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Issue

06/2004

WIND BLATT
The ENERCON Magazine

Global
currents

Pages 4-5: New office in France

Bienvenue chez ENERCON


Pages 10-11: Wallonian wind project

Young shareholders
Pages 14-15: Interview with Powercorp Manager

Is Australia going backward?


2 WIND BLATT 6/2004

Editorial
Dear Readers,

Christmas is just around the corner


and the year is coming to a close.
However, actions to maintain our
planet’s climate are still only
progressing slowly.

Russian President, Vladimir Putin, has


signed the federal law concerning the
ratification of the Kyoto Protocol to
the Framework Convention of Climate
Change. This was a wise decision
because Russia is also endangered
by, for example, melting permafrost.

Unfortunately, the United States of


America are still shirking their Clean energy
responsibility on this topic. It
depends on whether the President Worldwide wind market at the
of the United States will change his
outlook on this matter.
“Presently, a lot of countries are Another substantial issue was the world
wide political situation for renewable ener-
entering a new way to a future,
In the coming year we will continue gies. As shown on a graph (right) the Ger-
to work hard together to propagate based on clean energy sources”, man feed-in law has to be seen in direct
the use of renewable energy in order Sales Manager Stefan Lütkemeyer context with the breakthrough of wind
to protect our climate. On this note, energy. That means, the main reason for
gathered from the results of the
I would like to thank you for your Germany being the world’s number one
commitment and wish you and sixth international ENERCON meeting wind country are the political frameworks.

your families a peaceful festive “Get together”.


Now Governments have started supporting
season and a prosperous start
green energy in order to fulfil their Kyoto
in the New Year. promises or because of a growing energy
demand combined with dwindling sources.
Yours sincerely, hey came to the ENERCON head- Many of them have planned to pass a simi-
T quarters in East Frisian Aurich from
all over the world: sales managers from
lar feed-in law, because a fair price for the
kilowatt hour is the best way to multiply
Europe – Scandinavia, Italy, Portugal and renewables in the energy mix.
Aloys Wobben, Spain as well as from overseas like Brazil
or India. They visited the first ENERCON At the Get Together Friedrich Herzog,
Managing Director ENERCON GmbH
nearshore project, an E-112 (4.5 MW), and ENERCON Sales Manager for Austria, made
wind farms with the new types E-70 and clear how the market depends on a law:
E-48. Following a tight schedule almost Since 06/2002, Austria has had a fair ge-
Cover photo: The new E-70 (site in 50 international ENERCON sales officers neral energy law, which let the market
Central Germany, Ense) is attractive used the meeting for discussions about grow faster then ever before. For 2005 the
for the international market. world wide economy and politics. Government is planning new regulations
6/2004 WIND BLATT 3

International ENERCON sales team at the Get Together.

as key to the future


International ENERCON meeting “Get Together” discussed

with a smaller tariff by tender. That will ditions Brazil is on the right path for a gro- At this Get Together two facts have been em-
mean a shock for the Austrian wind mar- wing wind market. phasised: There are almost as many different
ket. Herzog declares: “Due to often chan- models for a new feed-in law as there are
ging regulations we have an uncertain Asia expert Joern Kristensen gave informa- countries. And: A new energy century has al-
market situation, which is a problem for in- tion about Taiwan. “The Government is still ready started. Not only in Europe but also
vestment.” debating to adopt a “German-like” system overseas. “Clean energy is the key to the
with fixed prices. Presently, the negotiation future”, summed up Executive Officer Paulo
In other countries like in Greece, Portugal level is 2.00 NTD = app. 5.0 € ct”, he said. Pereira at the end of the Get Together.
and Spain or Italy, good conditions for wind
energy already exist. For example in Italy
the installed wind power is expected to
2003 / 2004:
reach 1,200 megawatts with the use of MW amendment of the Renewable Energy
Sources Act
green certificates. The potential of the 1.400
Export (Plan) March 2001:
Italian market is evaluated at about 3,000 1.200 European Court of Justice: German feed-
to 4,000 MW at present conditions and in- Export in model is in accordance with the
1.000 Germany (Plan) European competition law
cluding some enhancement.
Germany
800 April 2000:
Renewable Energy Sources Act
South America has slowly started with wind 600 January 1997:
power. Pedro Vial from Wobben Windpower Change in the Building Law; WECs are classified
400 as privileged building projects
in Brazil has waited a long time for this law.
The Alternative Energies Insentive Program 200 1991:
Feed-in Law
PROINFA, which foresees 1,100 MW of wind 0
1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005
energy until the end of 2006, now receive
Years
a remuneration system, that guarantees
50 to 56 euros for a MWh. With these con- ENERCON capacity has been influenced by German politics.
4 WIND BLATT 6/2004

Bienvenue
chez ENERCON
New sales and service office opens in Compiègne, France

The French Government’s objective management for single turbines as well as wind energy in the French energy mix was
is to produce 21 per cent of France’s for wind farms is a special plus for ENERCON only 0.06 per cent whereas nuclear power
as the turbines are capable of supporting had a share of almost 75 per cent.
power out of renewable energies even weak grids. The new ENERCON wind
by 2010. ENERCON will help to reach turbine, type E-70, with 2 megawatts rated The French feed-in law could change that.
power and different hub heights up to The contract period is 15 years from com-
this target. After implementation of
99 m, satisfies broad market demand. missioning, which has to start within two
its first wind farms, ENERCON years after application. In that context, it is
has now opened a sales and service As for the new E-48 (800 kW), its total height necessary to know that the date of the
of 90 m from the ground to the rotor tip is purchase contract is important for fixing
office near Paris.
a very interesting feature for the French the tariff, not the commissioning date. The
market. Common to both is the revolutio- feed-in law is a good start, but bureaucracy
nary rotor blade design allowing for the low sometimes slows changes. “In France, the
eter Schuster has already settled noise emission and a distinctive increase time for approval is a problem. Therefore,
P down in Compiègne. The ENERCON
sales manager for France is very fond of
in efficiency. Furthermore, thanks to their
gearless design, the ENERCON turbines are
small wind farms with three E-48 (below
2.5 MW) needing only the Simplified Agree-
the country and keen on developing France’s extremely maintenance-friendly. ment Procedure (Notice d’Impact) would be
wind market. Currently, France has in- one of the keys to moving things forward”,
stalled 299.8 MW capacity in 64 wind farms ENERCON’s new sales and service office in Peter Schuster explains.
(of which 17 are in overseas regions) and France is located in Compiègne, only 80 km
552 single wind turbines (of which 267 are north of Paris. “That means we reach every A big event for the new French team was
in overseas regions). For 2007, the Govern- wind farm and customer in less than one the inauguration of the ENERCON wind
ment’s target is an installed capacity of and a half hours; for longer distances we farm in Plouguin (Brittany) where inter-
2,000 to 6,000 MW (Source: suivi-éolien). have the high-speed train, the TGV”, re- esting discussions with visitors, farmers
marks Peter Schuster. Important for the and residents took place. ENERCON was
Schuster is convinced that the ENERCON growth of the renewable energy market is delighted to realise the community’s high
turbines have a lot of advantages in terms the feed-in law, true for France as well as level of acceptance, with its own group of
of economics and technology. The grid many other countries. In 2003, the share of musicians taking part in the inauguration.

Peter Schuster, sales manager for France. Tanja Pintschovius is member of the ENERCON team in France.
6/2004 WIND BLATT 5

pleasure for me to come back here to


work”, Tanja says.

Thierry Ternois is 31 years old. With his


wife and three children, he lives in Ardèche,
a region in the French Rhône valley with
quite strong winds. He is a mechanical
engineer and a graduate of Université de
Technologie de Compiègne (UTC). “I have
always been attracted by renewable ener-
gies and really hope that France, with its
wind power, is on the right track to diver-
sify its energy sources and give the rene-
wables a chance”, he explains. At ENERCON,
he is responsible for project management:
site preparation and coordination, trans-
Thierry Ternois shows that farming and wind energy are an excellent combination.
port, foundation works, commissioning and
The extension of the Plouguin wind farm is prior to coming to ENERCON. “This is one of taking over.
already planned. Another wind farm of six the reasons why I wanted to go back to
E-66 (2 MW) has just been installed in France. Another incentive is the very at- Renata Crut, 59 years old, was born in
Nibas/Saucours on the Picardy coast near tractive French wind market”, he explains. Lingen, Germany, but has been living in
Abbeville. France since she finished her studies. Now
Tanja Pintschovius is 33 years old and grew Peter Schuster’s assistant, she left Com-
Following is a short introduction to the up in Aurich, the town in the north of Ger- piègne only for two and a half years in
office staff in France: many where ENERCON’s headquarters are order to work on a wind farm project
located. After studying economics for tou- Germany.
Peter Schuster, 41, is sales manager for rism, she was working for ENERCON as
ENERCON in France. He has been doing bu- the assistant to the project management ENERCON GmbH
siness for ENERCON for almost eight years. supervisor and did project planning for ex- Bureau français
As a sales manager for Northern Germany, port projects. Since October, she has been 8, Chemin d’Armancourt
most of his customers were farmers, deve- supporting sales and project management 60200 Compiègne
lopers and public utilities. To date, the gra- in France. Years ago, she lived in Paris for France
duate economist has been in sales for some months and always spent her holi- Phone +33 3 44 37 35 10
14 years. He had already worked in France days in this beautiful country. “So it is a Fax +33 3 44 37 35 20

100 turbines in the


land of the gods
On the island Lesbos ENERCON has
just installed the 100th wind turbine in
Greece. The E-40 is part of an enlarge-
ment of wind Farmaeoliki Antissas a.e.,
near Terpandros Aiolika Parka a.e., for
customer Elliniki Technodomiki. In 46 m
hub height there are ideal wind condi-
tions of almost 8 m/s. The realisation
was no problem especially because a
grid connection has already been there.
Near the wind farm a fossil tree was
found, therefore the developer had to
On the island Lesbos the 100th ENERCON wind turbine in Greece has been installed. The photo how ever
change the position of the site a little. shows the wind farm Terpandros Aiolika Parka a.e. , where the 98th turbine has been built.
6 WIND BLATT 6/2004

Maximum safety and


cost effectiveness
The importance of regular service intervalls in wind turbines

Regular maintenance checks of this, the use of nitrogen is complicated. “We think that systematic and early hazard
This does not include the damaging effec- detection is more important”, explains
as a precautionary measure
ts on the environment and the danger for Michael Hölscher, Technical Director of
can also protect wind turbines persons who may be in the turbine. ENERCON Service.
from fire outbreaks.
If one considers that out of the over 7,400 Hölscher feels that the quarterly mainte-
ire prevention in wind energy tur- ENERCON wind turbines installed world- nance periods are necessary, for example,
F bines is a complex subject. Due to
the construction and height, possible fires
wide practically non of the turbines have
ever had a mentionable fire or initial fire,
as a precautionary measure to prevent
fires. During maintenance, all vital com-
or initial fires are difficult to control. installing this type of expensive extin- ponents undergo visual and mechanical
guishing system would have to be looked at checks. Fires break out occasionally due to
Now and then various fire prevention solu- with at critical eye. ENERCON has repaired short circuits. This means that special
tions are discussed but offer no real gua- any damage caused by fires. In addition, attention has to be paid to check weak
rantee for safety. Due to the complex elec- the cause for these fires was examined by spots such as cable connections and PCBs.
trical system, water cannot be used to well-known fire damage experts. The re- If a source of risk is detected, this can be
extinguish fires. Instead nitrogen or other sults were then immediately taken into closely checked in all turbines of the same
similar gases have to be employed. Since consideration by ENERCON Service and type within just a few weeks during the
the wind energy turbine has to have excel- the appropriate measures were taken to course of maintenance intervals. Through
lent air ventilation properties and because remedy the problems. quarterly maintenance the service tech-

Number of remote monitoring status messages (average)


per year per WEC - Germany
10.00

8.00
7.50

5.50
5.00
5.00

4.80

0.00
until 2000 2001 2002 2003 Forecast 2004

The chart shows the advantages of quarterly maintenance. The change-over from bi-annual to quarterly maintenance intervals was introduced in 2001.
Less shutdowns mean higher availability; therefore higher yields and less expenditures for the customer.
6/2004 WIND BLATT 7

Maintenance cost
for customers
Maintenance cost comparison for turbines
with EPK and those without ENERCON
Partner Konzept. The blue arrow indicates
that the operating costs with EPK remain the
same, while with just a simple maintenance
contract (green arrow) the increase over the
years is apparent. With maintenance, (red
arrow) which only covers necessary repairs,
the costs soar considerably. It is obvious that
regular maintenance checks within the fra-
mework of the EPK contribute to reducing
failures and thus also reducing costs.

nician can quickly update or modify any Temperature monitoring, symmetrical po- just react when the damage is already the-
components subject to faults in all ENERCON wer limits, replacement of critical compo- re. Since approx. 90 percent of our turbines
turbines worldwide. nents, more intelligent software, and many are serviced within the framework of the
other details are decisive factors when it ENERCON Partner Konzept (EPK), ENERCON
Since 2001, ENERCON has been carrying comes to protecting ENERCON turbines has an interest in reducing dangers by
out quarterly maintenance checks (approx. against fire. carrying out regular maintenance. Our goal
every 2,000 operating hours) instead of is to achieve maximum safety and cost
just two per year which has cut the average All knowledge and experience concerning effectiveness", Michael Hölscher resumes.
number of status messages in half and hazard zones is channelled into the main-
consequently has increased the availability. tenance information and passed on to over With the type of sophisticated technology
650 service technicians in Germany. Main- in a wind turbine, fire hazards can never be
ENERCON’s Scada Monitoring System is tenance documentation are constantly up- excluded 100 per cent. However, ENERCON
one of the important factors in minimizing dated and used for all turbines. has taken the steps to substantially reduce
fire hazards. The E-70 alone transmits the risks. Comparisons within the wind
several thousand status messages to the “Especially since our maintenance intervals energy sector confirm that the amount of
Service department. These indicate any are short, we are able to carry out preven- fire damage is lower in ENERCON turbines
abnormalities and where they appear in tive maintenance to avoid damage and not and that this is the right approach..
the turbine. In the nacelle alone, there
are 80 sensors which check the tempe-
rature in the different areas. As soon as
there is a conspicuous change in tempe-
rature on one of the components, the tur-
bine shuts down. This would be the case
when the heat sink in the power converter
gets too hot. ENERCON has developed its
own control system which e. g. monitors
the power flow of specific components.
This means that several similar compo-
nents, such as the three pitch motors
used to adjust the rotor blade position are
monitored to see whether they all use
the same amount of power. If the values
differ, this could indicate a fault and Ser-
vice is alerted. More and more often this
also occurs as a warning message and
does not always cause an immediate shut-
down. ENERCON emphasises on elaborateness in service.
8 WIND BLATT 6/2004

A special present
for the young ones
Belgian artist sells shares of a wind project for children’s future

The county of Wallonia intends to garten or primary school. Parents, relatives The inauguration of that wind turbine in
meet the Kyoto target to produce and friends buy shares for their children and May 2004 became an enormous event with
22.1 per cent of renewable electricity by that they invest twice in their future: First fireworks and a spectacular ethnic dance
they put money into something financially show by a local youth group. The young
by 2010. But the reality looks
profitable, and then they save the climate. folks came dressed in historical Mongolian
different: The Government would costumes, swinging huge red flags and red
even be happy with 14 per cent. Delville is a special, very rare character. shining flambeaus.
Bernard Delville is one of the few He has forever been fighting for renewable
Belgian fighters for wind energy. His energies – and this often in the most char- The mountain range of Mesnil-Finnevaux
ming way by using his art works as a trans- across from Beauraing is a zone of wind
projects make renewables popular.
mitter for the message. For example in the compression. This fact well known to the
70’s he already installed a gigantic wind residents has been confirmed by the first
andrine is excited. The ten year old harp, made of bamboo and over hundreds months of power production by the E-40.
S Belgian girl opens her birthday pre-
sent from her godfather Luc. It’s an impor-
of kilometers long. Nowadays Delville lives
in the beautiful nature of Mesnil in Wallonia
“We are very happy with the E-40. Until
now it has produced even more than fore-
tant looking certificate with the picture of a near the border to France. casted”, smiles Bernard Delville.
wind turbine on it. Godfather Luc explains:
“Now you are owner of a small part of this There he has already achieved another In the middle of the year 2001 the commu-
mill. And this one will help our planet to wind project for children with an E-40. And nity “Allons en Vent” was founded by Del-
stay as beautiful as you know it.” with his hands the turbine became an art- ville. 44 shares of 400 euros each were sig-
work: Over the whole foundation area ned by sympathisers, parents and children.
The Belgian artist Bernard Delville had the Delville created a snail-shell out of wooden A measurement mast of 30 m height was
idea for this fascinating project: The share- sticks and gravel. Within these winding installed and the 3E group accomplished
holders for the three ENERCON wind turbi- forms the artist symbolises the motional the measurements. After 14 months the re-
nes E-48 which he is planning, go to kinder- power of the wind. sults were excellent. The middle wind speed

Installation of the first E-40 in Mesnil. Delvilles art works on the foundation.
6/2004 WIND BLATT 9

of 5.5 m/s at 30 m height let assume a wind explains. Delville aims 4,000 sold shares they can observe in the surrounding area of
speed of 6.0 m/s at 75 m, which is a profi- within three years. the wind farm.
table middle wind speed for midlands.
The young investors get six per cent for With another children’s project Delville was
Delville is convinced that his next project their shares. After two years they get a already very successful. Together with his
will also be a success. He just hopes that small amount. More over they get physical partners he made a tour through small vil-
there won’t be any problem with the grid, advantages like special offers in a book- lages and invited children to a “wind aca-
as there is a cabin of only 15,000 kV. But shop for books with environmental topics. demy” with an exhibition and games on
he believes in the technology. “The E-48 wind energy.
with the new blades has a higher effi- As the turbines will be built in a natural re-
ciency, and the people are already very in- servoir, the landscape is impressive. Del- The contract will be signed by the end of
terested in the project”, he says, and adds: ville already has the permission to install 2004. Foundation-work will probably start
“They like the idea of doing something the turbines over an area of 600 ha land. So in May 2005. “And it is not that we only let
positive for the future of their children.” No nature plays an important part within the Belgian children participate. We hope to
wonder 500 shares for 100 euro each have project. The children get responsibilities find young shareholders all over the
already been sold. Until now there are still like taking care of a biotope near the wind world”, Delville emphasises.
3,500 left. “If we sell all of them we don’t turbines. And they will paint signs which Contact: vents-houyet@skynet.be
even need a bank as financer”, Delville show tourists, what animals and plants www.vents-houyet.be

Inauguration with fireworks.


10 WIND BLATT 6/2004

Photo from left: Estonian Prime Minister Parts, Tullio Liblik, Mark Altvee form Ühisliisingu AS, Joern Kristensen (ENERCON Sales).

Keen interest
is there
Estonian Prime Minister visits ENERCON in Magdeburg

stonia’s Prime Minister, Juhan Along with the contract signing between fired power plants will not be able to cover
E Parts, showed extreme interest in
wind energy during his recent visit to
ENERCON and Roheline Ring there were
also discussions about the energy situation
the demand. Wind energy could become an
alternative to the threatening dependence
ENERCON’s Magdeburg production site. in general and in particular renewable on imports. The Estonian government is
Together with ENERCON’s Estonian custo- energies in Eastern Europe. The Minister aiming to cover 5.1 per cent of its energy
mer Roheline Ring, the PM took part in President of Saxony-Anhalt, Dr. Wolfgang mix with renewable energy by 2010. Not
the signing ceremony of a contract for Böhmer, also took part in the event. only has ENERCON realised wind energy
four E-70 wind energy turbines in Estonia. projects in Estonia, but also in Lithuania
Each turbine has 2 MW rated power. Roheline Ring UO is a pioneer in Estonian and Latvia.
During the PM’s visit, the PM asked a lot of wind energy. Together with the power
questions concerning the EEG (Renewable supply company Eesti Energia, they have Just as for the entire wind energy sector in
Energies Act) and the feeding-in of wind already developed the first commercial Germany, the export markets are becoming
power. wind energy project in Estonia compri- more and more important. This year ap-
sed of three ENERCON E-40/6.44 with a prox. 30 per cent of the company’s pro-
The construction for the turbine founda- 600 kW rated power. At that time the Tech- duction was for export. Next year this por-
tions is planned for Spring 2005. Petra nical University Tallin was also involved in tion will increase. Over 2,400 turbines are
Wernicke, Minister of Agriculture and the development. For more than two years, already running outside of Germany. In
Environment in Saxony-Anhalt, greeted under severe climatic conditions, these addition to Magdeburg and the head-
the Estonian guests at ENERCON in turbines have been feeding environmental- quarters in Aurich, ENERCON has pro-
Magdeburg. ENERCON Magdeburg Sales friendly power into the grid to the custo- duction sites in Sweden, Brazil, Turkey and
Manager, Frank Ihme, guided his guests mers’ utmost satisfaction. India. There they produce not only for the
through the generator production halls German market, but also for the respective
at ENERCON’s production site in Schilf- Estonia has to adjust to a growing demand markets in South America, Europe and
breite. for energy. By 2008, the existing oil shale Asia.
6/2004 WIND BLATT 11

How could we use


this weather?
Interview with Tullio Liblik, Managing Director of Roheline Ring from Estonia

In Estonia the interest Liblik: Roheline Ring started the first pro-
ject with three E-40s three years ago. Now
in renewable energies rises.
we signed the contract with four E-70s.
They will be erected rather close to the
he Managing Director of Roheline existing wind farm. We have already star-
T Ring, Tullio Liblik, speaks about his
experience with wind energy in Estonia.
ted preparation of the next wind project.
And we really hope that we will get per-
missions for grid and site for all 22 wind
WINDBLATT: Mr. Liblik, you already have turbines, so that we will be able to realise
some E-40s. How did you come to the a wind farm of about 40 megawatts.
idea of developing wind energy projects in
Estonia? WINDBLATT: Are there any other ways to
Tullio Liblik, Managing Director of Roheline Ring. get more for wind energy in Estonia?
Liblik: Yes, the first wind farm in Estonia
consists of three ENERCON turbines E-40. Liblik: In Estonia we get about 4.9 Cent/ Liblik: Yes, we are going to sell emission
They were erected two years ago. So they kWh for wind energy. This is one of the points. That means, with our wind energy
have been in operation for 25 months. lowest prices in Europe. For the first pro- we will reduce CO2 emission, as less fossil
ject we got a grant from the German go- products have to be burned. Nowadays this
WINDBLATT: How are the yields until now? vernment. This helped a lot. With our next reduction has a value. Now we are in nego-
project we had alot of experience with all tiations with different possible buyers. This
Liblik: The result in production was a little the civil works, so we panned the project is one of the ways to make our project cost
better than the estimation. much more carefully. And we were able to effective.
explain the profitability to the financers. It
WINDBLATT: How are the wind conditions is not much, but still we can run the busi- WINDBLATT: One word on the energy si-
in Estonia? ness on the plus side. Certainly the pay- tuation in Estonia. You use a lot of oil shale.
back time is rather long. And we really hope
Liblik: The wind direction in our area is that in the near future the price per Liblik: Mostly energy is produced by oil
from the south-east. And our wind farm is kilowatt hour will rise. shale. And the sources are large enough to
totally open to the main wind direction as it supply Estonia for a long time. We are inter-
is placed on the West Coast. But you were WINDBLATT: The Estonian Prime Minister ested in wind energy in order to protect the
asking about the idea ... That was two participated in the contract signing in Ger- climate and reduce pollution in the atmo-
years before we started to erect the first many. Did he give you hope, that there will sphere.
wind farm. This came out from the situa- be changes?
tion that we live on an island, the biggest in WINDBLATT: Do you think that the Euro-
Estonia. My partner and I were often sitting Liblik: The price we get is based on the pean Union forces new members to think
outside when we were smoking fish. One energy price which is influenced by the of Kyoto Protocol and climate problems?
day in summer when it was cold, windy, price for the main energy resource oil shale.
and raining, my partner asked me: How And I really believe that the price of energy Liblik: That is not the result of the Euro-
could we use this unpleasant situation? So by burning oil shale is going to rise. This pean Union. Most of the people in Estonia
we came to the idea of wind energy and we makes us optimistic that in the near future understand that we have to be careful
started reading articles about that topic. we will get a little bit better price than now. with our nature for the future of our chil-
dren.
WINDBLATT: In Estonia you get very little WINDBLATT: So, what will the future for re-
per kilowatthour. How do you finance your newable energies in Estonia – and for your WINDBLATT: Thank you for the inter-
projects then? company Roheline Ring – look like? view.
12 WIND BLATT 6/2004

Claus Weegen photographing the rotor blade tip with the photogrammetry camera.

Any flaws are


discovered
Quality control in rotor blade production using photogrammetry

ENERCON is now using a photo camera laus Weegen is looking through plains: “For photogrammetry, an object is

as a measurement instrument to check


C a photo camera at the tip of an
E-70 blade with the signal strip. The photo
photographed with a digital camera from
several different angles. Reference points
is used for a quality assurance measure- are stuck on the blade and calibrated
the rotor blade production quality.
ment called photogrammetry. Ralf Kelling, gauges applied. Later on, a computer pro-
ENERCON’s quality assurance manager ex- gramme is used to analyse these refe-
rence points. With a number of two di-
mensional pictures this software can now
produce a three dimensional picture of the
reference points. This is called a 3D trans-
formation.”

Photogrammetry has been used for addi-


tional quality control in the various produc-
tion areas at ENERCON Rotorblattfertigung
since September. Claus Weegen, who
works in process planning at Aero is in
charge of the system and carries out the
measurements. If a new mould for rotor
blade production is brought to the pro-
duction site, photogrammetry helps to align
the parts exactly. This facilitates bringing
Computer image of the tip: Each point shown is a measurement point which is transposed onto a CAD model
to be compared with it. The amount of deviation can be read off on a colour scale. Green points, in this case,
the various forms into the exact desired
mean that the measured value and the model are identical. contours during the gluing process. If one
6/2004 WIND BLATT 13

Info Service
Dec./Jan./Feb. 2004/05
14/12/2004 Course
Ankara/ “Wind Turbine Techniques”
Turkey Organiser, or information from:
German Wind Energy Institut (DEWI)
Phone +49 4421 48080
Fax +49 4421 480843
seminar@dewi.de
www.dewi.de

15/12/2004 Course “Wind Farm Projects”


Ankara/ Organiser, or information from:
Turkey German Wind Energy Institut (DEWI)
Phone +49 4421 48080
Fax +49 4421 480843
seminar@dewi.de
www.dewi.de

21/01/2005 The meaning of emission trading


Photo of rotor blade tip taken with a photogrammetry camera. Berlin/ for development of the renewable
Germany energy branch
of the mould components is not 100 per- measures are taken to prevent any future
Organiser, or information from:
cent aligned, photogrammetry discovers differences. “We had a look at various
German Wind Energy Association
any deviations immediately. This is also an measurement systems and photogram- (BWE), Andrea Horbelt
important checking method when com- metry turned out to be the best,” Weegen Phone +49 541 3506033
pleting the rotor blade, e. g. on the gluing explains. It is used for prototype rotor seminare@wind-energie.de
angles. blades, to optimise devices and to take spot www.wind-energie.de
blade measurements. In the long run, all
26-27/01/ “CLEAN ENERGY POWER 2005”
The area which initially intercepts the wind, blades will be checked this way.
2005 Organiser, or information from:
the so called leading edge of the blade, is
Berlin/ erneuerbare energien
especially vital because this is where it is Photogrammetry is only one of the many Germany Kommunikations- und
determined whether the wind will flow la- quality assurance measures used in the Informationsservice GmbH
minar along the blade. The tip of the blade rotor blade construction. Quality assu- Phone +49 7121 30160
is also part of this air flow area. Special at- rance ranges from material reception, Fax +49 7121 3016100
tention has to be paid to the tip area be- where the basic materials are checked, redaktion@energie-server.de
www.energie-server.de
cause this is where the air flow reaches the from the production on to loading the fi-
highest speed. According to specifications, nished blade for shipment. During the
15-17/02/ LAREF 2005
the deviations should only be infinitesimal. production, all procedures are constantly 2005 in “RIO 5 – World Climate and
This is particularly important with regards monitored and checks are carried out at Rio de Energy Event”
to noise emission. predetermined stages on each individual Janeiro/ Organiser, or information from:
part all the way to the finished blade. Brasil erneuerbare energien
Claus Weegen: “Due to the increasing size Furthermore continuous analyses are car- Kommunikations- und
Informationsservice GmbH
of our blades, we need a measurement ried out to maintain constant mixing pro-
Phone +49 7121 30160
system in order to avoid any problems.” portions for the various resin compounds.
Fax +49 7121 3016100
Before, this step in quality control was On top of that, the material’s optimal redaktion@energie-server.de
done using a template. However, with curing is measured with a thermal analysis www.energie-server.de
this we could only determine whether the device (DSC Analysis). Photogrammetry
rotor blade had the right shape. With was originally used in the aerospace in- 16/02/2005 Course “Grid Connection of
photogrammetry it is possible to determine dustry and for vehicle and boat design. Madrid/ Wind Turbines”
Spain German Wind Energy Institut (DEWI)
the deviation down to a fraction of a milli- This method has been around for years,
Phone +49 4421 48080
metre. The results are then discussed but has only recently become user-friendly
Fax +49 4421 480843
with the construction department and the with the current computer capacities and seminar@dewi.de
technical management, and if necessary, speeds. www.dewi.de
14 WIND BLATT 6/2003
6/2004

Albany wind farm in Australia.

70 megawatt Australia is a country with

excellent wind conditions.

for Australia nyway, wind energy grows slowly.


Mount Millar wind farm project on Eyre Peninsula A Alan Langworthy, Managing Di-
rector of Powercorp Australia, explains
arwin company, Powercorp Ope- tricity needs of about 36,000 typical South why.
D rations Pty Ltd, has won the main
sub-contractor role to assist one of the
Australian households.
WINDBLATT: Could you please describe the
world’s leading wind turbine manufac- These wind turbines will stand on 85 m steel development of wind energy in Australia?
turers, ENERCON GmbH, to construct the towers and have a total height of 120 m. The
wind farm at Mount Millar on the Eyre Mount Millar Wind Farm is going to reduce Langworthy: Wind energy is still quite
Peninsula. Australia’s greenhouse gas emissions by young in Australia even though work has
up to 4.2 million tonnes of CO2 during its been undertaken since the early 70s. Aus-
The Australian power company Tarong 25 year life and provide the electricity tralia was a leader in the old days of small
Energy will realise a wind farm project with needs of around 36,000 households. wind generators but lost momentum as the
35 ENERCON turbines, type E-70. The Chair wind industry picked up in Europe and
of Tarong Energy Mr Ken Dredge explains Established in 1988, Powercorp develops the US. The main reason for this is the
that the Mount Millar Wind Farm Project – intelligent power systems for remote diesel abundance of coal. For good or evil Austra-
comprising 35 wind turbines at a total cost power stations in the Northern Territory of lian coal is first quality black coal ideal for
of about $130 million – would be built on Australia. The company, headquartered in power generation. As a result Australia
an escarpment between the towns of Co- Darwin, Australia, develops management depends on coal for most of its power sup-
well and Cleve. systems for all levels of power station ope- ply. In recent years wind has featured more
ration, including demand side management as a direct result of the greenhouse gas
The 70 megawatt wind farm will generate and integration of fuel saving plants such debate and Australia’s worry over being
sufficient “green energy” to meet the elec- as hydro and wind turbines. branded a polluter from all the coal bur-
6/2004 WIND BLATT 15

Most Australians want


a strong wind industry
Alan Langworthy from Powercorp about wind energy in Australia

ning. It set a target of two per cent new re- not making a big noise at the fairs but buil- government will claim success in achieving
newable by 2010 and introduced a renewable ding wind farms. Often the largest at the the Kyoto target but with a manipulation of
certificate system. Over the last few years time. The others have a large sales team old hydro not by installing new green.
some 130 MW of new wind has been in- but not a big service structure. I think the
stalled of which more than 40 MW has quiet achiever with emphasis on service of WINDBLATT: When did it come into force
been ENERCON machines. This is mainly installed plant is the correct way to go. and which effect does it have? Which posi-
along the Southern coast line of Australia. tion does the coal-industry take concerning
WINDBLATT: Could you please say some- renewable energies? Are there any blocka-
WINDBLATT: What progress did ENERCON thing about the political development res- des caused by lobbyists for example?
make in this development? pectively progress?
Langworthy: Yes.
Langworthy: We have seen our market Langworthy: Politically I am ashamed to
share steady at 30 per cent and with the say Australia is going backward faster than WINDBLATT: Are there examples concer-
new Mount Millar 70 MW farm we will most other countries are going forward! ning the positive and independent develop-
maintain a higher market share until a We have had a review of the MRET scheme ment of wind energy?
couple of planned large parks are installed. which basically did nothing to recommend
But ENERCON will maintain this increased any improvement then the government is- Langworthy: Not really because these are
share with 110 MW installed and more on sued a white (advisory) paper that outlined toothless tigers – they have no real power
the horizon. a plan to support coal above all else. I think or interest to push the achievement only to
wind will be very quiet in Australia over the annoy the government which is of the op-
WINDBLATT: How are the conditions for next few years – especially because the posite party.
wind energy in Australia? Are there good conservative government has just in Octo-
locations and how is the wind potential? ber been re-elected. WINDBLATT: What view does the popula-
tion take on wind power plants and wind
Langworthy: There are good wind sites WINDBLATT: Could you please explain energy?
some with extraordinary average wind ve- the Mandatory Renewable Energy Target
locity. Unfortunately Australia is plagued by (MRET) in two sentences? Langworthy: I believe most Australians
three problems; in the Southern coast line want a strong wind industry and this is a
sites there are very strong objectors on the Langworthy: MRET is a certificate scheme surprise given the lack of pollution in the
basis of visual pollution. In some sites, that obligates the retailers to source two air in Australia. We have the not in my back
connection is a real issue because the per cent of the sales of electricity in the yard group alive and well though so sup-
sparse population means that the grid is year 2010 from new renewable sources. A port is not everywhere.
weak. Long thin wires are normal. Thirdly regulator sits and certifies what generators
we have severe cyclone zones that require are able to generate the certificates and WINDBLATT: Are there any bigger projects
tilt down design – not suitable for the E-66. these are offered for sale in the market. The planed in future?
penalty for noncompliance is $a40/MWh so
WINDBLATT: Which enterprises or manu- this is the lid on the trading price – not Langworthy: We are tendering on a project
factures are already established in Austra- much when you consider coal is selling in- that is double the Mount Millar project and
lia and how powerful is ENERCON com- to the pool price at between 10 to 30 there are several of these about. It is the
pared to them? dollars. The hope is that this target will be long term future that is in doubt not the
lifted and that generators will see a future short term contract position.
Langworthy: Vestas and GE are esta- driver to install green. The opposition party
blished although GE have not yet installed is proposing to lift it to five per cent. The WINDBLATT: Thank you very much.
turbines. ENERCON has a substantial ser- threat is that our ten per cent old hydro will
vice team. We tend to be quiet achievers have the base line lowered and that the Questions: Katharina Thyen
WIND BLATT The ENERCON Magazine
A d d r e s s e s
Blades for Portugal ENERCON International sales offices
ENERCON GmbH, International Dept.
Otto-Lilienthal-Str. 25
28199 Bremen · Germany
Phone: +49 421 2441520
Production facility for wind turbines in Viana do Castelo Fax: +49 421 2441539
e-mail: sales.international@enercon.de
AUSTRALIA
ENERCON Powercorporation Pty. Ltd.
Export Drive · Darwin Business Park
Berrimah · Northern Territory
E-70 with the NT 0828 · Australia
Phone: +61 8 89470933
Fax: +61 8 89470925
e-mail: mail@pcorp.com.au
new rotor blade design AUSTRIA
Hauptstr. 19A · 2120 Wolkersdorf · Austria
Phone: +43 2245 82828
becomes popular Fax : +43 2245 82838
e-mail: enercon@vienna.at
BENELUX
in Portugal. ENERCON Benelux BV
Paxtonstraat 1a
NL-8013 RP Zwolle · The Netherlands
Phone: +31 38 4228282
Fax: +31 38 4228010
e-mail: sales.benelux@enercon.de
BRAZIL
Wobben Windpower

O n a site of about
100.000 m2 ENERCON
is planning to build a rotor blade
Industria e Comércio Ltda.
Av. Fernando Stecca n° 100
Distrito Industrial - CEP 18087-149
Sorocaba - Sao Paulo - Brazil
Phone: +55 15 2101 1700
Fax: +55 15 2101 1701
e-mail: wobben@splicenet.com.br

production facility in the har- CANADA


Wind Power Inc.
Suite # 222 Lebel Manison
bour of Viana do Castelo, a town 696 Kettles Street, Pincher Creek
Alberta TOK 1 WO · Canada
Phone: +1 403 6272923
near Porto in Northern Portugal. Fax: +1 403 6273239
e-mail: wpi@windpower.ca
In this factory, blades for the DENMARK
Bredkaer Parkvej 62 · 8250 Egaa · Denmark
wind turbine type E-70 with 2 Phone: +45 87 430388
Fax: +45 87 430344
e-mail: kristensen@enercon.de
megawatt rated power will be EGYPT
c/o Zaki International Trading
produced. The ENERCON pro- 23 Kasr El-Nil StreetCairo 11111 · Egypt
Phone: +20 2 3923670
Fax: +20 2 4170023
duction facility is located close e-mail: zit@starnet.com.eg
FRANCE
to the harbour and offers an ex- ENERCON GmbH bureau français
8, Chemin d’Armancourt
cellent infrastructure for trans- F-60200 Compiégne
Phone: +33 344 371573
Fax: +33 344 371574
portation by sea. GREAT BRITAIN
Axiom House, Station Road
Stroud, Glos. GL5 3AP · Great Britain
Phone: +44 1493 782018
Fax: +44 1493 789094
Today almost 200 ENERCON e-mail : info@enercon.co.uk
GREECE
wind turbines produce the ENERCON S.A.
20, Pentelis Ave. · 15235 Vrilissia
Athens - Greece
same amount of megawatts of Phone: +30 106838490
Fax: +30 106838489
e-mail: enerconh@otenet.gr
green energy in Portugal. In INDIA
ENERCON (India) Ltd.
2004 (September) ENERCON had Kolsite House, Plot Nr. 31
Shah Industrial Estate
Veera · Desai Rd., Andheri (West)
a market share of 40 per cent in Mumbai 400 053 · India
Phone: +91 22 56924848
Fax: + 91 22 26730085
Portugal. e-mail: mktg@enerconindia.net
Windblatt is printed on mainly recycled paper. Printed with Ökoplus printing ink.

ITALY
ENERCON Service Italia S.r.l.
Via G. Della Casa 7· 82100 Benevento · Italy
Phone: +39 082 425257
The German market leader Fax: +39 082 4336883
e-mail: info@enerconitalia.it
started its activities in Portugal PORTUGAL
c/o Gellweiler Lda.
Travessa do Alecrim, 3 - 2°
with the erection of 20 E-40s in 1200 Lisbon · Portugal
Phone: +351 21 3407160
1997. The manufacturer will in- Fax : +351 21 3407169
e-mail: aesteves@gellweiler.pt
SPAIN
tensify the fruitful cooperation ENERCON Spain S.A.
c/o València Parc Tecnològic
with subcontractors such as Av. Juan de la Cierva, 27
E-46980 Paterna Valencia · Spain
Phone: +34 961 3662-90
Somague, Construcòes, Siemens Fax : +34 961 3678-75
e-mail : enerconspain@telefonica.net

and Cariano & Irmao, S. A. and SWEDEN


c/o Energy Converter AB
A new E-70 in Serra da Cabreira in Portugal. In future blades for this type will be Stenåldersgatan 19 · 21376 Malmö · Sweden
produced in Portugal. Tegopi. Phone: +46 40 143580
Fax: +46 40 222420
e-mail: scandinavia@enercon.de
TURKEY
ENERCON Service Ltd. Sti.
Imprint WINDBLATT MAGAZINE Editorial office:
ENERCON GmbH Aurich · Nicole Weinhold
The WINDBLATT magazine appears every two months and is
PK.: 23 Kiziltoprak · Istanbul · Turkey
regularly included in the newspaper “New Energy”, magazine of
Publisher: ENERCON GmbH · Dreekamp 5 · 26605 Aurich nicole.weinhold@enercon.de Phone: +90 216 4149202
Phone: +49 4941 927-0 · Fax: +49 4941 927-109 the Federal Association for Wind Energy. Fax: +90 216 3452959
Printed by:
www.enercon.de/english/fs_windblatt_e.html Steinbacher Druck GmbH · Osnabrück · Phone: +49 541 95900-0 Phone: +49 541 350600 or Fax: +49 541 3506030 e-mail: enercon@doruk.net.tr

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