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Wind International Internship Program
Broomfield, Colorado, May 7, 2008
UWIG/NREL Workshop on Power EngineeringEducation needs for the Wind Industry
Rashid Abdul, P.E.
2 2
INTRODUCTION
What has been done so farMeetings w/Drexel/Temple, Monterrey and Bilbao facilitated by Gamesa
Internal engagement/feasibility researchProjected Gamesa workforce needs assessmentGamesa Wind curricula draftedInternship opportunities identified
Objective of the meetingTo begin to solidify specifics of program structureEstablishment of next steps for implementation going forward
3 3
AGENDA
1 Wind International Internship Program - Overview
2 Partners introduction
3 Program structure and curricula
4 Resources, laboratories and facilities
5 Requirements for candidates
6 Next steps
4 4
AGENDA
1 Wind International Internship Program - Overview
2 Partners introduction
3 Program structure and curricula
4 Resources, laboratories and facilities
5 Requirements for candidates
6 Next steps
5 5
WIND INTERNATIONAL INTERNSHIP PROGRAM -OVERVIEW
To utilize strategic partnerships with colleges and universities that specialize in various facets of engineeringGamesa will work with such institutions to establish wind energy specific curricula, that encompasses both practical and theoreticalaspectsThe goal is to cultivate superiortalent and thereby produce and maintain a highly skilled workforce to ensure high productivity in an increasingly competitive industry
Program objectives Corporate Partners Academic Partners
GamesaGESOther companies
Drexel/Temple UniversityTecnológico de Monterrey (ITESM)Universidad de BilbaoProgram structure
18 months program structured as follows:Total of 6 months theoreticaleducation in Wind Power / Energy 12 month practical education in one of the corporate partners combined with stages at Academic Partners (Joint Modules)
1
6 6 6
Current collaboration Future collaboration
Bilbao Faculty of
EngineeringSpain
Drexel/Temple University
USPolitécnico
de MonterreyITESM Mexico
Bilbao
ITESM
Drexel/Temple
Com.Colleges
Com.Colleges
Com.Colleges
Technical Schools
TechnicalSchools
Com.Colleges
Com.Colleges
TechnicalSchoolsTechnical
Schools
Proposed International Collaboration for Wind Energy Engineering
WIND INTERNATIONAL INTERNSHIP PROGRAM -OVERVIEW
1
7 7
AGENDA
1 Wind International Internship Program - Overview
2 Partners introduction
Corporate partners:
• GAMESA
• GES
Academic partners:
• Drexel/Temple University
•Tecnológico de Monterrey (ITESM)
•Universidad de Bilbao
8 8
PARTNERS INTRODUCTION - GAMESA
1976. Gamesa begins operations, developing new technologies and applying them to emerging activities1994. Gamesa Eólica is incorporated as a company specialized in the manufacture of wind turbines1996. First wind farm completed2000. Gamesa is officially listed on the stock exchange 2001. Joins the selective Ibex 35 exchange 2006. GAMESA focuses on renewable technologies. Divestment in Aeronautics and Services
GAMESA history GAMESA figures for 2006
Turnover € 2,401 million EBITDA (BAIIA) € 411 million Net Consolidated Profits € 313 million Market Capitalization € 5,073 millionEmployees 5,420Accumulated MW installed 9,945
GAMESA market share
7%8%
28%Vestas
16%Gamesa15%
GE Wind
15%Enercon
Suzlon Energy
Siemens Wind 5%
Cliper Energy
6%
Rest
2
Shareholders
9%
Others63% 3% 5%
19%
IBV
Artisan Partners
Casa Cartagena
Iberdrola
9 9
PARTNERS INTRODUCTION - GAMESA2
Wind Turbine Manufacture and Sales
PromotionConstructionSales19%Turnover17% MWs supplied1)
ComponentsDesignManufacture76% Turnover62% MWs supplied1)
PhotovoltaicThermal5% Turnover17% MWs supplied1)
UNITED STATES EUROPE CHINA
SolarPromotion and Salesof Wind farms
3 BUSINESS MARKETS
1) 2007
1010
USA
4 Production Centers
(Pennsylvania)
EUROPE
23 Production CentersCHINA
2 Production Centers
(Tianjin)
PRODUCTION CAPACITY
NACELLES 3,935 MW/year
BLADES 7,550 Blades/year
TOWERS 571 towers/year
PARTNERS INTRODUCTION - GAMESA2
PRODUCTION CENTERS
1111
PARTNERS INTRODUCTION - GAMESA2
NUMBER OF MWs SUPPLIED IN 2007
520
533
1.8993.047
95
Total Europe China USA Others
36137
211
1.4851.899
31
Total Spain Italy France Germany Others
Europe
1212
-1.000
0
1.000
2.000
3.000
4.000
5.000
6.000
7.000
-500 0 500 1.000 1.500 2.000 2.500 3.000
China
MW to be installed by GAMESA 2007 – 2011 (G5X)
MW to
be i
nsta
lled
by G
AMES
A 20
07 –
2011
(G8X
)
MW to be installed by GAMESA 2007 - 2011
300
800
1.300
50 250 450 650
Spain
USA
ItalyFrance
UK Egypt
Pakistan
Mexico
Morocco
Canada
Portugal
Poland
GermanyS.Korea
Ball surface represents estimated MW to be installed
PARTNERS INTRODUCTION - GAMESA2
1313
5 R+D+I centers located in Spain and Denmark€ 40 million invested in 2006, and over 200 million over the past 5 years25 patent applications over the past yearTogether with other companies, led the Windlider 2015 industrial research project (development of a 10 MW wind turbine), keeping Spain at the cutting edge in wind energy
PARTNERS INTRODUCTION - GAMESA2
TECHNOLOGICAL STRENGTH
1414
AGENDA
1 Wind International Internship Program - Overview
2 Partners introduction
3 Program structure and curricula
4 Resources, laboratories and facilities
5 Requirements for candidates
6 Next steps
1515
PROGRAM STRUCTURE AND CURRICULA3
General concepts of Wind EnergyMechanical maintenanceElectrical maintenanceRegulation and controlProtections (High voltage)Health and SafetyConstruction and set-up
Core Theoretical Education
Introduction to GAMESA USA
Practical education at wind farm
Practical Education
Focused on getting a deep understanding and knowledge of specific technical areas
3 Joint Modules of 1-2 weeks duration during the Practical Education
Free election of courses and university for students
Content
300 hours (4 months) 1,820 hours (14 months)Total
1 2
Program structured in 3 modules – Total 18 months
Language courses On Demand (SPA, ENG, CHI)
GAME
SA S
pecif
ic
Basic university trainingJoint Module 1 Joint Module 2 Joint Module 3
Practical Education Joint Modules
3
1616
PROGRAM STRUCTURE AND CURRICULA - DETAIL3
General concepts
Practical Education Joint Modules1 2 3
SUBJECT THEORETICAL PRACTICAL
Core Theoretical Education
TOTAL H.Wind Energy general knowledge Prospecting a wind farmDefinition of a wind farm (i.e. Electrical structure, economic analysis)
Interpretation of measurements collected at wind farmStudy of potential locations for wind farms
24 hours
Mechanical maintenance
HydraulicsGearboxBrakesMaintenance typesFailure localization
Measure equipment usageNitrogen precharge in
accumulatorsTesting of tightening torquePitch system testing
72 hours
GAME
SA S
pecif
ic
1717
PROGRAM STRUCTURE AND CURRICULA - DETAIL3
Regulation and control
Practical Education Joint Modules1 2 3
SUBJECT THEORETICAL PRACTICAL
Core Theoretical Education
TOTAL H.
24 hoursGround and Top Interpretation of hydraulic & electrical scheme Functions of the Pitch, Brakes, Rotor & Yaw brakeConnectors & testing of optic fiberSGIPE
Ground (G52 & G80) & Top (G80)Electrical & hydraulic circuitsApplication of optic fibers to turbinesArchitecture & application of the SGIPE system
Electrical maintenance
GeneratorTransformerConverterElectric cabinet
Interpretation of electrical drawingsTesting electrical isolationTesting of electric cabinetsLocating electrical failures
72 hours
GAME
SA S
pecif
ic
1818
PROGRAM STRUCTURE AND CURRICULA - DETAIL3
Protections (High Voltage)
Practical Education Joint Modules1 2 3
SUBJECT THEORETICAL PRACTICAL
Core Theoretical Education
TOTAL H.32 hoursGround net
ProtectionsAuxiliary relay & measurement equipmentGAMESA‘s norms
MeasurementTesting of auxiliary relaysTesting measurement equipmentTesting of relay protection
Health and Safety Health and safety in the workplacePreventive organizationEvaluation of risksPreventive measures Fires extinctionEmergency and evacuation
Climbing stairs via life lineUse of emergency elevatorFive golden rules in HT cageFirst Aide
40 hours
GAME
SA S
pecif
ic
1919
PROGRAM STRUCTURE AND CURRICULA - DETAIL3
Construction and set up
Practical Education Joint Modules1 2 3
SUBJECT THEORETICAL PRACTICAL
Core Theoretical Education
TOTAL H.36 hoursContracting process – Civil
works of the wind farmAssembling of turbinesCommissioning
Commissioning practice
Total 300 hoursGAME
SA S
pecif
ic
2020
PROGRAM STRUCTURE AND CURRICULA - DETAIL3
Practical Education Joint Modules1 2 3
Introduction to GAMESA USA – ON BOARDINGOn-Boarding will take place during their first week at Gamesa USAIt involves internship orientation, a complete plant tour, meet and greet w/USA CEO Technician Assistant and/or Quality Inspector training will be conducted by a Training SupervisorPost-training evaluations will be completed to properly conduct SWOT analysis feedback from interns and instructor
PRACTICAL EDUCATION at WIND FARMInternship duties/responsibilities will be the equivalent of a Technician Assistant or Quality Inspector within GamesaWind farm site supervisor to serve as internship supervisor, and will monitor day-to-day progress
CONTENT
Core Theoretical Education
TOTAL H.1,820 hours
LOCATIONGAMESA USA (PA)
Mesquite and Abilene, TXMequon, WIBear Creek, PA.
2121
PROGRAM STRUCTURE AND CURRICULA - DETAIL3
Fundamentals and applications of wind energy
Practical Education Joint Modules1 2 3
SUBJECT THEORETICAL PRACTICAL
Core Theoretical Education
TOTAL H.
MONTERREY (ITESM)
Materials for manufacturing
Experimental analysis of mechanical systems
Power electronics control
Project Engineering
TO BE DETAILED
2222
Theory and PracticeResearch and Training
Program in WIND POWER GENERATORS
Academic Programs (SIP-MSM-MIE-DCI) and Laboratories at
Tecnológico de Monterrey
GAMESA EÓLICA/USRequirements
B.S. in Engineering(IME-IMA-IMT-IFI)
and Graduate Level
TRAINEEENGINEER
Practical Training atGAMESA
EÓLICA/US
Additional Training(GES-Gijón, ABB, etc.)
TRAINEDGAMESA
ENGINEER
RESEARCHTHESIS
Specialization (40-45)
Master (4)Doctorate (1)
Overall Working Scheme
PROGRAM STRUCTURE AND CURRICULA - DETAIL3
2323
Master of Science (M.S.)General orientation: engineering research Graduate level courses and thesis10 theory courses2 thesis courses
Specialization ProgramGeneral orientation: professional degreeGraduate level coursesNO thesis (only integration project)Associated to an existing M.S. program5 theory courses1 integration project course
TOTAL TIME: 2,160 hrsClassroom: 450 hrs.Independent work and thesis: 1,710 hrs.
Master of Sicence Program
Master’s ThesisGraduate Level Courses
Specialization Program
IntegrationProject
Graduate Level Courses
TOTAL TIME: 1,080 hrsClassroom: 225 hrs.Independent work and thesis: 825 hrs.
Academic Programs: General Structure at Tecnológico de Monterrey
PROGRAM STRUCTURE AND CURRICULA - DETAIL3
2424
Gamesa Eólica RequirementsTheory and practiceTopics
Renewable energyMechanical systemsElectrical systemsMtls & ManufacturingProject Management
Proposed ProgramSpecialization formatBased on existing M.S. programs in manufacturing and energy engineeringTentative name: Product Engineering and DesignTentative acronym: SIPGeneric name in order to accommodate other company’s requirements
Specialization Program in Product Engineering and Industrial Design
(new program acronym: SIP)
Gamesa EólicaRequirements
M.S. in Manufacturing Systems
(MSM)
M.S. in Energy Engineering
(MIE)
Academic Programs: Proposed Program for Gamesa Eólica
PROGRAM STRUCTURE AND CURRICULA - DETAIL3
2525
Academic ComponentsPhase 1 (6 months)
Undergraduate Level Courses (prerequisites if needed)Graduate Level Courses
Phase 2 (6 months)Integration Project
Complementary PracticePractical Training (6 months)
Specialization Program (Academic Components)
IntegrationProject (1)
Prerequisite (1) + Graduate Level Courses (5)
Full Time InvolvementTOTAL TIME: 3,000 hrs.
PROJECT PRACTICEAt Gamesa Eólica - Project(6 months)
THEORY & LABSAt Tecnológico de Monterrey(6 months)
COMPLEMENT PRACTICEAt Gamesa Eólica –More Training (6 months)
Research and Training in WIND ENERGY GENERATORS
PROGRAM STRUCTURE AND CURRICULA - DETAIL3
2626
Graduate Level Programs
Specialization Program in Product Engineering
Master in Manufacturing Systems
Master in Energy Systems
Doctorate in Engineering
PROJECT PRACTICEAt Gamesa Eólica - Project(6 months)
THEORY & LABSAt Tecnológico de Monterrey(6 months)
COMPLEMENT PRACTICEAt Gamesa Eólica –More Training (6 months)
Research and Training in WIND ENERGY GENERATORS
PROGRAM STRUCTURE AND CURRICULA - DETAIL3
2727
THEORY & LABS – Graduate Level CoursesSpecific courses based on MSM and MIE programs:
F 99210 Fundamentos y aplicaciones de la energía eólica(Fund. and applications of wind energy)M 99234 Materiales para manufactura (Mtls. for mfg.)M 5002 Análisis experimental de sistemasmecánicos(Experimental analysis of mechanical systems)E 99204 Control electrónico de potencia(Power electronics control)IN 99270 Ingeniería de proyectos (Project engineering)
Specific learning objectives to be set in coordination with Gamesa Eólica
PROJECT PRACTICEAt Gamesa Eólica - Project(6 months)
THEORY & LABSAt Tecnológico de Monterrey(6 months)
COMPLEMENT PRACTICEAt Gamesa Eólica –More Training (6 months)
PROJECT PRACTICEAcademically guided practice for project management component and technical componentEnrollment in project course
M 5016 Proyecto de aplicación (Application project)
Practice at Gamesa Eólica facilitiesFinal technical report
COMPLEMENTARY PRACTICEContinue practice at Gamesa Eólica facilitiesOptional: additional training (ABB, etc.)
Research and Training in WIND ENERGY GENERATORS
PROGRAM STRUCTURE AND CURRICULA - DETAIL3
2828
Practical Training at GAMESA EOLICA (12 months)
Research and Training Program in WIND POWER GENERATORS
Graduate Level Courses at Tecnológico de Monterrey (6 months)
FIRST PERIOD: 18 months SECOND PERIOD: 18 months
Specialization Level (20)
Master Level (4)
Doctorate Level (1)
Specialization (25)
• 50 engineers with practical training (12 months each)• => 600 months-engineer• 45 technical reports for integration project• 4 master level research thesis• 1 doctoral level research thesis
Gra
duat
e Le
vel
Deg
rees
Gen
eral
Wor
kSc
hedu
leO
VER
ALL
D
ELIV
ERA
BLE
S
Overall Working Scheme: DELIVERABLES
PROGRAM STRUCTURE AND CURRICULA - DETAIL3
2929
AGENDA
1 Wind International Internship Program - Overview
2 Partners introduction
3 Program structure and curricula
4 Resources, laboratories and facilities
5 Selection and admission process
6 Next steps
3030
EXISTING LABORATORIES & FACILITES
Small wind generators (1 and 20 kw)Mold manufacturing (high speed milling)CAD/CAMCAE: Bladed, FluentNon-destructive testingExperimental stress analysisAutomotive power trainPower electronics
PROPOSED LABORATORIES & FACILITIES
Large blade (45 m)Nacelle (2 MW)Composites ManufacturingNew space required:
OPTION A: technical school with aircraft maintenance program (request in progress)OPTION B: airport hangar
THEORY & LABS
At Tecnológico de Monterrey(6 months)
PROJECT PRACTICE
At Gamesa Eólica - Project(6 months)
COMPLEMENT PRACTICE
At Gamesa Eólica –More Training (6 months)
Research and Training in WIND ENERGY GENERATORS
RESOURCES, LABORATORIES AND FACILITIES4
3131
PROPOSED LABORATORIES & FACILITIES
Large blade (45 m)Nacelle (2 MW)Composites Manufacturing
Research and Training in WIND ENERGY GENERATORS
RESOURCES, LABORATORIES AND FACILITIES4
3232
PROPOSED LABORATORIES & FACILITIES
Large blade (45 m)Nacelle (2 MW)Composites Manufacturing
Research and Training in WIND ENERGY GENERATORS
RESOURCES, LABORATORIES AND FACILITIES4
3333
AGENDA
1 Wind International Internship Program - Overview
2 Partners introduction
3 Program structure and curricula
4 Resources, laboratories and facilities
5 Requirements for candidates
6 Next steps
3434
REQUIREMENTS FOR CANDIDATES5
Selection processInstitutional RecommendationSuccessful Interviews w/Gamesa Wind US - Human ResourcesJ-1Visa Eligible
Evaluation process during programMonthly performance evaluations w/one-on-one manager/intern meetingsPeriodic follow-up calls from Gamesa HR Overall candidate assessment – TN or Work Visa consideration
Support provided to studentsMonthly Stipend w/Per Diem and LodgingEquipment donation (3 blades and 1 nacelles per university)Orientation TrainingDedicated Supervision
3535
AGENDA
1 Wind International Internship Program - Overview
2 Partners introduction
3 Program structure and curricula
4 Resources, laboratories and facilities
5 Requirements for candidates
6 Next steps
3636
NEXT STEPS6
To finalize and agree on generic wind curriculaFurther discussion on contractual agreementsFinalize all initial candidates
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