Windpower Engineering & Development February 2021

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The technical resource for wind profitability

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Test busbar connections in windfarm networks with the Megger DLRO2

The DLRO2 is a two-amp handheld DucterTM Low Resistance Ohmmeter. Its many features are very fitting in windfarms.

The unit has the ability to test with very long test leads. This is excellent for applications such as testing lightning protection on wind turbines. The long test lead/mΩ test mode is a separate, easy-to-select, test mode that optimizes the DLRO2 for use with very long test leads. It can: n

Maximize compliance voltages

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Only test at 1 A with positive-only output tolerance to comply with 1 A minimum current requirements for wind turbine and aerospace applications

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Apply 1 A in a total resistance of up to 3 Ω, allowing potentially over 150m of test cable to be used

Additionally, the DLRO2 features a difference meter which provides the ability to quickly compare a number of subsequent measurements. The difference meter is perfect for testing a number of similar connections such as busbar joints, cable lugs, crimps, and much more. This makes it easy to identify connection with slightly higher measurements that could indicate a latent fault; something that could eventually develop into a major failure.

So, why not grab a DLRO2 for testing your wind turbines.

For a FREE copy of A Guide to Low Resistance Testing visit us.megger.com/getbook Reference Code: DLRO2_WPED_FEB

KC Series test leads allow easy and reliable measurement of lightning protection circuit resistance of wind turbines

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FEBRUARY 2021

WINDPOWER ENGINEERING & D E V E LO P M E N T / / V O L . 1 3 N O. 1

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COVER STORY

The U.S. can hit the ground running with these data-driven O&M tips for offshore wind

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In order to take advantage of the country’s offshore wind potential, owners must plan for O&M that is effective at preventing both downtime and underperformance during periods of high wind resource. Cover image credit Ørsted

IN EVERY ISSUE

FEATURES

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CONTRIBUTORS

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WINDWATCH

12 The United States needs more transparency around fire data

20 Q&A with European offshore wind expert Ventolines

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WIND WORK AROUND THE UNITED STATES

16 New cable designs are critical for floating wind turbines

22 Healthcare and safety: Important considerations on offshore wind farms

Some interesting product and policy news from our website.

On- and offshore wind project announcements from across the country.

2021 LEADERSHIP IN WIND ENERGY The U.S. wind industry is growing into new markets. Success would not be possible without the ingenuity and determination of these leaders.

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FEBRUARY 2021

The wind industry has been hindered by its unwillingness to share data on fire incidents when they happen. In order to ensure up-to-date best practices, the industry must take steps toward transparency.

As the demand for more renewable energy continues to rise, the industry will look further offshore into deeper waters where wind availability is higher and more consistent. Underwater cables must adapt.

www.windpowerengineering.com

The Dutch firm has signed on as offshore wind expertise partner for Mayflower Wind and has opened its first permanent U.S. office in Boston. We learn more about the company’s U.S. offshore plans

Companies with offshore wind operations are looking at ways to improve processes while reducing costs. A major part of this is maintaining the health and safety of offshore and remote employees.

WINDPOWER ENGINEERING & DEVELOPMENT

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WINDPOWER ENGINEERING & DEVELOPMENT

GARETH BROWN

DUNCAN HIGHAM

ANGELA KRCMAR

MAXIME TOULOTTE

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GARETH BROWN is CEO and co-founder 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.

DUNCAN HIGHAM founded SSI Risk Management (SSI) in 2012 and SSI Energy in 2016 and successfully grew the SSI Group into a multi-million dollar business prior to its acquisition by Remote Medical International. He graduated from Cardiff University and Imperial College in Economics, joined the Royal Marines in 2002 and carried out several operation tours of Afghanistan and various other locations, leaving as a Major in 2012. He received emergency medical training in Cape Town, South Africa. In his current role as VP Global Strategy, Duncan is responsible for the direction of growth for Remote Medical International with a particular focus and expertise in renewable energy emergency response.

ANGELA KRCMAR is wind global sales manager for Firetrace International. She has over 10 years of experience in the fire protection industry focusing on the renewable sectors including wind and battery storage. For the past 10 years Angela has led Firetrace efforts in the wind industry, contacting and visiting wind farms, owners and manufacturers in an effort to discuss needs and advantages of fire protection for wind applications. Angela is an active member of the AWEA Wind Environmental, Health, and Safety Standards Committee Meeting, member of the NFPA 855 Committee for Standard for the Installation of Stationary Energy Storage Systems and contributing member of the UL 6141 technical standards panel.

MAXIME TOULOTTE is the Head of Technical Marketing of Nexans’ Subsea and Land Systems (SLS) business group, where he has the responsibility to develop and maintain relations with technical and engineering departments of clients and partners for subsea high voltage cables. SLS is a global business group delivering high voltage cables systems and umbilicals, and with long experience in turnkey export cable projects. Nexans has also delivered the dynamic export cables for the first offshore floating windfarm, Hywind, located off Scotland. Maxime has held several positions as Sales & Tender Manager and Lead Engineer for high voltage submarine cable system projects. Maxime holds a master’s degree in Electrical Engineering from the Grenoble Institute of Technology, France.

WINDPOWER ENGINEERING & DEVELOPMENT

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FEBRUARY 2021

wind windWatch Watch NREL tests recyclable thermoplastic material for wind turbine blades

NREL researchers test a turbine blade mold.

Photo by Dennis Schroeder / NREL

The use of a thermoplastic resin has been validated at the National Renewable Energy Laboratory (NREL). Researchers demonstrated the feasibility of thermoplastic resin by manufacturing a 9-m wind turbine blade using this novel resin, developed by Arkema. Researchers have now validated the structural integrity of a 13-m thermoplastic composite blade, also manufactured at NREL. In addition to the recyclability aspect, thermoplastic resin can enable longer, lighter-weight and lower-cost blades.

Manufacturing blades using current thermoset resin systems requires more energy and manpower in the manufacturing facility, and the end-product often winds up in landfills.

The thermoplastic resin could also allow manufacturers to build blades on site, alleviating a problem the industry faces as it trends toward larger and longer blades. As blade sizes grow, so does the problem of how to transport them from a

NREL simulated 20 years of use of the thermoplastic blade to ensure durability. Photo

by Ryan Beach / NREL

manufacturing facility.

FEBRUARY 2021

WINDPOWER ENGINEERING & DEVELOPMENT

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WIND WATCH

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Onshore and offshore wind project incentives included in federal spending package

Dominion Energy files construction plans for 2,640-MW Coastal Virginia Offshore Wind project

The latest federal spending package extended the wind production tax credit by an additional year, also creating a new 30% investment tax credit for offshore wind projects starting construction by 2025. The PTC still applies at 60% for projects that start construction by the end of 2021, but it will drop to 0% come 2022. The offshore wind ITC has a 30% credit for projects that start construction before 2026, and many of the country’s planned offshore projects are expected to begin construction around 2024.

Dominion Energy filed a construction and operations plan (COP) with the Bureau of Ocean Management in December 2020 on the 2,640-MW Coastal Virginia Offshore Wind (CVOW) project, which is currently the largest planned offshore wind project in the United States. The COP will lay out construction, operations, environmental impacts and decommissioning plans for CVOW.

GE taps Missouri processor to recycle wind turbine blades GE Renewable Energy contracted Veolia North America to recycle blades removed during U.S. upgrade or repowering projects. The blades will be shredded at Veolia’s Missouri processing plant and made into raw material substituted for coal, sand or clay for manufacturing cement.

Virginia establishes training alliance to bolster state’s wind workforce Virginia is boosting its onshore wind workforce training efforts with the formation of the Mid-Atlantic Wind Training Alliance. The program will be run by Centura College, Mid-Atlantic Maritime Academy and will be hosted at The New College Institute.

The Mid-Atlantic Wind Training Alliance will offer industry-recognized certifications for the proper operation and maintenance of wind projects. The program is slated to start in early 2021.

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WINDPOWER ENGINEERING & DEVELOPMENT

New Jersey utilities board loops PJM in on offshore wind plans With a state goal of 7,500 MW of offshore wind energy by 2035, New Jersey is preparing its electrical grid operations for the large intake of new renewable energy.

In November 2020, the New Jersey Board of Public Utilities (NJBPU) requested that PJM integrate the state’s offshore wind goals into the grid operator’s transmission planning process, allowing PJM to manage the competitive solicitation process for offshore wind solutions.

Ørsted and U.S. trade unions team up to ready workers for offshore wind construction Looking for nearly 83,000 workers to build its 30-GW offshore pipeline, international developer Ørsted has partnered with North America’s Building Trade Unions to help U.S. construction workers transition to working in the emerging domestic offshore wind industry. Ørsted and NABTU are establishing long-term plans to have a unionized workforce ready to construct these projects and a permitting environment suited for developing them.

www.windpowerengineering.com

FEBRUARY 2021

Wind work around the

united states

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Cameron County, Texas Acciona completed its 10th U.S. wind farm, a 198-MW project in Cameron County, Texas, in December 2020.

The wind farm project also included construction of an 11-mile high-voltage line that will lead power generated by the system to the grid. That electricity will be sold on the ERCOT-South Texas market.

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i m ag e C r e d i t: e d f r e n e wa b l e s

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7 220-MW Cranel Onshore Wind Project comes online in Texas

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Refugio County, Texas RWE Renewables completed a 220MW wind project in Refugio County, Texas, comprised of 100 Vestas 2.2-MW turbines. Property taxes generated from the Cranell Onshore Wind Farm are projected to be more than $50 million, which will benefit Refugio and Bee counties and regional schools.

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EDF Renewables completes construction of 150-MW North Dakota wind farm

Kulm, North Dakota The 150-MW Merricourt Wind Project began commercial operation near Kulm, North Dakota, in December 2020. Upon completion, developer EDF Renewables handed operations to utility Otter Tail Power Company, which arranged an asset purchase and turnkey EPC agreement. The 75-turbine wind project created 260 construction jobs.

FEBRUARY 2021

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BayWa r.e. brings its largest wind farm online in Texas

Rotan, Texas BayWa r.e. completed construction of the 250-MW Amadeus Wind Project in Rotan, Texas, that is made of 96 GE turbines sited across 25,000 acres of state, federal and privately-held lands. Morgan Stanley signed a 10-year PPA on the project. Amadeus is jointly owned by Fengate and BayWa r.e., which will continue managing the wind farm.

Atlantic Shores proposes 2.3 GW of offshore wind in New Jersey

New Jersey Atlantic Shores Offshore Wind, a joint venture between EDF Renewables North America and Shell New Energies U.S., submitted a project proposal for offshore wind projects totaling 2,300 MW. Atlantic Shores’ proposal estimates it could complete its first project by 2027 and the largest proposed project could reduce New Jersey’s carbon emissions by 16%.

Construction starts on 300-MW Lincoln Land Wind in Illinois

Morgan County, Illinois Infrastructure and Energy Alternatives was awarded a $100 million contract in January for the construction of the 300MW Lincoln Land Wind farm in Morgan County, Illinois, that is expected to be completed by the end of 2021. Apex Clean Energy and IEA subsidiary White Construction will manage construction of the 107-turbine project.

Leeward Renewable Energy adds 171-MW of wind power to Colorado grid

Weld County, Colorado Mountain Breeze Wind farm, a 171MW project in Weld County, Colorado, designed and constructed by Leeward Renewable Energy, started commercial operation this winter. The wind farm uses 62 GE Renewable Energy turbines and created 300 jobs at peak construction.

Energy from Mountain Breeze is being sold to Xcel Energy.

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Acciona energizes 198-MW La Chalupa Texas wind farm

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Enel Green Power completes 435.5 MW of new wind construction in Midwest

Clark County, Kansas & Nodaway County, Missouri Enel Green Power finished two major wind projects this past winter: a 199-MW expansion of the Cimarron Bend wind farm in Clark County, Kansas, bringing the system to 599 MW; and the 236.5MW White Cloud wind farm in Nodaway County, Missouri. They were constructed under Enel’s Sustainable Construction Site model, with Cimarron Bend adopting a recycling program and donating supplies to local schools, and White Cloud’s O&M facility made from a repurposed building at the site.

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WINDPOWER ENGINEERING & DEVELOPMENT

www.windpowerengineering.com

FEBRUARY 2021

THE U.S. CAN HIT THE GROUND RUNNING WITH THESE

DATA-DRIVEN

O&M TIPS FOR OFFSHORE WIND

By Gareth Brown • CEO • Clir Renewables

The

U.S. offshore wind industry is set to take off in the coming years, with more than 5 GW of cutting-edge turbines due to come online by 2025 and take advantage of the country’s high offshore windspeeds.

However, in order to make the most of this fantastic opportunity to increase renewable energy’s share of the country’s generation mix, owners must plan for operations and maintenance (O&M) that is effective at preventing both downtime and underperformance during periods of high wind resource.

By incorporating the best practice and lessons mature markets have learned over the course of decades into O&M strategies, future offshore wind project owners and operators will be able to prevent any hold-ups in performance and ultimately maximize production from the first day of operations.

Lessons from mature markets

The “offshore” nature of offshore wind raises a number of very specific challenges for scheduling O&M. Whilst

FEBRUARY 2021

repairing a faulty onshore turbine might require a wait for specialized technicians and equipment to become available, maintaining an offshore turbine requires finding a window where technician and tool availability matches safe sea conditions and crew transfer vessel availability. This means that turbines can see extended downtime over winter when sea conditions are least favorable.

Calmer summer seas and lower winds allow for more opportunities to send the O&M team to site and minimize any lost revenue due to downtime; therefore, as a rule, offshore wind farms in Europe and Asia schedule routine on-site inspection and repair for this season. If any small errors and defects identified in the course of monitoring are fixed during this period, the turbine is less likely to fail during a peak production month and remain offline for an extended period while conditions are unsafe for on-site repair.

However, this forward-thinking strategy is often undercut by ineffective year-round monitoring of wind farm

performance. Small defects, particularly those that begin at a subsurface level or due to sensor error, are easily missed if an operator relies on visual inspections or standard, top-level data analysis.

It is vitally important that they are able to tackle all issues affecting turbine performance in these summer weather windows. If anomalies or early stage faults go under the radar, the owner will be faced with long term turbine underperformance at best, or a critical failure forcing the turbine offline in times of high resource with no safe access window to rectify it, at worst.

Finding the root cause

Typically, O&M teams rely on SCADA data to diagnose turbine issues.

However, if only turbine SCADA is analyzed, many small or sustained instances of underperformance (which can make a big dent on balance sheets if missed) will be lost in the data “noise” caused by fluctuation of resource.

It is essential to set the turbine’s data within the context of its

WINDPOWER ENGINEERING & DEVELOPMENT

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DATA-DRIVEN O&M TIPS

Ørsted

environment — inclusive of geospatial factors, vessel logistics and the proximity of neighboring turbines or farms — in order to gain an accurate picture of why a turbine might be underperforming. This contextual data is crucial to understanding whether underperformance

ADVANCE ICING FORECASTS.

KEEPING YOUR TEAM SAFE AND TURBINES OPERATIONAL

is due to times of low resource or a sign of a technical problem that can be addressed.

However, traditional methods of data analysis cannot handle the sheer volume of data needed to analyze an offshore wind turbine in the context of its environment.

Often, a team can take weeks or even months to sift through turbine data and get to the root cause of the problem. To add to the complexity, systems are typically not holistic, whereby different platforms are utilized depending on the particular area of analysis.

It doesn’t need to take this long. Artificial intelligence applied to the appropriate data model can identify underperformance from the data as it arises, rather than diagnose it months down the line. By building an intelligent model of turbine performance inclusive of all atmospheric, geospatial and meteorological data, it is possible to cut the time necessary to identify a potential failure down to hours.

Offshore unknowns As the sheer scale of offshore turbines and offshore wind farms increases, we are entering unknown territory around how these new designs interact with and are impacted by the harsh offshore environment.

www.indjiwatch.com/wa 10

WINDPOWER ENGINEERING & DEVELOPMENT

DATA-DRIVEN O&M TIPS

Turbines need cablerotor tip to tower base

While these turbines have been designed to produce vast amounts of energy in harsher conditions, there is still a lack of long-term data to indicate exactly how higher hub heights and harsher environments will affect turbine components — preventing owners from having a clear indication of asset condition and adjusting their maintenance strategy.

For example, the latest designed turbines being deployed with blades over 100 m in length.

However, longer blades require lighter materials and innovative internal structures, which further increases the tip speed. For onshore turbines, the industry has had time to gather data to suggest that these factors increase the risk of a blade developing leading edge erosion.

For offshore turbines, there is a lack of available data to confirm whether these blades will stand up to the constant interaction of microdroplets at high wind speeds typically seen offshore.

With in-depth, AI-driven analysis of contextualized turbine performance on site from day one,

owners will be able to monitor for dips in performance or signs of damage, learn how their technology is working in that environment and build a long-term O&M strategy based on real performance.

With this information, the O&M team can then watch for the first signs of erosion when on site, ultimately reducing the chances of blade erosion progressing to a crack or total blade failure.

Collecting and analyzing all available offshore wind farm data — quickly, and in context — is crucial to fully understanding turbine performance and targeting O&M to make the best use of available weather windows.

Rapid and in-depth AI-driven analysis of contextualized health and performance data has become best practice in mature markets, and by adopting leading software at the commissioning stage, the U.S. offshore wind industry has the chance to hit the ground running to achieve minimal downtime and maximal returns. WPE

As one of the leading international manufacturers of cables, wires and cable accessories, we provide system expertise to the wind power industry. Our main focus is on nacelles, cable-loops, down towers and tower controls/transformers, including medium voltage applications

HELUKABEL® USA | West Dundee, IL | helukabel.com

FEBRUARY 2021

WINDPOWER ENGINEERING & DEVELOPMENT

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The United States needs more transparency around fire data for safer wind operations

By Angela Krcmar • Global Sales Manager • Wind, Firetrace International

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WINDPOWER ENGINEERING & DEVELOPMENT

www.windpowerengineering.com

FEBRUARY 2021

Fire

is one of the most expensive losses for any wind farm owner and operator to manage. Beyond the potential devastation of the turbine, fires pose a serious hazard to human life and the environment. As such, the wind industry is already taking action to prevent fires and their spread, adopting strategic and technological solutions in order to ensure safer operations.

However, despite this ambition, the wind industry has been hindered by its own unwillingness to share data on fire incidents when they happen. While a handful of U.S. states mandate that all fires are reported to local authorities, current reporting lacks detail about the precise nature and cause of the fire. This lack of in-depth incident data prevents the industry from not only understanding the frequency of wind turbine fires, but whether current turbine designs or operational best practices expose owners and operators to greater risk.

Adobe Stock

FEBRUARY 2021

Evolving risks based on expert testimony Despite a lack of transparency around fire incident data, a few key risks have been identified from experts in the field. As designs have adapted to protect against environmental hazards like lightning, internal, mechanical or electrical failures causing sparks have become an increasingly common source of fire.

The risk of these mechanical or electrical failures occurring increases depending on turbine age and the number of skilled technicians available to perform maintenance. Overall, around 7% of the current wind fleet is now over 15 years old — a figure much higher in Europe and North America due to the maturity of the sector. Additionally, while there are now more than 60,000 turbines totaling 109.9 GW spinning in the United States, there are only around 7,000 technicians to manage that fleet. This gap between number of technicians and turbines increases the likelihood that a number of assets will simply lack regular and thorough maintenance, resulting in the accumulation of mechanical and electrical defects.

WINDPOWER ENGINEERING & DEVELOPMENT

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FIRE SAFETY BEST PRACTICES

GE

The changing climate, particularly along the West Coast, has created arid conditions that increase not only the risk that a spark will become a fire, but the likelihood of that fire growing and spreading into the environment.

Electrical sparks in poorly maintained transmission lines have already resulted in wildfires that have caused untold damage to communities – and ultimately bankrupted the utility following litigation.

It is therefore vital for the wind industry to take steps to manage these risks and prevent the spread of any fires that do start.

Best-practice in design and operations to reduce fire risk One of the first steps to reducing fire risk is to start with the turbine itself. While most turbines have been designed to reduce the risk of fires starting, some components can either increase the likelihood of sparks or increase the damage that a fire can cause.

For example, as turbines have grown in size for increased megawatt capacity, a number of manufacturers have opted for carbon blades to further decrease the weight without sacrificing strength in the face of high windspeeds. However, while these blades generally increase the lifetime of an asset, they still pose a significant hazard in the event of a fire, as carbon composite dust can be more explosive than previous designs.

Similarly, tower cables are necessary to transport electricity from the nacelle to the grid and cannot be designed out. However, while cable materials are difficult to set alight, if enough heat builds up at a splice, then a fire can start.

Faulty electrical transformers are a common root cause of wind turbine fires due to arc flashes – and if located in the nacelle, can cause total destruction of the asset.

As such, systems to monitor, protect and suppress fire are necessary to keep all the benefits of component improvements like use of carbon blades and higher turbine output while minimising fire risk. Owners and operators can ask their manufacturers

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WINDPOWER ENGINEERING & DEVELOPMENT

www.windpowerengineering.com

FEBRUARY 2021

FIRE SAFETY BEST PRACTICES

GE

to install these systems ahead of project construction or choose to retrofit them to currently operational projects.

Beyond the asset itself, there are a number of steps that can be taken at the O&M level to reduce fire risk. A common practice that can increase risk of fires is remote turbine shutdown and start-up – before a turbine is switched on again, technicians must first determine what the initial error was and whether restarting the turbine would result in another failure or sparks.

In order to ensure up-to-date best practice and allow for benchmarking between different strategies, the industry must take steps toward transparency. Once fire data is accessible, owners and operators can make more effective decisions around the level of fire protection needed to prevent significant financial and reputational losses. WPE

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WINDPOWER ENGINEERING & DEVELOPMENT

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NEW CABLE DESIGNS ARE CRITICAL FOR

FLOATING

WIND TURBINES

BY MAXIME TOULOTTE • HEAD OF TECHNICAL MARKETING NEXANS SUBSEA AND LAND SYSTEMS BUSINESS GROUP

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WINDPOWER ENGINEERING & DEVELOPMENT

www.windpowerengineering.com

FEBRUARY 2021

Offshore

wind is enjoying a boom time, contributing more and more to the global energy transition with smarter operations and more powerful wind turbines. Europe is still the largest market, accounting for nearly 80% of global offshore wind capacity, while installed capacity is growing by around 30% year on year.

Most wind farms are currently constructed close to shore in relatively shallow waters, a technology that has well matured and is now firmly established. As the demand for more renewable energy continues to rise, the industry is now looking further offshore into deeper waters where wind availability is higher and more consistent.

Oceans of opportunity Until now, most wind power generation has utilized static power cables from turbines anchored to the seabed in 50 to 60 m of water. However, wind turbines in deeper waters necessitate floating technology – wind turbines on floating bases anchored to the seabed. This is because the foundations for bottom-fixed wind turbines become very expensive to build and install in deeper waters. Floating wind turbines also require dynamic, high-capacity submarine cable systems to collect and export the power generated.

Offshore wind farms that could use larger floating turbines fall into two main geographic groups. The first group operates in water depths of 100 to 200 m, satisfying locations such as the European Atlantic coast, the United Kingdom and the Norwegian North Sea. The second group could accommodate wind farms in waters five- to 10-times deeper, such as the Mediterranean or the U.S. West Coast.

Waves and currents subject the power cables that connect the turbines to the seabed to significant dynamic stresses. Therefore, these cables must accommodate all movements and loading from the ocean in relation to the floating platform plus its weight.

Building on strong experience in offshore oil and gas Nexans has an advantage with its deep knowledge of the structural behavior of dynamic cables in umbilical projects for the offshore oil and gas industry. As such, it is one of a few companies with an established track record in both high-voltage submarine cable systems and dynamic cables and power umbilicals. Current development projects effectively bring the two disciplines together.

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FLOATING WIND TURBINE CABLE DESIGNS

The decades of experience Nexans has gained from working on numerous oil and gas field projects has been invaluable in perfecting its manufacturing techniques.

It also showed that further development work was needed to efficiently carry the high voltages of power that large floating wind farms will require to export. They will feature enormous turbines that will eventually reach power levels of around 20 MW, whereas the current output is in the range of 7 to 10 MW. The high-voltage level needed for offshore wind farm export cables not only requires a larger cable, but it cannot tolerate any ingress of water or moisture into the insulation. It needs a water barrier, which, in static cabling, is accomplished by using a lead sheath extruded on the cable. Such a sheath cannot be used in floating offshore wind applications as it is unable to flex and withstand the dynamic movement causing fatigue cracking.

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WINDPOWER ENGINEERING & DEVELOPMENT

This limitation prompted Nexans to develop alternatives, such as a metallic foil or polymer sandwich, suitable for applying to cables many kilometers in length. This barrier needs to be thick enough to provide reliable protection but not so thick that it resists the cable’s movement.

Making this type of structural change to a known design will obviously affect other properties.

Therefore, by taking a holistic approach to engineering design, Nexans covers various factors such as strength, flexibility, flotation and temperature regulation. Here, the predictive models built from decades of experience in the oil and gas industry are an invaluable data source for Nexans design teams.

An added benefit is that, at a negligible cost, Nexans can incorporate optical fibers within the dynamic power cables to enable

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end-to-end communication. This can give operators an early warning when any part of the cable suffers stress or experiences a spike in local temperature.

Supplying cables to the world’s first floating wind farm Norwegian energy operator Equinor, previously known as Statoil, was one of the first oil and gas operators to transition into floating wind farms. In 2009, it installed the world’s first full-scale floating turbine – the Hywind Demo – in the North Sea off the Norwegian coast. The unit is based on a 2.3-MW turbine with 82-m rotor diameter.

Some years later, in 2017, Equinor commissioned the world’s first operational floating wind farm – the Hywind Scotland Pilot Park, located 30-km off the coast of Aberdeenshire. In this project, the rotor diameter increased to 154 m while the overall height was set at 253 m.

Having demonstrated the proficiency of

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FLOATING WIND TURBINE CABLE DESIGNS

its static and dynamic cables and associated accessories at the Norway site, Nexans was also contracted to provide the dynamic cable systems for this project.

With water depths varying between 95 and 129 m, the pilot farm covers approximately 4 km2 and is connected to the shore by a 30-km export cable. The average wave height is 1.8 m, while the average wind speed is 10 m/sec.

Featuring an installed capacity of 30 MW, it comprises five 6-MW turbines connected through an inter-array cable network that feeds into a single export cable carrying energy back to shore. The cable systems were engineered, manufactured, tested, transported, sealed off, prepared for pull-in and delivered in individual, installationready lengths.

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A buoyant future Since the Hywind project’s success, other floating turbines have been deployed, and more projects are in the pipeline. Equinor recently started construction of Hywind Tampen, the world’s first floating wind farm to power offshore oil and gas platforms.

Consisting of 11 wind turbines, the 88MW project is intended to provide electricity for the Snorre and Gullfaks offshore field operations in the Norwegian North Sea. The development will be a testbed for further developing floating wind and exploring the integration between gas and wind power generation systems.

Technically, the expanding size and generation capacity of offshore wind turbines has contributed considerably to these offshore power plants’ attractiveness and commercial viability. And judging by expert projections, offshore wind is set to become a critical pathway for the global energy transition. According to the International Energy Agency (IEA), moving into deeper waters using floating – rather than fixed – wind turbines have the potential to meet the world’s electricity demand several times over by 2040. WPE

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1/28/2021 9:43:41 AM

Ventolines performing work on the Block Island offshore windfarm near Rhode Island. Fred Olsen Windcarrier supplied the jack-up vessel from Europe. The components were taken out to it on U.S.-flagged vessels. Ørsted

Q&A

with offshore wind expert

The has signed on as

Dutch firm Ventolines

offshore wind expertise partner for Mayflower Wind, a huge offshore wind project starting 30 miles south of Martha’s Vineyard, Massachusetts, and has opened its first permanent U.S. office in Boston. Windpower Engineering & Development connected with Thibaut de Groen, Ventolines’ director of contracting and construction, and Lorry Wagner, the firm’s new U.S. representative, to learn more about the company’s U.S. offshore plans.

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Ventolines

What project aspects will Ventolines be performing for Mayflower Wind?

For Mayflower, Ventolines will provide T&I (transport and installation) expertise on the electrical offshore substation, the wind turbine foundations, the electrical cables to collect the energy and get it to shore, and the wind turbines themselves. Shell and Ocean Winds staff are in management positions — we are supporting them on technical matters.

What experience does Ventolines have to meet the challenge?

We supervised the installation of the five wind turbines off Block Island, Rhode Island, which was the first U.S. offshore wind farm. We also supported our client Deepwater Wind on grid

WINDPOWER ENGINEERING & DEVELOPMENT

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connection, turbine takeover and asset management.

We’ve done technical due diligence and helped negotiate turbine supply and service contracts for the Skipjack Wind Farm off the Maryland coast, developed by Ørsted; and South Fork Wind off New York’s Long Island, a partnership between Ørsted and Eversource.

In the Netherlands, we’re currently involved in 1,500 MW of major onshore wind projects, including the country’s largest, Windplan Groen (“Wind Plan Green”). And we have a lead role on all aspects, from early development to asset management, of the world’s

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largest freshwater offshore wind farm, Windpark Fryslân. There we have 89 turbines under construction right now for a total of 383 MW. What are some of the main differences in offshore installation between the United States and Europe?

One of the main differences is that the Jones Act requires U.S.-flagged vessels to transport the components between ports and installation vessels at the project site. On the Block Island project, we used this method with Fred Olsen Windcarrier, which supplied its Brave Tern jack-up installation vessel from Europe.

It was a complex logistics challenge and one that required loading the towers and blades from one vessel to another on the high seas. To do that you have to manage the movement of materials and vessels while they are moving up and down in changing weather conditions, and without damaging the components during transfer. All while doing this safely and efficiently to avoid a standstill, which is extremely costly. However, since we have experience in the Netherlands using feeder barges to shuttle components from land to a single installation vessel, we are used to this.

What other lessons learned and takeaways from Block Island will make future U.S. offshore projects go more smoothly?

Block Island had a challenging blade installation schedule. Installation for two blades had to be done at a 30° angle from the horizontal, which is uncommon.

Also, the wind speeds at low altitudes were sometimes higher than at hub height.

In the end, all the challenges were overcome and the project was installed successfully. Lorry Wagner came to see it with a delegation from the Icebreaker Wind project he was working on in Lake Erie. They were surprised that when they asked for a tour of the construction site, it had already been completed in half the time expected.

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What logistical and supply chain challenges does the U.S. offshore wind market face?

In Europe there is already a trained workforce, a well-developed supply chain, port infrastructure and installation vessels. That’s because we now have over 4,500 gridconnected offshore wind turbines across 11 countries, vs. the seven offshore turbines in the U.S. as of today. Of course all of this lies ahead for the U.S., and as we build out the industry here, we’ll be assisting the development of these same capabilities.

We’ve faced many challenges in all phases of building an offshore wind farm. That includes understanding the interests of local stakeholders, governments and companies, as well as being able to properly address the problems of people who suffer indirect or direct nuisance. You have to determine the most suitable foundation for a wind turbine based on the site conditions in the ocean, and understand turbine contracts and be able to negotiate them.

As soon as you sign your signature on a contract, the balance of power shifts from employer to contractor — any further changes will cost money. We help ensure that everything is correctly spelled out.

This includes the power curve — the power the project will generate at the most common wind speeds in that area — and the availability — how often is the turbine ready to produce power? These are some of the most crucial features a developer negotiates with the turbine manufacturer so that they have the best warranty possible.

We also oversee the manufacturing of components at the factories in Europe, where many of these components will continue to be made. We perform our due diligence there before the equipment ever reaches the U.S.

What challenges did you face while providing technical support during turbine selection for the Skipjack and South Fork projects?

Ventolines led the turbine procurement for the developers. The most challenging aspect was to work with projects in a development phase where the position or number of turbines were not fixed, yet turbine components needed to be ordered and put into long-term storage (partly to qualify for U.S. tax credits). Everything is in flux until the permitting agencies say, “Here is what you can do.”

Another recurring challenge was to ensure compatibility of a newly announced turbine product with U.S. power systems and U.S. standards, whereas such products are typically designed for the EU market.

What lies ahead for the U.S. offshore wind industry?

The first project in federal waters just started generating power at the end of September 2020 — Dominion Energy’s pilot project with two turbines in Virginia.

Now that the federal government has awarded 16 leases for offshore wind farms in seven states, we’ll see a rapid expansion and many companies getting involved.

These states have committed to developing 29 GW of offshore wind power, and the West Coast is considering its own plans. That compares to 18.5 GW offshore so far in Europe. So Mayflower Wind is just the start of what is possible.

In the Netherlands, very clear regulatory frameworks have been drawn up to which developers must adhere. We normally set up a participatory process in which the developers provide people with the best possible information and involve them in shaping the plan — for example, by thinking together about the integration of the wind or solar project into the landscape.

We hope to be able to use our experience on these kinds of topics and find common ground on the economic benefits of wind turbines to towns and workers, as well as the good it does for the environment and helping to slow climate change. WPE

WINDPOWER ENGINEERING & DEVELOPMENT

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HEALTHCARE AND SAFETY: IMPORTANT CONSIDERATIONS ON OFFSHORE WIND FARMS

BY DUNCAN HIGHAM • VP GLOBAL STRATEGY REMOTE MEDICAL INTERNATIONAL

As

• •

Health and safety plans Offshore work environments are challenging for a host of reasons including their remote locations and the physical challenges of the work and work environment.

These all create unique health and safety challenges, each of which should be addressed in a health and safety plan.

The facts speak for themselves and underscore the need to ensure the plan in place is airtight when it comes to responding to injury and illness on an offshore wind farm. These statistics were reported for 2019 by the Global Offshore Wind Health and Safety Organization. Of the 865 incidents reported in 2019: • 41 incidents resulting in an emergency response or medical evacuation • 93 incidents occurred during lifting operations • 91 incidents during access/egress • 76 incidents during manual handling • 291 incidents occurred in a turbine

Most plans make assumptions based on best case scenarios. For example, if the worker has a medical issue that requires evacuation, the trained first aider can administer CPR during the 45 minutes it takes for the helicopter to arrive.

The best plans, however, anticipate worst case scenarios and provide answers to questions like these: • What happens if the helicopter is not available or cannot come for several hours and the worker needs to be evacuated by boat?

• What is the process for evacuating the worker by boat? What is the process for getting them to shore?

• Who is trained to safely lower the worker from the turbine while administering first aid?

• Is the first aider able keep the worker alive for several hours? Anything over 10 minutes in a critical case would be a significant ask of a first aider.

• Is a working automated external defibrillator (AED) available? Who is trained to use it?

the world continues to grapple with a global pandemic, companies with offshore wind operations are looking at ways to improve processes while reducing costs. A major part of this is maintaining the health and safety of offshore and remote employees. And while every organization has health and safety plans in place, they may need a checkup or update.

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WINDPOWER ENGINEERING & DEVELOPMENT

245 incidents occurred on vessels 274 incidents occurred onshore

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H E A LT H C A R E & S A F E T Y I N O F F S H O R E W I N D

They look at multiple “what if” scenarios for every type of incident.

Unfortunately, most people make broad assumptions when creating these plans and often find themselves unprepared. Leveraging the expertise of an independent quality, health, safety and environment (QHSE) advisor will help ensure that plans include emergency action checklists and communication plans that keep teams safe and able to effectively handle a medical emergency.

Keep in mind, offshore medical teams are not just treating employees who visit the ship’s hospital; they must also be prepared to deliver care in a 200-ft turbine or be able to lower the patient to safety.

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WINDPOWER ENGINEERING & DEVELOPMENT

Testing Even the best plan may be ineffective if it hasn’t been tested. This takes two forms: tabletop exercises and running scenarios on location.

A tabletop test is a meeting where simulated emergencies are discussed and exacting details are worked through. The process provides insights into the comprehensiveness and strength of the plan, uncovers weaknesses and provides an opportunity to improve the plan before an actual emergency transpires. Typically, a QHSE advisor will run three scenarios — man overboard, medical evacuation, CTV collision at sea — in a nonphysical setting.

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The next step is to run these same scenarios physically using a test mannequin. The response shows how effective the process goes, spots weaknesses and identifies opportunities for further training.

Testing the plan also presents an opportunity to challenge assumptions.

For example, even if a helicopter is available, this type of evacuation is extremely complex. The pilot must be specially trained to navigate turbines and tricky wind and weather conditions, or darkness may make an air evacuation impossible.

The myth of first aid training Companies may think that because they require every worker to complete first aid training, they have a group of “mini-paramedics.” The reality is that most are undertrained and ill-equipped to deal with major traumas. First aiders are usually trained every two years, yet studies show that if skills are not used regularly, they start to fade rapidly and are significantly reduced after about nine months. With a first aid course validity of two years, a patient would be significantly worse off potentially being treated by a first aider in the second year of their run-out.

If a medic is not available when a major medical issue or trauma occurs, it’s incumbent on the first aider to give treatment from the point of the incident, during the transfer to a vessel and during transportation to shore, a process that could take hours. Unfortunately, in the midst of an emergency, companies find that the first aiders don’t want to take on the liability, don’t believe it’s their “job,” or find they don’t know what to do because they took the course so long ago.

The surest way to guarantee proper medical treatment is available is to retain a professional staffing service that

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H E A LT H C A R E & S A F E T Y I N O F F S H O R E W I N D

provides trained medical personnel for land-based, offshore and remote medical support. These organizations, like Remote Medical International, provide a complete range of medical services including medical and safety staff, topside support, case management and evacuation services.

By providing all these services under one roof, there’s continuity of care from the incident to case resolution.

In addition, these teams have access to a plethora of news and information and can provide weekly briefs on new developments. This gives them the ability to anticipate what’s coming and put processes in place early to mitigate their impact on operations.

The best way a company can prepare is to arm itself with information and leverage the services of a medical staffing company that can provide monthly updates. Large energy companies employ these specialists full time. Smaller companies need access to up-to-date briefings on developing situations. Companies pay thousands of dollars for professional legal and HR firms; doing the same for a medical staffing company is not much different and can lead to strategic decisions being made by the company that could make it more competitive.

Improving care, minimizing cost A comprehensive plan combined with the support of a professional medical staffing company can heighten care and lower costs due to medical and health emergencies.

The biggest cost comes in the ability to successfully deliver a worker to the hospital for care so they can return to full fitness and work as soon as possible. The response time for medical help to reach an offshore wind farm can be several hours, yet a medic, even if they are on the opposite side of the facility, can arrive well before outside support, meaning they can take over more quickly from first aiders.

WINDPOWER ENGINEERING & DEVELOPMENT

25

While the medic can provide significant medical intervention to the patient, they will also have topside support the entire time they are treating the worker, enabling them to provide a high level of care. All of this is designed to give the patient the best possible chance of a full recovery. Not only does this reduce lost time from work, but it ensures workers get the best possible care. If that doesn’t happen, companies may have to pay for extended treatment and recovery or cover the cost of the worker and their family’s livelihood.

And if government and state safety organizations find there were mistakes or the company was unprepared for such an incident, they may also face fines. These would be much greater

than the cost of relying on the services of a professional medical staffing company.

Conclusion Plan, test, practice, get support. Take the time to develop a comprehensive health and safety plan, anticipate the “what ifs," test the plan and continually improve it. Seek out a medical services partner experienced in meeting the renewable energy industry’s unique challenges. Select an offshore medical services partner that offers a complete scope of services from planning to medical support and training, and that demonstrates a robust understanding of the dangerous conditions under which a crew operates. WPE

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2021

LEADERSHIP IN

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

The U.S. wind industry is growing into new markets, namely offshore development. Success would not be possible without the ingenuity and determination of our leaders. These individuals and companies are working for the growth of the entire wind industry.

VOTE

The future of the industry will build on the foundation of today’s efforts. Windpower Engineering & Development would like to acknowledge such achievements on the following pages. These accomplishments in engineering and product advancements are what drive us into new markets and create jobs.

We think they deserve recognition from you, too.

Vote online through October for one or more of the companies listed in this special section.

ONLINE

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

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WINDPOWER ENGINEERING & DEVELOPMENT

27

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LEADERSHIP IN WIND ENERGY

2021

ALA Industries Limited was founded in 1993 as a Manufacturer’s Representative. They are a top-tier hydraulic equipment supplier. ALA’s primary focus was the Latin American market.

ALA was Manufacturer’s Representative for international companies such as US Tsubaki, one of the largest manufacturers in the world of industrial, automotive, roller, and specialty chains, as well as Asahi Seiko, the largest manufacturer of mounted ball bearings.

ALA is currently responsible for the sales of Yuken, GRH, Vivoil, and Fluid Press. ALA services over 100 value-added distributors across the USA, Canada, and Central America with a complete line of industrial and mobile hydraulics. Our distributors are independent contractors engaged in “valueadded engineering.” ALA Industries Limited is based out of Portage, Indiana, USA.

ALA Industries Limited Portage, IN 877-419-8536 yuken-usa.com

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

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WINDPOWER ENGINEERING & DEVELOPMENT

ALA Industries Limited is a leader in engineering.

When it comes to the wind power industry, ALA has proven themselves through their advancement of the pitch control valve alongside Yuken. With wind conditions in the United States being extremely severe, the valves that Yuken has reimagined have withstood the test from these forces. Our proportional valves are covered by a prorated 3-year warranty period that begins at the date of installation.

During the first year of operation, the valve is covered by a full replacement warranty.

The level of confidence that ALA Industries has in our valves permits us to provide this 3-year warranty. Yuken has more than 4,000 installed valves at less than a 0.4% rate of warranty failures. With this, ALA Industries follows up with “kaizen changes” in material, design or process that addresses the causes and results in ever-increasing operating life of the valves. As it can be seen, ALA provides a prestigious product line throughout the Americas that aids the maximization of the end users hydraulic systems. The overall goal of ALA Industries Limited is to focus our time and energy not only on the success of our products, but also to be able to acknowledge areas of improvement and fix them within a timely manner. Within ALA Industries, our employees are dedicated, dependable, and respectful to their fellow employees and clients. They have a focus on servant leadership. Overall, ALA Industries Limited has positioned themself as a leader in engineering and the wind power industry due to their ability to have open communication with clients alongside providing premier and innovative products.

www.windpowerengineering.com

FEBRUARY 2021

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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, continues to provide a state-of-the-art mobile fleet division with office locations in Midland, Corpus Christi, Sweetwater and Nederland, TX, and Oklahoma City, OK.

Aztec Bolting Services 520 Dallas Street League City, TX 77573 1308 South Midkiff Road, #303 Midland, TX 79701 802 Navigation Boulevard #106 Corpus Christi, TX 78408 1113 Lamar Street Sweetwater, TX 79556 3620 HWY 69N Nederland, TX 77627 800.233.8675 www.aztecbolting.com

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

FEBRUARY 2021

2021

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 Services is proud to enter into this new year introducing a new selection of Enerpac tooling. And because Aztec is an authorized service center and a national distributor of Enerpac products, you can count on a lifetime warranty!

The new standard in torque wrenches.

Enerpac DSX Torque Wrench The new Enerpac DSX Square Drive Aluminum Torque Wrench delivers strength, safety, superior performance and ergonomic design. The DSX makes the ideal choice when you need a simple, lightweight, strong and safe torque wrench. Critical safety features are designed to prevent dropping of on-site components. The DSX also features a compact high-strength unibody design, which provides a small operating radius without sacrificing endurance.

Enerpac HMT The new HMT1500 Modular Torque Wrench is a versatile and durable hydraulic torque wrench. It has a powerful, lightweight design allowing it to perform 25% faster and is twice as durable as other tools in the same class. Interchange cassettes easily for on-site, on-the-fly adjustments across applications, and count on a safety driven performance through standard safety features.

Enerpac E-Pulse Pump The new lightweight, portable solution that is powerful enough to get the job done quickly and safely. The Enerpac E-Pulse Electric pump features a brushless DC motor and speed variable controls to provide typical power from larger pumps in a durable, portable package.

The Norbar Evotorque Battery Tool The Norbar Evotorque 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.

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 onsite calibrations of your products.

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29

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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

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

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WINDPOWER ENGINEERING & DEVELOPMENT

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.

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2021

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

2021

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 today’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

2021

Built From the Ground Up to Meet the Needs of the Wind Energy Industry Since 2004, Indji Systems has been delivering situational awareness solutions to the utility industry through the Indji Watch product. In 2013, our utility clients were becoming increasingly involved with the wind industry. To meet our client and industry needs, Indji Systems expanded and tailored the Indji Watch natural hazard monitoring and alerting product for wind farm operations. As a leader in fully automated monitoring and analysis of natural hazard information, Indji Watch provides superior awareness of significant weather events that endanger your employees, disrupt your operations and impact your profits.

Innovation

Innovation is the foundation of Indji Systems. We listen to our customers and create tools based on their needs. With wind farms stretching 20 or more miles, monitoring and alerting based on one or two points on the farm isn’t enough. You need coverage that includes all your assets. The unique Indji Watch patented system is the only system that provides dynamic modelling of hazards enabling the identification of threats to assets. Whether your asset is a turbine, substation or tie line, Indji Watch has you covered.

Indji Systems continues to innovate and recently introduced icing forecasts and alerts. Adding to that, the new Plan of Day dashboard give users the ability to quickly and easily identify rapidly changing weather at-a-glance, allowing them to be more proactive in mitigating potential impacts to their operation and employee safety.

From a system-wide overview right down to an individual asset, Indji Watch will ensure that you have the best possible picture of how the weather will impact your operations, allowing you to drive efficiencies, improve outcomes, lower costs and increase safety.

Indji Systems PO Box 515381 #32775 Los Angeles CA 90051-6681 650 641-2653 www.indjiwatch.com

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www.windpowerengineering.com

FEBRUARY 2021

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LEADERSHIP IN WIND ENERGY

2021

From tip to hub, Megger gives you high performance For over 130 years, Megger has pioneered new technologies to deliver genuine benefits for its customers. The company is rigorous in its evaluation of these technologies to ensure that the high standards of safety, reliability and durability for which its products are renowned are always maintained.

We have a strong focus on research and development, and look to reinvest a high proportion of our income in these activities.

This investment has attracted some of the worlds most talented and creative testequipment design engineers. To ensure that our products reflect real world needs, we have collaborative arrangements with major manufacturers of equipment used in all areas of the electrical energy supply industry.

Megger 2621 Van Buren Avenue Norristown, PA 19403

Megger test equipment offers versatile, power validation and the ability to offer turnkey testing solutions. Megger equipment’s testing performance can handle ground bond testing, routing maintenance and corroboration of protection systems. From tip to hub, Megger is your partner for reliable electrical test and measurement equipment. We offer an industry leading IP rating, noise rejection, impact resistance and temperature specifications, all of which allow operation in the widest range of environments.

Our products are designed with unique capabilities based on our application experience to ensure world’s best operating performance.

Intuitive product interfaces often reduce training time and ease product use.

866-254-0962 www.us.megger.com

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LEADERSHIP IN WIND ENERGY

2021

NTC Wind Energy provides utility scale wind turbine foundation solutions, products and services. Our patented Ironclad™ bolt caps are the premier bolt cap of the industry and are specified by nearly all foundation design engineers. In addition to cap installation and service, NTC Wind Energy provides IronClad grout sleeves, rock anchor bolt caps, foundation anchor bolt tensioning services, corrosion inhibiting grease, grease application tools and foundation anchor bolt restoration services.

NTC Wind Energy also specializes in solving unique problems associated with foundation construction. We’ve designed, fabricated and patented specialty tensioning tools to address problems associated with short bolts and tight tower wall clearances. We’ve also developed templates for bolt cage construction, cutting manpower by as much as 75% and greatly enhancing safety.

NTC Wind Energy developed and patented the first bolt caps in the wind industry over 20 years ago. In those days, lattice towers were just giving way to monopole towers and the industry was very small and tight.

Since that time, the industry has grown exponentially and NTC Wind Energy has grown with it.

NTC Wind Energy prides itself in finding innovative solutions to common problems in design and construction of onshore wind turbine foundations. Rock anchor bolt caps, grout sleeves, specialty anti-corrosion grease and grease applicators are just some of the products that NTC Wind Energy provides. Low clearance, precision bolt tensioning and bolt restoration services are also provided.

Over the years, NTC Wind Energy has developed five generations of bolt caps, each one an improvement over the last. Most recently, NTC Wind Energy developed a heavy-walled injection molded polypropylene copolymer bolt cap that is UV resistant and stands up to almost anything nature can throw at it, the IronClad Super Duty bolt cap. This cap can be installed and removed by hand and features the only integrated o-ring in the industry.

One of the innovative solutions that NTC Wind Energy has developed is a water-proof air relief port built into the Super Duty bolt cap. This prevents a common issue with moisture being drawn into the cap as it expands from exposure to sunlight when water is pooled on the base flange. The IronClad Super Duty bolt cap is the only cap available with this important feature.

PO Box 2280 Boerne, Texas 78006 Toll Free 1-800-359-0372 www.NTCwind.com

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LEADERSHIP IN WIND ENERGY

2021

RAD Torque Systems is a leading Canadian manufacturer of pneumatic, battery-powered, and electronic pistol grip torque wrenches. RAD Torque’s parent company, New World Technologies Inc., continues to invest in and employ the latest technology to achieve the highest level of innovation, quality, and performance – which has resulted in multiple patents.

Rad Torque 30589 Progressive Way Abbotsford, British Columbia V2T 6Z2 Canada radtorque.com

Precision Torque Without the Weight for Wind When you are hundreds of feet above the ground on a giant wind turbine, you want your tools to be light and precise. That’s why so many wind energy technicians choose RAD Torque wrenches.

For more than 20 years the RAD Torque team has worked with turbine manufactures and contractors to develop the most innovate products for their needs. RAD’s tireless commitment to research and development has resulted in the creation of the fastest, safest and most ergonomic torque solutions to build, assemble, and maintain turbines.

More importantly, RAD Torque’s E-RAD BLU is known as the most precise electric tool on the market making it the number one choice for wind energy technicians. Most recently, the industry has started using the B-RAD BL Select, a batterypowered torque gun, for portability and power.

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

FEBRUARY 2021

And when it comes to tight and awkward spaces, RAD’s team has developed offset gearboxes and 90- degree tools that fit inside the diameter and curvature of a turbine’s shell, which means no job is out of reach – even on more challenging turbine designs.

WINDPOWER ENGINEERING & DEVELOPMENT

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WINDPOWER ENGINEERING & DEVELOPMENT

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

Ashley Burk 737.615.8452 aburk@wtwhmedia.com

AZTEC Bolting ....................................................19 Dexmet Corporation ...........................................25 HELUKABEL USA ................................................11 Indj ..................................................................... 10 Megger ............................................................ IFC NTC Wind ...........................................................15 RAD Torque ....................................................... BC

SALES Jami Brownlee 224.760.1055 jbrownlee@wtwhmedia.com

ALA Industries .................................................. IBC

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

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WITH US!

Follow the whole team on twitter @Windpower_Eng 36

WINDPOWER ENGINEERING & DEVELOPMENT

www.windpowerengineering.com

FEBRUARY 2021

We make our

pitch control valves to last more than 5 years.

We warranty them for 3 years.

No one else does.

UNEXCELLED IN SPEED AND LIFE You can trust Yuken proportional valves, linear servo valves and servo-controlled systems.

Master Distributor: ALA INDUSTRIES LIMITED • Portage, IN • 877-419-8536 • www.yuken-usa.com FEB 2021_YUKEN - BLUE_FINAL.indd 33

2/2/21 3:05 PM

ADVANCED BOLTING TECHNOLOGY

With torque ranges up to 15,000 Nm, the E-RAD

Q

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Quiet – Operates at 75 db reducing noise level

TO

Fast – Decreased tightening times by up to 300%

1

#

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accuracy (+/-2.8%) and repeatability (+/- 2%)

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Accurate – Designed to provide a high degree of

INDUS D N

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Light – Unsurpassed power-to-weight ratio

UE TOO

BLU uses a patented gearbox design and the precision of an electric AC Servo motor. These tools deliver smooth continuous torque and are capable of torque and angle sequence. They also feature enhanced traceability with data collection.

WWW.RADTORQUE.COM

1.800.983.0044

E-RAD BLU