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                               ENERCON Magazine
                               for wind energy
                               Issue 03 | 2009

25 YEaRs!
Success through technology
Page 6

Hydropower station in
Raguhn, Germany: ENERCON
technology proves its worth
in hydropower
Page 10

WECs for Scottish islands:
Three promising projects on
the Orkneys
Page 14

Job ProfileS
PCT Installation Technician:
Precision teamwork on
precast concrete towers
Page 16

Hulvershorn foundry in
Bocholt, Germany: Consistent
quality over hundreds of
Page 18
                    international sales offices
                    ENERCON GmbH, SalES DEpt.
                    ENERCON Sales (headquarters)
                    Dreekamp 5 · 26605 Aurich · Phone +49 4941 927-0
                    Fax +49 4941 927 669                                                                            Page 3                            editorial
                    ENERCON Sales Bremen
                    Otto-Lilienthal-Str. 25 · 28199 Bremen
                    GERMANY · Phone +49 421 2441 510 · Fax +49 421                                                                                    enercon news
                    2441539 · e-mail:
                                                                                                                    Page 4                            News from the ENERCON world
                    ENERCON Soporte Area Argentina
                    Blanco Encalada 1204-4/B
                    C1428DCJ Ciudad de Buenos Aires · ARGENTINIA
                                                                                                                                                      Title Story
                    Phone + 54 11 47 886 114 · Fax + 54 11 47 886 114                                               Page 6                            ENERCON – 25 years! Success through
                                                                                                                                                      technology leadership
                    ENERCON Austria Ges.mbH · Hauptstrasse 19
                    2120 Wolkersdorf · AUSTRIA · Phone +43 2245 82828
                    Fax +43 2245 82838 · e-mail:                                                  Page 8                            Congratulations on ENERCON’s 25th
                    baltIC StatES/EaSt aSIa                                                                                                           anniversary: Founder of a new era
                    ENERCON Denmark · Bredkær Parkvej 62
                    8250 Egaa · DENMARK
                    Phone +45 87 430 388 · Fax +45 87 430 344
                                                                                                                    Page 10                           ENERCON hydropower station in
                    ENERCON Services Belgium BVBA· Sales Belgium                                                                                      Raguhn, Germany: ENERCON technology
                    Bernhard Fink · Stationsstraat 97
                    B-2440 Geel · BELGIUM                                                                                                             proves its worth in hydropower
                    Phone +32 14 591 611· Fax +32 14 591 612

                    bRazIl                                                                                          Page 12                           Wind-diesel system on Bonaire: A dozen
                    Wobben Windpower Ltda.
                    Av. Fernando Stecca nº 100 · Distrito Industrial CEP
                                                                                                                                                      E-44s for a Caribbean diver‘s paradise
                    18087450 Sorocaba · São Paulo · BRAZIL
                    Phone +55 15 2101 1700 · Fax +55 15 2101 1701
                    e-mail:                                                                                                         international
                    CaNaDa                                                                                          Page 14                           WECs for Scottish islands: Three
                    ENERCON Canada Inc.
                    1000 de La Gauchitière Street West · Suite 2310                                                                                   promising projects on the Orkneys
                    Montreal, Québec · H3B 4W5 · CANADA
                    Phone / Fax +1 514 363 7266
                                                                                                                                                      Job Profiles
                    ENERCON GmbH bureau français                                                                    Page 16                           Precast Concrete Tower Installation
                    1, rue des Longues Raies · ZAC des Longues Raies
                    F-60610 La Croix Saint Ouen · FRANCE
                                                                                                                                                      Technician: Precision teamwork on
                    Phone +33 3 44 83 67 20 · Fax + 33 3 44 83 67 29                                                                                  precast concrete towers
                    ENERCON GmbH, Greek Branch
                    20, Pentelis Avenue · 15235 Vrilissia, Athens · GREECE                                                                            Suppliers
                    Phone +30 210 6838 490 · Fax +30 210 6838 489
                    e-mail:                                                                 Page 18                           Hulvershorn foundry in Bocholt,
                    Italy                                                                                                                             Germany: Consistent quality over
                    ENERCON Italia · Via Luciano Manara, 5
                    00044 Frascati (Roma) · ITALY · Phone + 39 06 94 01 69 1                                                                          hundreds of castings
                    Fax + 39 06 94 01 69 299 · e-mail:

                    lUxEmbURG & tHE NEtHERlaNDS
                    ENERCON Benelux BV · Paxtonstraat 1 a
                    8013 RP Zwolle · THE NETHERLANDS
                    Phone +31 38 4228 282 · Fax +31 38 4228 010
                                                                                                                    Page 20                           Hitachi Engineering & Services:
                    e-mail:                                                                                                  ENERCON’s Installation, Sales and
                    NEw zEalaND                                                                                                                       Service Partner for Japan
                    ENERCON GmbH · Andrea von Lindeiner · PO Box 340206
                    Birkenhead · Auckland 0746 · NEW ZEALAND
                    Phone +64 9 4199 231 · +49 4941 976 959-147
                    e-mail:                                                                                            addresses & events
                    pORtUGal                                                                                        Page 2                            ENERCON Addresses
                    ENERCON GmbH Sales Portugal · Parque Empresarial de
                    Lanheses · Lugar de Segadas · 4925 424 Lanheses
                                                                                                                    Page 5                            Info-Service
                    Viana do Castelo · PORTUGAL
                    Phone +351 258 803 500 · Fax +351 258 803 509

                    SpaIN                                                      Imprint
                    ENERCON GmbH, Sucursal en España
                    Ronda de Auguste y Louis Lumière 23
                                                                               Publisher: ENERCON GmbH · Dreekamp 5 · 26605 Aurich · Germany
                    Edificio 21 A · Parque Tecnológico                         Phone +49 4941 927-0 · Fax +49 4941 927-109 ·
                    46980 Paterna (Valencia) · SPAIN
                    Phone +34 961 824 558 · Fax +34 961 828 143                editorial office: Volker Uphoff, Ruth Brand, Teelke Bojarski
                                                                               Printed by: Steinbacher Druck GmbH, Osnabrück, Germany
                    SwEDEN                                                     copyright: All photos, illustrations, texts, images, graphic representations, insofar as this is not expressly stated to the
                    ENERCON Energy Converter AB
                    Stenåldersgatan 19 · 21376 Malmö · SWEDEN                  contrary, are the property of ENERCON GmbH and may not be reproduced, changed, transmitted or used otherwise without
                    Phone +46 40 143 580 · Fax +46 40 222 420
                                                                               the prior written consent of ENERCON GmbH.
                                                                               frequency: The WINDBLATT appears every three months and is regularly included in the “new energy”, magazine for renewa-
                    ENERCON GmbH · Sales Turkey                                ble energies, of the German Windenergy Association.
                    Holger Bohlen · Dreekamp 5 · 26605 Aurich · GERMANY
                                                                               Subscribe: Phone +49 4941 927-667 or
                    Phone +49 4941 927-0 · Fax +49 4941 927-109
                    e-mail:                           cover photo: E-126 at wind farm in Aurich-Georgsfeld, Germany.
                                                  EDITORIAL        wINDBLATT 03 | 2009         3

Dear Readers,
Last September, Germany was able to celebrate another milestone on the way towards a rege-
nerative energy supply system: There are now 25,000 MW of wind power installed generating
clean electricity. This corresponds to the consumption of 13 million private households. The
wind energy sector thus demonstrated once more what it is capable of achieving. The new
Federal Government, which will be constituted soon, will be instrumental in deciding whether
we continue to make such great strides towards a fully regenerative energy system: In order
for us to keep growing, we remain dependent on framework conditions that allow us to find our
place in a market dominated by a small number of large electricity providers. If however our
lifeblood the German Renewable Energy Sources Act, were to be modified in crucial aspects,
we might quickly face hard-to-overcome obstacles.

To protect us from being squeezed out of the market by the operators of large conventional
power plants, the new government must prevent the power grids from being blocked by an
inflexible base load from coal-fired and nuclear power plants. A new study by the Fraunhofer
Institute for Wind Energy and Energy System Technology (IWES) has shown that as early as
2020, there will be little room left for conventional power plants. The need for large-scale
conventional power plants with continuous electricity production will drop by about 50 % com-
pared to 2007. Which means there is no reason to keep nuclear power plants running and
build new coal power plants, because in 2020, half of the electricity will already be provided by
renewable energy sources and pumped storage power stations.

This electricity comes from many regenerative power stations. Building them creates more
and more new jobs – not least at ENERCON. In October, we inaugurated another new factory:
In the harbour of Magdeburg, a state-of-the-art facility for the production of precast concrete
towers (PCT) went into operation. The planned production capacity will be 200 PCT per year.
These towers with hub heights up to 138 m make the production of clean energy profitable at
inland sites, too.

The Climate Summit soon to be held in Copenhagen will show just how serious the governments
of the world are in their fight against the most urgent problem of our time. So far, renewable
energies play almost no role in their concepts for fighting climate change. When negotiating the
follow-up agreement to the Kyoto Protocol, it will be crucial that the international community
agrees to base the worldwide energy supply of the future on renewable energies. Because there
is no other way to secure a long-term climate-friendly energy supply for all of humankind!

                                     Yours sincerely

                                                                               Aloys Wobben
                                                           Managing Director ENERCON GmbH
                                                     4     wINDBLATT 03 | 2009               NEWS

                                                                                                          Hölscher. The Rothensee site is located be-            rifa, Spain. Construction work had started in
Picture: Federal State Capital Magdeburg/B.Kapelle

                                                                                                          tween the motorway and the inland harbour,             May 2008. “The construction phase took 13
                                                                                                          allowing for a fast and efficient transport of         months in total. The commissioning of the last
                                                                                                          the segments to the construction sites. Early          five turbines in Pesur is currently in full swing,”
                                                                                                          next year, a railway line will be completed in         says project manager Christian Oberbeck. He
                                                                                                          Rothensee. Materials such as sand and gravel           expects the commissioning of all wind turbi-
                                                                                                          that are needed for concrete production will           nes including the EEE units to be completed
                                                                                                          then be delivered directly to the factory. In          in the last month of this year after an existing
                                                                                                          addition to the concrete plant, a state-of-the-        transmission substation has been extended.
                                                     Inauguration ceremony with ENERCON Managing          art assembly facility for prestressing tendons
                                                     Director Aloys Wobben (2nd from left) and Reiner     has been set up. It contains a 135-metre-long          The project was initiated by Sociedad Eólica de
                                                     Haseloff, Minister for the Economy of the State of
                                                     Saxony-Anhalt (2nd from right).                      steel cable assembly unit, meaning that all            Andalucía, S.A. Their goal – the replacement of
                                                                                                          prestressing tendons can now be manufac-               246 old wind energy converters in the power
                                                                                                          tured in-house. Attached to the facility is a          range of 100 to 180 kW with 37 E-70 turbines
                                                     Inauguration of new precast concrete                 central laboratory where all materials used            – will thus soon be accomplished. The total in-
                                                     tower factory in Magdeburg                           worldwide for the tensioning of the towers are         stalled power of the wind farms increases from
                                                     On 2 October, tower manufacturer WEC Turm-           tested. The company expects to create about            30.6 to 74 MW. The performance of the WECs
                                                     bau GmbH inaugurated its new production              100 additional jobs at the new site.                   already in operation in Pesur 1 is outstanding:
                                                     facility in Magdeburg-Rothensee in Eastern                                                                  “Since September 2008, twelve of the 21
                                                     Germany. The new plant in Magdeburg‘s inland         WEC Turmbau also built a new facility in               WECs have been feeding between 460 and
                                                     harbour “Hansehafen” was officially launched         Emden: Starting in October, prestressing ten-          630 thousand kWh per month into the grid.”
                                                     by Reiner Haseloff, Minister for the Economy         dons for PCT will be assembled here. ENER-             Their availability is at 98.2 percent.
                                                     of the State of Saxony-Anhalt, and Aloys Wob-        CON PCTs consist of up to 36 segments that
                                                     ben, Managing Director of ENERCON GmbH.              are joined at the construction site. The ne-           Tarifa is the first large-scale repowering pro-
                                                                                                          cessary strength and flexibility of the towers         ject in Spain. “More wind farm overhauls are
                                                     The new facility was built over the course of        is provided amongst others by prestressing             under consideration,” explains Oberbeck.
                                                     only 15 months. Engineering firm Baumert &           tendons which are inserted into tubes that run         However, no more projects will enter the con-
                                                     Peschos planned the building and managed             from the base through the outer wall to the            struction phase in Spain as long as the new
                                                     the construction phase. GM Stahlbau GmbH             top segment and finally are tensioned. These           feed-in tariff has not been legislated. “We are
                                                     supplied the structural steel components, and        tendons can now be processed in Emden from             expecting the government to make their deci-
                                                     H&G Hochbau GmbH built the foundations. The          where they can be shipped directly to over-            sion later this year, so the race for sites should
                                                     concrete batching equipment came from Lieb-          seas construction sites together with the con-         start next year.”
                                                     herr. Traba GmbH & Co KG made the windows            crete segments.
                                                     that ensure a maximum of natural daylight in-
                                                     side the factory.                                    By January, a new three-storey office building         ENERCON‘s longest railway transport
                                                                                                          will be attached to the tensioning facility. It will   went to British Columbia
                                                     The new building is 350 m long and 71 m              also have room for a training centre. “Here
                                                     wide and offers enough production floor space        we can offer optimised training programmes
                                                     to increase the efficiency of precast concrete       e.g. for the staff of the concrete factories that
                                                     tower (PCT)manufacturing for ENERCON. “The           we plan to set up outside of Germany,” adds
                                                     arrangement of the stations in the spacious          Hölscher. The first class will presumably be
                                                     factory building – from the ironworking unit         made up of staff from the factory in Matane,
                                                     via the concrete casting stage to the finishing      Canada, that is scheduled for 2010. The new
                                                     area – is designed to ensure fluent processes,”      facilities increase the production capacities of
                                                     explained Norbert Hölscher, Managing Director        WEC Turmbau (Emden and Magdeburg) to up
                                                     of WEC Turmbau. Compared to the factory at           to 400 PCTs per year.
                                                     the previous site in Magdeburg Alt-Salbke, the                                                              May 2009: First train with ENERCON rotor blades
                                                     output capacity has increased from 15 to 25                                                                 leaving Thunder Bay westwards.

                                                     concrete tower segments per day.                     Repowering complete at Tarifa
                                                                                                          Last August, ENERCON hoisted the last rotor            When during the spring and summer of this
                                                     “This new site offers the advantage of a             hub for the repowering of wind farms Pesur 1           year, ENERCON‘s logistics department needed
                                                     direct trigonal traffic connection,” added           and Energía Eólica del Estrecho (EEE) in Ta-           to ship components for 34 E-82 turbines to the
                                                                                                         NEWS       wINDBLATT 03 | 2009        5

                                                    southwest – the turbines can be spaced more          nerec 2009

                                                    closely together than usual. ENERCON‘s site          (Oslo/Norway)
                                                    assessment team were thoroughly involved             North European Renewable Energy
                                                    in the project from the start and optimised          Convention
                                                                                                         Norwegian Exhibition & Conference
                                                    the site setup in cooperation with the custo-
                                                                                                         Centre (Lillestrøm near Oslo)
                                                    mer. Due to the location on a mountain ridge
                                                                                                         7-8 October 2009
                                                    with a single road through the wind farm, the
                                                    ENERCON installation teams are hoisting the
                                                    rotor blades individually. Thanks to the outstan-
                                                    ding and thorough preparation on the part of         bWea31 2009
Single rotor blade installation on Bear Mountain.   the customer, this project will be one of the fas-   (Liverpool/England)
                                                    test installations ever carried out by ENERCON.      31st Annual Conference & Exhibition
Bear Mountain wind farm in Western Canada,                                                               on Renewable Energy
they did so by using sea and rail transport al-                                                          ACC Liverpool
                                                                                                         20-22 October 2009
most all the way to the construction site. Only     25,000th MW of wind energy in Germany
for the last 25 km from the station in Dawson       on the grid – an E-82 in Bavaria!
Creek (BC) to the site, trucks were used to car-    In late September, German Minister for the
ry the rotor blades and accessories containers.     Environment Sigmar Gabriel pressed a button          agritechnica 2009
                                                    that marked a milestone en route to the ener-        (Hanover/Germany)
All in all, the components travelled 10,000         gy revolution: The start-up of an E-82 turbine       International German Agricultural
kilometres. The starting point for the three        in the Ochsenfurt-Erlach wind farm near Würz-        Society Exhibition for Agricultural
shipments was in Aurich, Germany. A freight         burg (Bavaria) means there are now 25,000            Machinery
train of regional railway operator EGOO hauled      MW of wind power providing Germans with              Exhibition Grounds Hanover
the rotor blades and containers to Emden,           clean energy. By now, wind energy in Germany         10-14 November 2009
where they were loaded onto seagoing ves-           can provide 13 million homes with clean elec-
sels. The ships then sailed to the other side       tricity. More than 9,400 MW of installed wind
of the Atlantic Ocean, up the Saint Lawrence        power come from ENERCON.
                                                                                                         3rd european renewable energy
River past Montreal, through the Great Lakes                                                             Policy Conference
all the way to Thunder Bay in the very west         In his speech, Gabriel called the development        (Brussels/Belgium)
of Lake Superior. Here, the WEC components          of the renewable energies industry in Germa-         EREC renewable policy conference
were loaded onto freight cars of the Canadian       ny a success story. It created industrial jobs at    Flagey Convention Centre
National North American Railway that carried        a time when most other sectors suffered job          16-17 November 2009
them the rest of the way – 2,600 kilometres         losses. Moreover, this landmark event proved
to Dawson Creek. The trains were 840 metres         that there was no reason to hold on to nuclear
long and travelled for up to ten days. Between      power. Those who prolonged the service life of
                                                                                                         business Plus 2009
each pair of loaded freight wagons, an empty        nuclear power plants were slowing down the
wagon was interspersed to compensate for            growth of renewable energies, not least jeo-
                                                                                                         The Northwest Job Fair
the overhang of the rotor blades.                   pardising thousands of jobs, said the Minister.      Nordseehalle Emden
                                                                                                         25-26 November 2009
By now, installation work on the wind farm on       Joachim Keuerleber, ENERCON‘s Sales Direc- 
the Bear Mountain ridge top is in full swing.       tor for Southern Germany, spoke of the long
“The wind farm is scheduled for completion          road ahead in particular in Bavaria. The State
in October,” says project manager Nils Win-         is currently governed by a conservative-liberal      new Zealand Wind energy
gert. The project is founded on a partnership       coalition whose goal it is to achieve a 30 %         Conference 2010
between utility AltaGas, Calgary (Alberta),         electricity share from renewable sources by          (Palmerston North/New Zealand)
                                                                                                         Exhibition and conference on New
and the Peace Energy Cooperative, a local           the year 2020. “In order for this to happen,
                                                                                                         Zealand‘s wind industry
renewable energies initiative with about 400        a very substantial portion of Bavaria‘s power
                                                                                                         29-31 March 2010
members. The Bear Mountain ridge is located         supply must come from wind energy, because 
on the edge of the Peace River Plateau be-          this sector has by far the largest potential for
tween the prairie and the early foothills of the    exploitation and economic viability,” Keuerle-
Rocky Mountains. Since the wind here blows          ber said. So far, wind energy converters only
very predominantly from one direction – west/       supply 0.7 % of the electricity in the State.
6    wINDBLATT 03 | 2009              TITLE STORY

ENERCON – 25 years!

Success through
technology leadership
In July, ENERCON celebrated its 25th anniversary. During this time,                                                    “The Flüger furniture store in Norddeich
the company has evolved from a small founder-owned company with                                                        and the municipal utilities in Norderney
innovative ideas for a “niche” product to the German market leader in                                                  and in Norden were our first customers in
wind energy, all the while remaining true to its motto “Energy for the                                                 the region. In the first year of production,
                                                                                                                       we made five turbines; in the second year,
world”. Until today, ENERCON has installed more than 15,000 wind
                                                                                                                       twenty,” remembers Klaus Peters, who has
energy converters worldwide with a total power of 18.5 GW, roughly
                                                                                                                       been with ENERCON from day one and is
corresponding to the power of 18 nuclear power plants. The company’s                                                   now Overall Production Manager. Company
drive for innovation has been a major success factor.                                                                  founder Wobben was the only person back
                                                                                                                       then who was convinced that one day, they
ENERCON came into being when company                       In 1984, Aloys Wobben and a small team                      would build 1000 machines per year.
founder Aloys Wobben had an idea: In the                   manufactured the frequency converters
wind energy converters of the time, rotor and              needed for turbine yawing in a former car-                  Switching to direct drive
generator turned at a fixed speed because                  pet warehouse in Aurich in Northwest Ger-                   technology
they had to adapt their power feed to the                  many. As the WEC manufacturers of the day
50 Hz frequency of the power grid. The grid                were unwilling to take up the idea of grid                  The zero series production allowed
determined the rotational speed. However,                  decoupling, Aloys Wobben decided to press                   ENERCON to gain valuable experience. The
wind turbines produce more energy, if they                 on with the development of his own WEC.                     biggest source of problems turned out to
can adjust their rotational speed to the wind              One year later, the first E-15 turbine with                 be the gearbox with oil leaks and gear-
speed. Wobben’s idea was to use a conver-                  55 kW of rated power was erected near the                   wheel breakages. As a result, the decision
ter to transform the variable frequency of the             home of the company‘s founder. This ma-                     was taken to dispense with this component
generator and thus adapt it to the grid. This              chine, with some modifications, is still in                 completely. After years of intensive deve-
makes it possible to decouple WEC and grid,                operation today: Apart from the converters,                 lopment, the first gearless WEC was built in
and the WEC can adjust its rotational speed.               it consisted entirely of supplied parts.                    1992: An E-36 turbine, the precursor of the

ENERCON history: From the beginnings – first prototype; installation of two E-16 on the island of Norderney; an E-40 on the island of Fehmarn ...
                                                                                                           TITLE STORY      wINDBLATT 03 | 2009           7

E-40 that would soon be widely sold. At the               period of cautious probing on both sides           sail rotor propulsion system and optimised
same time, options were explored to reduce                – SKET had had bad experiences in earlier          hull and propeller shapes. The company has
the load on the rotor, resulting in the intro-            takeovers – a synergetic relationship evol-        also been active in the fields of hydropower
duction of adjustable rotor blades that can               ved that combined the strengths of two dif-        (see also the technology article on page 10)
rotate around their own axes to turn out of               ferent company cultures: SKET came with            and seawater desalination, and the sup-
the wind when necessary.                                  great experience in large-scale industrial         ply of wind-diesel systems that provide an
                                                          projects, ENERCON contributed its innovati-        efficient and environmentally-friendly elec-
In parallel, manufacturing capacities were                ve spirit and flexibility. Manufacturing capa-     tricity supply in stand-alone systems.
expanded. The most successful approach                    city doubled within just one year, positioning
proved to be the in-house production of                   the company perfectly for the wind turbine         Culture of innovation
those components for which a satisfactory                 boom that started after the turn on the mil-
supplier could not be found on the market.                lennium, not least thanks to the amended           ENERCON’s success is founded on a culture
When no annular generators of the required                German Renewable Energy Sources Act.               of innovation that permeates all parts of the
size existed in the early 1990s, ENERCON                                                                     company from research & development to
began to develop their own generators. Be-                Growing production capacities                      manufacturing, where engineers are con-
cause the efficiency of the conventional rotor            and technology advances                            stantly looking for ways to improve products
blades left to be desired, the company desig-                                                                and processes and to implement ideas that
ned their own optimised rotor blade shapes                Even during the years of growth in which a         create solutions. The company also ma-
and set up a series production facility.                  lot of energy was directed towards expan-          nages to strike the right balance between
                                                          ding production capacities, ENERCON never          bringing in outside expertise and relying on
In the course of the 1990s, ENERCON fully                 lost sight of the advancement of their pro-        home-grown skills for filling management
industrialised their wind energy converter                duct design and technology. The develop-           positions. And since the knowledge requi-
production. Milestones included the begin of              ment focus lied on the introduction of the         red for creating cutting-edge WEC tech-
E-40 series manufacturing in Aurich (1993);               new rotor blade design for all turbine types;      nology needs to be passed on to the next
the first international production facilities             the enhancement of power electronics; the          ENERCON generation, the company training
in India (1995) and Brazil (1996); as well                continued differentiation of the model ran-        policy has been exemplary right from the
as the acquisition of machine engineering                 ge; and the widening of the range of appli-        start. Currently, it is offering apprenticeship
company SKET (1998) based in Magdeburg                    cation of gearless turbine technology.             opportunities in 20 different vocations.
in Eastern Germany, which constituted the
breakthrough to large-scale series produc-                At the end of 2007, the most powerful              At the end of the day, ENERCON also owes
tion. By now, development had progressed                  WEC to date made its appearance in the             its growth capacities to the high custo-
to the E-66/1.8 MW.                                       ENERCON product offering: The E-126 with           mer satisfaction, which in turn is founded
                                                          6 MW of rated power. In addition, ENERCON          on the high technical availability and the
With SKET, ENERCON acquired a formering                   developed their own fuel-efficient cargo ship      proven reliability of ENERCON’s WEC tech-
GDR large-scale enterprise. After a brief                 for transporting WECs, with an innovative          nology.

... the SKET factory in Magdeburg; an E-66; manufacturing of generators – to the E-126.
8    wINDBLATT 03 | 2009           TITLE STORY

Congratulations on ENERCON’s 25th anniversary

Founder of a new era
On the occasion of the company’s 25th anniversary, ENERCON has re-                                        sable partner on our common path into a more
ceived a number of congratulatory notes – from customers, suppliers,                                      climate-friendly energy future.
banks, politicians, and others in the wind industry – in recent months.
Windblatt prints a few of them on these pages, as well as an interview                                    Perfect story of a successful
with an ENERCON employee who has been with the company for over                                           green entrepreneur
20 years. Windblatt wishes to thank all authors.                                                          The story of Aloys
                                                                                                          Wobben provides
Greeting from Chancellor Merkel                   means that ENERCON’s prospects for growth               us with a picture-
Thanks to the                                     are excellent. For the future, I send my best           perfect example
entrepreneurial                                   wishes for continued success to the company             of a successful
spirit of its foun-                               and its people.                                         green entrepre-
der, the innova-                                                                                          neur. 25 years
tive drive of its                                 Cutting-edge technology by                              ago he started
engineers, and                                    ENERCON                                                 as inventor in
the commitment                                                                                            the garage, so to J. Trittin, MP for the German
of its employees,                                 25         successful                                   speak, at a time Green Party
ENERCON today                                     years                  for                              when people sni-
is among the lea- A. Merkel, German Chancellor    ENERCON embo-                                           ckered at the Green party and their ideas for an
ding makers of                                    dy 25 successful                                        energy revolution, and when green engineers
wind energy converters in the world. Besides      years of an                                             and inventors were still regarded as outsiders.
research and development, the manufacturing       increasing use                                          Today, his most modern turbine produces as
operations secure many thousand future-           of wind energy                                          much electricity in one day as his first one did
proof jobs in Germany. This makes the com-        worldwide, and                                          in one year.
pany an outstanding example of the growth         of economic pro-
experienced by the renewable energies sector,     gress in low- C. Wulff, Prime Minister of               The renewable energies industry continues to
and the opportunities available to industry and   i n f r a s t r u c t u r e the State of Lower Saxony   add new chapters to its success stories, crises
business in Germany.                              rural regions of                                        notwithstanding. Today, more that 280,000
                                                  Lower Saxony. With its cutting-edge techno-             people in Germany work in renewable ener-
The creation of a sustainable and climate-        logy, ENERCON has fully earned its position as          gies, outnumbering the coal industry and nu-
compatible energy supply system is one of         market leader in Germany.                               clear sector by far. ENERCON makes a huge
the great challenges of the coming decades.                                                               contribution, employing about 8,000 people in
The Federal Government backs a broad and          To protect the climate and to reduce the de-            Germany. Oftentimes, the company has been a
climate-friendly energy mix to prevent one-       pendency on fossil fuels, Lower Saxony‘s                veritable locomotive of innovation in the wind
sided dependencies. This includes electricity     State Government has set itself the goal to             energy industry, an industry that has been gro-
generation from coal and gas, nuclear power       increase the share of renewable energies in             wing and must continue to do so – because if
as a bridge technology, and the expansion of      the total energy consumption to 25 % by the             we are to reach the “2 degree” goal, the chan-
the renewable energies sector in a very sub-      year 2020, in particular by growing the wind            geover to renewable energies must happen
stantial role.                                    energy sector. Without ENERCON‘s innovative             worldwide. We will not be able to do this with
                                                  and high-end quality wind energy converters,            new coal power plants and old nuclear stations.
The Renewable Energy Sources Act has put          we would not be able to achieve this ambitious
the necessary framework in place. The fact        goal in such a short time frame.                        Founder of a new era
that other countries are following our examp-
le confirms that we are on the right track. We    The State Government counts on ENERCON                  Those entrepreneurs who acted as trailblazers
can continue to expect a dynamic expansion        and the strength and performance of the                 of industrialisation shared certain traits: Not
of the worldwide wind energy market which         company‘s entire team. You are an indispen-             only did they pioneer their particular field of
                                                                                                         TITLE STORY        wINDBLATT 03 | 2009              9

technology, they                                     From apprentice to E-126                              What has changed
were also suc-                                       construction supervisor                               since then?
cessful designers                                    Windblatt: Back in 1987, you were ENERCON‘s           People used to
and      business                                    first apprentice. What were your reasons?             think it was funny
architects. They                                     Stefan behrends: I had completed a training           when somebody
had an idea that                                     course in metalworking and design enginee-            said, „I work at
nobody could dis-                                    ring at the community college, and I needed           ENERCON.“ Today,
suade them from.                                     to add a work placement to earn my diploma.           people are keen on Stefan Behrends
At the same time, H. Scheer, MP, Chairman            It was important to me to be able to do some          working here. And
                    of the World Council for
they had enough Renewable Energy                     real work. ENERCON was the perfect place              with larger wind turbines comes greater res-
strength      and                                    for that.                                             ponsibility – I‘m construction supervisor for the
endurance to outlast any dry spells.                                                                       E-126 turbine now. If something goes wrong,
                                                     What kind of company was it back then?                there‘s a lot more pressure today.
All of these traits can be found in Aloys Wob-       There were about a dozen employees. Our
ben, the founder of ENERCON. He is a pioneer         “factory” was a workshop that could just              At what point were you certain that you would
of wind energy and still his own R&D manager;        about fit two cars, and we had storage room           stay with the company?
he pays attention to detail and sees the big         for two E-16: When they were finished, we had         When ENERCON built their first factory in 1991
picture at the same time; he is a successful         to install them so that we could produce ano-         and started series production of the E-32,
businessman with staying power. Mr. Wobben           ther unit.                                            I knew that we were on to something big.
holds a fundamental ethical conviction: That
our earthly civilisation must quickly and reso-
lutely turn its back on the cardinal sin of fossil   Promoting climate protection                          As reliable as the sun
and nuclear energy use, and can only survive if      together                                              When            Aloys
it relies on the same sources of energy as na-       25 years of                                           Wobben, Ulrich
ture itself – renewable energy. Mr. Wobben is        ENERCON – a                                           Schmack, and
an outstanding founder of this new era, which        quarter-century                                       myself were in-
we are running out of time to bring about.           of entrepreneur-                                      vited to attend
                                                     ship in renewa-                                       the Chancellor‘s
Innovation and craftsmanship                         ble energies, of                                      energy summit
“made in Germany”                                    pioneering spirit,                                    and        represent
                                                     staying power,                                        the renewables F. Asbeck,
Energy for the                                       and the courage U. Schmack, CEO of                    sector, we really CEO of SolarWorld AG
world – this has                                     to always look Schmack Biogas AG                      represented the
been ENERCON‘s                                       for new paths.                                        industry in all its diversity. You could hardly
motto during 25                                      But also 25 years of overcoming resistance,           find greater opposites – not only with regard
years of building                                    preserving the joy of successful moments, and         to our technologies, but also personally: We
wind       energy                                    appreciating the achievements that have been          are very different in build, temperament, and
converters. We                                       made.                                                 demeanour. And this is a good thing, because:
can leave it up                                                                                            It‘s all in the right mix. Not just the mix of rene-
to the media to H. Albers, President of Ger-         Aloys Wobben has made it his purpose in life to       wable energies from solar to wind power, but
decide whether man WindEnergy Association            rise to the challenge of tapping new sources of       also of the people who represent them.
Aloys     Wobben                                     energy and developing technology that saves
should be considered the “Gyro Gearloose             our environment. Without ENERCON, the rene-           Wobben is a genius inventor and engineer. He
of wind power” or the “Bill Gates of East Fri-       wables sector in Germany would not be what it         employs 12,000 people and his company ma-
sia”. One thing is for sure: From the tinkering      is today. Beyond figures and statistics, there is     kes millions in revenue, but you can still find
of engineer Aloys Wobben has sprung a glo-           a new awareness of environmental matters in           him tinkering in the workshop. I appreciate the
bal company that stands for innovation and           politics, business, and the population at large.      straightforward manner in which he stands
craftsmanship “made in Germany” like few             The challenge of jointly promoting climate pro-       up for clean energy and opposes the dinosaur
others do. On behalf of the German WindEnergy        tection has forced each and every one of us to        technologies. But in particular, I appreciate his
Association, I would like to use this occasion       grow stronger in recent years. We have accep-         products. I own a few units myself, and they
to offer warm congratulations and to thank           ted the challenge, and just what the response         just keep turning as reliably as the sun rises
ENERCON for the excellent cooperation.               will be is still largely up to us.                    every morning!
10    wINDBLATT 03 | 2009         TECHNOLOGY

                                                 First ENERCON hydro-power station: Turbine chamber on the left, fish passage and flushing canal on the right.

Hydropower station in Raguhn, Germany

ENERCON technology proves
its worth in hydropower
After successfully concluding the test operation phase started in                                         dent sites economical; and the implemen-
January of this year, ENERCON‘s first hydropower station fully connec-                                    tation of the water turbine as an upstream
ted to the grid in Raguhn in Germany‘s Eastern state of Saxony-Anhalt                                     rotor with extremely narrow runner gaps
                                                                                                          around the hub as well as near the casing
last June. The operator is Wasserenergie Raguhn GmbH & Co. KG, a
                                                                                                          (advanced minimum gap technology). The
subsidiary of ENERCON GmbH.
                                                                                                          flow of water is directed straight onto the
The station is located on the Mulde river, a    ration control and electrotechnical equip-                runner without any prior diversion. This in-
tributary of the Elbe, and employs two S-pipe   ment,” says Rolf Rohden, manager of the                   creases energy yield while at the same time
turbines developed by ENERCON. “In the          New Technologies department at Wobben                     considerably reducing the risk of harming
development of the ENERCON water turbine        Research & Development (WRD) in Aurich.                   fish life.
design, we focused on improving efficiency
compared to conventional turbine design; on     Gearless turbine concept                                  In fact, the ENERCON turbine design can
better environmental properties; a simple,                                                                generally be called highly fish-friendly. With
robust design with optimised maintenance        Essential characteristics of the ENERCON                  regard to fish passage, the design has the
features; as well as the use of tried-and-      concept include a gearless design; fully                  following advantages:
tested ENERCON standard components from         variable speed operation that makes the ex-               - The E-turbine always operates at variable
wind energy technology for automatic ope-       ploitation of even low-head or tide-depen-                speed. The low rotational speed reduces the
                                                                                                  TECHNOLOGY       wINDBLATT 03 | 2009          11

speed of the runner and thus substantially       ved since the German reuni-
lowers the risk of injuring fish.                fication – the water is crystal
- The low number of runner blades minimi-        clear again. The project must
ses the amount of impact and shear sur-          fulfil many requirements with
faces.                                           regard to fish and water pro-
                                                 tection: For example, water-
The hub of the E-turbine uses a fully sphe-      courses in Europe must be
rical design in line with the minimum-gap        passable for fish travelling
turbine concept. In addition to improving ef-    to their spawning grounds.
ficiency by reducing flow losses in the gap,     An open fish ladder facilita-
this also reduces the risk of injuring fish      tes the fish‘s upstream and          Raguhn hydropower plant: Technical overview
that may have been swept into the turbine.       downstream travel; nearby,           Turbines: 2 ENERCON S-pipe turbines with 3 blades each
                                                 there is a rivulet for microor-      Total power: 2100 kW
Self-adaptive software controls                  ganisms.                             Annual electricity production: 9.3 million kWh p.a.
the runners                                                                           Nominal volumetric flow rate: 25 m3/s
                                                 The design of the downstream         Runner diameter: 2.5 m
The turbines are controlled by adaptive          fish channel which doubles
software with learning capabilities. The         as flushing channel for the
software controls the safety system as well      rack system takes into account the expe-            a comprehensive fish monitoring system.
as the DC motors of the blades: If the river‘s   rience of Arne Gluch from Saxony-Anhalt‘s           “So far, we have a very positive impression.
water volume decreases, thus increa-             state office for flood prevention and water         The animals accept the power plant as part
sing the head, the control system pitches        management. The ladder has 20 steps,                of their habitat,” says Karl Ihmels, respon-
the blades further into the water stream.        each of which is 20 centimetres high. About         sible engineer for hydropower stations.
In the opposite case, the blades can be          1 cubic metre of water passes through per
pitched out of the water stream. The soft-       second. To make sure that amphibians and            The construction of the power plant has
ware stores the parameters such as head          small fish can make it against the current,         had a positive side effect for flood preven-
and water volume used for each operation,        there are resting areas between the cham-           tion: “Local authorities, the state office for
compares them to the energy yield, and           bers in which the animals can gather their          flood prevention, and ENERCON worked
adjusts subsequent control operations ac-        strength for the next leap.                         closely together to overhaul Raguhn‘s flood
cordingly, explains Rohden. This adaptive                                                            protection system while building the power
system ensures that the turbines always          Monitoring project assesses                         plant,” says civil engineer Ihmels. Where
operate at maximum yield according to the        impact on animal life                               there used to be waste heaps of rubble
available water levels.                                                                              from old houses along the river bank, there
                                                 In order to assess the impact of the hydro-         is now a protective wall made from natural
In GDR times, the Mulde was one of the           power station on animal life, especially the        materials that protects the town from the
most polluted rivers, but things have impro-     fish habitat, the project is accompanied by         Mulde‘s flood waters.

Installing the drive train.                                              The ENERCON generator.
12      wINDBLATT 03 | 2009            TECHNOLOGY

Wind-diesel system on Bonaire

A dozen E-44s for a
Caribbean diver‘s paradise
In April of this year, ENERCON and a number
of local partners began the installation work
on a wind farm with twelve E-44 /900 kW
turbines on the Dutch Caribbean island
of Bonaire. By mid-September, half of the
turbines were finished. The second half will
still be installed before October. As of next
year, the wind farm in combination with six
diesel generators is intended to provide all
electricity needed on the island – a conside-
rable amount: Bonaire is a diver‘s paradise
with about 15,000 inhabitants and 100,000
tourists every year.                                                Wind farm installation in Morotin, Bonaire, in August.

“On Bonaire, we and our partners are buil-            with Eneco, Rotterdam) and includes, besi-                how they would procure building materials
ding what will currently be the world‘s lar-          des the wind farm with twelve E-44 turbines               and equipment, and how they proposed to
gest wind-diesel hybrid power station,” says          on the Northeast coast, the installation of a             ensure quality. Even before the work began,
ENERCON project manager Stefan Keim.                  diesel power station by MAN in the South-                 ENERCON wanted to be able to review all
The project was planned by Dutch renewa-              west of the island. A 15-kilometre cable                  measures concerning health and safety,
ble energies engineering firm Evelop (now             connects the two units. The electricity cus-              planning, process control, and quality assu-
                                                      tomer is Water en Energie Bedrijf Bonaire,                rance.
The Bonaire Wind-Diesel-System                        the Netherlands Antilles utility company.
                                                                                                                ABJL, a company based on the neighbouring
     The Bonaire hybrid system is the largest         Participation of local partners                           island of Aruba, was awarded the contract
     wind-diesel-project in the world. It will pro-                                                             for building the foundations. The materials
     vide the entire island. Thus, extensive pre-     Bonaire is the second-largest island in the               not availabe on Bonaire were brought in by
     patory grid studies were carried out in order    Netherlands Antilles after Curaçao. “While                ship. The sand came partly from Aruba and
     to ensure the system components were             major building projects on the islands are                partly from Colombia, gravel was imported
     adequately designed and dimensioned.             typically contracted to American or Dutch                 from Colombia as well as from Venezuela.
     In the event of a fault, the batteries sta-      companies, it was our goal to achieve a                   The reinforcing steel came from Germany,
     bilise the grid and bridge long enough to        direct involvement of local companies and                 the concrete batching trucks from Aruba.
     be able to power up a diesel generator.          local workers,” explains Keim. ENERCON                    Miles Heavy Trucking based on the neigh-
     ENERCON placed the cells into containers         was able to use the experience gained when                bouring island of Curaçao was hired for the
     so that all cabling could be installed and       the company built an E-33/330 kW turbine                  road transport of equipment and machinery.
     the whole assembly tested before it was          on Bonaire in 2007. “We called on prospec-                They also provided the installation crane.
     shipped to site. The SAFT NiCd cells have        tive contractors to submit detailed plans                 The company acquired a modern 300-tonne
     a power capacity of 3000 kW for 2 minu-          for transport and the construction of foun-               crane specially for this job.
     tes. The battery is charged and discharged       dations and access roads.” The companies
     using tried-and-tested ENERCON converter         were asked to specify exactly what stages                 ABJL started building the foundations in
     technology.                                      they would complete in what time frame,                   April. “A team from Wobben Windpower
                                                                                                TECHNOLOGY      wINDBLATT 03 | 2009         13

(WWP) in Brazil came over and monitored          After the sun came up, we
the fulfillment of the project plan on-site,”    had to water the fresh concre-
reports Keim. WWP has comprehensive ex-          te, otherwise it would start to
perience with building foundations in very       crack. Around noon, work on
hot climates. In addition, the Brazilian team    the foundations had to stop for
had previously overseen the installation of      the day,” remembers Keim.
the Guanacaste wind farm in Costa Rica
where they coached a team that had little ex-    There are currently about
perience in WEC construction. “The Brazilian     20 installation technicians
team under construction supervisor Fer-          working for ENERCON on
nanda Perigo contributed substantially to the    Bonaire. Initially, part of the
steady improvement of quality and produc-        team worked on unloading The “Togo” with components from Brazil docking at the pier.
tivity in the construction phase,” says Keim.    the ships and transporting the
                                                 goods to the temporary storage area by the      and then assigns the power setpoints to the
There is a weekly ferry service between Aru-     stadium and then on to the construction site    WECs,” explains Rolf Rohden, manager of the
ba and Bonaire, but there is no harbour on       in Morotin, while the others were already       New Technologies department at WRD. The
the island that could accommodate contai-        installing the bottom tower segments and        control console consists of three computers
ner ships. To deliver the E-44 turbines, two     pre-assembling machine houses, genera-          with touch screens displaying the data from
large freighters docked at the pier in the       tors, and rotors. By now, the whole team is     diesel units, WECs, and consumer units. The
capital town of Kralendijk. The WEC nacel-       on the construction site. “We will finish in-   data are constantly changing, regulated by the
les came from Brazil, the steel towers and       stallation before the start of the rainy season programmable logic controller. In the back-
transformers from Aurich and Magdeburg           at the end of September,” says Keim. In the     ground, one of the PCs measures and stores
via Bremerhaven, Germany. Says Keim: “One        coming months, the other components of          all important power station parameters.
challenge was to take the towers from the        the wind-diesel system will be installed.
quayside through the winding streets of Kra-                                                     During the test phase, the wind-diesel sys-
lendijk to a storage area near the stadium.”     Power Management System                         tem works completely manually. The operator
                                                                                                 enters the setpoints for the WECs. Analogue
Building foundations in a hot                    ENERCON supplies the battery units for the      dashboard instruments constantly display
climate                                          hybrid power station as well as a Power         the most important parameters: These inclu-
                                                 Management System (PMS) developed by            de the voltage of all three phases, the grid
The climate on Bonaire is hot and – particu-     Wobben Research & Development (WRD).            frequency, as well as the power values. “If
larly inland – very dry (except for the rainy    The system coordinates the interaction of       the main power supply were to fail, a small
season from October to December). The is-        wind energy and diesel generators according     battery supplies power to the programmable
land is covered with rocks, sparse bushes,       to the power requirements of the island. “The   logic controller for the analogue instruments
and cactuses. During the mid-day hours,          PMS constantly polls the maximum available      so that the operator always has an overview
the heat becomes unbearable: “We started         output of the wind turbines, factors in the     of the most important parameters of the
pouring the concrete at 3 o‘clock at night.      operating range of the diesel generators,       wind-diesel station,” says Rohden.

Battery units: Container with SAFT NiCd cells.                              The PMS control desk.
14    wINDBLATT 03 | 2009             INTERNATIONAL

WECs for Scottish islands

Three promising projects on
the Orkneys
On the Scottish Orkney Islands, three ENERCON wind energy con-                                                 The directors of the Trust are island residents
verters will begin to feed power into the grid of Scottish & Southern                                          and are elected at the annual general mee-
Energy this autumn. Two WECs are owned by companies that belong                                                ting. The Board of Directors holds monthly
to the families on whose land the wind turbines are installed. The third                                       meetings to take decisions on pending issu-
                                                                                                               es. Currently, the Trust is working on addres-
turbine, an E-44, is a community-owned wind energy converter ope-
                                                                                                               sing fuel poverty on the island; re-developing
rated by the Westray Development Trust. The Trust plans to invest the                                          the golf course; expanding and diversifying
proceeds from selling the electricity for the benefit of the community.                                        the course offerings at the local Learning
                                                                                                               Centre; improving the efficiency of waste
After five years of planning and a construc-             Wind energy supports island                           disposal and storage; and driving forward
tion phase of just under six months, the E-44            development                                           the production of bio fuels.
turbine of the Westray Development Trust is              Westray has about 600 inhabitants on an
now ready to be connected to the grid. The               area of just under 50 square kilometres. The          The Trust was able to raise the equity capital
900 kW WEC on the island of Westray, situ-               E-44 will be owned by Westray Renewab-                for the E-44 through a grant from the “Big
ated about 30 kilometres north of Orkney‘s               le Energy Ltd., a company founded by the              Lottery Fund”. The UK‘s National Lottery fun-
Mainland, will produce around 3,500 MWh                  Westray Development Trust. The Trust was              ded the project with 760,000 pounds. “The
of electricity per year. Here, the wind speed            set up following an island conference held            majority of the balance came from Triodos
at hub hight is constant at 10.6 m/s. Thus,              in 1998 to address concerns about de-popu-            Bank, which has a branch in Edinburgh,”
the turbines are expected to operate at full             lation. “The turbine is a means of generating         reports Stephenson.
load for more than 4,000 hours per year.                 an income for the Trust to enable it to carry
This exceeds productivity forecasts made for             out projects for the benefit of the isle,” says       The Trust has been working on the WEC
various offshore wind turbines in the German             David Stephenson, one of the voluntary di-            project since 2004. “We obtained planning
North Sea.                                               rectors of the Trust.                                 consent during 2005,” says Stephenson.

E-44 rotor hub at Birsay Moor near Dounby (Mainland, Orkney).            E-44 turbine owned by the Westray Development Fund.
                                                                                                 INTERNATIONAL               wINDBLATT 03 | 2009              15

“But we were unable to find a top-class ma-
nufacturer willing to supply a single turbine
to such a remote site – until an ENERCON
sales representative visited our island last

Sources of income for farming
Thanks to its excellent wind resources,
Burgar Hill on Orkney‘s Mainland has been a
pioneering site for wind energy since 1983.
During the 1990s, a two-blade 3 MW aero-
generator prototype on a 45-metre concrete
tower stood here; it was dismantled in the       Operator Mervyn Spence at the foundation for E-70 turbine on 159-metre-high Burgar Hill.
year 2000. Currently, there are five wind tur-
bines of the megawatt category producing         divers and hen harriers, this is also a habi-            All in all, it took Wallace seven years to
electricity on Burgar Hill.                      tat for short-eared owls. In addition, there             make his first wind energy converter a re-
                                                 were concerns that the turbine would have                ality. Two years, he says, were wasted with
The E-70 that is currently being installed by    a negative visual impact on the nearby Ring              futile efforts, three years went into the plan-
ENERCON will be the first WEC in the wind        of Brodgar, a prehistoric stone circle that is           ning process, and the remaining time was
farm to be planned and operated by land ow-      part of a UNESCO World Heritage Site. “We                taken up by finding a supplier, preparing the
ner Mervyn Spence and his family. For this       were able to overcome these objections                   site, and erecting the turbine. “We chose
purpose, they set up the company Burgar Hill     through a bird study and a visibility analy-             ENERCON because of their very high re-
Renewables Ltd. “We do not have any finan-       sis,” says David Wallace, director of Birsay             putation as a supplier of high quality wind
cial stake in the other turbines, but we do      Energy Ltd.                                              turbines throughout the world,” explains
receive a land rental based on production,”                                                               Wallace the reason for his choice.
explains Spence. Like many farmers on the        Birsay Moor – a Wallace family
Orkney Islands, Spence is looking for new        project
opportunities and prospects for his farming
business. “We are looking to diversify and       Birsay Energy was founded by the Wallace
create an alternative source of income to our    family: 69-year-old David, his wife, sister,
                                                                                                                                   Westray turbine
traditional farming income.”                     and children as well as his daughter-in-
                                                 law are the owners of the company. David                   Burgar Hill & Birsay Moor turbines
Orkneys: World heritage site and                 Wallace used to work in the slate business
bird paradise                                    in Grange-Over-Sands in Cumbria (North-                                                               Kirkwall
                                                 western England). His family has been
The Orkneys are a paradise for birds. About      owning land in the Orkneys for more than
500 metres from Burgar Hill lies a special       two centuries – in total, about one thousand                                         Thurso
protected area where red-throated divers         hectares. “We originally farmed the land
and hen harriers live and nest. “We had to       where the turbine is located, as my father
carry out an extensive bird study over two       had done before me, but then decided to di-
breeding seasons. The study proved that our      versify out of farming, which was becoming
wind turbine would not have any detrimental      unprofitable.”
effect on the birds,” says Spence.                                                                                                                                 Banff
                                                 Since he retired, Wallace has been spen-
The E-44 turbine in Birsay Moor near Doun-       ding about three months every year on                                              NO

by in the West of the Mainland is also lo-       the island. His island home is in Holodyke
cated in a protected area. The moorland          Dounby, where his great-grandfather built a                    IE      GB

here has been designated a Site of Special       house in the 19th century. Wallace loves the                                 FR                 0 12,5 25   50    75      100
Scientific Interest (SSSI) and enjoys Euro-      open landscape of gentle rolling hills and
pean protected status. Besides red-throated      the steady brisk wind.                                   ENERCON turbines on Orkney Islands.
16    wINDBLATT 03 | 2009           JOB PROFILES

Precast Concrete Tower (PCT) Installation Technician

Precision teamwork on
precast concrete towers
About 50 teams are currently busy installing precast concrete towers                                       operator who is working the jib and crane
for ENERCON wind energy converters in Germany, other European                                              rope. “This segment is special because it‘s
countries, and overseas. Each team consists of seven to twelve tech-                                       made of steel and completes the concrete
                                                                                                           part of the tower,” says Waragasch. Slow-
nicians. The teams erect concrete towers from 63 to138 metres high.
                                                                                                           ly and with millimetre precision, the “steel
They prepare foundations and precast segments for assembly; join the
                                                                                                           pot” – as the first steel section is also
segments; and fit the towers with ladders and rest platforms.                                              called – eases into its spot. The workers
ENERCON is in the process of setting up new teams that will be based                                       press heavily against the wall of the steel
in regional Service subsidiaries in Germany as well as in international                                    pot to adjust its placement. They measure
locations.                                                                                                 the transition area of the two segments
                                                                                                           with smoothing trowels and call out num-
This autumn will see two new additions                 creating the footing for the second concrete        bers to Waragasch that indicate the size of
to the wind farm surrounding the Arcelor-              tower.                                              the remaining gap between tower and steel
Mittal steelworks in Bremen, Northern Ger-                                                                 pot. As the segment is lowered down, glue
many: Two E-82 wind turbines on 108-met-               A work platform surrounds the unfinished            oozes from the joint. The workers scrape off
re towers. The concrete tower installation             tower. Eugen Waragasch (24) and three               the glue and then raise the platform to the
team headed up by Andreas Pollmann (27)                other workers stand on the platform that            top edge of the steel pot. Here, they insert
has been on-site for two weeks. The first              is raised 80 metres above the ground. Via           steel cables into the tower wall that will la-
tower has been erected quickly, and right              radio, Waragasch controls the placement of          ter be used to tension the tower. Once that
beside it, the foundation team is already              the final tower segment, guiding the crane          is done, the platform takes everybody back
                                                                                                           down onto solid ground.

Job Profile PCT Installation Technician                                                                    “Our work on the tower is done for now,”
                                                                                                           explains Pollmann, the team leader. Other
The ENERCON Service is seeking precast concrete tower technicians for the installation of its wind         Service departments take care of the next
energy converters – for its German subsidiaries as well as for its subsidiaries in France, Sweden,         installation stages: First comes a special
Canada and Turkey. Completed vocational training in a technical field as well as practical experience      team that tensions and grouts the prestres-
on construction sites are vital. The ability to work at heights is an essential prerequisite for the job   sing steel tendons. Other teams install the
and the willingness to travel and work abroad.                                                             nacelle on top of the tower and connect the
                                                                                                           turbine to the grid. “At the very end, the
Key qualifications:                                    Advantages:                                         concrete tower specialists are needed once
  Completed vocational training in a technical         + Diverse tasks in the construction of precast      again,” says Pollmann.
  field / high technical affinity                        concrete towers
  Enthusiasm for wind energy                           + Practical introduction to all aspects of the      “Today, the majority of ENERCON wind tur-
  Physical fitness, ability to work at height            job                                               bines in Germany are installed on precast
  Flexibility, mobility, good team player              + Highest safety standards apply; annual re-        concrete towers,” says Michael Honczek,
Tasks and responsibilities:                              fresher courses in safe working practices         one of currently three team coordinators
  Assembling concrete towers from prefabri-              and use of safety equipment                       with ENERCON Service in Germany. The
  cated segments; preparing foundations and            + Different working places (partly abroad),         demand for PCT is increasing outside of
  tower segments for installation; fitting tow-          career opportunities in WEC installation/         Germany, too. Accordingly, the number of
  ers with steel accessories                             service                                           concrete tower installation teams has been
                                                                                                       JOB PROFILES          wINDBLATT 03 | 2009         17

on the rise in recent years. “By now, we
have 50 active teams worldwide,” says
Honczek. There are ten teams in Portugal,
two in Italy, six in Sweden, and two each in
France and Turkey.

The ENERCON Service is currently restruc-
turing its operations in Germany. In the
past, Service headquarters in Aurich co-
ordinated all domestic installation teams.
Now, the teams are managed exclusively
by the regional Service subsidiaries. The-
se are based in Pewsum/Lower Saxony
(Northwest), Scherfede/North-Rhine West-
phalia (Central), Würzburg/Bavaria (South),
Schönberg/Mecklenburg-Western Pomera-
nia (Coast), and Magdeburg/Saxony-Anhalt
(East). International support coordination
continues to operate out of Aurich.                 Wind farm at Bremen steelworks: Installing the small steel segment for the 108-metre tower.

“At the moment, we are recruiting precast           three to four weeks to get an unskilled per-              technician picks up any remaining tasks.
concrete installation technicians, both in          son who has never worked in tower instal-                 “We rotate positions so that everyone in the
Germany and abroad,” says Honczek. Ap-              lation fully up to speed,” reports Honczek.               team is familiar with everyone else‘s role
plicants must have successfully completed                                                                     and can fill in if needed,” explains team lea-
their vocational training in a craft or a tech-     A concrete tower is built step by step: Some              der Pollmann.
nical field, and have some practical expe-          teams specialise in pre-assembly. They use
rience with working at a construction site.         mortar to assemble the circular segments                  ENERCON is forming precast concrete to-
Because the teams work in changing loca-            for the bottom of the tower, which are pre-               wer installation teams in its foreign mar-
tions in Germany and abroad, a willingness          fabricated in multiple parts. They set the                kets where needed. „In Portugal, we are
to travel, great flexibility, and a valid driving   first segment onto the foundation, and put                already well established,“ reports Stefan
license are indispensable.                          the E-module in place. Next comes the in-                 Hinz, Installation Manager at the ENERCON
                                                    stallation team that builds the tower up to               Service Center in Aurich. “However, we are
Among ENERCON’s concrete tower in-                  the large steel section at the top. Finally, the          still looking for concrete tower installation
stallation teams, one can find mechanics,           finishing teams install tower ladders, cable              technicians in Canada, Sweden, France,
metalworkers, bricklayers, concrete con-            holders, rest platforms and safety nets, and              and Turkey,” says Hinz.
struction workers, or heating technicians.          take care of any cosmetic issues such as
After the job interview, the most important         touching up the green paintwork of the to-                In Canada e.g., ten teams are being formed
step toward employment is the medical               wer exterior.                                             in the province of Québec. In 2010 and
exam that verifies an applicant‘s overall                                                                     2011 alone, ENERCON will build around
physical fitness and their ability to work          At sites, every member of the installation                180 towers for WEC in Québec, ordered by
at height. After passing the medical, in an         teams has a clear assignment: Three tech-                 the Hydro Québec utility. For this purpose,
introductory training for the job the new           nicians make sure that there is a ready                   ENERCON is setting up a concrete tower
employees are trained in safe working               supply of segments on the ground, and pre-                factory in Matane on the Saint Lawrence
practices and taught how to use protection          pare these segments for installation. The                 River. In France, five concrete tower instal-
equipment during abseiling and height res-          team leader manages work schedules, ma-                   lation teams are being formed that will be
cue exercises. Honczek: “In addition, we            terials supply, and logistics. Four workers               based at various existing ENERCON Service
show them how to fill in their work reports,        are on the platform. The radio operator, who              stations. “We need two additional teams
track travel times, place material orders,          is also the second team leader, keeps the                 each in Turkey and in Sweden,” says Hinz.
and file travel expenses.”                          radio contact to the crane. One technician                “For organising the teams, we are working
                                                    mounts the ladders inside the segments;                   out of Izmir and Malmø. The teams will then
Next comes the practical, hands-on trai-            another mixes the glue, prepares the shea-                be based as close as possible to the major
ning at the construction site. “It takes about      thing pipes, and sets spacers; the fourth                 installation projects in each country.”
18    wINDBLATT 03 | 2009         SUPPLIER

Hulvershorn foundry in Bocholt, Germany

Consistent quality over
hundreds of castings
Many core components of ENERCON wind energy converters
– blade adapters, stator support stars, axle pins – are made
of spheroidal graphite cast iron, an iron-carbon alloy that is
very tough, durable, and highly ductile. It is used in all those
places in the WEC where the strain on tower and rotor is
particularly high and variable. One of ENERCON’s most
important suppliers of cast components for E-40, E-70, and
E-82 wind turbines is the Hulvershorn iron foundry based in
the north-western town of Bocholt, a medium-sized compa-
ny with more than 120 years of metal casting expertise.

“In recent years, the wind energy industry      started off by producing the
has become a very attractive market for         cast components under a sub-
our products. ENERCON is among our most         contract with another supplier.
important customers because this coope-         After four years, ENERCON ini-
ration allows us to stay in close touch with    tiated a direct contact.
the latest technological developments in
wind energy,” says Hermann-Josef Bongert,       One reason is the high, con-
Sales Director at the Hulvershorn iron          sistent quality of Hulvershorn’s
foundry in Bocholt.                             castings. The manufacturing
                                                of cast components starts
One third of production output                  with making patterns for the Preparing moulds for E-82 blade adapters in Factory II.
for wind industry                               castings. Says Bongert: “We
                                                create 60 to 70 percent of patterns in-        metal parts as well as the specially included
With six electrical furnaces, the foundry       house.” The patterns are based on dra-         sample specimens for quality control.
produces about 20,000 tons of spheroidal        wings provided by the customer. Typically,
graphite cast iron, grey cast iron, and ADI     they consist of multiple pieces and are        Cast components weighing
(austempered ductile iron) – a cast iron that   made of plastic. The patterns are placed       between one kilo and ten tons
is alloyed with nickel, molybdenum, and         into flasks that are then filled with sand.
copper, and quenched in a salt bath. Custo-     After the sand has hardened, the mould         The cast components made by Hulvershorn
mers include gearbox manufacturers, pump        makers remove the pattern pieces. Then         weigh between one kilogramme and ten
and valve makers, machine tool makers, the      they place pre-shaped, refractory-coated       tons. “It is easy enough to cast one single
machine engineering sector in general, the      sand cores into the moulds that create the     workpiece that matches the specifications
printing and paper industry, the textile in-    required cavities during casting. Finally, the precisely. But what is crucial is that also
dustry, as well as makers of clutches and       molten iron is poured into the mould from      after casting one hundred or one thousand
ship‘s drives, and the automotive industry.     a large crucible.                              blade adapters, each unit fits exactly into
About one third of the foundry‘s output is                                                     the machine,” says Bongert, who has been
destined for the wind industry. “We‘ve          After the material has cooled down, the wor-   with the company for 28 years. For this
worked with the ENERCON-specific shapes         kers empty the flasks, break the mould off     reason, components are 100 % quality
since 2000,” says Bongert. The foundry          the workpiece, and remove any superfluous      checked before they ship. Material from
                                                                                                             SUPPLIER        wINDBLATT 03 | 2009            19

each casting is subjected to a notched bar                   tory, two bogie hearth
impact test, in which a pendulum hammer                      furnaces were set up
swings and hits the sample in a pre-not-                     at the beginning of the
ched place. The energy needed to achieve                     year. They are used for
the fracture is measured and evaluated for                   the annealing and heat
strength. Ultrasound is used to check for                    treatment (isothermal
the required structure. At Hulvershorn, QA                   and ferritic annealing)
encompasses the entire production cycle,                     of welded structu-
starting with the quality of the moulding                    res, steel containers,
sand, the moulds themselves, the melting                     cast components, and
components, and the melt analysis; and                       machine engineering
ending with the cooling down, emptying                       parts. There is also an
out, and finishing. A team of 20 people is                   area for the prepara- Foundry foreman Mark ter Steege: Customer support using simulation software.
dedicated to quality assurance.                              tion and finishing of
                                                             metal workpieces in this factory. “Factory III”  cast component shrinks by about 1 %. Mate-
Two new production sites                                     is a joint project with Bocholt-based metal      rial from so-called risers ensures exothermic
                                                             processing company ABZ-Terodde GmbH.             reactions that keep the iron liquid for longer
The foundry currently employs 230 staff.                     “This enables us to supply our customers         at these points of the mould and thus pre-
After its destruction during bombing raids                   with assembly-ready cast components in-          vent porosities. The software provides highly
in World War II, it was rebuilt at a new lo-                 cluding final coating,” says Bongert.            accurate predictions about the temperature
cation on the outskirts of Bocholt in 1949.                                                                   changes as the mould is cooling down so
But since then, the town has caught up and                   Single source for all components                 that the mould can be equipped with risers
Hulvershorn’s premises are now surroun-                                                                       and chill bars accordingly. “We need these
ded by industry and other businesses; the                    Hulvershorn has gradually brought more           simulations to prepare offers and for pro-
closest residential areas are not far away.                  and more elements of the manufacturing           duction planning,” says ter Steege. “Ideally,
Because the company was unable to ex-                        chain in-house. “This way we can set our         customers already take them into account in
pand any further at this site, in 2007 and                   own priorities depending on current orders,      their own design engineering.”
2009 it erected two new production buil-                     be it in pattern making or in finishing,” ex-
dings in another Bocholt industrial estate                   plains Bongert. Customers are increasingly       Partner with expertise
with convenient motorway access.                             looking for components from a single sour-
                                                             ce: “This ensures greater flexibility should     In ENERCON’s research & development or-
One of these new buildings houses a state-                   modifications become necessary.”                 ganisation WRD, the Hulvershorn foundry
of-the-art foundry specially adapted to the                                                                   has an excellent reputation as a professional
requirements of series-production casting.                   The original Hulvershorn factory still houses    partner in the preparation of new cast com-
Since 2007, Hulvershorn has been manu-                       parts of manual mould making, automated          ponents. “We discussed our requirements
facturing their wind industry components                     mould making, and pattern making. Foundry        with Hulvershorn, and they used software
mostly in this “Factory II”. In the third fac-               foreman Mark ter Steege (35) works here.         simulations to verify that the patterns are
                                                                                        He supports cus-      actually castable before going into produc-
                                                                                        tomers in the pre-    tion. This way, it only took a relatively short
                                                                                        paration of new       time to create components suitable for se-
                                                                                        casting projects by   ries production, including pattern making,”
                                                                                        using simulation      reports Arno Hildebrand, senior design
                                                                                        software that cal-    engineer with WRD.
                                                                                        culates the solidi-
                                                                                        fication processes    “The Hulvershorn iron foundry as a supplier
                                                                                        in metal casting.     of cast components is a Mittelstand compa-
                                                                                                              ny in the best sense of the meaning. They
                                                                                        When        cooling   have proved their flexibility and expanded
                                                                                        down from 1360        their capabilities to keep up with the gro-
                                                                                        degrees Celsius to    wing demands of ENERCON as a major
                                                                                        room temperature,     customer,” comments Oliver Smidt, head of
Painted E-82 rotor blade adapters, vertical lathe in the background (Factory III).      the volume of a       materials management at ENERCON.
Hitachi Engineering & Services

ENERCON’s Installation, Sales
and Service Partner for Japan
In recent years, ENERCON has expanded its activi-
ties on the Japanese market. In 2007, the first wind
farms of a somewhat larger size could be installed.
The most important partner in the Japanese market
is Hitachi Engineering & Services (HES): They develop
projects, carry out labour for Enercon Service Japan,
help with installation, and operate systems on behalf
of independent power companies. They have also been
ENERCON‘s exclusive sales partner since 2002.

By the end of this year, ENERCON and            Division. “Unfortunate-
Hitachi Engineering & Services will have        ly, Japan‘s windy areas
installed a total of 193 wind energy con-       are weak grid areas.
verters with 255 MW of rated power. This        So generally, electric Pillars of successful cooperation: Tadashi Hashimoto of Hitachi Engineering &
constitutes a market share of about 10 per-     power companies are Services and Jørn Kristensen, ENERCON Sales Manager for East Asia.
cent. Among ENERCON‘s major customers in        conservative when it
Japan are companies such as J-Power and         comes to receiving wind power.”                     energy systems. The product offering also
Okinawa Electric Power as well as the city of                                                       includes gas engines and turbines, me-
Suttsu on Hokkaido. “These three major re-      Choosing ENERCON as a wind turbine manu-            tal rolling mills, ultrasonic detectors, laser
peat ordering clients understand ENERCON’s      facturer for the first time in 1997 according       measuring devices, motor diagnostic sys-
less-trouble WEC and service philosophy”,       to Hashimoto was closely related to these           tems as well as data and control systems.
says Tadashi Hashimoto, Director and CEO of     challenges. “HES started out as after-service       The annual revenue in 2008 was 813 milli-
the New Energy Division at HES.                 company for general power plants, that‘s            on euro. Out of the total work force of more
                                                why we could understand and appreciate              than 2700 people, 60 work in wind energy.
The largest individual wind farm so far has     ENERCON‘s synchronous generating system
been ordered by J-Power, an independent         and after-sales philosophy.” Today, the New         “Japan is a difficult market, because of the
operator, wholesaler, and project planner for   Energies Division at HES specialises exclusi-       prudent power companies,” says Jørn Kris-
energy generation systems with headquar-        vely in wind energy. Currently, there are two       tensen, ENERCON Sales Director for East
ters in Tokyo. The 33 E-70 turbines on the      major sites where HES and ENERCON are               Asia. “Technically, it is feasible to connect a
Nunobiki plateau with a view of the Mount       installing turbines. One is the Shiura project      couple of turbines to any grid in Japan with-
Bandai volcano have been generating eco-        – 8 x E-82 – in Aomori prefecture in the north      out endangering grid security. But despite
friendly electricity since 2007.                of Japan to be complete in November, and            years of trying, no power company has ever
                                                another is Minami-Satsuma project in Kago-          allowed us to demonstrate that our turbines
The biggest obstacle facing wind energy         shima prefecture in the south end of Japan          can actively adopt the production of electri-
in Japan is the strength of the power grid,     (7 x E-82), complete within December.               city to the grid situation.” However, not least
according to Tadashi Hashimoto. “Except for                                                         due to the new government‘s plans to redu-
Tokyo, Osaka, and Nagoya, the distribution      The HES enterprise group has its headquar-          ce greenhouse gas emissions by 25 % from
network in our country is a little weak to      ters in Hitachi City, about 150 km north of         1990 levels by 2020, ENERCON continues
support the connection of large wind farms,”    Tokyo. The company is active in the ma-             the promotion of its technology in Japan –
explains the director of HES‘s New Energy       nufacture, installation, and maintenance of         together with HES.

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