounting holes, wrapping bearings in volatile corrosion inhibitor (VCI) paper, packaging in vacuumed-sealed bags and individual crating (stacked in two-high sets).

Bearings should be left in their original packages until just before mounting to prevent exposure to contaminants, especially dirt, and should be handled with clean, dry hands and clean rags. Prior to installation, they should be placed on clean paper, kept covered and never be exposed to a dirty table or floor.

Customized solutions to extend turbine life When turbines go offline because of maintenance issues or equipment failure, the high cost of repair crews and crane day rates can send costs soaring. Upgraded pitch bearing solutions can improve turbine life and efficiency and reduce downtime by: • • • • •

Increasing turbine reliability even in harsh environments Extending seal and bearing service life Reducing operation and maintenance costs Improving pitch control for increased performance Reducing installation and replacement time

Since bearing health is dependent on a variety of factors, it’s important to work with a manufacturer that can perform a failed bearing analysis and test the new solution using simulation programs to determine which upgrades may be necessary to mitigate risk of future failure. In addition, value-added services, such as condition monitoring and predictive maintenance, can further extend the service life of wind turbines well beyond their expected lifespans. WPE

FEBRUARY 2020

Adobe Stock

WHATEVER THE WEATHER Optimize asset performance by understanding a wind resource, not relying on it

By Gareth Brown, CEO, Clir Renewables

NEW

research released in 2019 showed wind speeds had increased across North America, Europe and Asia since 2010 — and the trend is expected to continue. This study featured in the journal Nature Climate Change offered a stark contrast to the majority of previous research, which has demonstrated a long-term reduction in wind speed. Naturally, this has resulted in some excited assertions of a possible boom for wind power in the near future.

It’s certainly stating the obvious to suggest that a strong wind resource is fundamental to the success of wind power as an energy generating technology. However, the assumption that this potential change in wind speed will have a significant

FEBRUARY 2020

effect on the wind industry must be taken with a pinch of salt — particularly as the increase in wind speeds plateaus at 3 m/s, far from the 5 to 7 m/s that turbines require to generate electricity.

The suggestion of increasing wind speeds in the near future cannot be depended upon as a means to increase annual energy production (AEP). To maximize AEP across their portfolios, asset owners must focus instead on increasing their understanding of each asset and how they relate to the surrounding environment. Taking an AI-driven, contextual approach to asset optimization will maximize and secure project returns.

WINDPOWER ENGINEERING & DEVELOPMENT

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WHATEVER THE WEATHER

Wind vs. turbine Wind power differs from oil, gas or coal power generation in countless ways, but a key contrast is in terms of consistency of resource intake. For coal, oil and gas, an operator has control over intake. This makes it far simpler to identify underperformance.

When generating energy from wind, however, there’s no control over resource intake. Wind resource can change completely in a short period of time, making it much more difficult to understand the reason for underperformance: has there been a drop in wind speed, or is there a fault within the turbine?

The indicator most operators use to assess asset performance is "turbine availability." Availability is a simple indicator of an asset’s reliability and potential for energy generation — after all, if the turbine is turned off it will not produce energy. However, "availability" tells owners nothing about whether the asset is performing as it should be with the current wind resource, or why it isn’t.

When availability is used to benchmark performance, longstanding underperformance issues are labeled as wind speed variation or missed entirely. This means that operators do not recognize low-level performance issues caused by faults within the turbine or misalignment, for example. A complete understanding of underperformance — and the extent to which it is due to resource versus technology — will empower asset owners and operators to increase AEP by up to 5%.

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WINDPOWER ENGINEERING & DEVELOPMENT

www.windpowerengineering.com

Context is key Low wind speed is not the only environmental factor that can reduce energy production. There are a number of other contextual influences acting on a wind turbine that can impact performance: • •

•

Ice buildup on turbines during colder months leads to increased loads on the blades, making it more difficult for the rotor to turn.

Turbulence and blockage caused by nearby buildings, trees or other wind turbines can drastically alter the energy yield in comparison to initial forecasts.

Imposed curtailment due to noise, the grid or local wildlife.

While SCADA data can indicate whether a turbine is underperforming, asset owners must understand how the environment is affecting each of their assets in order to find the root cause. To identify environmental issues such as blade icing or blockage as the source of any anomalies or patterns of minor underperformance, data collected from the turbine must be set in context.

Identifying and analyzing these environment-based issues requires digitizing the surrounding environment.

FEBRUARY 2020

WHATEVER THE WEATHER

This level of asset understanding is almost impossible to achieve through traditional data analysis methods.

However, advanced, deep domain methods of data analysis using machine learning and AI can analyze and compare data streams from within the turbine and the surrounding environment and flag problems and quickly advise on their solutions. This allows operators to act on issues before they significantly curtail performance.

supporting increased risk management capabilities. This can lead to lower insurance premiums, the ability to borrow more capital and achieve greater financial returns. Greater understanding of asset performance allows for certainty around predicted output for investors, setting asset owners up to secure more favorable project financing.

In short, wind resource — whether it is increasing or decreasing — isn’t the be-all and end-all of energy production. Asset owners need to move on from the predictions and claims long-term wind speed studies generate and focus on optimizing their portfolio — now.

By understanding their assets’ relationship with whatever wind speed each is afforded, owners will future-proof their portfolios and ensure they perform at their best, whichever way the wind blows. WPE

A fine line Misalignment of pitch and yaw are common sources of turbine underperformance. This should make resolving misalignment a priority for asset owners looking to maximize portfolio performance — after all, angling the nacelle away from the wind by as little as 4º can reduce AEP by 1%.

Yaw misalignment is one of the simplest fixes to increase AEP as it is often due to sensor or controller error that will be rectified by replacement of the faulty part. However, identifying misalignment can be a complex, long-winded process, requiring operators to sift through a significant volume of data comparing the performance of individual turbines to others across the wind farm.

In contrast, using digital tools to compare power curve data between peer turbines to identify whether pitch or yaw has been misaligned massively reduces the time-cost involved in analyzing the data. As such, owners can identify and fix misalignment before it has a significant effect on AEP.

SAFETY

Power up Sometimes wind farm underperformance is not due to the influence of environmental factors or issues within the turbine itself, but is the fault of an overly conservative derating strategy that curtails turbine output at a fleetwide level. While derating is a useful strategy to prevent blockage effects and increase asset lifetime, many derating strategies lower turbine performance to an excessive extent.

In order to find the optimal balance between preventing blockage effects and maximizing production, advanced analytic methods evaluate data from multiple sources within and around the turbine to provide asset-by-asset recommendations. By taking a tailored approach to their assets, owners can significantly improve annual energy production while maximizing lifespan.

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Financial certainty Understanding how assets interact with the environment and finding potential opportunities for optimization will improve far more than turbine output. A complete understanding of assets will lead to greater certainty around performance,

WINDPOWER ENGINEERING & DEVELOPMENT

Specifically designed with operator safety in mind, AcraDyne’s Gen IV Controller/ HT Dual-Lever Nutrunner system provides an intuitive, intelligent solution even in the harshest conditions.

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www.aimco-global.com

1-800-852-1368

has reached an

OPPORTUNITY MOMENT in its

24

WINDPOWER ENGINEERING & DEVELOPMENT

www.windpowerengineering.com

FEBRUARY 2020

BY MIKE CASEY

PRESIDENT & FOUNDER TIGERCOMM

Public record levels nationwide, but these sectors are also

support for different forms of renewable energy is at

facing growing risk and cost from aggressive NIMBY (not in my backyard) opposition at the local level.

The onshore wind industry is now seeing half-billion-dollar power projects killed because 50 people shout at officials in a county commission meeting. Despite its lower viewshed impact, solar isn’t immune from NIMBY attacks either. Last fall, sPower almost lost its permit to build a utility-scale solar farm in Spotsylvania County, Virginia, because of residents citing false health concerns, among other things.

Offshore wind would do well to look for the applicable lessons in the experiences and responses of other clean economy sectors.

Rough public affairs waters are just beginning. The country's first proposed offshore project, Cape Wind, was stopped by attacks from wealthy neighbors. The federal government recently pushed an effective “pause button” on a critical offshore wind project off the coast of Massachusetts, while the sector faces very real community pushback in Maryland, New York and Delaware.

And we shouldn’t forget the seemingly obscure 2016 Coast Guard “study” pushed by lobbying pressure from Maersk, a leading global shipper with significant interests in the oil and gas industry.

The study was riddled with outside influence, and it resulted in a call for U.S. offshore wind turbines to be set back from shipping lanes at a distance that’s five-times that required in Europe.

But this moment also represents an opportunity for offshore wind to save itself money and heartache.

Incumbent sectors fuel professional NIMBY efforts To do that, it’s crucial for the sector to understand what it’s really up against. Often, the local problems that clean economy sectors face are exacerbated and leveraged by incumbent sectors that view renewable developers as long-term market threats. The result is that opposition campaigns are getting more sophisticated, supported by professional organizers, funded by incumbent energy sectors and connected through online resources.

As far back as 2012, fossil fuel-funded operative Jon Droz and the American Tradition Institute were caught coordinating supposedly

NREL

FEBRUARY 2020

WINDPOWER ENGINEERING & DEVELOPMENT

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OFFSHORE WIND PUBLIC AFFAIRS

organic, local NIMBY groups through “dummy businesses” and “counter intelligence.” A watchdog group exposed Anadarko Petroleum Corporation’s scheme to manufacture a perception of a wind turbine fire “crisis” throughout the American West.

The results of professional NIMBY pushback against clean energy mean increased costs for most, project death for some and even failed companies. Luckily, with still only five operating offshore turbines to date in the United States, offshore wind has the opportunity to glean and use the lessons available from other sectors’ collective experience.

Offshore wind has the advantage of being driven at this early stage not by a collection of startups, but rather experienced, deeppocketed players drawn to the growth potential of an industry with a Capex of $70 billion.

WHERE HAVE NEWSPAPERS DISAPPEARED?

26

Ways the sector should tackle public affairs Cleantech marketing communications and public affairs firm Tigercomm has spent several months aggregating the public affairs approaches, wins and losses of several clean economy sectors.

That list includes solar, onshore wind, residential PACE and micromobility.

Compressing that analysis here produces several big takeaways.

First, policy debates, regulatory institutions and the motivations of elected officials are not merit-driven.

Politics and policy run on different motivations, and both are full-contact sports. They must be approached on their terms, with robust public affair programs that are built into companies’ business plans from the start.

Second, offshore wind companies are not a new industry, but rather a new sector that’s out to take market share from mature incumbents. The disrupted aren’t going to take that lying down.

They’ll use their significant experience

with leveraging the government to defend market incumbency. Our public affairs programs have to be designed to win a race to define the offshore wind sector, as well as each new project.

We still find that among clean energy developers, the legacy mentality of quietly working regulators is the norm.

But offshore wind companies need to treat their projects as the equivalent of a political campaign or issue campaign.

The party that frames first creates an advantage that is difficult to overcome.

Being quiet when you’re trying to win over a community is a losing strategy in an age of increasingly professionalized online NIMBY opposition.

Third, public affairs programs have to win the race to define on the digital track.

The decline of local journalism means 1,300 U.S. towns are now “news deserts,” devoid of local news media outlets. This is particularly true in small communities where clean energy projects must often seek local approval in order to build a project. Online platforms, particularly

SINCE 2004, THE U.S. HAS LOST MORE THAN 1,800 NEWSPAPERS – 62 DAILIES AND 1,749 WEEKLIES

WINDPOWER ENGINEERING & DEVELOPMENT

www.windpowerengineering.com

FEBRUARY 2020

OFFSHORE WIND PUBLIC AFFAIRS

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Facebook, have filled the void. They need to take center place in public affairs programs to solve for the risk that misinformation can spread throughout local communities weighing a regulatory decision.

Fourth, offshore wind projects should be narrated as a product with compelling, simple-language framing anchored to a core community need. And, that definition has to be driven home through visual storytelling regularly by people who are relatable for locals. Narratives from people always trump facts and figures.

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U.S. sector’s success at stake The offshore wind sector can accelerate its growth by standing on the shoulders of other clean economy sectors. Some of its companies are already investing to make their case to local communities. Others lag behind. Given the opponents’ interest and ability to lump all the sectors’ companies together, it’s in everyone’s interest to invest in public affairs programs at scale. The growth rate of each company hinges on the sectors’ collective ability to avoid the "mistake path" that other clean energy sectors have fallen into. If the sector gets ahead of the project opposition that it will increasingly face in the years ahead, it will be better positioned.

Rising seas will lift all boats, and rough waters could sink all of them. The time to choose our forecast is now. WPE

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2020 LEADERSHIP IN

WIND ENERGY Celebrating the companies and individuals leading the wind power industry.

This year will be significant for the wind industry.

The U.S. industry is predicting 2020 to be the largest installation year ever. And offshore wind contracts are annouced almost every day, and they’re just waiting for site approval.

To keep wind-generated power flowing, we at Windpower Engineering & Development know it is important to recognize the leaders that push the industry forward. Here, you’ll see the accomplishments of fellow engineers and companies. Congratulations to the 2019 winners!

We think companies deserve recognition from you, too. Vote online through October for one or more of the companies listed in this special section.

VOTE

ONLINE

2019 WINNERS BEARINGS

Aurora Bearing Company

ELECTRICAL/ELECTRONIC

Megger

FASTENING/JOINING

Aztec Bolting

HARDWARE/COMPONENTS

Dexmet Corporation

OPERATIONS & MAINTENANCE

Abaris Training

windpowerengineering.com/leadership Select the company you think has provided leadership in the wind industry.

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FEBRUARY 2020

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LEADERSHIP IN WIND ENERGY

2020

Abaris Training Resources, Inc. is recognized as the leading provider of advanced composite training for wind blade manufacturers, repair technicians, and engineers worldwide. Abaris has over 35 years of experience teaching composite structural repair techniques and methodologies to the aerospace industry and over the past decade, transferred that knowledge to those now serving the wind energy industry. Abaris now offers two windblade repair courses; R-5 “Basic” and R-15 “Advanced” courses, building skills for skin, core, tip, trailing edge, carbon spar repairs, and more.

Abaris Training is the world leader in advanced composite training. We have trained more

Abaris Training Resources, Inc. 5401 Longley Ln, Ste 49 Reno, NV 89511 775.827.6568 Training@abaris.com www.abaris.com

than 27,000 students since our inception in 1983, across a number of industries ranging from aerospace to automotive to marine to wind energy and more. Our goal is to teach the latest technology to our students in a friendly yet professional atmosphere. Currently we offer over 23 different courses covering many disciplines surrounding engineering, manufacturing, repair, and NDI of advanced composite structures. Classes are available in three different facilities: Reno, NV; São José dos Campos, SP, Brazil; and at the KVE facility in Maastricht, The Netherlands.

All courses are taught by highly motivated instructors, all of which have vast experience and knowledge of composites and are acknowledged for being the top in their respective fields. In addition to training at Abaris facilities, Abaris can host entire groups at our facility or bring the training to you. Our Direct Services division specializes in organizing either off-the-shelf, or custom courses to our customers, worldwide.

windpowerengineering.com/leadership Voting for this company will identify it as a leader in the wind power industry.

FEBRUARY 2020

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LEADERSHIP IN WIND ENERGY

2020

INTUITIVE, INTELLIGENT TOOL DESIGN AcraDyne® is the design and manufacturing division of AIMCO, which offers the most complete portfolio of critical fastening and bolting solutions for the automotive, electronics, aerospace, energy services, and general assembly industries. AcraDyne produces a complete line of DC Controlled Tools ranging from 1 to 17,000 Nm. AcraDyne provides cost-effective solutions by resolving challenges related to tightening and critical bolting strategies, tool selection and installation, joint failure analysis, audit trails, and methods.

This, combined with operator training, maximizes the production efficiencies its tools provide. AcraDyne tools are designed and made in the USA.

Safety is Vital in Critical Bolting The Wind Industry presents challenges when dealing with tool operator injuries. Remote locations and hazardous working conditions mean it can often take hours for help to arrive once an injury occurs.

AcraDyne’s Gen IV Critical Bolting Platform is one of the most advanced bolting systems in the world. The HT dual-lever nutrunner/Gen IV controller system enhances safe tool operation and provides an intuitive, intelligent solution even in the harshest conditions.

Protect Your Most Valuable Asset — the Tool Operator AcraDyne’s nutrunners are designed with ultimate operator safety in mind. The dual-lever design helps prevent: • Injuries from accidental tool start Two-hand operation with no tie-down feature requires the operator to use both hands on the trigger simultaneously, eliminating accidental tool start and keeping both hands out of harm’s way • Strain caused by awkward tool operation Multiple handle styles ensure the safest, most ergonomic tool for your application

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The Gen IV iEC controller/tool system measures traceable, dynamic torque directly at the square drive and the built-in transducer ensures accurate torque values. AcraDyne’s HT tools deliver high speeds in torque ranges 50 – 17,000 Nm. The ergonomic, robust design includes five handle configurations.

windpowerengineering.com/leadership Voting for this company will identify it as a leader in the wind power industry.

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FEBRUARY 2020

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LEADERSHIP IN WIND ENERGY Aurora Bearing Company was founded in 1971 and manufactures the world’s most complete range of rod end and spherical

2020

Aurora Bearing Co’s new LCOM Spherical Bearings outperform “LS” bearings

bearings. Configurations range from 2-piece economy commercial and molded race construction through 3-piece precision designs. Aurora also produces a full line of military spec rod ends, spherical bearings, and journal bushings. Custom designed rod ends, spherical bearings, and linkages are a specialty.

For more information, contact: 630-859-2030 Fax: 630-859-0971 aurorabearing.com

Aurora Bearing Company 901 Aucutt Rd. Montgomery, IL 60538 Ph: 630-859-2030 Fax: 630-859-0971 aurorabearing.com

Like all Aurora Bearing spherical bearings, the LCOM series features a one piece steel raceway, swaged around the ball for a smooth, precise, close tolerance fit, along with the benefit of the strength and vibration resistance of steel. In addition, this series is optionally available with Aurora’s proprietary AT series PTFE liner, for a zero clearance, self lubricating fit.

Aurora LCOM Spherical Bearings were designed to offer a higher level of performance with dimensional interchangeability for the “LS” spherical bearing category; a market segment which has remained largely unchanged since the 1950s. “LS” bearings are characterized by being of 3 or 4 piece construction, with an inner ball, an outer ring, and a one or two piece brass, bronze, or copper alloy race between.

Since the early 1950’s users of these bearings, which are also marketed with a “FLBG”, “RS”, or “VBC” prefix, have had to accept their low strength and poor vibration resistance due to the low strength race material. Aurora’s LCOM bearings incorporate superior materials and manufacturing processes to overcome the performance deficiencies associated with “LS” bearings.

COMM-M Bearings are stronger choice for DIN ISO 12240-1 applications

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Metric spherical plain bearings built to DIN ISO 12240-1 (formerly DIN 648) schedule K often are made with inner races or rings made of brass, bronze or copper. For many low demand applications these bearings have proven to give satisfactory service. However, in applications with high loads or high vibration levels or both, the bearings can quickly develop excess clearance due to a deformation of the relatively soft race material.

This weakness is addressed in the Aurora Bearing Company’s COM-M series spherical bearings. Like all Aurora inch dimension spherical bearings, these metric bearings all feature a 1 piece steel raceway, cold formed around a chrome plated, alloy steel ball for strength, precision, and structural integrity.

Aurora COM-M series bearings are available in sizes from 3mm to 30mm., and follow the dimensions of DIN 648 schedule K. Bearings are optionally available with Aurora’s self lubricating AT series ptfe liner, for a smooth, zero clearance fit that is self lubricating and maintenance free.

Maintenance free & corrosion resistant rod ends from Aurora

The Aurora CM/CW-ET series rod ends offer a combination of features unique in the rod end industry. Instead of the low strength steels typically found in stainless rod ends, the ET series features bodies made from heat treated 17-4PH material. Not only do they offer excellent corrosion resistance compared to conventional rod ends, they provide greater load capacity, strength, and durability as well. The ET series comes standard with Aurora’s exclusive AT2100 PTFE liner. This, combined with a heat treated 440C stainless ball, gives a durable, zero clearance, self lubricating, maintenance free bearing interface to go with the benefits of the heat treated body. Their two piece design allows exploiting these high performance features to be exploited at an economical price. The Aurora ET series bearings can be used to enhance the performance of equipment in wash down, marine, and other environments that require extra corrosion resistance.

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LEADERSHIP IN WIND ENERGY AZTEC BOLTING SERVICES, INC. has been a leading provider of bolting tools to the wind energy industry for over 30 years.

Aztec Bolting utilizes the latest products from Enerpac to Skidmore for all your torque and tension requirements. We offer the finest tools available for sale or rent, including hydraulic tools that can yield up to 80,000 ft./lbs. Aztec Bolting also provides calibration services and repairs through our ISO 17025 accredited mobile fleet and calibration facility at the company headquarters in League City, TX. Working alone, or on site with your labor force, Aztec is committed to delivering the right solution, to meet your timing and budgetary requirements. Aztec Bolting Services, based in League City, TX, has expanded our service area with new offices in Port Arthur, TX, and continues to provide a state-of-the-art mobile fleet division with additional office locations in Midland, Corpus Christi and Sweetwater, TX, Nederland, TX, and Oklahoma City, OK.

Since 1987, Aztec Bolting Services has been providing innovative equipment and superior technology. As a distributor of Enerpac Bolting and Tensioning Products, Skidmore-Wilhelm, Stahlwille, and Norbar hand torque wrenches, electronics and torque multipliers, we are prepared to assist our customers in achieving their Wind Power Construction and Maintenance goals.

Aztec Bolting is proud to enter into this new year introducing the new Norbar Evotorque Battery Tool. The new battery tool boasts high accuracy through features including a built-in torque transducer, a brushless motor, and is fully programmable with safety, smart technology, and comfort at the forefront of design.

“Aztec’s mission is to provide quality products and services to meet every torque and tension need with the utmost care, quality and service.”

Enerpac Wind Tensioners Aztec Bolting is proud to deliver the Enerpac Wind Power Generation Bolt Tensioners. The Enerpac tensioners offer high precision with low maintenance. If your project requires critical fastening applications whether in high performance or tight spaces, the new line of Enerpac PGT, FTR, and FTE Series Tensioners offer universal solutions with precision and speed.

Enerpac S-Series Aztec’s hydraulic torque wrench systems are foundational in wind turbine applications. The Enerpac S-Series Hydraulic Torque Wrench is the fundamental square-drive torque wrench. It is incredibly versatile with a light and sleek design, which delivers up to 25,140 Ft/lbs of torque. The S-Series also features a 360 degree swivel manifold and durable rigid steel design.

Aztec Bolting Services 520 Dallas Street League City, TX 77573 1308 South Midkiff Road, #305 Midland, TX 79701

Enerpac W-Series Another example of a quality wrench is the Enerpac W-Series Steel Hexagon Torque Wrench. The W-Series sets the standard in versatility, reliability, and durability. The innovative design sports a pinless construction with a quick release drive and auto crank engagement. This hexagon torque wrench has a 360 degree swivel manifold and you won’t need tools for changing hexagon heads.

802 Navigation Boulevard #106 Corpus Christi, TX 78408 1113 Lamar Street Sweetwater, TX 79556 3620 HWY 69 N Nederland, TX 77627 800.233.8675 www.aztecbolting.com

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2020

And because Aztec Bolting is an authorized national distributor of Enerpac products, you can count on a lifetime warranty. Aztec Bolting and Enerpac products are guaranteed.

Our professionals can be on-site anytime, anywhere with our ISO 17025 Accredited Mobile Calibration Fleet. Our Mobile Units can provide more versatile services than ever before from Controlled Bolting Training to on-site calibrations of your products.

Voting for this company will identify it as a leader in the wind power industry.

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LEADERSHIP IN WIND ENERGY PPG Engineered Materials (formerly Dexmet Corporation) manufactures precision expanded metal foils and polymers for applications in aerospace, power generation, filtration and automotive industries. Dexmet was founded in 1948 and is based in Wallingford, Connecticut and was acquired in 2019 by PPG. For over 60 years Dexmet has been at the forefront of expanding technology and has redefined the standards for micro mesh materials providing the greatest range of products and capabilities for foil gauge metals and thin polymer films.

Dexmet manufactures thin, light-weight precision expanded Copper and Aluminum from .001” thick and widths reaching over 48” that can meet specific weight, conductivity and open area requirements required by aerospace or wind generation applications.

Precision MicroGrid® materials from PPG Engineered Materials are the industry standard for expanded materials used in lightning strike protection, on carbon fiber structures with OEM aircraft manufacturers as well as EMI/RFI, and ESD protection for sensitive internal instrumentation.

The Dexmet Quality System is ISO AS9100:D and ISO 9001:2015 certified.

Engineered Materials Wallingford, CT +1 (203) 294-4440 www.dexmet.com

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FEBRUARY 2020

As the power output requirements increase

for wind turbines, wind generator manufacturers are moving towards larger blades to rotate these larger turbines at lower wind speeds. As the wind blades increase to over 45 meters in length, blade construction is moving away from the more traditional all fiberglass construction to utilize more carbon fiber. The carbon fiber provides a substantial weight savings and increased strength to combat the extreme stress loads exerted on the blades during operation.

Carbon fiber, however, is conductive and more prone to be struck by lightning. Without proper protection, they are susceptible to severe damage and catastrophic failure.

For two decades Dexmet has been working with aircraft designers developing precision expanded MicroGrid® foils for lightning strike protection on carbon fiber composite aircraft and its components. Benefiting from the development work done in the aircraft industry, Wind Blade Manufacturers are now realizing the importance of having the proper lightning strike protection for larger carbon fiber blades.

As with aerospace applications, weight is always critical so PPG Engineered Materials provides different conductive materials to minimize the weight based on the different strike zones. As with all rotary blades, lighting is more prone to hit the leading edge and the outer blade surfaces towards the tips where the highest amount of static energy is generated. For these locations, the heavier, more conductive materials are utilized. As you move towards the root of the blade, a lighter weight material can be incorporated to reduce weight and cost. The variability with our expanding process provides the capability of producing a custom material based on desired weight, conductivity, or open area to meet exact application requirements.

2020

PPG MicroGrid® Proven Lightning Strike Protection • Proven Technology for Lightning Strike Protection • Highly Conductive Patterns Matched to Specific Requirements • Open Area Design for Easy Dry or Wet Layup without Delaminating • Easily Repairable for Low Maintenance Costs and Minimal Downtime MicroGrid® Materials for Hybrid-Carbon Fiber Wind Turbine Blades PPG MicroGrid® materials are thin, open area products applied to a layer on the top of the structural carbon fiber spar/web or other systems that utilize carbon such as de-icing solutions that consume carbon heating mats on the leading edge. PPG MicroGrid® materials can achieve the critical conductivity, sometimes in conjunction with the carbon components, to dissipate 20-25 years’ worth of lightning strikes.

Expanded copper and aluminum MicroGrid® meshes are essential at extending the life of hybrid carbon fiber composite blades.

PPG engineered materials are used in conjunction with the other parts of the entire lightning strike protection system for a wind turbine blade. Our mesh can provide connections between receptor(s) and anchor blocks/root through which high voltage current pass to ground connections.

To learn more about the benefits of PPG Engineered Materials, witness its lightning protection performance or understand how it can reduce your maintenance costs and down time, contact PPG at sales@dexmet. com or visit our web site and let us show you how to incorporate the innovative MicroGrid® materials into your composite designs and start recognizing the benefits today.

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LEADERSHIP IN WIND ENERGY

2020

HELUKABEL: The Worry-Free Cable Experience HELUKABEL USA, based near Chicago IL, is a global manufacturer and supplier of cables, wires and cable accessories. Our extensive product line includes flexible and continuousflex control cables, data/network/BUS cables, VFD/servo cables, torsion cables for wind turbines, single-conductors, and multi-norm cables with domestic and international electrical approvals.

HELUKABEL combines excellent cable quality, innovation and technical expertise with a vast product portfolio and smooth logistics operations. We call that the worry-free cable experience!

New automation technology means new cable challenges. With almost 40 years in the cable business, we have designed our products to provide an uninterrupted flow of power and data to todayâ&#x20AC;&#x2122;s automated manufacturing systems, regardless of working conditions.

Our cable engineering expertise allows us to meet and exceed customer expectations as industry technology becomes more advanced. We continuously provide new cable solutions for our customers, which allows them to maintain their position at the forefront of the market.

HELUKABEL cables have long service lives, and have been tested to multi-million flexing cycles. This makes the automated manufacturing process leaner by reducing downtime and increasing productivity. We also develop and manufacture complete cabling protection systems for robotics applications.

Combining a product portfolio of over 33,000+ line items with worldwide logistics operations allows us to deliver the cable products you need, when you need them. With a fully automated logistics center in Germany, and a large warehouse near Chicago IL, we are able to serve the North American market on a justin-time basis. Truly making HELUKABEL your one-stop shop cabling solution provider.

HELUKABEL, USA T: (847) 930-5118 sales@helukabel.com www.helukabel.com

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LEADERSHIP IN WIND ENERGY

2020

Established in the late 1800s, Megger has been the premier provider of electric test equipment and measuring instruments for electrical power applications. The trademark was first registered in May 1903 and is guarded by the company. Although weâ&#x20AC;&#x2122;re best known for our world famous range of insulation testers, Megger provides a full service solution to meet your electrical test and measurement needs. Manufacturing insulation testers is where Megger started; the Megger brand name is so well known today that maintenance professionals often incorrectly use it as a verb when they refer to doing an insulation test on wiring. This famous name dates back to 1889, when the first portable insulation tester was introduced with the MEGGER brand name on it.

At Megger, we understand that keeping

the power on is essential for the success of our customerâ&#x20AC;&#x2122;s business. That is why we are dedicated to creating, designing and manufacturing safe, reliable, easy-to-use portable test equipment backed by world-leading support and expertise.

We can assist your acceptance, commissioning and maintenance testing for predictive, diagnostic or routine purposes. By working closely with electrical utilities, standards bodies and technical institutions, we contribute to the dependability and advancement of the electrical supply industry.

Megger 866-254-0962 megger.com

We focus our expertise in developing innovative testing solutions that are world class in safety, performance, reliability and easy to use. Megger is committed to providing our customers with measurement results and insight to make informed decisions about their assets, increasing uptime and safety.

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FEBRUARY 2020

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LEADERSHIP IN WIND ENERGY Megger Baker instruments is an established pioneer in the area of electrical testing of motors, generators and coils, with a product range that offers comprehensive, standards-based testing and analysis for motor health and Quality Control. Off-line (“static”) testers can expose issues with motor circuits and insulation condition, including turn-to-turn insulation. On-line (“dynamic”) testers monitor the behavior of the entire powermotor-machine system in real time, often providing insight into where in the system a problem lies. With service and training offerings, Megger Baker Instruments has your motors covered.

2020

The Baker name has been foremost in electric motor and coil testing for over half a century.

Megger Baker Instruments 4812 McMurray Ave., Ste. 100 Fort Collins, Colorado 80525 www.megger.com/baker

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LEADERSHIP IN WIND ENERGY Norbar Torque Tools introduces EvoTorque2, where we have brought together durability, low cost-of-ownership, Norbar quality and accuracy, and all the features you need, and rolled them into one, price-competitive tool.

EvoTorque2 is easy to program, presents a small and lightweight package, stores thousands of readings, and can be serviced in the field. There are too many features and advantages to list in a few short lines of text, so the best way to measure the advantages and value of EvoTorque2 is to try it yourself.

Stack us up against the competition – you’re going to be amazed!

2020

Norbar EBT EvoTorque Battery Tool – Another radical change comes to battery powered torque multipliers!

Norbar Torque Tools has jumped into the battery tool market, and made a big splash!

Meet EBT – EvoTorque Battery Tool, with everything our EvoTorque2 electric brought you, but along the way we lost the power cord, and picked up an 18V battery.

Operating the same EvoLog software as EvoTorque2, EBT is the perfect complimentary tool, because it is set-up, programmed, and operated exactly the same as its corded big brother. With a brushless motor, a durable and accurate Norbar gearbox, and a built-in transducer, Norbar has set the bar high in the world of battery tools.

With an accuracy of +/-3% OF READING, EBT hits the target every time, across the full range of the tool. If accuracy matters to you, if durability matters to you, and if unparalleled service and support matter to you, the only name you need to remember is NORBAR.

Norbar Calibration Fixtures – Accuracy and durability brought to the field!

Norbar Torque Tools knows how critical it is to have and prove the calibration and accuracy of your torque tools. We have been providing calibration equipment to the Wind industry around the world. We can package and configure equipment to suit all your needs, and our modular design allows your equipment to grow and change as your needs grow and change.

Whether you need fixtures to calibrate hydraulic wrenches, or joint-simulators to calibrate your non-impacting torque tools, or just a way to calibrate or verify torque wrenches, Norbar has the equipment and expertise to cover all your needs!

Norbar Torque Tools, Inc. 36400 Biltmore Place Willoughby, OH 44094 Phone: 866.667.2272 Fax: 440.953.9336 Email: info@norbar.us www.norbar.us

Norbar HandTorque Multipliers – Big range and a small size, with a Certificate of Calibration!

Norbar Torque Tools Compact Series Torque Multipliers are designed to deliver high torque ranges, in user-friendly gear ratios, packaged in a small and lightweight package. Because size and weight considerations are critical to your business, Norbar has developed a line of torque multipliers that make life in the tower easier by providing a powerful 27:1 gear ratio – an operator input of 100 lb-ft generates 2700 lb-ft of torqueing power!

When it comes to real convenience, Norbar has designed the Compact Series Torque Multipliers to accept the same torque reactions as you will use on your EvoTorque2 tool, saving you even more time and money down the road.

All Compact Series Torque Multipliers include a Certificate of Calibration, and are delivered in a high density plastic carrying case.

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FEBRUARY 2020

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LEADERSHIP IN WIND ENERGY WIND TURBINE BRAKE SOLUTIONS SUPPLIER PINTSCH BUBENZER is a world leader in braking system design and manufacturing, with safety built into every product.

PINTSCH BUBENZER offers wind turbine manufacturers and wind farm operators innovative braking systems for rotor, azimuth and rotor-locking motions, utilizing efficiently designed disc brakes, clutches and hydraulic systems. The well thought-out design of all system components and the high and constant quality standards maintained in production, installation and final acceptance ensure smooth and reliable operation, minimum expenditure for maintenance and long service lives.

Pintsch Bubenzer USA

With quality products from PINTSCH BUBENZER investors save trouble, time and costs over the full useful life of their systems and increase thereby their profits in a longterm manner. In addition, our optional brake monitoring systems further reduce downtime and maintenance expense by identifying minor adjustment and wear issues before they become serious maintenance problems. This is an especially important enhancement for offshore wind farms.

8 Bartles Corner Rd STE 102 Flemington, NJ 08822 pintschbubenzer.de

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LEADERSHIP IN WIND ENERGY

2020

Rotor Clip is a global leader in the manufacture of tapered, constant section and spiral retaining rings meeting Inch, DIN, ANSI Metric and JIS standards. This includes the manual and automatic tools needed to install/remove every ring we sell.

Rotor Clip also manufactures wave spring rings as well as self-compensating hose clamps, all produced in a lean environment dedicated to eliminating waste and ensuring quality through IATF 16949, ISO 9001 & ISO 14001 registration, and AS9100C certification.

Bearing Retention & Preload Solutions through Engineering Expertise.

Rotor Clip TruWaveÂŽ single-turn wave springs are suited for applications that include connectors, fluid power seals, noise and vibration attenuation, and bearing preload.

The design of standard single turn wave springs with gap typically used for preloading components features sharp corners at the cut off area of the spring ends. These sharp corners can scratch the surface of the bearing as well as the mating parts when the wave form shows a steep incline depending on the load specification.

Rotor Clipâ&#x20AC;&#x2122;s patented single-turn wave spring design solves this problem by flattening the ends of the spring so that they will not create excessive wear that can damage the application.

This new design also offers the potential for cost and weight savings in applications where design engineers would typically choose a multi-turn wave spring with shim ends to prevent wear on mating components. However, multi-turn wave springs with shim ends require more material in their production, which adds to both cost and weight.

As with all of our wave spring designs, there is no charge for tooling on custom designs with this end feature.

Feel free to contact our technical sales staff (tech@rotorclip.com) to find out if your design can benefit from our new single-turn wave spring design. Maybe you have questions about another of our retaining ring, wave spring or hose clamp products. Our technical sales engineers are here to help you find the right solution for your application. www.rotorclip.com

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LEADERSHIP IN WIND ENERGY

Abaris Training .......................................................................... BC Aimco Global ..............................................................................23 Aurora Bearing Comapny ........................................................19 Aztec Bolting ...................................................................cover, 27 Dexmet Corporation ..................................................................15 HELUKABEL USA ........................................................................11 Megger ....................................................................................... IBC Norbar Torque Tools, Inc. ........................................................... 1 Pintsch Bubenzer USA ................................................................7 Sterling Rope ............................................................................... 14 Abaris Training ...............................................................................29 Aimco Global ..................................................................................30 Aurora Bearing Company ............................................................ 31 Aztec Bolting ...................................................................................32 Dexmet Corporation ...................................................................... 33 HELUKABEL USA .......................................................................... 34 Megger .............................................................................................35 Megger Baker Instruments .........................................................36 Norbar Torque Tools, Inc. ............................................................ 37 Pintsch Bubenzer USA .................................................................38 Rotor Clip .........................................................................................39

SALES Jami Brownlee 224.760.1055 jbrownlee@wtwhmedia.com Ashley Burk 737.615.8452 aburk@wtwhmedia.com

Neel Gleason 312.882.9867 ngleason@wtwhmedia.com @wtwh_ngleason Jim Powers 312.925.7793 jpowers@wtwhmedia.com @jpowers_media

LEADERSHIP TEAM VP of Sales Mike Emich 508.446.1823 memich@wtwhmedia.com @wtwh_memich

EVP Marshall Matheson 805.895.3609 mmatheson@wtwhmedia.com @mmatheson

Managing Director Scott McCafferty 310.279.3844 smccafferty@wtwhmedia.com @SMMcCafferty

Publisher Courtney Nagle cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel

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EVERYONE NEEDS

PROTECTION...

…Especially from lightning.

The Megger DLRO10HD offers reliable testing to make sure you’re protected in the event of a lightning strike.

When a strike occurs, current flows to ground through the lightning protection system. The systems resistance to ground should be measured regularly to ensure that the protection will work when needed. For these measurements a low resistance ohmmeter, like the DLRO10HD, should be used.

Megger also makes a test lead set specifically designed for testing wind turbines. They are long enough to assess the continuity of lightning protection conductors in wind turbine blades and are ideally suited for use with the DLRO10HD.

Features of the wind turbine lightning protection test lead set include: n

Available in 328 ft (100 m) length

n

Suitable for use on site or in the manufacturing plant

n

10A rated

n

The lead set offers reversible terminations. One termination is a duplex handspike, while the other is a heavy-duty Kelvin clip

Look to Megger for lightning protection.

For your FREE copy of Megger’s Guide to Low Resistance Testing, Visit us.megger.com/getbook Reference Code: DLRO10_Lightning_FEB

Turn Your Job Into A Career Take Our Hands-On Windblade Repair Courses Composite Windblade Repair Designed for those responsible for performing structural repairs to composite wind blades, this course covers fundamentals necessary to understanding aerodynamic skin, core, and trailing edge repairs.

• Feb 3-7, 2020 • Aug 10-14, 2020 • Nov 9-13, 2020 Advanced Windblade Repair A follow-on to our Composite Wind Blade Repair course, this course is for those directly involved in providing high performance repairs to large area damage, spars, and tips.

• Feb 10-14, 2020 • Aug 17-21, 2020 • Nov 16-20, 2020

Dedicated to Excellence Since 1983

(R-5) Composite Windblade Repair (R-15) Advanced Windblade Repair +1.775.827.6568 www.abaris.com