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TECHNOLOGY
TroBat_REW_1502 1
1/27/15 11:55 AM
VOLUME
18
ISSUE
MARCH/APRIL 2015
Analyzing
Gearbox
Failure
and preventing it
Solar
Bonded solar PV
arrays could provide
safer solar power.
p. 28
1503rew_C1 1
Data Points
Geothermal
Hydro
Where, when
and how modules
degrade.
Grooved couplings,
not welds, provide
fexible piping
solutions.
Better storage could

lead to breakthroughs
in balancing a
renewable-heavy grid.
p. 36
p. 38
p. 48
3/13/15 1:41 PM
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1503rew_C2 2
3/13/15 1:41 PM
contents
PROJECT PROFILE
Thunder Bay
Generating
Station.
46
features
18
COVER STORY
Getting to Grips with

Grinding Gearboxes
There are many reasons
why the gearbox on a wind
turbine might experience a
failure. Here are some O&M
considerations to lessen the
likelihood that it happens
to you.
Chris Giuffre
28
SOLAR
Bonded PV Arrays
Could Provide Safer
Solar Power Traditional
equipment grounding
methods could be replaced
by bonding hardware for
large-scale PV arrays as
evidenced by the results of a
field test conducted by TUV
on the newly constructed
6.4-MW Manadaly Bay
Convention Center array in
Las Vegas, Nevada.
48
HYDROPOWER
AND ENERGY STORAGE
A Solution to
Intermittent
Renewables Using
Pumped Hydropower
Pumped storage hydropower
plants could ultimately
provide one of the most
cost-effective means of
frequency regulation for
the EU grid of the future.
Nathalie Lefebvre, Marie Tabarin,
and Olivier Teller
Bill Brooks
18
1503rew_1 1
ON THE COVER
Wind turbines dot a
harsh landscape, making
them more difficult
to service. Credit:
ExxonMobil.
RENEWABLE ENERGY WORLD MAGAZINE
MARCH/APRIL 2015
3/13/15 1:34 PM
Reliable energy automation solutions

for wind farms

1503rew_2 2
3/13/15 1:34 PM
features
departments & columns
38
GEOTHERMAL
Geothermal Piping Systems

Get into the Groove In the hot,
rocky, volcanic terrain of the Indonesian
Ring of Fire, the piping systems for
geothermal power plants need flexibility
that welded joints just cant offer.
5 Editors Letter
Peeking Under the Hood of
Renewable Energy Technology
36 Data Points
Examining PV Module Failures
46 Project Profle
58 Training and
Educational Events
59 Calendar
59 Advertisers index
60 Last Word
Biomass Electricity at Thunder

Bay Generating Station
Australia at the Crossroads
Alfred Chua
On RenewableEnergyWorld.com
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1503rew_3 3
MARCH/APRIL 2015
3/13/15 1:34 PM
The TRIO. Goes anywhere. Thats why

its everywhere.
The ABB TRIO is a favorite of installers worldwide. Partly, because of scale the TRIO serves
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tomorrow. Sign up for the TRIO rebate program at www.abb-solarinverters.com/trio-rebate

1503rew_4 4
3/13/15 1:34 PM
From t he Editor
CHIEF EDITOR Jennifer Runyon

ASSOCIATE EDITOR Meg Cichon
SENIOR OPERATIONS MANAGER
Stephanie Kolodziej
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accept any liability for errors or omissions.
Policy gets a lot of focus in Renewable Energy World because when it

comes to renewables, policy is still the driving force behind its adoption. Need convincing? Check out the Last Word on page 60 to see how
the Australian government injected uncertainty into the Australian
renewable energy industry just by considering a change to its RET.
With this issue, however, we chose to write about the engineering
innovations that actually make these incredible systems work. Over
the next 60 pages, youll fnd technological advances in each renewable energy segment that are enabling greater adoption of renewable
energy systems worldwide. You will see how lubricants are enabling
wind turbines to work longer, harder and in harsher environments in
our cover story on page 18. You will understand how advances in racking technology are making PV systems safer and easier to install in
our story on page 28. Did you know that pumped hydropower energy storage plants could more easily provide the grid-balancing services that will be increasingly necessary as wind and solar power take up
a greater proportion of the generation mix? Read how on page 48. Our
project profle on page 46 shows how advances in wood pellet technology allowed the province of Ontario in Canada to become completely
coal-free.
Technology advancements are the reason for the existence of renewable energy and this is the issue in which we celebrate them. I hope
you enjoy it!
Hungry for more about renewable energy technology advances? Register to attend Renewable Energy World Conference, North America,
set to take place December 8-10 in Las Vegas. Were putting together
a comprehensive conference agenda right now that includes technical
papers from leaders in the industry. Hope to see you there!
1503rew_5 5
MARCH/APRIL 2015
3/13/15 1:34 PM
REGIONAL
news
EUROPE
Cable Contract for 350MW Wikinger Offshore

Wind Farm Granted
Prysmian Group has been awarded a 60 million contract by Iberdrola Renovables Offshore
Deutschland GmbH to supply and install wind
turbine inter array cables for the Wikinger offshore wind farm, located within the West of
Adlergrund cluster in the German Baltic Sea.
Under the contract, Prysmian is responsible for the design, manufacture, installation, burial, termination and testing of a total
of 81 km of 33 kV submarine cables in different cross-sections to connect the 70 wind turbines and an offshore substation that form
the 350-MW wind farm. Cables will be produced in Prysmians facility in Drammen,
Norway. Installation works are scheduled to
be complete by the end of 2016.
Prysmian has three production facilities
dedicated to submarine cables, situated in Arco
Felice (near Naples, Italy), Pikkala (Finland) and
Drammen (Oslo, Norway); two installation vessels, Giulio Verne and the recently upgraded Cable Enterprise, as well as well-proven
in-house cable protection equipment, and specialized operations teams.
In May 2014 Prysmian Group was awarded a contract with 50Hertz Offshore GmbH to
design, produce and install multiple 220 kV
HVAC (High Voltage Alternate Current) 3-core
extruded submarine cable systems between
planned offshore wind parks within the West
of Adlergrund cluster.
1503rew_6 6
MARCH/APRIL 2015
Solar PV Leases
Available for Six
Million EU Homes
European municipal utility network Trianel GmbH and
Conergy launched a partnership that enables municipal utilities in the Trianel network to offer solar leasing for homes with no upfront costs. Under the terms of
the agreement, Conergy will design, install and maintain
solar installations tailored for each customer.
Trianel is a network bringing
together municipal electric utilities that develops new business
models to support
their independence and competitiveness. Its
100-plus shareholders supply
a combined six
million homes in
Facade of a Dutch row of new houses

with solar panels. Credit: Shutterstock.
Germany, Austria, the Netherlands and Switzerland.

Anke Johannes, CEO at Conergy Deutschland GmbH,
said: Services such as Trianels EnergieDach follow a
trend that will boost solar installations in the residential segment.
Trianels EnergieDach service enables municipal utilities to install residential PV systems at no cost to homeowners. The utility undertakes the initial investment, set
up, and operational management of the system. The customer, as system operator and leaseholder, uses the electricity generated for their own consumption. Tests in Heidelberg, Germany demonstrated that customers should
save as much as 9,000 (US $13,000) over the 25-year
term of the lease, with the option to buy additional electricity at preferential rates.
3/13/15 1:34 PM
Five UK Biomass Plants

Get Financing
UK anaerobic digestion (AD)
The seven-year term finance
plant development company
facility, provided by Royal Bank
Tamar Energy has secured 32
of Scotland plc will refinance
German Wind
Power Sets
New Record
In January
million in financing for its portfo-
the existing five plants and be
Wind turbines fed over 10,000
lio of five AD plants. According to
used to finance the next wave
gigawatt-hours (GWh) of elec-
Tamar Energys chief executive
of AD plants in Tamar Energys
tricity into Germanys grid in
officer Willie Heller, the deal is
development pipeline.
the first month of 2015, setting

a new record, the BDEW Ger-
the first senior non-recourse debt
Anaerobic digestion is the
financing for an industrial-scale
process by which organic waste
man Association of Energy and
AD facility in the UK. Law firm
material is converted into ener-
Water Industries and ZSW Cen-
Watson Farley & Williams served
gy. The food, vegetable and agri-
tre for Solar Energy and Hydro-
as advisor on the deal.
cultural organic waste, known
gen Research reported. That is
as feedstock, is broken down
approximately one fifth of the
AD plants is comprised of five
by micro-organisms and con-
annual production from wind
facilities; the 1.5-MW Holbeach
verted into biogas (a mixture of
in 2014.
facility in Lincolnshire, 1.5-
carbon dioxide and methane),
MW Farleigh plant in Hamp-
which is used in combined heat
erated from wind, 200 GWh were
shire, 2-MW Halstead plant in
and power plants or cleansed of
generated offshore, the organi-
Essex, 3-MW Retford plant in
carbon dioxide and injected into
zations noted. German offshore
Nottinghamshire and 3-MW
the National Grid. In addition,
wind has a boom year ahead,
Hoddesdon plant in Hertford-
a by-product of the AD process
with the German Engineering
shire. It recently signed a power
is digestate, which is a nutrient-
Association expecting installed
purchase agreement with EDF
rich substance commonly used
capacity to reach 3 GW by the
Energy for power produced by
as a renewable fertilizer or soil
end of 2015, corresponding to an
the five AD plants.
conditioner.
investment of 10 billion.
Tamar Energys portfolio of
Of the total 10,000 GWh gen-
NORTH AMERICA
Report: Wind Power Essential To EPA Clean Power Plan

A new report released by the American Wind Ener-
power and reliability are answered in AWEAs
gy Association (AWEA) said that adding wind power
report, Wind energy helps build a more reliable
can help the U.S. meet the Environmental Protec-
and balanced electricity portfolio, based on grid
tion Agencys (EPA) Clean Power Plan by cutting car-
operators real-world experience integrating wind
bon pollution while keeping the lights on.
power as well as dozens of studies conducted by
The 15 most common questions about wind
grid operators examining how higher levels

1503rew_7 7
[ cont >]
MARCH/APRIL 2015
3/13/15 1:34 PM
REGIONAL
news
[wind power cont. from p. 7]
of wind use
can be achieved.
As wind energy has grown to pro-
Giant Battery Storage

Project Complete
vide a larger share of our electricity mix,
Blattner Energy announced that it completed construction
wind turbine technology has matured
on one of the largest battery storage projects on the mar-
so that modern wind plants are able to
ket today. The 20-MW Lee/DeKalb energy storage system in
provide the same grid reliability servic-
northern Illinois provides the regional transmission organi-
es as conventional generators. Chang-
zation, PJM Interconnection, the frequency regulation sup-
es in wind output are not a major issue
port needed for the area.
for grid operators because all power
Blattner Energy was responsible for engineering the sys-
plants are already backed up by all
tem, procuring the technology and equipment, the installa-
other power plants, and grid operators
tion and interconnection of the system technology, as well
already deal with large fluctuations in
as completing the testing and start-up activities at the site.
electricity supply and demand. In fact,
Greensmith Energy Management Systems was the integrator
the gradual and predictable changes
of eight 10 X 40-foot containers, which housed 2.5 MW of LG
in wind power are also much easier for
Chem lithium-ion batteries each the same type of batteries
grid operators to address than the large-
currently used in some high-performance electric vehicles.
scale outages that can occur at conventional power plants.
Stephen Jones, director of solar, Blattner Energy, said: Battery storage will be a key technology in supporting the stabil-
Technological advances have

enabled U.S. wind farms to set gener-
ity of our grid and the intermittency of some renewable generation sources.
ation records as a percent of demand

over the past two years, all without
reliability problems:
At times more than 60 percent
P&G To Use Biomass Power
of Xcel Energys Colorado power
The Procter & Gamble Compa-
30 percent of the total energy.
system;
ny (P&G) announced the devel-
The new facility will replace
opment of an up to 50-mega-
P&Gs boiler with a more effi-
ERCOT, the main Texas power sys-
watt biomass plant that will
cient combined heat and power
tem; and
help run one the companys
biomass unit. Biomass will pro-
largest U.S. facilities.
vide 100 percent of the steam,
Nearly 40 percent of generation in
33 percent in the Southwest Power

Pool (area that covers all or parts of
Constellation will build, own
and up to 60-70 percent of the
and operate the $200 million
total energy used to manufac-
The largest grid operator in the U.S.,
cogeneration plant, which will
ture P&G products like paper
PJM, recently reported it could reach 30
supply steam to P&Gs Albany,
towels and toilet tissue.
percent of wind power while maintain-
Ga., paper manufacturing facil-
The plant will significantly
ing electricity reliability.
ity and generate electricity for
increase P&Gs use of renewable
local utility, Georgia Power.
energy, helping move the com-
several states in the Southwest).
According to Wind Vision, a 2015

Department of Energy report, wind
For more than 30 years, the
pany closer to its 2020 goal of
could double from todays amount to
Albany facility had used an
obtaining 30 percent of its total
reliably supply 10 percent of the nations
onsite biomass boiler to con-
energy from renewable sources.
electricity demand by 2020, 20 percent
vert wood scraps into renew-
by 2030 and 35 percent by 2050.
able steam, providing about
1503rew_8 8
MARCH/APRIL 2015
Georgia Powers purchase

of energy from
[ cont >]
3/13/15 1:34 PM
NuScale Power has attained the Triple Crown for Nuclear Plant Safety. With NO
operator action, NO AC or DC power, and NO added water, the NuScale Power
Module will achieve safe, self-cooled shutdown, and maintain it indefnitely. Using
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eliminates many of the complex mechanical systems found in conventional nuclear
power plants and other small modular reactor designs. Safety: The Element of Nu.
NuScale Power
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nuscalepower.com
2015 NuScale Power, LLC. All Rights Reserved.

1503rew_9 9
3/13/15 1:34 PM
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1503rew_10 10
3/13/15 1:34 PM
[biomass cont. from p. 8]
Constellation, at or below
Georgia Powers avoided cost,
MIDDLE EAST & AFRICA
is part of the companys multifaceted strategy to encourage and cultivate renewable

energy sources in Georgia and
was made possible under a
program developed in coordination with and approved
Roadmap For
Universal Energy
Access In Tanzania
By 2030 Complete
by the Georgia Public Service

Commission. Constellation is
More than 100 private sector, government and NGO representatives,
currently under contract to
as well as community leaders and energy innovators, spent two days
sell 42 MW of capacity and
in Tanzania in February working to support the United Nations Sus-
energy from the 50-MW facil-
tainable Energy For All initiatives 2030 objectives of delivering access
ity to Georgia Power.
to modern energy services for all, doubling the rate of improvement
The plant is scheduled to

begin commercial operation
in June 2017.
in energy efficiency and doubling the share of renewables in the global energy mix.
Tanzania, one of Sustainable Energy for Alls 14 African current
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U.Ed.14-0642/14-WC-1119ajp/smb
1503rew_11 11
MARCH/APRIL 2015
11
3/13/15 1:34 PM
REGIONAL
news
providing access to energy for
Small-scale Hydro Plant To Deliver

Power to Malawi Community
its entire population. Accord-
The Scottish Government has awarded SgurrEnergy a contract to
ing to the International Energy
design and implement a hydroelectric scheme in Malawi that will deliv-
Agencys World Energy Outlook
er renewable energy to an off-grid community.
priority countries, is working to overcome challenges in
2014, 36 million people, some 76
During the three-year project SgurrEnergy will manage the design
percent of Tanzanias popula-
and installation of a 100-kW hydroelectric scheme in Mulanje, as well
tion, do not have the benefits of
as a community education program to provide skills for the operation
electricity.
and maintenance of the technology. The team will also conduct tree
The consultation, facilitated

by the UN Foundations Energy Access Practitioner Net-
planting as a watershed management program and provide health

clinic equipment to make best use of the new power supply.
Partners on the project in Malawi include the Mulanje Electricity
work together with the WWF,
Generation Authority (MEGA), Practical Action and Mulanje Renew-
served as an opportunity for an
able Energy Agency (MuREA). More than
in-depth multi-stakeholder dis-
1000 people live in the village of Mulanje.
cussion around energy solu-
Minister for Europe & Internation-
tions for Tanzania, drawing
al Development, Humza Yousaf, said that
in the perspectives of govern-
the project is important for the future of
ment, energy sector compa-
the country. We might take electricity for
nies, and civil society. Richenda
granted but a reliable, cost effective and
Van Leeuwen, Executive Direc-
clean power source enables medics to treat
tor, Energy Access, UN Foun-
patients safely and will help school stu-
dation said that the two-day
dents study after dark, he said. He added,
event showcased how decen-
the skills and training of local people in
tralized renewable energy
Malawi will provide a legacy for the project far beyond just this one
solutions such as solar home
location. The project builds on the special relationship between Scot-
systems and community micro-
land and Malawi, making a real difference to peoples lives.
grids complement efforts
Credit: SgurrEnergy.
This development will reduce the amount of imported fuel con-
underway on conventional grid
sumed by diesel generators and will benefit local industry and schools.
extension.
The local medical clinic will, for the first time, be able to use refrigera-
Tanzanias clean energy
tors and sterilization, and be able to administer medical care after sun-
future must take into consid-
set using the clean energy produced by the project. Floods devastated
eration integrated energy solu-
the area of Mulanje in January, destroying houses, livestock and crops.
tions including renewables and
This is the latest in a number of Malawi-based projects for SgurrEn-
abundant gas deposits in the
ergy, including recent met mast installation and management of a year-
country, said Dr. Kandeh K.
long wind measurement campaign. Part of the Scottish Governments
Yumkella, Special Represen-
wider Malawi Renewable Energy Acceleration Programme, funded
tative of the Secretary-Gener-
from the International Development Fund and led by the University of
al and CEO, Sustainable Energy
Strathclyde, this project aims to assess feasibility of wind energy tech-
for All, on the conclusion of the
nologies on a domestic and commercial scale in Malawi, with a particu-
two-day-long consultations.
lar focus on the potential for alleviation of poverty.
12
1503rew_12 12
MARCH/APRIL 2015
3/13/15 1:34 PM
ASIA
Geothermal Technology
Partnership Formed,
Indonesian Project
Advances
Australian Government
Urged To Recommit to
Renewable Energy
Senvion Australia called on the Australian
Government to end the investor uncertainty by
recommitting to an effective Renewable Energy
Target (RET).
The call came after the release of the inde-
AltaRock Energy and ON Energy announced a part-
pendent Climate Change Authoritys (CCAs)
nership to further the commercialization of enhanced
legislative review of the RET that suggested
geothermal energy as a new source of electric power.
that the government consider increasing and
The companies have entered into a partnership that
extending the RET scheme beyond 2020.
will provide advanced tools for geothermal developers,
The CCA found that, in the absence of cred-
through a joint venture.
ible alternative policies, RET-type arrange-
According to the agreement, which was established
ments might be required to support increased
on the heels of a successful demonstration in the
penetration of renewables in electricity for
city of Gwangju, South Korea, AltaRocks Stimula-
some time.
tion Services business unit will contribute stimulation
The CCA Report highlights that cutting the
technology and ON Energy, the exclusive U.S.
RET will result in a windfall to big polluters
drilling services partner of Hanjin D&B, will provide
of $9.3 billion at the expense of tens of thou-
deep drilling services. By combining technical
sands of jobs and billions of dollars of invest-
resources, the companies aim to take a leadership
ment in the clean energy sector.
position in the commercialization of products for deep

geothermal reservoirs.
Senvions chief executive, Andreas Nauen,

said the lack of a long-term and bipartisan pol-
The agreement is utilizing a novel water hammer
icy on renewables had stalled investment and
drilling machine that Hanjin D&B, the Korean manufac-
damaged Australias reputation as a safe place
turing partner for ON Energy, used to achieve a depth of
to invest.
over 12,000 feet, at up to ten times the drilling speed of
The endless reviews including two in
conventional drilling and as much as 50 percent lower
the last year alone have damaged Austra-
cost. The water hammer is tailored for hard rock and can
lias international reputation and brought the
handle a wide variety of geologic conditions.
local industry to a standstill, Nauen said.
Cost reductions in the geothermal industry will be
Senvion employs over 160 people in Austra-
realized by reducing both the cost of drilling, as well
lia and has invested more than $2.5 billion in 18
as increasing the success rate. When used in conjunc-
wind farm projects across Victoria, New South
tion with deep drilling, stimulations improve the natural
Wales and South Australia. The South Austra-
rock permeability and increase the productivity of injec-
lian Government has approved the companys
tion and production wells. AltaRock and ON Energy have
plans to build the $1.5 billion Ceres Project, that
planned to collaborate on an integrated demonstration in
will create a further 500 construction and 50
2015 at the Newberry Volcano EGS project in Deschutes
ongoing jobs on the Yorke Peninsula. However,
[ cont >]
the project faces uncertainty as a result of the
County, Oregon.
lack of clarity around the future of the RET.

1503rew_13 13
MARCH/APRIL 2015
13
3/13/15 1:34 PM
REGIONAL
news
Analyst: China Will Overtake the US as

Leading Wind Power Producer by 2016
According to Pranav Srivastava,
a wind power analyst with GlobalData, while it is true that
the U.S. generates the largest
amount of wind energy compared to any other nation, China
has the worlds largest wind
power installed capacity and its
plans to install more wind power
capacity this year mean that it
will surpass U.S. wind power
generation by 2016.
China produced about
169 Terawatt hours (TWh)
of electricity in 2014 while the
U.S. was slightly over 175 TWh,
Wind Farm in China. Credit: Shutterstock.
he said. Srivastava attributed

the lower wind power production in China to the
increased from 402 Megawatts (MW) in 2001 to
country having slower wind speeds and an
110 Gigawatts (GW) in 2014, at a Compound Annu-
inadequate grid infrastructure covering the
al Growth Rate (CAGR) of 50.5 percent. In terms
rapid increase in the number of wind turbines in
of cumulative installed capacity in 2014, China is
remote areas.
clearly ahead, as U.S. capacity currently stands at
He added: For a fairer assessment, we can use
approximately 66 GW.
installed capacity to estimate the extensiveness
Globaldata reported that China added about 18
of wind power development in a country. Chinas
GW of new installed wind capacity in 2014, whereas
cumulative wind power installed capacity
the U.S. only added around 4.9 GW.
[ geothermal cont. from p. 13 ]
In related geothermal news,

Alstom announced that it has
Alstom will deliver the plant

by the end of 2016.
Indonesia, with its unique
leverage on the huge geothermal reserves, made the decision

to fast-track the development
been awarded a 61 million con-
geology, houses the worlds
of Indonesias power indus-
tract by PT Pertamina Geother-
largest potential geothermal
try and has signed numerous
mal Energy to design, supply,
source, which is estimated to
geothermal-related contracts in
install and commission a 30-MW
be nearly 30,000 MW. The
the last few years.
geothermal plant for the Kara-
Indonesian authority, in
ha Power Plant in West Java,
looking to reduce overall green-
in Indonesia, see our feature story
Indonesia.
house gas emissions and
on p. 38.
14
1503rew_14 14
MARCH/APRIL 2015
For more on geothermal energy
3/13/15 1:34 PM
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1503rew_15 15
3/13/15 1:34 PM
REGIONAL
news
LATIN AMERICA
Andritz
A
n
Wins Contract for Nuble
Hydropower Plant Equipment
The Andritz Group has received
a contract from Hidroelectrica Nuble to supply electro- and
hydro-mechanical equipment for
the 136-MW Nuble hydropower
project in Chile.
The US $57.4 million award
includes the supply of two Francis turbines and generators, balance of plant services, control
and protection equipment, and
intake and diversion gates.
The run-of-river plant will be
located near San Fabian on the
Nuble River in Chiles Revion VIII.
Map of Chile. Credit: Shutterstock.
HydroWorld.com reported this
and seven in the development
announced plans to develop
past October that Hidroelectri-
pipeline. President Pablo Jose
Nuble. CGEs development unit,
ca Nubles parent company, utility
Perez Cruz said the company
CGE Generacion, signed an agree-
Electrica Puntilla S.A., had award-
expects to increase its current
ment in 2006 with MGM Interna-
ed Andritz and Vial y Vives of Chile
hydropower capacity of 74 MW
tional of the United States for sale
a $257 million contract to build
installed and under construction
of carbon credits from Nuble to
and equip the $350 million plant.
to a total of 500 MW.
help finance its construction.
Electrica Puntilla has six operating run-of-river hydro plants
Chilean utility Compania General de Electricidad S.A. originally
Reprinted with permission from

Hydroworld.com.
55-MW San Pedro III Solar PV Power Plant On Track

The San Pedro III solar photovoltaic plant, locat-
generate approximately 150GWh a year once con-
ed near Calama in Chile, has successfully reached
nected to the grid.
financial close. Mott MacDonald was the lenders
The initial phase of the plant, totaling 33-MW,
technical advisor during the projects financing and
is currently under construction and scheduled
is now monitoring construction of the plant. San
to be connected to the grid during the first quar-
Pedro III is part of an ambitious program to deliver
ter of 2015. The second phase comprising the
150 MW of photovoltaic capacity to the region. The
remaining 22 MW should be completed later in
55-MW facility will be delivered in two phases and
the year.
16
1503rew_16 16
MARCH/APRIL 2015
3/13/15 1:34 PM
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visit in Munich, Germany!

1503rew_17 17
3/13/15 1:34 PM
COV E R S TO RY
Getting To Grips with
Grinding
Gearboxes
CHRIS GIUFFRE, Contributor
Despite the recent evolution of direct drive systems,

the gearbox remains an integral part of the vast
majority of operational wind turbines worldwide. It is
the central component of the drive system and a critical interface between blades and generator. Unsurprisingly, it is also one of the most expensive single
components of the system as a whole, constituting
13 percent of the overall value of the typical onshore
wind turbine.
Tere are many reasons why

the gearbox on a wind turbine
might experience a failure. Here are
some operations and maintenance
considerations to lessen the likelihood
that it happens on your wind farm.
Its clear that, should such a valuable piece of equipment fail, the fnancial and operational impact on a
wind farm owner is likely to be extensive. This potential impact has been exacerbated over the past decade
by the growth of wind turbines and their components in size and capacity.
18
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MARCH/APRIL 2015
3/13/15 1:34 PM
Wind turbines on a hill

with morning light.
Credit: Shutterstock.
1503rew_19 19
MARCH/APRIL 2015
19
3/13/15 1:34 PM
cov e r s to ry
However, as the feet in

more established wind power
markets such as Australia, Europe and the United
States continues to age, the
projected 20-year lifecycle
of a wind turbine has often
mistakenly been applied to
internal components in postwarranty operational expenditure budgets. Despite great
strides in gearbox reliability brought about through
increased design standardization and the development
of condition monitoring systems (CMS) such advances have not always been
consistently adopted industry-wide for fnancial reasons.

Concurrently, gearbox manufacturers have been forced to
adapt to a diffcult fnancial climate. Of the eight major gearbox
manufacturers in the global wind energy supply chain, several have taken measures to optimize the manufacturing process
from the ground up from forging to fnal inspection. Those
that have failed to adjust have faced a sharp drop in sales or
even insolvency.
Moreover, the ability of these privately-owned frms to safeguard themselves against the impact of contractual liability for
defective design is not always clear, posing a signifcant issue for
operators post-warranty. Should serial production of a critical
component cease, routine repairs and replacements can become
a more complex and expensive undertaking.
These market trends and fnancial pressures, in conjunction
with the unique mechanical loads and stresses placed on gearboxes on a day-to-day basis, have directly and indirectly affected the
both the likelihood and the fnancial impact of gearbox failure.

1503rew_20 20
3/13/15 1:34 PM
cov e r s to ry
Offshore wind farm.

Credit: Shutterstock.
GCubes claims data reveals that gearbox-related failures are

the second most frequently reported form of component damage in the North American wind energy market, following blade
damage. Of the estimated 175,000 geared turbines in operation
in 86 countries worldwide, there are around 1,200 incidents of
gearbox failure reported annually a rate of one incident per
145 turbines per year.
The overall claims cost of an individual incident, when both
component damage and associated business interruption are
taken into account, commonly reaches $300,000 and has in some
unique cases exceeded $500,000. In cases of serial defect, these
fgures can rapidly be multiplied across entire wind farms and
portfolios.
In the post-warranty landscape in the U.S. and Europe, and,
indeed, as wind energy seeks expansion into emerging markets around the globe such as Chile and South Africa, there is
a clear industry imperative to keep a lid on these unscheduled
maintenance costs and reduce downtime as much as possible.
It is therefore critical that

asset managers take proactive, preventative steps to
ensure that this fnancial and
operational risk is managed
appropriately.
Root Causes of Gearbox Failure

The sheer number of recognized root causes of failure
serves to illustrate the complexity of modern gearboxes, comparative to other turbine components. A recent
report by GCube lists 16
root causes for gearbox failure. Amongst the most signifcant are issues relating
1503rew_21 21
MARCH/APRIL 2015
21
3/13/15 1:34 PM
cov e r s to ry
Damaged gears in a wind turbine gearbox. Credit: Renewable

Energy Loss Adjusters (RELA).
A broken gearbox is a big problem for a

wind farm operator. Credit: Renewable
Energy Loss Adjusters (RELA).
to the bearings, which are responsible for more than half of

gearbox failures. Breakdown and cracking of the bearings
over time particularly when black oxide coatings are not
used or the system is not adequately lubricated can cause
scuffng and generate debris that causes wider damage to
the gearbox mechanism. Likewise bearings using a 3-point
suspension layout commonly demonstrate an above-average
failure rate.
Abnormal loads are also a common cause of gearbox failure
and loss. Blade behavior has a direct impact on the loads experienced by the gearbox, and rapid acceleration and deceleration
can exact a huge amount of stress on the driveshaft, while inappropriate load sharing between bearings can also lead to high
stress and strains causing cracks.
These factors, combined with manufacturing defect and
human error during the operational phase, rank among the most
frequent causes of gearbox-related downtime worldwide.
O&M Considerations Extend Beyond Failures

When it comes to assessing the variables affecting the length
of downtime, the impact on the balance sheet and the total cost
of insurance claims, the root cause is only one part of a bigger
22
1503rew_22 22
MARCH/APRIL 2015
picture. The fnancial impact

of any technical failure is ultimately determined by a number of interlinked factors,
including:
Nature of damage The
extent and scale of the failure, including the number of
gearboxes damaged on site
and any consequential damage to other equipment in
the nacelle and on site. Costs
are also directly infuenced
by factors including whether affected components can
be repaired, rather than
fully replaced, whether damaged equipment has a salvage
value and whether the root
cause of damage is sudden
and unforeseen and is therefore covered by insurance or
3/13/15 1:34 PM
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1503rew_23 23
3/13/15 1:34 PM
cov e r s to ry
Wind turbine gearbox. Credit: Shutterstock.
Wind turbine gearbox. Credit: Shutterstock.
can be attributed to gradual wear and tear.

Location Claims costs can be elevated not only as a
result of inappropriate siting decisions, but also as a consequence of the territory in which they are located. The migration of the wind energy industry into more remote geographies worldwide has, in many cases, affected access to
manufacturing and repair facilities, O&M equipment and
skilled labor. Local permitting regulations and the generosity
of fnancial incentives in a particular country have also been
known to affect the total cost of claims.
24
1503rew_24 24
MARCH/APRIL 2015
Equipment specifcations Naturally, the size,

cost and availability of a
gearbox on the market has
a direct infuence on the
overall cost, should a partial or full replacement be
required. The ability to conduct uptower repairs and
the interchangeability of the
gearbox with other models can bring down the cost
should a loss be incurred.
Risk management
Any insurer paying gearbox-related claims will be
on the lookout for evidence
that proactive, preventative
risk mitigation options have
been pursued. This sort
of activity will commonly
include regular scheduled
inspections, swift action on
behalf of the O&M team to
identify and rectify gearbox performance issues
using CMS before they manifest as a loss, and building
in additional lightning protection based on site experience. The responsiveness
of suppliers can be boosted via framework agreements including pre-agreed
replacement times.
Other A number of further variables may come
into play in the event of a
failure, including the timing of the incident relative
to peak and off peak seasons and scheduled crane
3/13/15 1:34 PM
For more information,

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www.renewableenergyworld-events.com
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1503rew_25 25
Presented by:
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3/13/15 1:34 PM
cov e r s to ry
Gearbox Lubrication Challenges

Increase with Advanced Designs
The main challenge for wind
signifcantly more compact
turbine gearbox lubricants
gearboxes. The market is
is their ability to cope
now anticipating new design
with changing gearbox
developments that will
designs, which are focused
increase the power output of
on increasing gear ratios
wind turbines gearboxes by
and output performance
30 percent in the short-term
without adding weight to
future (from single to double-
the gear confguration. The
digit megawatt) another
drive to minimize uptower
change that lubricants need to
weight has resulted in more
respond and adapt to.
compact gearbox designs
In addition, new market
with case hardening of
growth for wind farms
the gear surfaces. Case-
in more remote locations
hardened gears are
such as desserts or high
susceptible to micropitting
plateaus of Asia Pacifc, with
and require a gear lubricant
temperatures ranging from
that protects against this
-50 C in China up to +45 C
form of wear.
in India, requires lubricants
In the 1990s, a change in
that offer a wide operating
wind turbine gearbox design
temperature range and strong
that increased power output
corrosion protection. The
from kilowatt to megawatts
use of fne flters to protect
surprised and disrupted many
gearbox components from
lubricant manufacturers. It
wear also means that the gear
has taken its toll on wind
oil must retain an acceptable
farm O&M professionals
level of foam performance
who had to cope with
even after repeated cycling
unscheduled downtime and
through such flters.
critical component wear due
Thorsten Sueling,
to increased load pressure on
ExxonMobil Fuels & Lubricants
26
1503rew_26 26
MARCH/APRIL 2015
availability, the extent of

additional infrastructure
required on site in order
to conduct repairs and the
risk of currency fuctuation,
where repairs or replacement may involve soft currency conversion.
There are clearly a large
number of factors that infuence the overall impact of
a gearbox-related loss on
claims and the balance sheet.
From the operators perspective, therefore, the ability to
reduce the number of variables as much as possible is
crucial.
While some of these variables are arguably outside an operators control
and it is unrealistic to
suggest that gearbox failure
is ever likely to be entirely eradicated taking ownership of those factors that
can be controlled by pursuing self-mitigation strategies
is entirely possible and can
have a substantial positive
impact in the long-term.
In particular, while a turbine supplier may set an
inspection date every few
years, more frequent inspections earlier in the lifespan
of the gearbox help technicians to design measures that
will extend the longevity and
increase the performance and
reliability of the equipment.
Preventative maintenance
3/13/15 1:34 PM
cov e r s to ry
can be carried out every six months, including checks to the oil
and the oil flter, observation of leaks and identifcation of unusual noises from the gearbox. Internal visual inspection using
endoscope or fberscope often aids this investigation. Technicians should be on the lookout for oil contamination within one
month of initial operation, which grinds particles from surfaces
in gliding contact that can cause immediate damage.
The frequency of this kind of inspection work can be reduced
by the use of CMS, combining vibration, acoustics and oil analysis with thermography, component performance assessment and
visual inspection. Condition monitoring provides an early warning of any abnormality and can reduce overall downtime by more
than a month, affording operators the opportunity to conduct
planned, rather than unplanned repairs.
While gearbox incidents will continue to occur throughout
the global wind energy market, its critical that asset managers and their project teams continue to develop their awareness of the macro trends affecting their peer group. For site
owners and operators,

developing an awareness of
the root causes of gearbox
failure and exploring all of
the available self-mitigation
strategies is the only way to
bring down the frequency of
incidents and the total associated unscheduled maintenance costs. In doing so,
they can also keep insurers
on board and contribute to
the elevation of O&M standards across the industry.
Chris Giuffre is a Business
Development Executive with
GCube Insurance.
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1503rew_27 27
3/13/15 1:34 PM
SOLAR
Bonded PV Arrays
Could Provide Safer
Solar Power
Traditional equipment grounding methods could be replaced by
bonding hardware for large-scale PV arrays as evidenced by the
results of a feld test conducted by TUV on the newly constructed 6.4MW Manadaly Bay Convention Center array in Las Vegas, Nevada.
BILL BROOKS, Contibutor
Most electricians are referred to as indoor wiremen and

are experts at installing electrical equipment indoors, but
some lack experience working with exposed cables and outdoor equipment bonding. Traditional methods of bonding and
grounding include the extensive use of bare copper conductors
for equipment bonding. While copper is preferred for bonding
steel, it is not the best choice around exposed aluminum members. Aluminum and copper should not come into direct contact due to galvanic corrosion issues. Over time, copper has a
tendency to erode aluminum and can even cause structural
failure of thin aluminum extrusions when in direct contact.
Even though the National Electric Code (NEC) supports
the bonding of PV module frames to their metal support
structures (see sidebar: PV System Equipment Bonding and
Grounding Requirements, p. 30), this method has only recently become widely accepted by the PV industry and authorities having jurisdiction (AHJs). While this practice was common for PV system installations during the 1980s and 1990s,
extra focus on bonding aluminum PV module frames in the
mid-2000s caused many jurisdictions to question whether
this practice was appropriate. During the mid-2000s, methods that connected each PV module to an equipment grounding conductor became widely accepted. This was primarily due to installation information found in many PV modules
28
1503rew_28 28
MARCH/APRIL 2015
manufacturing literature for

products listed to UL 1703,
the safety standard for PV
modules.
Over the past few years,
a new safety standard has
been under development, UL
2703, entitled, Mounting
Systems, Mounting Devices,
Clamping/Retention Devices,
3/13/15 1:34 PM
Test site at the Mandalay Bay

Convention Center rooftop in Las
Vegas. Credit: Unirac.
and Ground Lugs for Use with Flat-Plate Photovoltaic Modules

and Panels. One of the main reasons for the development of this
standard was to have a method to evaluate bonding methods
that a mounting system may employ to address the requirements
of NEC 690.43.
Review of TUV Field Evaluation Report

In November 2014, TUV performed testing on bonding equipment in place at the Mandalay Bay Convention Center 6.4-MW
PV array in Las Vegas, Nevada. The equipment at the test site
was the Unirac RM Roof

Mount low-sloped roof mounting system. The feld evaluation report provided by TUV,
dated December 1, 2014, was
based on the procedure set
forth in the Bonding Path
Resistance test in Section 13
of UL 2703. This test requires
a 4-wire design that uses two
1503rew_29 29
MARCH/APRIL 2015
29
3/13/15 1:34 PM
solar
PV System Equipment Bonding and Grounding Requirements

Article 690 in 2014 version (and the 2011 version)
within the same raceway, cable, or otherwise run
of the National Electric Code (NEC) and states the
with the circuit conductors.
following:
Exception No. 1: As provided in 250.130(C), the
(A) Equipment Grounding Required.
equipment grounding conductor shall be permitted to
Exposed non-current-carrying metal parts
be run separately from the circuit conductors.
of PV module frames, electrical equipment,
Exception No. 2: For dc circuits, the equipment
and conductor enclosures shall be grounded
grounding conductor shall be permitted to be run
in accordance with 250.134 or 250.136(A),
separately from the circuit conductors.
regardless of voltage.
Informational Note No. 1: See 250.102 and 250.168
This section references two important sections
for equipment bonding jumper requirements.
in Article 250, Grounding and Bonding, sections
Informational Note No. 2: See 400.7 for use of
250.134 and 250.136(A), restated below:
cords for fxed equipment.
250.134 Equipment Fastened in Place or
250.136 Equipment Considered Grounded.
Connected by Permanent Wiring Methods
Under the conditions specifed in 250.136(A) and
(Fixed). Unless grounded by connection to the
(B), the normally non-current-carrying metal
grounded circuit conductor as permitted by
parts of the equipment shall be considered
250.32, 250.140, and 250.142, non-current carrying
grounded.
metal parts of equipment, raceways, and other
(A) Equipment Secured to Grounded Metal
enclosures, if grounded, shall be connected to an
Supports. Electrical equipment secured to
equipment grounding conductor by one of the
and in electrical contact with a metal rack or
methods specifed in 250.134(A) or (B).
structure provided for its support and connected
(A) Equipment Grounding Conductor
to an equipment grounding conductor by one of
Types. By connecting to any of the equipment
the means indicated in 250.134. The structural
grounding conductors permitted by 250.118.
metal frame of a building shall not be used as the
(B) With Circuit Conductors. By connecting
required equipment grounding conductor for ac
to an equipment grounding conductor contained
equipment.
conductors to inject current into the test sample and another two
conductors to measure the resultant voltage drop from the current injection point to the current receiving point. The worst case
scenario was chosen for the bonding path test by injecting current at one corner of a 150 x 150-foot PV array and receiving the
current at the opposite corner of the same array approximately
210 feet away. A simple diagram of the test setup, provided in the
TUV report, is shown in Figure 1a (p. 34).
This bonding test shown in Figure 1 was duplicated with
30
1503rew_30 30
MARCH/APRIL 2015
another test using a 6 AWG

solid copper equipment
grounding conductor. Since
the copper conductor would
typically be run around the
perimeter of the array, rather than through the array,
the length of copper used
was 315 feet to be consistent
3/13/15 1:34 PM
RM
ROOF
MOUNT
BALLASTED FLAT ROOF RACKING SYSTEM
INTEGRATED BONDING THAT MAKES A DIFFERENCE

3 R D
P A R T Y
12
ROOF
M E T R I C S
M O D U L E S
MOUNT
INTRODUCES
V E R I F I E D
B Y
D N V
G L
PER HR
MAN
THE
POWER
OF
SIMPLICITY
TO
THE
BALLASTED FLAT ROOF SOLAR INDUSTRY. THE SYSTEM CONSISTS OF
ONLY TWO MAJOR COMPONENTS
MINIMIZING PREPARATION WORK AND INSTALLATION TIME. SEAMLESSLY

DESIGN AROUND ROOF OBSTACLES, SUPPORT MOST FRAMED MODULES
AND
BOND
THE
SYSTEM
LEARN MORE
WITH
JUST
THE
TURN
OF
WRENCH.
UNIRAC.COM

1503rew_31 31
3/13/15 1:34 PM
solar
Test site at the Mandalay Bay

Convention Center rooftop in
Las Vegas. Credit: Unirac.
with conventional installation methods. The test setup

with the solid copper wire is
shown in Figure 2 (p. 35).
During the test, an 11-amp
current and a 33-amp current were injected into the
grounding circuit for each set
of conditions. These two currents were chosen to coincide
with the requirements of UL
2703 and to go well beyond
those requirements, by a factor of 3. These currents simulate not just a single ground
fault in one string, but simultaneous ground faults in 3
strings, which is much more
than the standard requires.
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1503rew_32 32
MARCH/APRIL 2015
Closeup of the bonded array at the test site in Las Vegas. Credit: Unirac.
It is interesting to note that the change in current had no impact

on the ground path resistance of either the bonded array or the 6
AWG copper conductor.
3/13/15 1:34 PM
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1503rew_33 33
3/13/15 1:34 PM
solar
The key result from these tests was that the bonding path
resistance for the bonded array was 0.0034 (3.4 milliohms)
versus 0.1245 (125 milliohms) for the 6 AWG copper conductor. The typical published resistance values for 6 AWG copper
is approximately 400 m per 1000 feet so a 315-foot conductor should have resistance of approximately 126 m, exactly
what was measured. Clearly, the bonded array performed superior to the solid copper conductor, by a factor of 36. This means
that a bonded RM PV array has 2.7 percent of the resistance
of a solid copper 6 AWG conductor and will therefore carry 36
times as much current in a fault condition. Since fault currents
are typically quite low in a PV array, and sometimes go undetected depending on the accuracy of a ground-fault detector, the
RM bonding method is more likely to detect faults, resulting in a
safer installation.
In addition to the worst-case test using a 150 x 150-foot array,
testing was performed on a smaller 75 x 150-foot array as seen
in Figure 1b. This testing was done to determine if there was
any appreciable change in the results from the bonding path
resistance test. In this case, the solid 6 AWG copper conductor
was only 150 feet long for this test given the small array section.
Given the shorter bonding path for both the array section and
the solid copper, the bonding path resistance was 2.2 m for
Approx. 150 ft.
the array section and 57 m

for the solid copper. These
results are expected given
the shorter paths of both systems. The array section path
distance was reduced from
roughly 210 feet with the
150 x 150-foot array down to
about 167 feet. This shorter
distance was roughly 80 percent of the 210-foot distance
and the ground path resistance reduced to 65 percent of
the original path resistance.
The reason for large
improvement in ground path
resistance with the bonded
array is because the resistance of a single path is simply the series resistance of
the conductor normally a
copper conductor like solid
6 AWG. A bonded metal
Approx. 75 ft.
6 AWG wire
12 AWG wire
6 AWG wire
12
AWG
DMM:
Voltage drop
across array
DMM:
Voltage drop
to verify
supply current
12 AWG
wire
Current shunt
6 AWG
wire
6 AWG wire
34
1503rew_34 34
MARCH/APRIL 2015
DMM:
Voltage drop
across array
Current shunt
6 AWG wire
Power supply:
Set to desired injection current
Power supply:
Set to desired injection current
Figure 1a: Test setup 150x150-foot array. Credit: Unirac.
12
AWG
DMM:
Voltage drop
to verify
supply current
Figure 1b: Test setup 75x150-foot array. Credit: Unirac.
3/13/15 1:34 PM
solar
12 AWG wire
6 AWG wire
12
AWG
DMM:
Voltage drop
across array
DMM:
Voltage drop
to verify
supply current
Current shunt
Power supply:
Set to desired
injection current
Approx. 315 ft.
12
AWG
12 AWG
wire
6 AWG wire
6 AWG
wire
DMM:
Voltage drop
across array
DMM:
Voltage drop
to verify
supply current
Current shunt
6 AWG wire
Power supply:
Set to desired
injection current
Approx. 150 ft.
Figure 2: Test setup for 315-foot and 150-foot solid 6 AWG copper wire. Credit: Unirac.
structure has literally thousands of current paths from one point

to another point. Each of these different paths is in parallel, rather than series, with one another. Parallel resistors add according
to the reciprocal of their resistance so the resistance always goes
down with parallel resistance paths. With thousands of parallel
paths, the resistance drops signifcantly.
Finally, with thousands of paths, comes the beneft of redundancy. With a bonded metal array, dozens of connections can be
broken and there will be almost no change in ground path resistance. The many other paths simply take slightly more current.
With a single equipment grounding conductor, a single connection can be broken and everything that the wire was connected to
can become ungrounded. When a conductor is run 315 feet, rather than 3 feet from the bonded array to a ground bus in a combiner box, the probability that a failure occurs in that 315 feet is
much more likely than a failure in the shorter 3-foot section.
In Conculusion
In summary, bonding systems, tested to UL 2703, represent a
large improvement in the performance and ease of meeting the
equipment grounding requirements of the NEC. AHJs need to
understand the benefts of these types of bonding and grounding confgurations since these tests show that they are superior
to conventional methods often used in the feld today. The benefts of a bonded PV array are not only in ground-fault detection, but also in lower touch voltages, and better redundancy. In
addition to better compliance with the intent and language of
the NEC, bonding methods are much easier for the installer to
install properly.
One of the major feld problems with PV systems today
is that archaic bonding and
grounding methods are often
diffcult to perform properly
in the feld. This means that
mistakes and bad connections are extremely common.
PV array mounting methods
that use products specifcally designed to create electrical bonds at each connection
point will ensure long-lasting
safety for the exposed metal
parts of a PV array.
Given the likelihood that
exposed cables may become
damaged over the 20-30
year life of a PV system, having well-bonded and grounded PV array structures is key
to the long-term safety of PV
systems.
Bill Brooks is the founder
of Brooks Engineering in
California.
1503rew_35 35
MARCH/APRIL 2015
35
3/13/15 1:34 PM
dat
a
poi
nt s
EXAMINING
FAILURES
THREE TYPICAL FAILURE SCENARIOS FOR WAFER-BASED CRYSTALLINE PV MODULES

Light-induced degradation
0.5 5%
Glass AR degradation
Ethylene vinyl acetate discoloring

Delamination, cracked cell isolation
<3%
<10%
Power (%)
Pnominal
Contact failure
junction box/
string interconnect
Glass breakage
Loose frame
Potential induced degradation
Diode failure
Cell interconnect breakage
Corrosion of cell
and interconnect
Warranty
Time
Infant-failure
Midlife-failure
Wear-out-failure
CREDIT: IEA
FAILURE TYPES AT THE START OF THE WORKING LIFE
Unknown defect
The most important failures in
6%
Delamination 5%
the feld are j-box failure, glass
breakage, defective cell
20% Optical failure
Transport damage 5%
interconnect, loose frame, and
delamination. Other defects
Loose frame 6%
were not well defned. The rate
is given as a percentage of the
Defect cell interconnect 10%
19% Power loss
total number of failures over a
5-year period from 2006 to 2010
based on a volume of
Glass breakage 10%
approximately 2 million modules.
19% J-box and cables
CREDIT: IEA. Information is based on a study conducted

by DeGraaff, et. al. for NREL, http://www1.eere.energy.gov/solar/pdfs/pvmrw2011_01_plen_degraaf.pdf
which
wh
h can
ca be
e downloaded
dow oad d here.
h e.
36
1503rew_rev_36 36
MARCH/APRIL 2015
3/23/15 10:31 AM
A recent International Energy Association (IEA) report looked at the

performance and reliability of PV systems and specifically examined
module failures. This months Data Points is a review of their findings.
http://www.iea-pvps.org/index.php?id=275
Yo
ou can
can download
dow
wnload the 14
40 -pa
age
e re
eporrt at th
nk.
You
140-page
report
thiss lin
link.
Encapsulation and
backsheet
9%
Cells
10%
Laminate internal
electrical circuit
36%
J-box and cables
12%
FAILURE TYPES FOR MODULES

8 YEARS IN THE FIELD
It is predicted that 2 percent of PV
modules will not meet the
manufacturers warranty after 11-12
years of operation. This study shows a
high rate of defective interconnections
in the module and failures due to PV
module glass breakage.
Glass
33%
CREDIT: IEA. Information is based on a study conducted

by DeGraaff, et. al. for NREL, w
which can be
e downloaded
do
ow oad d here.
e..
http://www1.eere.energy.gov/solar/pdfs/pvmrw2011_01_plen_degraaf.pdf
TEST FAILURES FOR CRYSTALLINE PV (INNER RING)

AND THIN-FILM PV (OUTER RING) PROJECTS
1,740 crystalline PV projects and
370 thin-flm projects were
tested between 2006 and
10%
2013. A test is considered
a failure if one or more
7%
11%
PV modules will not
3%
pass the specifc test.
4%
One certifcation
9%
6%
project may
contribute to one or
8%
several test failures.
9%
9%
4%
Initial measurements
Thermal cycling test, 200 cycles
Damp heat test
Humidity freeze test
12%
Thermal cycling test, 50 cycles
11%
10%
Mechanical load test
18%
Mechanical load test (5400 Pa)

Cut susceptibility test
Bypass diode thermal test
17%
Reverse current overload test
22%
10%
Light induced degradation

All other tests (<3%)
9%
The distribution of failed tests
indicates parallels between crystalline and
thin-flm modules. Of these projects 49
percent of all crystalline tests and 43
percent of all thin-flm tests failed during
the four test series in the climate chamber
of the TV Rheinland test laboratory
Hot-spot endurance test
5%
6%
(shown in blue), which include 200 cycles

of thermal cycling test (TCT200), damp
heat test (DHT), humidity freeze test (HFT),
and 50 cycles of thermal cycling test
(TCT50). The climate chamber tests are a
good indication of module longevity, the

quality of the materials, and the
workmanship of the products. IEA noted
that failure rates for the most critical damp
heat test have declined in recent years.
CREDIT: IEA
1503rew_rev_37 37
MARCH/APRIL 2015
37
3/23/15 10:31 AM
G E OT H E R M A L
Geothermal Piping Systems

Get into the Groove
In the hot, rocky, volcanic terrain of
the Indonesia Ring of Fire, the piping
systems for geothermal power plants need
fexibility that welded joints just cant ofer.
ALFRED CHUA, Contributor
How do you design outdoor piping to account for changing elevation, uneven terrain, seismic and thermal movement, and the
reroutes required of a drilling fuid system? This was the challenge faced by engineers and contractors for Indonesias largest geothermal power plant, Wayang Windu. The pipe-joining
method would need to offer fexibility and superior maintainability, and project personnel sought a method that would
not be susceptible to inclement weather or pose undue safety
hazards. Welding and fanging

couldnt meet those parameters, but a solution was found
in grooved mechanical piping.
Harnessing Indonesias
Geothermal Potential
Located on the Ring of Fire
and home to more than
200 volcanoes, Indonesia is
Aerial view of the Wayang Windu

Geothermal Power Plant in
Indonesia. Credit: Victaulic.
38
1503rew_38 38
MARCH/APRIL 2015
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The piping system near the Wayang Windu Geothermal
Steam-fumeroles near the Wayang Windu Geothermal
Power Plant in Indonesia. Credit: Victaulic.
Power Plant in Indonesia. Credit: Victaulic.
estimated to have about 28

GW of geothermal potential
for power generation, which
is about 40 percent of the
geothermal potential for the
entire world. 41 volcanoes are
found on the island of Java
alone, providing abundant
geothermal resources and
holding the highest potential
for energy production. Fittingly, this refects the locales
demand for energy. Home to
135 million inhabitants
about 60 percent of Indonesias population Java is one
of the most densely populated
areas in the world. To meet
energy demand, geothermal
plants have been expanding
to increase output.
The Wayang Windu Geothermal Power Plant sits in
the heart of this activity in
Pangalengan, West Java. A
Star Energy plant, Wayang
Windu is a fash steam power
plant listed as one of the largest in the world. Currently a twounit site with exploration for unit 3 underway, Wayang Windu
has a total installed capacity of 227 MW. The frst unit was completed in 1999 and has been producing at full capacity of 110 MW
since 2000. The second unit, with capacity of 117 MW, was been
online since 2009.
While the need for geothermal energy is clear, construction or
expansion of plants, wells and the piping systems that connect
them often presents several challenges that must be considered
in the design phase.
Piping System Design Challenges

Located in a highly active seismic zone, Wayang Windu experiences shifts in the ground, both subtle and extreme, on a
daily basis. The power plants buildings and infrastructure are
designed to absorb this movement, but other necessary components long stretches of outdoor piping, for example dont
afford the same fexibility. In addition to seismic movement, outdoor piping systems are subject to thermal expansion and contraction that must also be accommodated.
The Wayang Windu site sits at an altitude ranging from 1,700
to 2,200 meters above sea level, with piping systems spanning a
signifcant portion of that elevation change. Joint or pipe fexibility would be ideal to enable the systems to easily follow the contours of the uneven terrain.
At Wayang Windu, the drilling fuid piping system traverses the feld to enable the circulation of lubricating fuids
1503rew_39 39
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3/13/15 1:35 PM
g e ot h e r m a l
primarily condensate for drilling and repair work. As

exploration continues, personnel would need to be able to dismantle and reassemble the piping system to account for rerouting and expansion.
All told, the requirements for the drilling fuid system were
fexibility to withstand seismic and thermal movement and
accommodate changing grades, and maintainability to ease system reroutes and extensions. As an outdoor piping system, it also
had to withstand the elements. Galvanized pipe was specifed to
resist corrosion and wear.
Engineers quickly realized that welding, often considered the
default pipe-joining method, would pose problems. Welding produces rigid joints that would not provide the fexibility to accommodate thermal and seismic movement. When such movement
is not properly accounted for, stress at the joints can result, in
some cases leading to leaks. The uneven terrain could also have
caused misalignment issues during assembly, necessitating quite
a bit of rework and slowing the construction schedule.
Welding galvanized pipe

vaporizes the protective zinc
coating near the welds, which
would require additional time
to repair in the feld. Safety
issues with welding were also
a concern. Welding galvanized steel exposes the worker to fumes that can lead to
metal fume fever, and the
sparks produced could pose a
fre hazard to the dense jungle surrounds during the dry
season. Adverse weather conditions during the wet season could also affect welding
activities, requiring additional
protective measures.
Workers at
the Wayang
Windu
Geothermal
Power Plant
in Indonesia.
Credit:
Victaulic.
40
1503rew_40 40
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1503rew_41 41
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g e ot h e r m a l
Finally, the permanent joints produced by welding would not

permit the pipeline to be easily relocated or expanded, a requirement that could not be compromised.
Flanging provides a more maintainable joint that permits the
dismantling and reassembly of piping, but the method is subject
to some of the same limitations as welding in terms of fexibility. Flanges, like welded joints, are rigid, so the joining method
requires additional devices or expansion loops to accommodate
piping defection caused by movement. Routing piping systems
joined with fanges over uneven terrain is just as challenging as
it is with welding.
Grooved Piping Ofers Flexibility, Maintainability

To alleviate these problems, grooved mechanical piping was
specifed for the drilling fuid system. The engineer and contractor discovered that the design, installation and maintenance benefts of fexible grooved mechanical couplings stood in direct contrast to the issues associated with welding and fanging. Flexible
couplings enable quick, easy assembly and disassembly without
heat or fame, and permit controlled linear and angular movement at the joint.
A grooved mechanical pipe joint consists of four elements:
grooved-end pipe, a gasket, coupling housing, and nuts and bolts.
(See image, p. 44.) The pipe groove is made by cold forming or
machining a groove into the end of a pipe. A gasket is centered
around the joint of two abutted grooved pipe-ends, and the coupling housing segments are placed over the gasket so that the key
sections of the housing engage the grooves. The bolts and nuts
are then tightened with a socket wrench or impact wrench. In
the installed state, the coupling housing encases the gasket and
engages the grooves around the circumference of the pipe to create a leak-tight seal in a self-restrained pipe joint. The completed
joint is visually inspected; metal-to-metal bolt-pad contact confrms proper assembly.
Standard grooved couplings can be installed up to fve times
faster than welded joints and three times faster than fanged
joints. Ready-to-install couplings, a recently developed technology that allows the coupling to be pushed onto the pipe-end as a
fully assembled unit, can double the time savings.
Grooved couplings do not require heat or fame to assemble, nor does installation produce fumes, reducing risk to personnel and property. They can also be installed in any weather
42
1503rew_42 42
MARCH/APRIL 2015
condition without tents or

heating equipment.
Grooved couplings create
a union at every joint so that
when maintenance or system alteration is required, the
couplings can be removed by
loosening the nuts and bolts
and removing the housing
and gasket from the joint. The
removal of two adjacent couplings permits the removal
of a section of pipe. Groovedend pipe and couplings can
be reused, with assembly following the same procedure as
initial installation.
Flexible grooved couplings
permit a limited amount of
linear and angular movement. The interaction of the
components permits this
movement: the dimensions
of the coupling key are narrower than the groove in the
pipe, allowing room for the
key to move within the pipe
groove, while the width of
the coupling housing allows
for pipe-end separation,
leaving room for controlled
expansion, contraction and
defection.
Independent testing conducted at the ATLSS center,
a member of the NEES (Network for Earthquake Engineering Simulations) testing group, demonstrated the
reliability of grooved system
components when exposed
to seismic movement.
3/13/15 1:35 PM
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1503rew_43 43
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g e ot h e r m a l
Water-flled assemblies joined with

grooved couplings were pressurized to
200 psi and exposed to accelerations up
to 50 percent greater than the Northridge, California, earthquake. No pressure loss or leakage was observed during
the tests.
Housing
Gasket
Groove
Te Outcome
Bolt/nut
Victaulic Style 77 fexible couplingsand
grooved-end fttings were used to join the
drilling fuid system at Wayang Windu,
Groove
meeting the requirements for fexibility
and maintainability and offering additionAnatomy of a grooved coupling. Credit: Victaulic.
al benefts on site.
Style 77 couplings feature a two-piece
housing, two nuts and bolts, and can withstand pressures of
Summary
up to 1,000 psi. The couplings provided the inherent fexibility
Seismic and thermal moveneeded to accommodate seismic and thermal movement and
ment, changing elevation,
deployment of the drilling fuid system over the uneven terrain
uneven terrain, and the need
at Wayang Windu.
to disassemble and relocate
The ease and speed of installation of grooved components
the piping system contributcontributed to rapid completion of the project and eliminated to a complex construction
ed construction delays due to rain. Welding machinery did
scenario. Grooved mechanical
not need to be transported along the length of the pipeline
piping was the answer to the
as it was assembled, and the galvanized fnish on the piping
installation challenges, providwas maintained throughout the installation process, ensuring the requisite fexibility and
ing corrosion resistance and protection throughout the sysmaintainability. Like geothertem. The lack of hot works also eliminated safety issues and
mal energy itself, grooved pipfre hazards.
ing systems are reliable, effThe drilling fuid system has been in operation for 15 years
cient and sustainable. The use
with the original pipe and couplings still in use. Victaulic couof grooved piping is increasing
plings were also used to join the 9-kilometer condensate piping
on utility and process piping
system and the 8-kilometer brine system for unit 2, which have
systems in the power industry,
been in operation since 2009.
and Wayang Windu demonThe drilling fuid system was recently rerouted as part of the
strates the value such systems
unit 3 exploration process, validating the maintainability of
can bring to plant construction
grooved piping systems. Sections of pipe were dismantled and
and expansion.
repositioned, helping to achieve production targets. New sections
of pipe were grooved off-site, and shipments were coordinated
Alfred Chua is the Power, Oil &
to further improve jobsite effciency, limit downtime and reduce
Gas Manager for Victaulic in
overall costs.
Southeast Asia.
44
1503rew_44 44
MARCH/APRIL 2015
3/13/15 1:35 PM
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1503rew_45 45
3/13/15 1:35 PM
the
he
project
Profling Stand-out
Renewable Energy
Projects Worldwide
Biomass Electricity at Thunder Bay

Generating Station
Ontario Power Generations (OPG) 150-MW
Thunder Bay Generating Station (TBGS) went
online in February 2015. The station has been
converted to use advanced biomass. Bringing the plant into service is the beginning of
advanced biomass-fuelled electricity in Ontario and North America. OPG is also supporting
biomass research through its sponsorship of
the OPG Bioenergy Learning Research Centre at
Confederation College in Thunder Bay.
Like OPGs Atikokan Generating Station,
which was a fnalist for Renewable Energy
Worlds 2014 project of the year, TBGS has the
fexibility to respond to changes in electricity
demand and provide dispatchable power when
it is most required.
Advanced biomass has handling and storage characteristics similar to coal and emissions from it contain about 75 percentless
nitrogen oxide and virtually no sulphur dioxide.
The advanced biomass pellets used at TBGS are
made from lumber mill sawdust.
Because plants grow and are harvested in
a continuous cycle, sustainably harvested biomass is recognized around the world as a
renewable source of energy that has climate
change benefts over fossil fuels.
2.
1.
46
1503rew_46 46
MARCH/APRIL 2015
3/13/15 1:35 PM
1. The Thunder Bay Generating Station was Ontarios last

remaining coal-fired facility. Phasing out coal-fired electricity
generation is the equivalent to taking up to 7 million cars off the
road.
2. In 2003, coal made up 25 percent of Ontarios electricity
generation. Now its 0 percent. Ontario is the first jurisdiction
in North America to eliminate coal-fired electricity. Thunder Bay
Generating Station was the most recent station converted to the
use of advanced biomass.
3.
3. The plant is expected to generate 150 million kilowatt-hours

of renewable power, enough to power 15,000 homes each year.
4. Using wood-fiber sourced from sustainably managed forests,
the plant generates renewable, dispatchable, peak capacity
power that reduces greenhouse gas emissions by approximately
90 percent as compared to coal.
5. The movement away from coal, like that which took place at
the Atikokan Generating Station in September, has resulted in
eliminating up to 30 megatons of emissions annually.
6. A truck unloads advanced pellets at Thunder Bay. Advanced
biomass is low in moisture content, water repellent, and
condensed, greatly improving its storage and handling properties.
All images provided by Ontario Ministry of Economic Development,
Employment and Infrastructure.
4.
6.
5.
1503rew_47 47
MARCH/APRIL 2015
47
3/13/15 1:35 PM
H Y D RO P OW E R A N D E N E RG Y S TO R AG E
A Solution to Intermittent
Renewables Using
Pumped Hydropower
Pumped storage hydropower plants could ultimately provide
one of the most cost-efective means of frequency regulation
for the EU grid of the future.
NATHALIE LEFEBVRE, MARIE TABARIN, AND OLIVIER TELLER, Contributors
Integrating large quantities of renewable generation with lowcarbon technology will require the development of large fexible carbon-free generation and storage assets. Over the last 40
years, numerous large capacity pumped-storage hydropower
plants (PSPs) have been built worldwide, many of which could
be retroftted to provide grid-balancing services that the grid of
the future will need.
Almost all PSPs are equipped with fxed rotating speed units.
This technology imposes a fxed power capacity per unit in
pumping mode: the pump is either stopped or operating at full
capacity. The result of this is that other types of fexible generation plants must be kept online when the pumps are in operation. In a country like Austria where hydro generation represents a large fraction of the energy mix, keeping some PSP units
in generation mode and some units in pumping mode provides
a portion of the frequency regulation needed. However, operating this way has a negative impact on the cycle effciency, literally resulting in the intermittent generation heating up the water
in the upper reservoir. The fxed operating speed also limits the
ability of the hydraulic unit, when operating in turbine mode, to
keep a high effciency over a large head and fow range.
New variable speed technology for PSPs was recently introduced in Europe. A key beneft of this new technology is that
is gives PSPs the ability to regulate power both in pumping
and generation modes instead of just in generation mode, like
conventional units. Because this new technology allows for
additional fexibility for PSPs, once equipped with them, these
48
1503rew_48 48
MARCH/APRIL 2015
PSPs are now among the best

solutions to provide necessary
ancillary services for the grid.
While there are a few variable speed PSPs already commissioned or under construction in Europe (the 1000-MW
Linthal plant; the 942-MW
Nant de Drance and the 800MW Venda Nova plant), the
industry has no experience
upgrading a conventional
plant into variable speed.
Upgrades are much more
complex than developing new
3/13/15 1:41 PM
Overflow basin of Le Chelyas Pumped Storage

Hydropower plant. Credit: Alstom.
plants because they require accommodating the existing embedded parts of a pump turbine and civil work. Variable speed motor
generator volume is generally larger than conventional and necessitates the installation of large power electronic equipment close to
the units in what would usually be very constrained cavern areas.
Te eStorage Project
In 2013 a consortium of energy stakeholders from across the EU
joined together to create the eStorage project. The consortium
consists of Elia, EDF, the Imperial College, Kema, and Alstom.
The aim of the eStorage project is to develop cost-effective
solutions for the widespread deployment of GWh-scale variable
speed pumped hydro storage plants (PSP) across the EU and to
enhance grid management systems in order to advance the costeffective integration of large amounts of renewable generation.
The consortium set out to do

the following:
Demonstrate the technical and economic feasibility of upgrading the existing
Le Cheylas PSP to variable
speed technology, enabling
a new regulation capacity in pumping mode, and
increasing its overall effciency in both the turbine
and pumping modes.
Enhance and validate the
functionality of IT systems to demonstrate new
1503rew_49 49
MARCH/APRIL 2015
49
3/13/15 1:41 PM
h y d r o p ow e r a n d e n e r g y S to r ag e
balancing capabilities with energy storage by looking at closer

to real-time market systems.
Quantify the benefts of an EU-wide rollout of variable speed
PSP under alternative future development scenarios.
Propose changes to the market and regulatory frameworks
in order to create a viable business model for energy storage and enable a wide deployment of fexible storage technologies in the EU.
Develop and examine technology solutions that would allow
for the upgrade of 75 percent of European PSP (totally 30 GW
of capacity) to variable speed to obtain additional capacity for
fexible balancing in pumping mode.
This article is a discussion of the frst goal of the eStorage project, the conversion of le Cheylas PSP to variable speed.
Te Demonstration Site: Le Cheylas PSP

The PSP Le Cheylas is located in the French Alps and has been
operated by EDF since commissioning in 1979. The facilities generate electricity using the river Arc infow conveyed from Longefan to Le Flumet reservoir by a 20 km long tunnel, with an annual average generation of 550 GWh and store it on a daily cycle, by
pumping at night from le Cheylas reservoir into le Flumet.
There is only one powerhouse, which is equipped with two
identical 270 MVA reversible units, each located in a shaft. A
water conveyance system common to the 2 units connects the
powerhouse to the 2 reservoirs. The eStorage project consists
of converting unit 2 to variable speed.
Hydraulic Design
In order to take advantage of
power regulation in pumping mode, the hydraulic
design would need to allow
increased water fow variation, which meant re-engineering the hydraulic design.
The key design target was
to allow a power variation in
pump mode of 80 MW under
the full head range (i.e. constant power variation close
to 30 percent of the units
nominal power, leading to a
quite extended speed variation of +/- 7 percent). Both the
pump and the turbine design
represented an ambitious
challenge, at the crossroad
between variable speed technology and refurbishment
(see table 1, below).
TABLE 1: ALSTOM VARIABLE SPEED HYDRAULIC

DESIGNS FOR ONGOING PROJECTS
N Units
Head
(m)
Power
(MW)
Speed
(rpm)
New /
refurbishment
Country
Nant de
Drance
250-390
157
428.6
+/-7%
New
Switzerland
Linthal
560-724
250
500
+/-6%
New
Switzerland
Tehri
127.5-225
255
230.8
+/-7.5%
New
India
Le Cheylas
245-261
250
300
+/-7%
Refurbishment
France
Power-Plant
50
1503rew_50 50
MARCH/APRIL 2015
3/13/15 1:41 PM
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1503rew_51 51
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The pump design is the key part of a variable speed upgrade.

When compared to a typical pump-turbine refurbishment two
new hydraulic challenges constrain the design. The lower pump
power limit is set by an instability area where it is not possible to operate (called the humped zone) while the high power
limit is defned by cavitation

phenomena.
Since the entire generator
needed to be changed in this
case, engineers could select
whatever rotation speed they
desired. The choice of the
new reference speed from
a hydraulic point of view is
therefore a balance between
cavitation and hump criteria.
For design optimization, the
decision was made to keep
the existing reference speed
as the appropriate solution to
maximize the pump power
variation.
For obvious economic and logistical reasons it
was decided to modify only
non-embedded parts: the
runner and the wicket gates.
These components have higher water velocities and they
bring the best effciency / cost
trade-off. The existing draft
tube, stay ring and spiral casing were left unchanged.
An additional constraint
was that the turbine must still
match the existing transients
performances. This was even
more challenging since Unit 1
would not be upgraded.
Electrical Design
Pit turbine 1 of Le Cheylas pumped storage hydropower plant.

Credit: Alstom.
52
1503rew_52 52
MARCH/APRIL 2015
Installing a new double fed

induction motor-generator
(DFIM) inside an existing pit
requires special attention to
existing limitations such as
structural design, auxiliary
3/13/15 1:41 PM
interfaces as well
as the capacity of
the crane to handle
the increased rotor
dimensions and
weight. The integration of a new frequency converter
has a direct impact
on space requirements, the cooling system and the
power supply and is
therefore one of the
key elements to be
checked in the early
stage of the project.
The 47.8-m gate operating ring at Le Cheylas pumped storage hydropower plant.
The DFIM uses
Credit: Alstom.
the exchange
between the wound
rotor and the
frequency converter to provide the speed variation, per Figure
factor is lower than for a syn2 (p. 45.). As a consequence, the stator needs to be oversized in
chronous machine.
sub-synchronous mode, due to the additional power transiting
Beyond the generator
from the rotor to the stator, which could lead to power limitation
motor, the whole units elecdue to the given civil works.
trical equipment had to
Keeping the existing stator could have been considered if the
be reengineered: several
reactive power supply could have been reduced. The reactive
parts of equipment could be
power is partially provided by the frequency converter. Howreused while others had to
ever, in such a case, the stator winding needs to be compatible
be replaced. Of course new
with the rotor winding. Due to a requirement for a power factor
ones must ft in the powerdecrease from 0.91 to 0.85 in generating mode, the replacement
house premises. For example,
of the existing stator was compulsory.
synchronous rotor excitation
Another constraint on the DFIM design was to ft the stator
devices must be dismantled
and rotor within the motor-generator pit. The pit dimension is
while stator MV gears could
a factor limiting the DFIMs maximum output, especially as the
be reused.
rating of the stator is bigger than its synchronous counterpart for
Most of the new equipment
the same power at the main transformer.
that had to be installed in the
The DFIM wound rotor is also 23 percent heavier and has
powerhouse was for the DFIM
more volume than a salient pole synchronous rotor, which
rotor feeding. The equipment
impacts the shaft line behavior. Due to the cylindrical rotor and
includes: Heavy duty power
to the bigger volume, the weight is greater, as the utilization
tapping on the MV side of the
1503rew_53 53
MARCH/APRIL 2015
53
3/13/15 1:41 PM
units power transformer; Short circuit current limiting reactors;

a MV breaker; a special VSI transformer; harmonic flters; a VSI;
segregated phase bus ducts from the VSI to the rotor ring cubicle; a rotor over-current and over-voltage protection cubicle; and
non-conventional current transformers and voltage transformers
for rotor current and voltage measurement at very low frequency.
It has to be noted that the largest pieces of equipment required
for rotor excitation (VSI transformer and VSI) represent roughly
150 m of ground space, which might be diffcult to fnd in some
Bassin du Flumet
Sens Turbine
Centrale du Cheylas
Sens Pompe
Bassin du Cheylas
North
Images: Google Earth
Figure 1: Le Cheylas pumped storage plant (PSP) set-up. Credit: Alstom.

Pgrid
Pgrid
Pvsi
Pvsi
Ps
Ps
Air gap
IM
Converter +
transformer
PD
Air gap
IM
Converter +
transformer
PD
Pr
Pr
Pmech
Pmech
Subsynchronous
Oversynchronous
Figure 2: The rotor/converter exchange in the PSP. Credit: Alstom.

54
1503rew_54 54
MARCH/APRIL 2015
underground power stations.

Hence, large pieces of equipment such as the tapping
transformer or VSI module
would need to be placed outside of the power station.
On the stator side, more
traditional pieces of equipment need to be placed
including: isolated phase bus
ducts (part of which may be
reused from existing synchronous unit); starting/braking
short circuit breaker used for
the DFIM launching in motor
mode and for the re-generative braking sequence; and
depending on their condition,
age and rating a generator circuit breaker and phase
reversal disconnectors. Last
but not least, the unit power
transformer would need to be
replaced in order to accommodate a higher MVA rating.
This replacement provides an
opportunity to increase stator
voltage and optimize DFIM
design.
Some important features
of the synchronous unit
such as black start operation, isolated network feeding
or line charging capacity
must also be undertaken by
the variable speed unit. Black
start operation without tapping energy for rotor excitation is obtained thanks to a
low-power feeder that energizes the VSI enough to create
voltage on the stator side and
3/13/15 1:41 PM
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1503rew_55 55
3/13/15 1:41 PM
from there build up stator voltage.

Mechanical design modifcations were also necessary especially where the machine shaft line
and bearing were impacted. The most critical feature for the shaft line was the natural bending frequency, which was overcome by the re-arrangement of the unit layout. The thrust bearing
needed to be redesigned with a higher capacity to
support the supplement of the unit axial load that
comes mainly from the DFIM rotor. In addition,
the new rotor overweight required changes to the
powerhouse lifting equipment.
Economic Analysis
In order to perform an economic analysis of the
upgrade the consortium modeled the operation of Le Cheylas PSP considering the possibility (or not) of offering primary and secondary control reserve using operational data from 2010 and
2012. Le Cheylas PSP, in its present confguration, is already able to provide fexibility in turbine mode, and the upgrade of unit 2 would not
Planned unit layout for the pumped storage plant
modify this characteristic. In pumping mode, the
upgrade. Credit: Alstom.
upgrade would allow it to offer +/- 40 MW of frequency control.
The main results concerning frequency control supply are
MWh. That price is contracthe following:
tually defned for 3 year Le Cheylas supplies much more frequency control: sum of
periods. RTE organizes the
primary and secondary reserves represents an increase of
secondary frequency control
+57%. Primary reserves produced an average of 41 GWh/
through mandatory bilateryear and secondary 62 GWh /year.
al contracts with producers
Logically, this increase comes from unit 2 pumping periods.
that must reserve an asked
But it is also coming from the new generation periods: the
volume for every half an
more energy is pumped, the more energy is then generated.
hour.
Frequency control is supplied when generating this additionConsidering this fxed
al energy.
price, the annual value of
Unit 2 is almost always supplying frequency control while
additional fexibility turned
pumping, and unit 2 is much more used than Unit 1 for
out to be around 2 million
pumping.
per year at todays prices
The current price that the transmission system operator,
and it is expected the price
RTE, uses in France to compensate the electricity producer
paid for frequency reserves
for delivering capacity for frequency control is around 17 /
will increase in the future to
56
1503rew_56 56
MARCH/APRIL 2015
3/13/15 1:41 PM
refect the greater need for

ancillary services.
Overall
Now that the technical
issues have been identifed,
assessed and solutions have
been put forward that demonstrate the feasibility of
the upgrade, the next step
is actually doing the construction. Not only will the
corresponding unit beneft
from an improved hydraulic design and achieve greater dynamic and energetic performance, but the unit
will also undergo a complete
rebuild, which will result in the extension of its operational

lifetime.
Finally, it is important to note that this type of upgrade is
about 10 times less expensive than the cost of building of new
power plant and can be implemented in much shorter time
frame this upgrade could be completed about 3 times faster than the time it would take to build a new project. Moreover, by developing storage capacity and fexibility in pumping
mode (corresponding to periods with the lowest availability of
fexible capacities), this conversion can be considered as part
of the solution for the integration of an important share of
intermittent generation in the European power mix.
Nathalie Lefebvre is a project director with EDF in France,
Olivier Teller is a product director with Alstom Hydro, and
Marie Tabarin, who has left the company, was a product manager with Alstom Hydro when this paper was written.
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1503rew_57 57
MARCH/APRIL 2015
57
3/13/15 1:41 PM
Renewa ble Energ y

Tra ining Event s
Here is a sampling of training institutions that offer renewable energy educational events and certificate programs throughout the year.
Visit their websites to see specific dates, locations and topics offered. Many universities and community colleges also offer renewable energy training programs.
Renewable Energy Policy Master Class

Heatspring Learning Institute
Online
6 April 12 June
Solar PV Mastery Training

Kaplan Clean Tech Education
Baltimore, MD, USA
20 25 April
Renewable Energy and Communication

Tower Technician Program
Airstreams Renewables
Tehachapi, CA, USA
30 March 8 May
Solar PV Mastery Combo

everblue
Chicago, IL, USA
27 April 1 May
NABCEP Continuing
Education Conference
Albany, NY, USA
30 March 1 April
PV and Solar Thermal

Structural Considerations
Midwest Renewable Energy Association
Online
27 April 24 May
The Renewable Energy Mini-MBA

Green Power Conferences
Cape Town, South Africa
3 17 April
Carbon Management
The European Energy Centre
Edinburgh Napier University, Scotland
28 29 April
Design & Install Grid Connect

Photovoltaic Systems
Global Sustainable Energy Solutions
Sydney, Australia
29 April 1 May
Dam Safety Inspection
The International Centre for Hydropower
Trondheim, Norway
1 6 June
Application deadline: 25 April
If you would like your training event to considered for inclusion in this listing, please email REWNews@Pennwell.com subject line: Education and Training.
READ the Industrys

Most Trusted Renewable
Energy News and
Information FREE!
Get up to minute
renewable energy
news and information
the way you want it
online, by email or
on your smartphone!
1503rew_58 58
3/13/15 1:41 PM
Renewa ble Energ y Wor ld C a lenda r Ma rch a nd A pr il 2015

Selected multi-day conferences, expos and events for the Renewable Energy Industry
Intersolar China
1 - 3 April 2015
Beijing, China
W:www.intersolarchina.com/en/
2015 China International Bioenergy

and Biomass Utilization Summit
21-22 April 2015
Beijing, China
W: http://www.bbs-summit.com/en/
Renewable & Alternative Energy

Exhibition & Conference
2-4 April 2015
Islamabad, Pakistan
W: http://www.reap.org.pk/
National Hydropower
Annual Conference
27 - 29 April 2015
Washington, D.C, USA
W:www.nationalhydroconference.com
SOLAREXPO
8-10 April 2015
Milan, Italy
W: www.solarexpo.com
United States Society on Dams 2015
Annual Meeting and Conference
13-17 April 2015
Louisville, KT, USA
W: http://www.ussdams.
org/2015conf.html
Solar Solutions International 2015
15-16 April 2015
Vijfhuizen, Netherlands
W: http://www.solarsolutions.nl/en/
Adver t iser s Index
2015 International Marine

Renewable Energy Conference
(IMREC) and Marine Energy
Technology Symposium (METS)
27-29 April 2015
Washington, DC, USA
W: http://www.nationalhydroconference.
com/index/co-locatedevents.html
SNEC PV
28 - 30 April 2015
Shanghai, China
W:www.snec.org.cn
Large-Scale Solar Thermal Systems

4-8 May 2015
Berlin, Germany
W: http://www.renac.de/
All Energy
6-7 May 2015
Glasgow, Scotland
W:www.all-energy.co.uk
Renewables and Mining Summit
and Exhibition - Chile
6-7 May 2015
Santiago, Chile
W: http://www.energyandmines.
com/chile
POWER-GEN India & Central
Asia (Incorporating Renewable
Energy World India)
7-9 May 2015
New Delhi, India
W:www.indiapowerevents.co
AWEA WINDPOWER
18 - 21 May 2015
Orlando, FL, USA
W: www.windpowerexpo.org
For more information on the products and services found in this issue click here.
EDF Renewable Energy20
Power-Gen Middle East45
ETA - Florence Renewable Energies27
Power-One Inc.4
Hammond Power Solutions27
REW Asia33
HydroVision International51
REW.com10
IHS Globalspec15
REW North America25
National Hydropower23
Siemens AG2
Nuscale Power9
Solar Promotion International GmbHCV2, 17
Pennsylvania State University11
Surrette Battery Co. Ltd.57
Power-Gen Africa55
Trojan Battery CompanyCV1A
Power-Gen Europe43
Unirac31
Power-Gen India/Distributech India16

The Adveritsers Index is published as a service. The publisher does not assume any liability for errors or omissions.
1503rew_59 59
MARCH/APRIL 2015
59
3/13/15 1:41 PM
Last
the
WORD
Australia at the Crossroads
Chris Judd is
CEO and Managing

Director of Senvion
Australia.
60
1503rew_60 60
MARCH/APRIL 2015
Over a year ago, the Australian Government announced a review of the

Renewable Energy Target (RET) an
effective policy that is the main driver of investment in large-scale renewable energy.
Unfortunately, this review, the
fifth in twelve years, has resulted in
a period of investor uncertainty that
has crippled the clean energy sector.
The stalled investment is regrettable,
because renewable energy in Australia makes a lot of sense.
We have world-class wind, solar,
wave and geothermal resources, and a number of well-designed
clean energy projects that are ready
to proceed under the right policy
framework.
Our energy system is particularly greenhouse gas intensive with a
heavy reliance on brown and black
coal. The most effective way for Australia to reduce emissions is to transform the energy sector and increase
supplies from clean energy.
Lower than expected energy
demand in recent years means that
there is a reasonable buffer between
peak energy demand and available
supply, making it a safe time to make
significant changes to the current
fossil-fuel intensive generation mix.
Australia has seen slow-downs
across a number of sectors such as
automotive manufacturing and mining. Investing in renewables will
create sustainable job opportunities

in the clean energy sector, particularly in regional communities.
In addition, more renewables in the
current electricity market increases
competition, putting downward pressure on energy prices.
Due to the uncertain policy environment, Australia is now out of step
with the rest of the world. 2014 was a
bumper year for investment in renewable energy around the globe for
example, annual installations of wind
energy exceeded 50 gigawatts for the
first time. At the same time, Australia saw an 88 percent reduction in
investment in large-scale renewables
compared to 2013.
It is not a coincidence that the countries with the most supportive policy environments are now reaping the
economic and employment benefits
of a healthy renewable energy sector. The global experience is clear
transforming energy systems requires
a clear, stable and long-term policy
framework that investors can rely on.
While negotiations about the future
of the RET have recently started again,
the industry cant stand an uncertain
policy environment for much longer.
Our political leaders must make a
commitment to renewable energy and
end the policy uncertainty, so that our
industry can get on with delivering
the clean energy power plants needed
for a low-carbon future.
3/13/15 1:41 PM

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Cable Contract for 350MW Wikinger Offshore

Facade of a Dutch row of new houses

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RENEWABLE ENERGY WORLD MAGAZINE

Five UK Biomass Plants

The seven-year term finance

plant development company

facility, provided by Royal Bank

Tamar Energy has secured 32

of Scotland plc will refinance

million in financing for its portfo-

the existing five plants and be

Wind turbines fed over 10,000

lio of five AD plants. According to

used to finance the next wave

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Tamar Energys chief executive

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tricity into Germanys grid in

officer Willie Heller, the deal is

the first month of 2015, setting

the first senior non-recourse debt

Anaerobic digestion is the

financing for an industrial-scale

process by which organic waste

man Association of Energy and

AD facility in the UK. Law firm

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Water Industries and ZSW Cen-

Watson Farley & Williams served

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tre for Solar Energy and Hydro-

as advisor on the deal.

cultural organic waste, known

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AD plants is comprised of five

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