Challenges facing WTG upgrades.

Upgrades: Preventing damages, avoiding repairs. Page 6

Foundations: Eliminating cracks and their causes. Page 12

Husum WindEnergy 2010: New impulses for renewable energies? Page 15

The Availon journal for independent wind energy service | September 2010

The capability of a service provider to offer proven processes for developing and implementing upgrades is not just a question of technology. It is also a reflection of their commitment to improved quality and customer orientation. Page 3

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IMPRINT Published by: Availon GmbH · Jacksonring 2 · 48429 Rheine · GermanyFon +49 5971 8025-0 · Fax +49 5971 8025-109 · www.availon.eu Edited and designed by: EXPECT MORE Kommunikation GmbH · Breite Straße 4 48431 Rheine · Germany · Fon +49 59 71 80 40 9-0 · Fax +49 59 71 80 40 9-100 · www.expect-more.de V.i.S.d.P: Dagmar da Costa Photos: Ulrich Wozniak (S. 6–7), Solido Bautenschutz GmbH (S. 12–14), A. Birresborn / HUSUM Wind-Energy 2008 (S. 15, 17), Meteomedia (S. 21–22) Copyright: All contributions (text, photos, graphics, logos and tables) published in ON Service are copyright protected. The copyright is owned by Availon GmbH, unless stated otherwise. Reprin-ting, storing in databases, on online services and Internet pages or copying onto data media is only allowed with prior written permission by Availon GmbH. Number of copies: 2,000

Contents | September 2010

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Focus onCover article: Challenges facing WTG upgrades.

ChangesUpgrades: Preventing damages, avoiding repairs.

InterviewDevelopment: International strength with a Regional Focus.

ReviewFoundations: Eliminating cracks and their causes.

Current NewsHusum WindEnergy 2010: New impulses for Renewable Energies?

FeatureCooperation: More power with partners.

InterviewForecasting: The wind dilemma.

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The development of wind turbine generator (WTG) upgrades should be an integral part of every independ-ent service provider’s (ISP) portfolio. By changing only a few parameters of a WTG control system, optimization can often be achieved with little effort. By contrast, other improvements require a lot of know-how and, in some cases, specialized knowledge and a considerable amount of development work, before they are ready to be launched in the market. The capabilities of ISPs can be measured by their ability to master the challenges faced in the develop-ment and introduction of such WTG optimizations. Turbine owners and operators should check whether their ISP has proven processes in place for developing and implementing upgrades.

A Long ProcessIt is necessary to recognize and describe a problem at the beginning of the development process. The catalyst for such an analysis can come from many directions, includ-ing from the ISP, as a result of fault analyses, from on-site installers reporting about recurring irregularities within certain turbine components or from operators suggesting possible optimizations. However, the knowledge of a prob-lem alone does not necessarily lead to an upgrade. What is more decisive is the route to the solution that can be long and difficult.

Most Knowledge from Fault AnalysesThe first step is to determine the cause of the problem. Neither evident nor obvious, problem analysis is typically one of the greatest challenges in a development process. Independent service providers, who carry out regular, and thus continuous, fault analyses on turbines serviced by them, are the most knowledgeable and have access to

key data necessary for identifying and analyzing problems. A detailed cost/benefit analysis can determine whether the development of a turbine upgrade makes economic sense, as the decision to introduce an upgrade is an investment from which the owner expects a short-term return.

Tackling the Root of the ProblemAn important tool for identifying the root of a problem is a Root-Cause Analysis. The basic principle: by remedying the cause, the deviation can also be removed. If an ISP tack-les a problem while excluding any side issues, a sustainable upgrade can be developed that will provide noticeable improvements.

In-House Know-How and Competent PartnersTo develop a concrete solution, an independent service provider should have in-house mechanical and electrical engineering know-how. They should have access to very specific competencies from partners during the develop-ment process. In order to seamlessly retrace every devel-opment step of an upgrade, a continuous documentation process also makes sense. This is important even when carrying out simple design changes, particularly if the solution unexpectedly fails to produce the desired on-site improvements. A risk assessment is a recommended addi-tion to project documentation since an upgrade may lead to design changes for turbine components that could affect its operational safety.

Finally, the prototype of an upgrade must demonstrate what it can do. This sometimes requires longer on-site testing, including prototype evaluation, to ensure practical suitability, as well as the sustainability of turbine improve-ment.

Not Only Good but Continually Striving to be Better.

“He who stops being better stops being good.” What is the relevance of this quote from Oliver Cromwell, founder of the English Republic, to the development of wind turbine upgrades and the associated quality assurance measures? The provision of fully developed upgrades leads to significant improvements that contribute to a considerable increase in the availability and performance of wind turbines.

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DMAIC Makes it PossibleThe path to an upgrade can be reduced to a simple formula: DMAIC (Define – Measure – Analyze – Improve – Control). DMAIC is a core process of Six Sigma. Since the 1970s, Six Sigma has a proven track record in the industry as a statistical quality management system and is a recognized and successful method for defining DMAIC processes. The systematic use of such methods as part of the development of WTG upgrades is a reliable way for realizing measurable improvements in turbines.Decision makers should not only check whether ISPs use such systems for development processes, but also whether or not they support these with further quality assurance measures.

The Desire to ImproveWhy is certification important? Companies that seek certification are willing to introduce processes that improve the quality of operational procedures and their capabilities. The implementation of quality assured, standardized processes, benefits the client since improved quality results in a greater focus on the customer. Those wishing to ensure a high quality must meet a large number of challenges and invest consid-erable efforts during the certification process – this is particularly true for high performance WTG service companies with a considerable number of employees and departments.First, existing processes or operational procedures, as well as interfaces between individual areas or departments, must be described. Then, opportunities and methods for improving these procedures must be identified. Finally, the respective optimizations must be carried out, and

an audit from an independent body must confirm that the introduced processes represent quality-assuring measures based exclusively on measurable results.

Continual improvements must be made, since these are not static processes but operational procedures that are subject to permanent change as part of day-to-day business. In return, the client encounters a company permanently working on the optimization of its capabilities and able to guarantee the quality of all processes and products through structured operational procedures.

Established StandardEN ISO 9001 is the main standard for quality assurance of independ-ent service companies. This standard is mandatory for the sector. The successful management of a company requires systematic control and steering. The introduction of a quality management system, such as EN ISO 9001, is designed to continuously improve performance. A company is certified only if it demonstrates the ability of its products and/or ser vices to meet the demand of customers and the certifying authorities.According to EN ISO 9001, the eight basic quality management princi-ples are derived from these principles: (see box).

Sector-Specific CertificationWhile EN ISO 9001 is a general industry standard applicable to many sectors, the wind division of Germanischer Lloyd (GL Wind) goes one step further with its certification by focusing specifically on the wind energy sector and its related companies. As a global competence center,

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accredited for certifications relating to all relevant standards in the wind and sea energy sector, GL Wind carries out testing, certification and assess-ments, and actively participates in the development of national and inter-national standards.

Full Proof of CapabilitiesGL Wind certification currently includes the areas of operational manage-ment and remote monitoring, service assignments, health and safety, quality management systems, and training and education systems. An audit, according to GL Wind, ensures a close examination of all the relevant activities of an independent WTG service provider in regard to the needs and requirements of the wind energy sector. Management, staff qualifica-tions, fault-and-repair processes, and maintenance strategies of a company, are reviewed. The certification also includes the control and implemen-tation of field assignments, as well as the documentation and analysis of service assignments, machine conditions, and fault patterns. Additionally, the certification focuses on health, security, the environment and the train-ing system of a service provider. This test confirms the ability of a service company to grow using its own resources.

Sorting the Wheat from the ChaffThe consistent use of proven development strategies for upgrades, along with the total commitment to higher quality and increased customer service will “sort the wheat from the chaff” and will substantially determine the selection of an independent WTG service provider. The wind energy sector faces major challenges, and companies that “stop being better stop being good.”

On-site installers can provide information about recurring irregularities.

Quality management EN ISO 90011. Customer focus

2. Management responsibility

3. Participation of all persons involved

4. Process-focused approach

5. System-focused management approach

6. Continuous improvement

7. Objective decision-making process

8. Supplier relations for mutual benefit

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Turbines containing three-point bearings provide an excellent upgrade example. With the traditional bearing configuration, fatal consequences may result if the main bearing fails, and the damage is not detected in time. The damage produced by the failure allows the main shaft, including the rotor, to move toward the back of the nacelle. The wind pres-sure acting on the rotor pushes the entire gear-box up to nine millimeters backwards until the displacement of the drive train is finally stopped by a steel block. However, as the gear-box rests against this steel block, the pressure of the drive train is transferred to the plan etary carrier bearings. The result is the complete destruction of the planetary carrier bearings and, therefore, the gearbox.

Constant Monitoring of the Gearbox PositionContinuously monitoring the gearbox’s posi-tion would prevent any serious or costly damage from occurring. A new upgrade, mainly consisting of two inductive proximity switches was developed to solve this prob-lem. Using control system error messaging along with the remote monitoring system; the constantly monitor the position of the gear-box. If the drive train deviates from its origi-nal position, a fault message is transmitted to the remote monitoring system. To prevent any further damage to the gearbox, the turbine is then immediately shut down by the control system immediately. Afterwards, the turbine can only be restarted on-site once the posi-tion of the gearbox has been inspected.

A Tolerable InvestmentAn on-site inspection can evaluate the degree of damage to a main bearing. The damage to a main bearing can be significantly reduced through the immediate shut down of the turbine. Under normal conditions, the replace-ment of the main bearing is inevitable already represents a considerable investment, yet is less than to the cost incurred by a complete gearbox replacement. To prevent such situa-tions from becoming critical, this upgrade is readily available.

Additionally, three more upgrades exist for Vestas®’ turbines, including a new carbon brush mounting system for 2 MW turbine generators, improved ventilation for transfor-mers and modifications to the control box.

Lengthy Replacement with Problems During maintenance, the replacement of carbon brushes used in Vestas®’ V80 and V90 - 2 MW turbine generators is time consuming due to issues arising from the original attachment of the brushes. When removing the brush attach-ment, other components may fall into the slip ring compartment. Due to the arrangement of the generators, the fallen components are difficult to reach without dismantling the slip ring even further. The added work contributes to lost time and higher service costs.

New Mounting System and Brushes with Less Wear The new attachment solution significantly decreases the time needed to replace carbon brushes. It also prevents parts from falling into

Upgrades are a performance booster for any wind turbine generator (WTG), as the optimization of turbine components leads to a reduction of recurring faults and higher availability. Upgrades can also prevent serious damage and avoid high repair costs.

When the Situation Turns Critical …

Two sensors are connected to the remote monitoring system via the fault detection of the control system

and constantly monitor the position of the gearbox.

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the slip ring compartment during maintenance and repairs. In addition, the new upgrade increases the service life of the carbon brushes.

The original mounting system consists of only one spring, causing the brush sides to wear unevenly during operation. As a result, the brushes have a limited service life of approximately 12 months. The new mount-ing upgrade, coupled with a configuration change, prevents this irregu-lar wear of the carbon brushes. Field trials have shown that the upgrade increases service life from 12 months to 18 months on average.

The service box makes it possible to control the turbine directly, using an operating console in the nacelle.

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A new air conditioning system aims to make salt deposits in the transformers a thing of the past, thereby considerably increasing the service life of Vestas® wind turbines.

Improved Ventilation Concept for TransformersA further improvement has been developed in the ventilation manage-ment of the transformer used in the Vestas®’ 2 MW turbines. The upgrade applies to turbines installed in extreme weather locations, such as along coastal areas where transformers fail and need replacement every two years. This represents a substantial investment. Replacements are neces-sary because of unfavorable air circulation and contamination due to the salt in the air. The salt accumulates on the transformers and leads to corrosion of other components. The upgrade uses special deflec-tors to direct the air through the nacelle so less enters the transformer room. Using a specially controlled fan, only 20 percent of the cooling air is channeled into the transformer, which is sufficient for cooling. The new air-conditioning system for the Vestas®’ 2 MW turbines aims to fully prevent the development of salt deposits in the transformers in the future, thereby increasing service life considerably.

Control box: Everything from a Single SourceIn addition to the upgrade for carbon brushes and the improved venti-lation concept for transformers, a control box facilitating work in the nacelle is now available for Vestas®’ turbines. Maintenance or other work performed in the nacelle of Vestas®’ turbines has repeatedly been a problem for operators. In the past, one person had to operate the WTG control system from the tower base so that work could be carried out in the nacelle.

With the new control box, this procedure is no longer required. The control box is a portable operating console connected by the Opto interface in the nacelle, control of the turbine directly from the nacelle.

Through the development of upgrades to various turbine systems, the service life of the turbines can be extended and unplanned mainte-nance costs can be reduced. The greater reliability of wind turbines will allow for continued implementation of this renewable resource for the coming years.

"Vestas" is a registered trademark of Vestas Wind Systems A/S, DK.

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Availon expanded from a successful regional independent

service company to a leading international service provider

with locations worldwide in just a few short years. ON Service talked

with Ulrich Schomakers, CEO of Availon, about the development

of the international wind turbine generators (WTGs) service market

and the significance of regional competence when servicing wind

turbines and wind farms.

International Strength with a Regional Focus.

ON Service: How are the markets developing in Europe and overseas?

Ulrich Schomakers: Germany is experiencing continuous growth, although at a comparably low level. During the upcoming years, growth is mainly expected in the area of repowering. Similar to the situation we faced in Germany last year, Spain is now feeling the effects of the economic crisis and consequently slower market growth. The market has reacted accordingly, and necessary financing has also de- creased. Despite certain reluctance regarding investments in wind energy in Spain, new wind turbines will continue to be constructed.

WTG servicing by smaller companies is not practical on the Iberian Peninsula. The result is that wind turbine operators are often faced with reduced wind turbine availability and additional costs. The tendency in Spain is to enter into cooperation with efficient and competent inde-pendent service providers (ISPs) who can also offer an adequate stock of spare parts and other turbine optimizations.

How does the situation in Eastern Europe and in the United States compare?

Some turbines that have been sold in Poland are serviced by smaller service providers, but this system does not seem to function well. The result is that owners are either approaching the original equipment manufacturers (OEMs) for servicing or are contacting an ISP able to offer an extensive range of services. We have already received initial enquiries and plan to offer the same high performance, including a local service station for this market as we do in other countries.

As a result of the oil disaster in the Gulf of Mexico, renewable energies are again receiving more attention in the United States. When looking at energy companies operating worldwide, it is apparent that their busi-ness activities regarding the planning and installation of wind turbines are currently largely focused on the United States. This is also partly due to very good wind conditions as well as large open geographical areas. At the same time, the grid infrastructure must also be extended. This work is already underway, with large energy suppliers cooperating with each other.

Does this problem of inadequately developed grids also apply to Europe – for example, in Spain?

Ulrich Schomakers, CEO of Availon GmbH

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Not that I am aware of. The energy suppliers on the Iberian Peninsula, who also operate large wind farms, upgrade their grids accordingly. In Eastern Europe, such activities are in the plan-ning stages.

The Italian wind energy industry is compara-tively young, as an increase in the installation of wind turbines can only be seen during the past few years. Regarding the grid infrastruc-ture, wind farms are mainly located in the southern part of the country, such as Calabria, while the majority of energy consumption takes place in the more industrialized northern regions. This energy has a long transport to the north, and Italy has dire need for a grid update. An investment in grid expansion would yield high returns, as the rates paid for feeding energy into the grid are very good in Italy. Ital-ians are also prepared to invest in efficient inde-pendent servicing to ensure efficient turbine operation and respective yields. The warran-ties of the first major wind farms are currently expiring, and as a consequence, the demand for ISPs is rising. We have already received initial enquiries from operators who want us to take over their entire projects.

The situation in the United States is quite differ-ent. OEM costs were often underestimated, as older projects have not provided the expected economic success. Some major energy suppliers have also set up their own services due to a lack of personnel resources. They are already reaching their capacity limits in standard ser- vices like maintenance and repairs. Staff also often lack the qualifications required for trou-bleshooting, carrying out complex repairs or maintaining gearboxes. Demand for service companies develop in two directions in the United States: 1) Custom-ers will expect all-round service or 2) Custom-ers will have their own maintenance teams, but will use ISPs for troubleshooting and other high level services.

An ISP is constantly challenged to grow internationally without neglecting the needs of regional customers. How impor-tant is the regional commitment for a service provider operating worldwide?

It is very important. We need local organiza-tions to react to specific service requirements in the individual countries and regions. At the same time, a global orientation can create synergies in the areas of material procurement, spare parts availability, product optimization and logistics. This will then provide consider-able advantages for the individual regions. There are also companies looking for world-wide partners who offer independent services for wind turbines. They will offer them the full value chain of services with one contact part-ner and a guarantee of the same high-quality service for all regions. This is possible with a

service partner who offers considerable inter-national experience, as well as experience in servicing individual local markets. In context, this also means that employees are centrally and regionally trained to such a degree that they have the know-how and qualifications required for their specific service activities. For example, in the United States, we have set up our own training. Employees from other countries, mainly Europe, receive technical training at our headquarters in Germany and are initially accompanied by our experienced personnel when completing practical work at regional sites. Many years of experience have shown that well-trained employees are criti-cal to providing excellent service work. Our investments in this area pay off, and as a result, our operators achieve a significantly higher availability.

International Strength with a Regional Focus.

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Foundat ions: Overcoming Challenges.

The article “Trouble at the Tower Base” in the April 2009 issue of ON Service was devoted to the problems and possible causes of the formation of cracks in wind turbine generator (WTG) foundations. This article follows up with methods for eliminating these complex problems.

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Solido Bautenschutz GmbH, based in Steinfurt, Germany, has specialized in recon-structing building structures, including WTG foundations, for more than 25 years. Gregor Gervink is the Managing Director.

“The rapid development of the wind energy sector at the end of the 1990s resulted in a constant increase in turbine size and output,” said Gervink. “Prior experience in the construc-tion of WTG foundations could no longer keep pace with this rapid development.”In most cases, “trouble at the tower base” is caused by cracks in the foundation base, changes in the grouting joints of WTGs with anchor bolt foundations or by the detachment of cement embedded foundation parts.

Cracks in the foundation base Gervink describes a maintenance issue that his company solves with a reconstruction concept that consists of a base head cover and a highly elastic coating.

“To withstand enormous dynamic loads, the concrete base and the body of the foundation of a WTG are heavily reinforced with steel. The reinforcement absorbs the loads and passes them through the foundation and into the ground,” Gervink said. “However, concrete offers limited elasticity, resulting in cracks that eventually appear in the foundation base. The cracks allow water to enter the structure, causing corrosion of the reinforcement steel.”

Special cover, clever coatingThe base head cover is made of a combination of composite sheets, a fabric-reinforced web of plastic material and stainless steel elements.

However, the foundation has to be fully repaired prior to installing this base head cover.

“Along with Remmers Baustofftechnik, we have developed a special process to solve this issue. The coating is made from extremely elastic polyurethane and is applied to the surface in six successive layers. This method ensures a perfectly even coating. The cracks must be prepared first by opening them into a ‘V’ shape. Tape, made from the same ma terial as the coating, is then secured over the cracks. The coating is then applied as six individual layers. This system produces a very low overex-tension of the coating (maximum five percent) so that no more cracking occurs.”

Ten-year guaranteeAfter the foundation base is completed, the prefabricated base head cover is installed in segments, and the fabric-reinforced webs of plastics material are thermally welded to each other. To ensure that the top layer of the cover remains absolutely watertight, the base head cover, reinforced with composite sheet, is pressed against the tower by a stainless steel ring. A UV-resistant cellular rubber strip cre- ates a watertight seal, effectively closing the

gap between the tower and the base head cover. The lower corner is pressed against the concrete by a tensioned stainless steel bowden cable, of which its circular geometry guarantees the rigidity and dimensional stabil-ity of the construction.

“The particular advantage of this development is that it can be dismantled and reinstalled at any time for a subsequent inspection of the foundation,” Gervink said. “Using this patented process, we have already successfully recon-structed about 40 turbines. The first turbine, reconstructed in 2005, has not shown any further signs of damage. Based on the positive experiences we have had, we are able to offer a guarantee up to 10 years.”

Defective grouting jointsCracks to the foundation base aren’t the only concern that wind turbine operators must be aware of. Changes to the grouting joints of WTG towers, whose tower base is fixed to the foundation by anchor bolt construction, also must be monitored.Gervink describes the consequences of defec-tive grouting joints and a solution offered by Solido Bautenschutz GmbH.

1. and 2. A stainless steel bowden cable presses the base head cover against the concrete of the tower.

3. A high-pressure water jet is used to remove old grouting material from

defective grouting joints.

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“Processing and material faults, often lead to defective grouting joints, which in extreme situations, can develop into a standard safety issue. Additionally, defective grouting joints are also a direct result of increased wear on the tower flange, tower flange welding seams, anchor bolts and the foundation.”

Reconstruction in segmentsDuring the initial phase of reconstruction, all of the internal technical equipment is covered by foil to protect against soiling. The anchor bolts are released and the existing grout-ing joint is removed segment-by-segment, using a high-pressure water jet. To ensure the stability of the turbine, diametrically opposed segments are repaired simulta-neously. The uncovered anchor bolts are decoupled, and the grouting joint is restored using a high-strength grout-ing mortar. To restore the grouting, shuttering is installed on the inside and outside of the flange, which is perfectly horizontally aligned, and the high-strength grouting mortar is poured into the shuttered off area below the flange. The formation of bubbles must be avoided to ensure load transfer from the flange to the concrete.

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1. First the core holes are measured. 2. Then the turbine is lifted by special lifting cylinders … 3. … and new core holes are drilled.

“Once the grouting joint has been removed, the anchor bolts can also be checked for corrosion or notching. During the reconstruction, we also produce hardened samples of the new grouting joint to be checked by the nearest build-ing material testing center. This allows us to accurately determine the time for further processing, pretensioning of bolts and restarting of the WTG,” Gervink said.

Loose foundation partsAccording to Gervink, another frequent problem is the detachment of concrete embedded foundation parts.

“High dynamic stressing and occasional poor workman-ship the concrete encasing of the built-in part and flange to work free over time,” Gervink said. “This leads to gaps between the concrete and the built-in part, which can increase in size as a result of water entering. This results in wet concrete powder which is transported or pumped out of the base or into other areas of the gap.”

Considerable effort pays offSuch a problem can only be resolved with considerable effort, as the cavities and gaps on and around the built-in foundation parts must be filled again. This is the only way to restore the stability of the turbine. To achieve this, the turbine must be lifted several millimeters by special lifting cylinders that are placed underneath the first coupling flange.

“The lifting cylinders allow the base to be leveled and relieved of the load. This is important when filling the cavities so that the mortar can dry without any deforma-tion caused by the wind load,” Gervink said.

Next, core holes are drilled into the foundations and the cavities are flushed with water. Concrete powder residue that might prevent the grouting mortar from spreading can remain in the cavities. The cavities are then filled with a high-strength mortar suspension through the core holes. Once the mortar has set, the foundation can be released by retracting the lifting cylinders.

Gervink is convinced that “the different challenges facing WTG foundations can be mastered if experienced engi-neers and good craftsmen work together.” Longstanding experience with different reconstruction concepts seem to confirm this. With more than 20 employees, Solido Bauten-schutz GmbH has successfully reconstructed more than 100 turbines – protecting the investments of turbine opera-tors to their satisfaction.

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New Impulses for Renewable Energies? HUSUM WindEnergy 2010.

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“This year the fair will attract more than 900 exhibitors and some 30,000 visitors,” said Hanno Fecke, managing director of the Husum Congress Center on the growing interest in the HUSUM WindEnergy exhibition. “We have expanded the exhibition space by 40 percent in response to the increasing demand. In addition to a higher number of exhibitors, some companies have also grown and require more exhibition space. Despite the expansion we still won’t be able to accommodate all exhibitors. As in past years, we have a waiting list,” Hanno Fecke said.

Better Infrastructure and New Congress CenterThis year, more than 10,000 visitors will be able to enjoy a shuttle service to the trade fair. A so-called “late night collection service” will return guests of HUSUM Wind-Energy 2010 to their accommodations as late as 10:30 p.m. each night. “When you look at leading trade fairs for other sectors, the situation is basically the same. You either book a horrendously expensive hotel room close to the exhibi-tion grounds, or you accept longer commuting times in

Theodor Storm, the most famous prodigy of Husum, Germany, referred to his hometown as “the gray town by the sea.” However, this North Frisian gem in Schleswig-Holstein will be anything but “gray” during the HUSUM WindEnergy 2010 exhibition, which is scheduled from Sept. 21–25. So what trends can be expected at this year’s leading trade fair of the wind energy industry, and what topics will it focus on regarding wind turbine generator (WTG) services?

return for cheaper accommodations. There is always a lack of hotel rooms during large trade fairs. Even major cities cannot cope with the high volume of people generated by such an event. The same applies to the Husum exhibi-tion, although the prices are comparably lower,” Fecke said.

In regard to improving the infrastructure, the construc-tion of the new congress and exhibition center is close to Fecke’s heart. “Together, with the town of Husum and the state of Schleswig-Holstein, we have invested 16 million Euros in this center thus far,” he said.

Visitors and exhibitors will also be delighted that the new lightweight construction exhibition halls are now equipped with air conditioning.

Focus on Supply Chains The HUSUM WindEnergy exhibition, with its renowned traditional and relaxed atmosphere that helps make visitors’ stays as pleasant as possible, offers people a wide range of interesting topics and issues to learn about and discuss.

“Apart from standard topics, such as onshore and offshore wind energy, we present the entire service and supply industry. In this context, it is surprising how many manufac-turers in the renewable energies sector still do everything themselves,” Fecke said. “Compared to other industries, such as the automotive industry, this is quite unusual. No car manufacturer, for instance, would think of producing the tires for his cars in-house. Therefore, one of the themes of the trade fair will focus on the optimization of supply chains and the outsourcing of individual operations to specialized firms. Companies will certainly start to rethink this area more often.”

Considerable Competition from AsiaFor the first time, Fecke has also detected considerable competition from Asia at the fair. Asian firms are encroaching into the European market by acquiring companies, along with buying their technology and knowledge.

Hanno Fecke, Managing Director

of the Husum Congress Center

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Due to a rapid international expansion, patent attorneys will, for the first time, make their rounds during HUSUM WindEnergy 2010 to closely examine the products of exhi-bitors.

“The organizers will also have to deal, to a considerable extent, with patent infringements,” Fecke said.

Challenges of the Offshore Wind Energy SectorAccording to experts, growth in offshore wind energy will mirror the growth witnessed in the onshore sector during the last 15 years. However, Fecke reports that the offshore wind industry faces enormous challenges, including in the area of servicing.

“Key questions revolve around the organization and imple-mentation of services for the offshore sector. For instance, will concepts similar to the two-weekly shift patterns used on offshore oil platforms be adopted? Are strategies at all comparable to those used in servicing the onshore market? This is a viewpoint that I personally do not share. From my perspective, there will be a clear separation between onshore and offshore services, due to their very different requirements,” Fecke said.

Qualifications in the Onshore SegmentFecke still regards the qualifications of the service providers and their employees as the key issue within the onshore sector.“The sector has developed so fast during recent years that the service technology could barely keep up,” Fecke said.

“Some techniques used in the onshore service sector have also reached the point where one has to ask how employees can gain further skills. This is also a question of age, because strenuous activities can only be performed up to a certain age. How can one provide well-qualified engineers with the new skills required for the sector and use it to their advantage in the future?” This question refers particularly to the Wind-career Job Fair, taking place on Sept. 25, revolving around job opportunities in the wind energy sector.

Given this wide variety of topics and complex issues, HUSUM WindEnergy 2010 is eagerly anticipated. According to Fecke, the HUSUM WindEnergy exhibition is in a leading position regarding technology and innovation for the wind industry. “The event is also an occasion for people to refuel and to set new goals,” Fecke said. “This is why the location of this trade fair is so special.”

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More Power with Partners.The virtues of an independent wind turbine generator (WTG) service provider should be speed, innovative strength and reliability. However, this is nearly impossible without competent partners.

There’s no doubt that independent service providers (ISPs) have the necessary know-how to ensure a quick response in the event of turbine faults and problems due to many years of experience, regular fault analyses, feed-back from field maintenance and service staff, as well as discussions with clients. Developments and successes of ISPs, such as aftermarket turbine improvements, and increas ing the availability and yield of WTGs, also demons-trate their capabilities.

High Level of Customer OrientationIt is understood that ISPs are not manufacturers and should focus on their core competencies; therefore, they depend on the know-how and reliability of partnering produc-tion companies. The selection of the right partners plays a crucial role in establishing the ability of a service provider to offer a high level of customer satisfaction.

Quick ResponseWhen choosing partners, ISPs need to ensure that possible partners meet rigorous quality standards such as ISO certi-fication. To guarantee a high availability of spare parts, it is also important to check whether a partnering company is able to maintain appropriate inventory levels to insure quick deliveries to minimize downtimes. In this area, a part-ner has to rely on the competence of the service provider

– as only they can assess how many spare parts or compo-nents should be stored to ensure a quick response.

Transfer of Know-HowStrong, dedicated cooperation between ISPs and their part-ners is particularly important when developing turbine upgrades. Generally, such developments are initiated by the service provider or by a highly-qualified team of engi-neers, solely focused on optimizing turbines. Partners also contribute significantly to the development process by offering their particular area of expertise to the project. An example of this is the development of a mounting method for the carbon brushes of a generator. It became appar-ent during maintenance work that the current mount-ing method made replacement of the carbon brushes tedious and problematic. Developers improved the moun-ting method, but also changed the configuration of the carbon brushes, considerably increasing their service life.

An improvement like this can only be implemented by an ISP if a partner is prepared to closely cooperate with them in finding a solution (See related article on page 6).

Correct Assessments for RisksA positive relationship between an ISP and its suppliers and sub-contractors is a profitable, win-win situation for both parties, and particularly in the case of long-term collabo-ration. As part of this process, the service provider should carry out a risk assessment. Examples of questions that need to be answered include:

1. Does the size and economic situation of the partner ensure availability as a supplier or sub-contractor for several years to come?

2. What know-how will the external company bring to the partnership?

3. How flexible is the partner in terms of produc-tion, know-how and the ability to adapt to changing conditions?

4. What personnel resources, as well as storage capacities, can be devoted to the cooperation?

5. How good is communication with the partner?

Careful SelectionThese questions demonstrate that an excellent coopera-tion between an ISP and an external company is – most likely – developed over many years and not day-to-day. As a result of the financial crisis, more and more companies have entered the wind energy sector in recent years, offering their services as partners of independent service compa-nies. This is quite understandable, given that wind energy is still a sector offering enormous growth potential. Whether these new players will succeed in forming a dynamic team with ISPs can only be determined in intensive discussions. Responsible ISPs must act with the interests of their custom-ers and should thoroughly check each potential partner-ship offer.

Feature

1919Feature

20

The Wind Dilemma. Wind either blows or it doesn’t. If it was that simple, life would be much easier for owners and opera-tors of turbines or wind farms. How reliable are wind predictions? What type of weather pattern produces winters with comparably low wind strengths? ON Service asked these questions and others to Alexander Lehmann, a weather forecaster on the German national television network ARD, and Founder and Head of the Energy Service of Meteomedia.

ON Service: How is wind generated or how is this phenomenon explained meteorologi-cally?

Alexander Lehmann: Wind is nothing more than equalization between different pressure systems. For instance, let’s say you divide a bathtub into two halves with a partition, and you fill both halves with different levels of water. If you then remove the partition, the water would flow from the high to the low pressure area – the area containing less water. Like water, air also has a specific weight and a specific pressure, and this air pressure is measured to create forecasts. Air also moves from a high-pressure area to a low-pressure area. The rotation of the earth also plays a decisive role by deflecting the air, so that there is also air movement around the high-pressure and low-pressure areas – counter-clockwise for low-pressure areas and clockwise for high-pressure areas.

Interview

21

The Wind Dilemma. Wind strength is not only important for the generation of energy by wind turbines but also for scheduling service assignments, including work at considerable heights. Is it possible to reliably predict wind? When it comes to weather, generally anything that can be measured can be predicted. Wind is one of the parameters recorded by weather stations. However, it is more difficult to predict wind than temperatures. A forecast spanning a period of two to four days is usually reliable so that a good prediction of trends is possible.

As far as service assignments for wind turbines are concerned, these should be scheduled for calm days to prevent yield loss. Weather forecasts assist by predicting strong winds and other hazardous weather scenarios such as thunder-storms, which must be taken into account.

How easy is it to make a geographical forecast for a specific area?

The more complex a terrain, the more complex the wind forecast. Ultimately it depends on whether there is a measur-ing station available for a certain area that is able to collect useable data about wind behavior over longer periods of time. This allows for reliable forecasts to be made, rather than relying on information based solely on assumptions.

Predictions about wind behavior can also be made using complex mathematical models. Local measurements can validate the accuracy of these models, so weather stations are vital for forecasting wind at locations with a difficult topography.

Are these factors also taken into consideration when planning new weather stations?

That would be ideal, but a certain infrastructure is required for establishing a weather station. First, there must be a site available for the station. Somebody may also have a special interest in constructing a weather station on his land. If the station is not self-sufficient, it also requires a electrical connection and a radio network for transmitting meas-ured data.

Meteomedia owns more than 500 measuring stations in Germany and 810 in Europe; is this disproportionate in terms of the surface area?

Generally, we want to extend our measuring station network. In addition to having access to the data from the approxi-

Alexander Lehmann: 41, has been an employee of the

European Weather Service Meteo-

media for more than 10 years. Five

years ago he founded the Energy

Service Department of Meteomedia

which he continues to manage.

The department currently services

more than 400 customers from the

energy sector. Among other things,

Alexander Lehmann also moderates

the weather broadcast for the ARD

television channel.

Interview

22

mately 810 European measuring stations, we can also access measurement data, some of which is available free of charge from other weather services.

A weather service is obviously interested in accessing as many measuring points as possible. Due to its history, the Meteomedia measuring stations are currently concentrated in Germany, Switzerland, Liechtenstein and Luxembourg, but we are constantly expand-ing our own network of measuring stations. Because growing a network of measuring stations is costly, as a private sector enterprise, Meteomedia is often dependent on partners or investors to assist in this area of development.

During the last two years the wind energy sector did not achieve the expected yields, as low winds characterized both years. In your opinion, is there a concrete reason for this?

There are certain situations in the atmosphere that are responsible for the occurrence of very specific weather patterns. I will use Europe as an example.

Particularly noticeable in this long-term com - parison are differently positioned configu-rations with fewer high-wind phases than during the last very cold winters. Normally the wind in Europe blows from a westerly direc-tion, driving the mild Atlantic air up to Western Europe. According to the long-term average, that is why Europe can expect rather mild winters. It is due to the North Atlantic Oscilla-

tion (NAO), which is responsible for the fluc-tuation of pressure conditions between the low-pressure system over Iceland and the high-pressure system over the Azores. The NAO index is based on the differences in atmos-pheric pressure abnormalities between the Azores and Iceland and is used to measure the strength of the west wind drift in the North Atlantic, determining the climate in Europe, particularly in winter.

In the past two years, specifically during winter, the low-pressure system over Iceland and the high-pressure system over the Azores were not as distinctive as in other years. If the low-pressure system over Iceland and the high-pressure system over the Azores are very distinctive during winter, a depression forms and brings mild and moist air across Germany

from the West – carrying sufficient wind. This was rarely the case during the last two years.

Is it possible to make any forecast in regard to wind energy yields for the upcoming years?

I am not an expert in producing wind assess-ments. Estimated future yields are normally based on historic data. It is a type of interpola-tion of what has occurred in the past.

As a meteorologist you are a weather expert. Is wind energy a reliable source of energy?

Wind energy is a reliable source of energy and has a future. However, questions remain about suitable locations for wind turbines and the type of data necessary for predicting locations capable of sufficient long-term yields.

Meteomedia weather station in Kißlegg, a health resort in the

Bavarian Allgäu.

Hurricane “Kyrill” swept over Germany on January 19, 2007 with top speeds of over 124 mph, causing considerable damage particularly in the country’s heavily wooded areas.

Interview

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Anzeige_e.indd 1 29.07.2010 06:36:16