CASE STUDY: BERGEY EXCEL WIND TURBINE INSTALLATION NOVEMBER 2002

CASE STUDY: BERGEY EXCEL WIND TURBINE INSTALLATION NOVEMBER 2002 Case Study compiled by: Rhonda Gatzke, Member GEO 11/2002

Some Some of of the the project project participants: participants: Metro Metro Parks Parks www.metroparks.net www.metroparks.net Green Green Energy Energy Ohio Ohio www.greenenergyohio.org www.greenenergyohio.org Geoff Geoff Greenfield, Greenfield, Third Third Sun Sun Installer Installer and and Distributor Distributor Geoff@Third-Sun.com Geoff@Third-Sun.com www.third-sun.com www.third-sun.com Phil Phil Irwin, Irwin, Vanner Vanner Inc. Inc. AC AC Power Power Inverter Inverter Provider Provider PHILI@vanner.com PHILI@vanner.com www.vanner.com www.vanner.com CONTENT Preparing the tower s foundation Assembling the tower Installing the wind turbine Erecting the wind mill Balance of System components Permits (Zoning, Building, FAA) 1

2 A hole hole is is drilled drilled for for a pier pier at at each each leg leg of of the the tower. tower. Construction Construction of of the the three three 36 36 diameter diameter piers piers entails entails a total total of of 20 20 yards yards concrete. concrete. Each Each pier pier is is 20 20 feet feet deep deep and and contains contains an an engineered engineered 500 500 pound pound cage cage of of rebar rebar to to provide provide the the foundation foundation with with appropriate appropriate tensile tensile strength. strength. Concrete Concrete is is innately innately strong strong in in compression. compression.

3 Four Four 36 36 anchor anchor bolts bolts are are mounted mounted into into each each pier. pier. Each Each set set of of anchor anchor bolts bolts must must be be perfectly perfectly aligned aligned with with the the bolt bolt holes holes in in the the flange flange on on the the base base of of each each tower tower leg. leg. Only Only 1 1 / 16 / 16 tolerance tolerance exists exists between between each each anchor anchor bolt bolt and and its its mating mating bolt bolt hole hole diameter. diameter. A wooden wooden triangular triangular jig jig is is used used to to achieve achieve this this critical critical positioning. positioning.

4 A fourteen fourteen day day (minimum) (minimum) cure cure period period is is required required for for the the concrete. concrete.

5 The The 120 120 tall tall Rohn Rohn SSV SSV free free standing standing truss truss tower tower is is delivered delivered to to the the construction construction site site in in 20 20 sections. sections. Total Total weight weight ~1500 ~1500 pounds. pounds. The The tower tower is is made made of of (galvanized) (galvanized) steel steel tube tube construction construction with with flanges flanges on on each each section section and and angle angle diagonal diagonal cross cross bracings. bracings. The The diameter diameter of of steel steel tubes tubes increases increases toward toward the the base base of of the the tower. tower.

6 Assembly Assembly of of tower tower begins begins at at the the TOP TOP of of the the tower. tower. To To attach attach the the cross cross bracing, bracing, a drift drift pin pin aligns aligns the the holes holes and and will will lever lever (with (with force) force) the the parts parts into into alignment. alignment. Then Then a set set of of vice vice grips grips clamps clamps the the parts parts together. together. Then Then the the ½ ½ bolt bolt with with lock lock nut nut secures secures that that point. point.

7 The The tower tower is is assembled assembled on on its its side side and and later later erected erected by by use use of of a crane. crane. The The first first two two legs legs are are assembled assembled on on the the ground. ground. Then Then the the third third leg leg is is attached, attached, with with its its free free end end supported supported by by a scaffold. scaffold. During During assembly, assembly, wooden wooden shim shim blocks blocks are are used used to to help help level level the the first first two two legs legs along along the the uneven uneven ground. ground.

8 At At the the base base of of the the tower, tower, this this becomes becomes a largescalscale effort. large- effort. Meanwhile, Meanwhile, a pre-fabbed pre-fabbed power power room room appears appears on on site site which which will will house house the the Balance Balance of of Systems Systems (BOS; (BOS; electrical electrical controls). controls). Ladder Ladder pegs pegs are are bolted bolted onto onto the the third third leg. leg.

9 The The power power cable cable is is fed fed down down the the middle middle of of the the tower tower and and attached attached w/uv w/uv resistant resistant heavy heavy duty duty cable cable ties. ties. Bergey Bergey Excel Excel wind wind turbine turbine arrives arrives weighing weighing >1400 >1400 lbs. lbs. The The tail tail fin fin is is attached attached to to the the tail tail boom boom and and nuts nuts are are torqued torqued to to specification. specification.

10 The The powerhead powerhead is is then then attached. attached. This This is is accomplished accomplished by by lifting lifting up up the the top top of of the the tower tower (using (using crane) crane) and and resting resting it it atop atop a wooden wooden platform platform to to provide provide the the necessary necessary clearance. clearance. Then Then the the powerhead powerhead is is lifted lifted off off of of the the pallet pallet by by use use of of the the crane crane and and moved moved into into position. position. Locating Locating the the bolt bolt holes holes between between the the tower tower and and the the powerhead powerhead requires requires use use of of the the drift drift pin pin and and great great effort, effort, including including use use of of a jack jack to to position position the the third third leg leg into into alignment. alignment. Note:cross Note:cross braces braces are are only only finger finger tight tight at at this this point. point. The The tail tail boom, boom, weighing weighing >100 >100 lbs, lbs, is is attached. attached.

11 Tail Tail damper damper and and furling furling cable cable are are attached attached by by 2 2 cotter cotter pins. pins. Making Making electrical electrical connections connections to to the the powerhead: powerhead: Slip Slip rings rings from from Yaw Yaw shaft shaft carry carry AC AC voltage voltage to to terminal terminal block block in in wiring wiring box. box. Opening Opening the the nacelle nacelle allows allows manipulation manipulation of of damper damper angle angle (shown (shown as as long long steel steel pipe) pipe) The The crane crane (w/100 boom) (w/100 boom) is is readied readied for for lift. lift. At At 84 84 up up the the 120 120 high high tower, tower, two two legs legs are are attached attached with with slings slings for for pick pick up. up.

12 With With the the powerhead powerhead at at eye eye level, level, and and a 2x4 2x4 supporting supporting the the tail tail boom, boom, the the blades blades can can be be installed. installed. Pulltruded Pulltruded fiberglass fiberglass blades blades are are attached attached with with deformed deformed nuts nuts driven driven with with an an impact impact wrench. wrench. Hand Hand tightening tightening is is possible, possible, but but not not advised. advised. Final Final torque torque is is applied applied with with calibrated calibrated torque torque wrench. wrench. The The nosecone nosecone (spinner), (spinner), seen seen in in background, background, is is attached attached w/three w/three bolts bolts and and the the tower tower is is ready ready for for raising. raising.

SAFETY SAFETY FIRST. FIRST. The The tower tower is is lifted lifted slowly. slowly. Special Special attention attention and and planning planning are are required required to to ensure ensure that that the the wind wind turbine s turbine s blades blades and and tail tail have have sufficient sufficient clearance clearance from from the the crane. crane. The The crane s crane s boom boom is is initially initially positioned positioned to to ensure ensure that that boom boom movement movement is is TOWARD TOWARD crane s crane s center center of of gravity gravity during during tower tower raising raising so so that that crane crane does does not not extend extend beyond beyond its its balance. balance. 13

SAFETY SAFETY FIRST. FIRST. Radio Radio communication communication and and hand hand signals signals are are used used between between the the contractor contractor and and crane crane operator. operator. One One leg leg of of tower tower skids skids along along the the dirt dirt ground ground during during raising raising until until tower tower is is fully fully vertical vertical and and suspended suspended above above piers. piers. 14

15 Using Using a lever lever to to help help position position the the tower tower leg leg onto onto the the anchor anchor bolts. bolts. IT IT FITS! FITS! The The tower tower legs legs are are attached attached one one at at a time time to to their their anchor anchor bolts. bolts. Here Here the the flange flange is is secured secured between between double double nuts nuts on on the the anchor anchor bolts. bolts. Prior Prior to to the the tower tower raising, raising, the the level level of of all all three three legs legs was was predetermined predetermined and and set set within within 1 1 / 16 / 16 This This was was accomplished accomplished by by using using a water water level level to to fix fix the the location location of of the the bottom bottom nut nut on on the the anchor anchor bolt. bolt.

16 Furling Furling cable cable and and winch winch are are installed. installed. The The wind wind turbine turbine must must be be furled furled before before climbing climbing the the tower. tower. Tower Tower must must be be climbed climbed to to disconnect disconnect the the crane. crane. Safety Safety precautions precautions when when climbing climbing the the tower tower are are imperative. imperative.

17 Beginning Beginning at at the the top, top, all all cross cross bracing bracing bolts bolts (500 (500 +) +) need need to to be be torqued torqued to to specification specification and and supplied supplied a final final lock lock nut. nut. This This approach approach locks locks tower tower into into plum plum and and straight straight alignment. alignment. This This process process required required ~20 ~20 man man hours. hours. Plan Plan ahead ahead to to avoid avoid any any unnecessary unnecessary trips trips up up and and down down the the tower. tower. Tower Tower climbing climbing warrants warrants rest rest every every 20 20 feet. feet. Sturdy Sturdy boots, boots, leather leather gloves, gloves, hard hardhat, hat, full full body body harness, harness, safety safety lanyard, lanyard, positioning positioning hooks hooks and and tethered tethered tools tools are are required. required.

18 Each Each leg leg is is grounded. grounded. Lightning Lightning arrester arrester is is installed installed on on wiring wiring box. box.

Inside Inside Power Power Room: Room: Balance Balance of of Systems Systems A-Transformer A-Transformer (STEPS WILD AC VOLTAGE (STEPS WILD AC VOLTAGE OUTPUT FROM BERGEY WIND OUTPUT FROM BERGEY WIND ALTERNATER FROM ~150V TO ALTERNATER FROM ~150V TO ~48V ) ~48V ) B-Bergey B-Bergey 48V 48V Regulator Regulator (RECTIFIES WILD AC TO (RECTIFIES WILD AC TO CONTROLLED DC and CONTROLLED DC and PREVENTS BATTERY PREVENTS BATTERY OVERCHARGE) OVERCHARGE) B C 19 C-Vanner C-Vanner Power Power Center Center DC DC Control Control Module Module (PROVIDES DC OVERCURRENT (PROVIDES DC OVERCURRENT PROTECTION) PROTECTION) AC AC Power Power Inverter Inverter (CONVERTS CONTROLLED DC (CONVERTS CONTROLLED DC TO CONTROLLED AC) TO CONTROLLED AC) AC AC Control Control Module Module (DISTRIBUTES CONTROLLED AC (DISTRIBUTES CONTROLLED AC TO LOADS (and GRID, if TO LOADS (and GRID, if available)) available)) D-48V D-48V NiCAD NiCAD Battery Battery Bank Bank A Photos Photos taken taken inside inside power power room room prior prior to to electrical electrical hookups. hookups. D

1 6 7 2 3 8 9 20 4 Tower 5 Power room Schematic Schematic of of electrical electrical power power system. system. 1.Bergey Excel R-48 wind generator wild AC output 2.Bergey tower wiring, 3 x #6 AWG MC Armored Cable 3.60A 600V 3-pole fusible, 3R rainproof disconnect with 3 x 60 Amp fuses and LA603 Arrestor 4.3 x # 6 AWG THHN in 2 PVC conduit, trenched 5.Step down transformer 6.Bergey VCS-10 controller (AC to DC) 7.Vanner RE-4500 48 VDC inverter with DC module and AC module includes DC over current protection and AC output breakers. 8.48 VDC battery Bank 9.AC circuits: outlets, light, fan, baseboard heater Third Sun Renewable Energy Title:Glacier Ridge one line schematic (740) 448-3111 Geoff@Third-Sun.Com Page: 1

Application Application for for Zoning Zoning Certificate Certificate is is through through Township.The Township.The most most common common zoning zoning issue issue is is height height restrictions; restrictions; permission permission to to exceed exceed normal normal limit limit may may require require a variance. variance. 21

Application Application & Approval Approval of of Building Building Permit Permit is is through through County. County. Permitting Permitting may may require require fee fee (usually (usually <$300), <$300), plot plot plan, plan, construction construction plans, plans, structural structural analysis analysis w/pe w/pe stamp, stamp, and and UL UL Listing Listing for for electrical electrical equipment. equipment. 22 NOT AVAIL

23 Federal Federal Aviation Aviation Administration Administration (FAA) (FAA) Requirements: Requirements: Usually, Usually, FAA FAA review review in in not not required required for for towers towers less less than than 200 200 unless unless the the turbine turbine is is near near an an active active airport. airport.

Anatomy Anatomy of of the the Bergey Bergey Excel Excel Nacelle Powerhead Alternator 24 Tail Boom Tail Fin Spinner (nosecone) Start-up Start-up Wind Wind Speed: Speed: 7.5 7.5 mph mph Type: Type: 3 3 Blade Blade Upwind Upwind Cut-in Cut-in Wind Wind Speed: Speed: 7 7 mph mph Rotor Rotor Diameter: Diameter: 23 23 ft ft Rated Rated Wind Wind Speed: Speed: 31 31 mph mph Overspeed Overspeed Protection: Protection: AUTOFURL AUTOFURL Rated Rated Power: Power: 7.5 7.5 kw kw for for battery battery charging charging / / 10 10 KW KW for for grid grid connection connection Furling Furling Wind Wind Speed: Speed: 35 35 mph mph Gearbox: Gearbox: None, None, Direct Direct Drive Drive Max Max Wind Wind Speed: Speed: 120 120 mph mph Generator: Generator: Permanent Permanent Magnet Magnet Alternator Alternator Output Output Form: Form: 3 3 phase phase AC, AC, Variable Variable Frequency Frequency Source: Bergey website www.bergey.com