coghlin perspective v3i1

THE ELECTRICAL CONNECTION 3

If there is one thing for certain, it is that our future supply of electrical energyis not certain. The use of fossil fuels to power America’s electrical generation hasa definite end to it. Although the absolute date is up for argument and debate,there is, for certain, an end to the available supply.

Renewable energy is more than a new business pursuit for CummingsElectrical, it is a passion. From our Renewable Energy Laboratory at our FortWorth office, to the wind farms we have helped design and construct from

Texas all the way to Wyoming, we are committed to helping solve our country’s future sustainableenergy needs. You may have guessed by now that this issue of the Electrical Connection is devotedto renewable energy—I’ve dropped a hint or two!

I hope you will enjoy hearing from our panel of industry experts and governors of windproducing states, and I personally thank them all for sharing their views on where the industryand country need to head in our change to sustainable energy-producing sources.

Rick Perry, Governor of TexasMike Rounds, Governor of South DakotaDenise Bode, CEO of American Wind Energy Association (AWEA)Rhone Resch, President and CEO of the Solar Energy Industries Association (SEIA)

I would also like to thank Greg Wortham, Executive Director of the Texas Wind EnergyClearinghouse, for his insightful article on the synergies being developed between renewableenergy and traditional fossil fuels.

I hope you find this issue interesting and informative. And, may the wind blow and the sunshine on our nation’s energy supply for the future!

Best Regards,

Tim Cummings

A publication from:

Cummings Electrical, Inc.14900 Grand River Road, Suite 124Fort Worth, TX 76155(817) 355-5300 (817) 355-5355 faxwww.cummingselec.com

Tim CummingsPresident

Todd RuddellVice PresidentPreconstruction Services

Randy WrightDirector of OperationsRenewable Energy Division

Jim ThompsonSales & Marketing ManagerRenewable Energy Division

Scott SmithBusiness Development Manager

Mickey ClarkChief Estimator

On the Cover:The Majestic Wind Farmcertainly lives up to itsname in this sunsetphoto. The MajesticWind Farm consists of53 GE 1.5 MW turbinesand is located in theTexas Panhandle nearAmarillo, Texas. This isjust one of several

wind farms Cummings Electrical has facilitated through its newlyformed Renewable Energy Division.

This special issue of The Electrical Connection is dedicated entirely to Renewable Energy Projects, the progressbeing made as well as the obstacles yet to beovercome here in the United States. We hopeyou enjoy it and welcome your feedback.

VOLUME 3 • ISSUE 1

The Electrical Connection is a resource for industrial endusers, property managers, building owners and operators,facilities managers, general contractors, architects,consulting engineers, as well as potential and existingclients of Cummings Electrical. Designed to feature topicsaffecting the electrical and construction industries. TheElectrical Connection also highlights Cummings Electrical’sachievements and capabilities.

The Electrical Connection is published by Oser-Bentley CustomPublishers, LLC, a division of Oser Communications Group, Inc., 1877N. Kolb Road, Tucson, AZ 85715. Phone (972) 503-1200 or (520) 721-1300, fax (520) 721-6300, www.oser.com. Oser-Bentley CustomPublishers, LLC specializes in creating and publishing custommagazines. Editorial comments: Karrie Welborn, [email protected] call or fax for a new subscription, change of address, or singlecopy. This publication may not be reproduced in part or in wholewithout the express written permission of Oser-Bentley CustomPublishers, LLC. To advertise in an upcoming issue of this publication,please contact us at (972) 503-1200 or (520) 721-1300 or visit us onthe Web at www.oser-bentley.com. March 2010

IN THIS ISSUE

Texas Energy InnovationSynergies for oil and gas companies in wind and solar sectors......................................................... 4

Wind Tower Descent and RescueSystem selection .................................................................. 8

Renewable Energy in the United StatesA forum with industry and political leaders ......................12

Cummings’ Renewable Energy Lab Is a small wind turbine a good investment for you?.......21

THE ELECTRICAL

CONNECTION

MESSAGE FROM THE PRESIDENT

TEXAS ENERGY

4 THE ELECTRICAL CONNECTION

Texas EnergyInnovationSynergies for oil and gas companiesin wind and solar sectorsBy Greg Wortham

Greg WorthamTexas Wind Energy

ClearinghouseExecutive Direcor

exas continues its leadership in energyinnovation—based in the Lone StarState’s oil and natural gas heritage—

with our state’s global role in new energy fieldssuch as wind and solar.

Texas leads the Western Hemisphere in windenergy operations, and is, in fact, one of the threemost intensive wind energy development areas inthe world. Texas companies also play a world-classrole in the largest solar projects on the globe. Aswith oil and gas, the Lone Star State’s leadershiparises from a combination of attributes: abun-dant energy resource, amenable energy-savvylandowners, favorable local and state governmentenergy business climate, robust infrastructure andproactive entrepreneurs with technical talent.

State of the WindTexas currently ranks as the sixth largest“nation” for installed wind energy capacity,trailing the USA, Germany, Spain, Chinaand India. Only China and India areoutpacing Texas in wind energydevelopment. While Europe’s wind energyinstallations are fairly mature, China andIndia have an unmatched intensity ofdevelopment in wind, as in so many otherenergy and industrial sectors. In theWestern Hemisphere, Texas has no rival.Since passing California in 2006, the LoneStar State has not looked back. IndividualTexas counties outrank most other states.

In North America, Texas has more than

9,000 megawatts (MW) of installed windenergy capacity. The USA as a whole hasroughly 25,000 MW installed, giving theLone Star State more than 35 percent ofUSA wind energy capacity as of mid-2009.Canada has about 2,500 MW installed—equivalent to Nolan County (Sweetwater).Mexico has 87 MW installed—equivalentto a small Texas wind project.

Elsewhere in the Western Hemisphere,all of South America features less than 400MW of wind energy installed—less thanvarious individual Texas counties, such asScurry (Snyder), Taylor (Abilene),Shackelford (Albany), Sterling and others.

Like Texas, USA wind energy leadership has

Wind Turbine, Dumas, Texas

T

TEXAS ENERGY


emerged in the past five years. As Texas seemedwoefully behind California in installed windenergy capacity, the USA trailed Europeanheavyweights Germany and Spain until justrecently. The USA surpassed Spain at roughlythe same moment in 2006 when Texas passedCalifornia; the milestones could be trackedwith construction of the same Horse Hollowwind turbines in Nolan County. The USApassed Germany in early 2009, first inmegawatt-hours generated and, soon thereafter,in total installed wind energy capacity.

The most important regulatory spur toUSA wind energy intensification has beenthe federal Production Tax Credit (PTC),while Texas state policies most responsiblefor wind energy growth in the 21st centuryhave been a Renewable Portfolio Standard(RPS), local economic development effortsand commitment to transmission expansion.

Texas wind energy development isprimarily concentrated in West Texas,although significant projects are nowoperational onshore along the South Texascoast. The General Land Office continuesto explore opportunities for wind energygeneration in the Gulf of Mexico. WithinWest Texas, there are significant centersof activity—Sweetwater-Abilene-Snyder,Fort Stockton-McCamey, Sterling City-Big Spring, for example—but turbinedeployment stretches from Jacksboro andStephenville in the east to west of Odessaand to the top of the Texas Panhandle.

The wind energy industry in Texas isnow comprehensive, producing enoughelectricity for millions of homes and involvingmultiple industrial sectors. Texas deepwaterports handle billions of dollars of importedturbine components annually, as do thestate’s railroads and trucking companies. Hugesteel components are manufactured fromNacogdoches to El Paso, and in communitieslike Abilene, Brownwood, Coleman,Longview, Fort Worth, Houston, San Angeloand more. Carbon fiber for blades ismanufactured in Abilene, and compositeblades are manufactured in Gainesville and ElPaso-Juarez. Turbine generators are assembledin Round Rock, and an Argentine

manufacturer of major transmission substationcomponents is locating a Sweetwatermanufacturing facility to complement thehome operation in Buenos Aires.

Texans will be investing roughly $5billion beginning in 2010 in new electricitytransmission infrastructure to double theamount of wind energy that can move fromWest Texas wind regions to metropolitanTexas markets by 2013. Additionalinvestments will enable Texas wind energyto be exported to West Coast and Midwesturban markets over the same time frame.Enhanced transmission capacity meansmillions of more dollars annually to Texasranchers and farmers in wind energyroyalties, as well as substantial new businessopportunities for wind energy prospecting,development, operations and servicing.

Beyond Texas, the USA-Canada Wind

Corridor heads straight north in a massive“V” that stretches from Alberta to Ontario,from the Rockies to the Ohio River Valley.With the strong roots in the industry thathave evolved here, Texas companies willhave significant business expansionopportunities for decades to come.

Lone Star Shining BrightTexas has substantial opportunities inconcentrated solar power plant development,especially in the Permian Basin, Trans-Pecosand western Panhandle. But beyond thoseregions with substantial potential, Texas isalready playing a leading role. City-ownedAustin Energy has already begun developmentfor its 30 MW project 20 miles northeast ofdowntown Austin; the project would be thelargest in the USA and among the 10 largestin the world when it comes on line in 2010.

Wind Farm, Gruver, Texas


Texas companies based in Abilene andBrownwood, for example, are playing centralroles in engineering, construction andfabrication at world-class solar project sitesin Nevada and Florida, including the 64MW Nevada Solar One project at Nellis AirForce Base and the 75 MW Florida Power &Light hybrid gas-solar project at FPL’sexisting natural gas-fired Indiantown, Fla.power generation facility. The Nevadaproject was the second largest concentratedsolar energy project in the world whencompleted in 2007. The Florida project willbecome the world’s second largest solarthermal project and the first commercialsolar-gas hybrid energy center.

Critical PathTexas lends many models to further expansionof wind and solar energy opportunities acrossthe USA. Texas has a unique regulatoryposition, as most of the Texas electricity grid isexempt from USA federal jurisdiction and isregulated solely by the Public UtilityCommission of Texas (PUC). The Texas gridis intrastate and is operated by the ElectricReliability Council of Texas (ERCOT).Because there are only extremely limitedconnections between ERCOT Texas and the

rest of the USA, the Federal EnergyRegulatory Commission (FERC) does nothave regulatory authority over most of Texas.

The state’s independence from FERCmeans that Texas can act relatively quickly fordramatic effects within the state. However, italso means that Texas actions can have onlylimited impacts outside of Texas. FERCregulation stretches over the remainder of thecontiguous 48 states but also requires whatis essentially a consensus across those statesbefore actions can take place.

This split in jurisdiction plays itself outmost visibly in crucial transmissioninfrastructure expansion. While Texas ispoised to begin construction on $5 billionof critical transmission infrastructure, othermulti-state initiatives face broaderregulatory challenges in the federallyregulated states. High-voltage transmissioninfrastructure is virtually nonexistent in themost intensive wind energy regions of theGreat Plains and the solar energy regions ofthe Southwest. In order to maximize newenergy business opportunities, a nationalcommitment has to be made to moveforward on a major backbone grid systemthroughout the Great Plains Wind Corridorand in the Southwest Solar Corridor.

Energy FutureTexas is the heart of the Western Hemisphere’swind energy and solar energy opportunities.Emergence of these industries continues theLone Star State’s legacy of world energyleadership and energy innovation. There aretremendous openings for proactive Texasenergy and infrastructure industrialparticipants to become involved profitably inmultiple aspects of these new energy sectors, aswind and solar continue to grow from Texasnorthward into Canada over the next decades.

Greg Wortham is Executive Director of theSweetwater-based Texas Wind EnergyClearinghouse (www.texaswindclearinghouse.us). Wortham is a graduate of Rice Universitymagna cum laude, has a Master of Public Affairsdegree from the Lyndon B. Johnson School ofPublic Affairs at The University of Texas andearned his law degree, with honors, at TheUniversity of Texas. Wortham was elected mayor ofSweetwater, Texas in 2007. He has practicedenergy law in Washington, DC, Austin, andSweetwater, and is licensed to practice in front ofthe Supreme Court of the United States. Worthamwas chief operating officer of a multi-fuel energycompany in New York City before returning toSweetwater in 2004. Contact Wortham [email protected] or 325-236-9499.

TEXAS ENERGY

Wind Farm near Sweetwater, Texas

Don’t forget to mark your calendars for theWindPower 2010 Show. This year it will be heldright here in our own backyard at the DallasConvention Center. The show will run fromSunday, May 23 to Wednesday, May 26. The2009 show in Chicago had more than 22,000attendees. The 2010 show is expected to draweven more—making it the largest wind powertrade show in the world.

Please plan on coming by the CummingsElectrical, Inc. Booth 8537 for a visit and somegood old-fashioned Texas hospitality.

For more information, please contact JimThompson by phone at 817-355-5337 or viae-mail at [email protected]. Welook forward to seeing you then.

WindPower 2010 Show


Wind Tower Descent and RescueSystem selectionBy William Wright

single rescue system cannotefficiently handle every scenario anauthorized rescuer may encounter

in the wind energy industry. One systemcan perform well for one application, butnot another. Some rescue systems are easyto use, but only for one application, whileothers require more skill, but can beadapted for use in multiple situations.Wind turbines in North America simplycome in too many different styles anddesigns to have a one-unit-fixes-all rescuesolution. In this way, rescue systems areanalogous to vehicles; the basic function issimilar, but depending on the road, someoutperform others.

Regardless of the turbine “road” youmust travel, all turbines require techniciansto climb them to perform maintenance. Inthe event of a fall, OSHA (1926.502(d)(20) of Subpart M) mandates a“prompt” rescue of the victim. Choosing asuitable rescue system for different types ofturbines can be a daunting task foremployers. Instead of asking, “What is thebest rescue system for the wind industry?”consumers should ask, “What is the bestrescue system for my turbine?” Regardlessof your choice, the system you chooseshould have the ability to raise, lower, dragand evacuate. It should also be operationalby one person because many turbine

rescues will involve the rescuer and therescue subject only.

It is important for wind power consumersto understand and evaluate the best rescuesystems available on the market prior topurchasing. Regardless of the manufacturer,type, operation, color or constructionmethod, the vast majority of these systemscan be divided into two categories:automatic descent control devices andmanual descent control devices. Specificfunctions and capabilities of the systems,along with anchor point recommendations,are delineated below. The complexities oftraining personnel necessary for rescuesystems is outlined as well.

A

William WrightGravitec Systems, Inc.Training Coordinator and Chief Instructor

Workers atop a wind turbine. Photo courtesy of Gravitec.

SAFETY


Automatic Descent Control DevicesThis family of automatic descent controldevices are also known as rescue wheels.Tractel’s Derope Up E, SKYLOTEC’sMILAN, DBI-Sala’s Rollgliss® R500Descender and ResQ’s REDPro™ all fall intothis category. These devices usually have afixed mechanical advantage with a 4:1 liftingratio. They are typically operated by turninga wheel toward the direction of travelintended, indicated by “Auf ” and “Ab”stamps on the wheel, which simply mean“up” and “down,” respectively.

Automatic descent control devices excel inscenarios where the evacuation and rescue islinear so that there is always a line of sight tothe anchor point. Simple to use and operate,the pre-loaded 3⁄8-inch rescue rope is strongenough to support one- or two-persondescents from 300 feet to 1,300 feet.Automatic descent control devices allow anautomatic descent rate between 2.8 feet and 5feet per second, depending on themanufacturer. If overhead anchor points areavailable, automatic descent control devicesare typically the quickest, most effective andsimplest devices on the market for emergencyevacuation and rescue. The cost of theseautomatic descent control devices generallyranges from $1,300 to $3,200.

Manual Descent Control DevicesManual descent control devices make upthe second family of rescue systems. Theyusually include rope, pulleys and progresscapturing devices. Some also have shorthaul systems used for lifting heavier loads.Manual descent control devices require ahigher level of user participation from therescuer. Unlike the automatic descentcontrol devices used during self- or assisted-lowering where the user can rely on theautomatic braking mechanism for descentcontrol, the manual devices require anauthorized rescuer to continually controlthe rate of descent.

Manually operated rescue systems for the

wind energy industry fall into one of twocategories: block and tackle systems or pre-rigged rope systems. Products such asMiller’s Series 70 Universal Rescue System,MSA’s Suretyman Rescue Utility Systemand DBI-Sala’s Rollgliss® Top R350 areblock and tackle systems. They generallyoperate in either a 2:1, 3:1, 4:1 or 5:1configuration and are only practical fordistances under 100 feet. The higher liftingratio allows for easier lifting compared toautomatic descent control devices, however,they can require up to five times the lengthof rope. They also require an overheadanchor point and do not work well overedges. The advantage of block and tacklerescue systems is that lifting and loweringare accomplished without an add-on pulleykit, reducing the possibility for user errorwhen lifting and making it the likely choicewhen performing suspended pick-offs. The

cost for block and tackle systems rangesfrom $600 to $2,000 and is usuallydetermined by the working length of thesystem and the lifting ratio.

Pre-rigged rope systems are distinctlydifferent from block and tackle systems.They typically consist of a single rope usedfor lowering and a compatible loweringdevice. Most systems of this variety have anadditional short haul (pulley) add-on for anincreased mechanical advantage whenlifting. Unlike block and tackle systems,pre-rigged rope systems can navigatecorners more easily. The single line alsoprevents rope entanglement and lengthrequirements are less than those for a blockand tackle system.

Gravitec’s G4 Wind Turbine Rescue &Evacuation System is one of a handful ofsystems that use pre-rigged rope. Thesesystems are an assemblage of components

G-4 Wind Turbine Evacuation and Rescue System. Photo courtesy of Gravitec.

SAFETY

SAFETY


from a number of different manufacturers.They may come equipped with edge rollersor protectors for navigating rope over sharpedges. They may also include descent deviceswith anti-panic features, industrial qualityanchorage connectors and a host of otheraccessories. This category of rescue systemsgenerally is the most versatile, lowest in price($800 to $1,800) and best equipped formore technical rescues. They do, however,require a higher level of training.

Rescue System TrainingWind turbine technicians typically do nothave the same caliber of training as anemergency rescue response team, thereforethe duration and complexity of rescuesystem training needs to be considered.Because a rescue event creates a high levelof anxiety and apprehension, the rescuetechniques should be effective, yet easy toremember. A rescue system is useless if therescuer is unable to operate it.

There is no magical equation to determinethe appropriate length of rescue systemtraining. Competent rescuers can begin tomake this determination during the initialrescue assessment when they identify all thepossible locations where a worker might

require rescue or evacuation. Identifyingthese locations will also help competentrescuers determine the necessary functionsof their rescue system. Rescue systemtraining should instruct the user on thesystem’s components and capabilities andinclude scenarios which closely simulate thereal-life rescue event. Training should alwaysinclude an observation of performance. Onan average, most rescue training lastsbetween two and five days. The ANSI/ASSEZ359.2 (American National StandardsInstitute and American Society of SafetyEngineers) standard provides direction onthe content of Authorized and CompetentRescuer training.

A Proactive Approach to RescueUnlike emergency responders who mustreact to the situation at hand, employers inthe wind energy industry have theopportunity to be proactive if they engagein pre-planning for rescue and evacuation.During the work planning phase,competent rescuers should perform detailedhazard surveys and write rescue proceduresfor those areas where hazards exist in aneffort to address and abate all fall hazards.

This will give them the upper hand in arescue event.

The nature of the work, the anchorlocation, the working load and limit andthe ease of use should all be factors indetermining the appropriate rescue system.Relying on an internal competent rescuerto make an informed choice based on thesefactors is a much more effective way toprotect workers than basing the decision onthe purchasing habits of other consumers.There is simply no such thing as the “best”rescue system for the wind energy industry.Individual companies should always selectrescue systems that best address theirspecific needs.

William Wright is the Training Coordinatorand Chief Instructor for Gravitec Systems,Inc., where he is responsible for managing afull-time staff of professional fall protectionand high angle rescue instructors. Wright hastraveled all over the United States, SouthKorea and Canada to teach workers at someof the world’s leading businesses how to betterprotect themselves while working at height,how to safely and effectively use their fallprotection equipment and how to rescuethemselves or others at height.

A Comparison of Commonly Used Automatic Descent Control Devices

Manufacturer Model Weight of Device Distance Maximum Lifting Ability Descent Speed Approx. Cost (300' of Working Length) (1 Person/2 People) User Weight (Feet/Second) 300' of Rope

DBI-Sala Rollgliss® 30 lbs 305 m/100 m 550 lbs Optional 3' $2,100 R500 Descender

Elk River, Inc. EZE-Man® 33 lbs 500 m/250 m 550 lbs Optional 3' $2,400 Auto Descent Device

Miller Fall Protection SafEscape 28 lbs 400 m/100 m 660 lbs No 4.5' $1,500 ControlledDescent/Self-Rescue System

ResQ REDPro™ 15 lbs 160 m/Max 2 People 440 lbs Optional 2.6' $1,387

SKYLOTEC MILAN 33 lbs 500 m/250 m 550 lbs Optional 2.9' $2,400

Söll AG 10 Hub B 25 lbs 400 m/150 m 500 lbs Optional 2' $1,500

Tractel Group derope UP E 33 lbs 400 m/125 m 500 lbs Optional 2' $3,200

RENEWABLE ENERGY FORUM




Renewable Energy in the United StatesWhat is its future?

We decided to ask industry and political leaders who should know . . .

Rick PerryGovernor of the state of Texas

Mike RoundsGovernor of the

state of South Dakota andPresident of the Council of State Governments

Rhone ReschPresident and CEO of theSolar Energy Industries

Association (SEIA)

Denise BodeCEO of the American WindEnergy Association (AWEA)



TEC: If predictions hold true, we will see a rebound in theconstruction of wind and solar farms starting in early 2010.How long do you think that this recovery and growth will last?

Denise Bode: A recovery in the wind industry depends on severalfactors. The second half of 2009 was strong because incentives thatwere part of the American Recovery and Reinvestment Act enabledwind farm developers to put in service a record amount of newcapacity. But that is not a long-term solution. Manufacturinginvestments are decreasing, production levels at current facilitiesare down and as a result, we are not creating new jobs. Our industryhas been subject to more than a decade of on-again, off-again taxpolicies. Without stable policies, investors are not getting the rightsignals about the U.S. commitment to renewable energy, and arenot committing to new manufacturing. Due to unstable policies, itis difficult to tell how long a recovery will last in the wind industry,and what kind of recovery it will be.

Gov. Rick Perry: Here in Texas, the future continues to look brightfor renewable energy. Texas currently has more than 9,300megawatts of wind capacity, and has led the nation in new windcapacity every year since 2005, a category that we’re a global leaderbut for four other countries. We are in the process of expandingour state’s transmission grid to accommodate as much as 18,000megawatts of wind generation in West Texas, in addition to thewind capacity along the Texas Gulf Coast. More than 45,000megawatts of potential wind projects are undergoing study forinterconnection at our grid operator, which is promising news forfuture construction of wind power in Texas.

We are also seeing interest in large-scale solar projects in Texas,with three utility-scale sized projects under active development andseveral more undergoing study. The transmission build-out underway in West Texas will help make our state one of the mostattractive places for solar developers to build and invest.

Gov. Mike Rounds: In South Dakota, the recovery for wind powerhas already begun. As a matter of fact, construction has started onmore than 300 megawatts of new wind power generation, which willmore than double our state’s wind power capacity. I believe that theindustry will have strong growth in the next year, and then level offto a steady growth rate. In South Dakota, as in much of the wind-rich central corridor of the United States, future wind developmentwill be stymied by lack of available transmission capacity. Regionaland multi-regional transmission improvements are essential forrenewable energy development in this country.

Rhone Resch: With forward-looking policies at the federal andstate level, the U.S. will expand our solar energy manufacturinginstallation and electricity production for the foreseeable future.

The speed of solar’s growth and development is, however,contingent on our government’s commitment to leveling theplaying field with fossil fuel companies, which have received morethan $100 billion in federal subsidies over the past decade.

Just as coal and oil have received substantial government assistanceto provide “cheap” electricity in the 20th century, the solar industryis working for the same treatment to meet the public’s demand forcheap, reliable and clean electricity in the 21st century.

If we invest in solar in the same way we invested in coal and oil,I believe we will see an era of unprecedented growth and prosperity,in utility-scale solar projects, commercial and residentialphotovoltaic installations and solar water heaters. In promotingthis, SEIA has unveiled the Solar Bill of Rights(www.solarbillofrights.com). These eight rights will give the solarindustry the freedom to compete with other energy sources and theliberty for consumers to choose solar—the clean energy choicefavored by 92 percent of the American public (SCHOTT SolarBarometer). After the initial “green conversion,” the field will beopen to developing more innovative ways to harness our naturalresources without irreparably harming the environment we dependon for basic sustenance.

Since solar relies on unlimited sunshine, it is guaranteed that it willnever run out, providing jobs and clean energy well into the future.

TEC: What action could the government take or possibly fail totake that would have either the most positive and/or negativeimpact on the construction of future renewable energy projects?

Denise Bode: For our industry to deliver the promise of abundantclean energy over a longer period than just a few years, we need astrong renewable electricity standard (RES), which will signal tobusinesses that the U.S. is committed to wind and otherrenewables. While new project construction signals an active windenergy market, the domestic manufacturing of wind turbinecomponents is just as important to our industry. The investmentneeded to establish wind manufacturing as a new manufacturingMinn-Dakota Wind Farm, South Dakota



sector in America can only occur with a long-term and stablemarket. We also need new transmission lines to carry wind energyfrom the wind farms to the demand centers and reforms in the waytransmission lines are planned, paid for and permitted. Withoutnew transmission, wind will not reach its potential. Finally, wewould like Congress to extend the incentives that it adopted lastyear for renewables. These incentives have made it possible tofinance new wind installation despite the poor economy and frozencredit markets.

Gov. Rick Perry: I believe the federal government needs toabandon plans to create new burdensome federal mandates andinstead look at what we’ve done here in Texas, the nation’s leader inrenewable energy. We’ve shown that the best thing government cando to ensure a fair and competitive marketplace is to establishlimited, reasonable and stable regulations, and then get out of theway of private industry. We are committed to ensuring that thestate’s electricity infrastructure can meet the demands of a growingpopulation of 1,000 people every day and keeps up with the needsof an economy that has outperformed the rest of the nation over thelast decade.

When you look at how the federal government and many otherstates have approached this issue, their proposals continue to stifleall energy projects, including renewable ones, with bureaucratic redtape, multiple levels of regulatory approval and unnecessaryenvironmental restrictions. These restrictions make it costly, timeconsuming and in some cases, impossible to build renewable energyprojects in an optimal location because of federal stipulations.

Gov. Mike Rounds: Government must support development ofrenewable energy projects through a diversified approach inrenewable energy technologies and resources. We need investmentin infrastructure (transmission), continued investment in advancedenergy research and storage, and consistent incentives for newrenewable energy projects. I believe long-term incentives are moreeffective in establishing developments that take more than 18months to properly engineer and build.

Rhone Resch: The most immediate action Congress can take is topass a jobs bill that recognizes solar as a job-creating engine. Firstand foremost, a strong jobs bill would include a temporaryexpansion of the 30 percent solar investment tax credit to 50 percentof the cost of solar systems that are installed in 2010. Additionally,a jobs bill should include a two-year extension, to December 31,2012, of the Treasury Department’s grant program for utility-scaleprojects, as well as the establishment of national net metering andinterconnection standards that allow the solar industry to competeon a fair playing field. These policies would immediately create jobsacross the country while removing market barriers.

In addition, expanding the solar investment tax credit to include

equipment used to manufacture solar energy generating property isone of the key priorities to promote solar manufacturing. This wouldbe achieved through the Solar Manufacturing Jobs Creation Act(S. 2755/H.R. 4085) that is making its way through Congress. Anotherpriority for the industry would be the creation of a Clean EnergyDevelopment Authority that assists with project financing at all levels.

Finally, Congress must introduce a price on the pollution thatcauses global warming, sending a signal to the markets that the eraof energy from fossil fuels is ending and the era of clean energytechnologies like solar has arrived.

TEC: While some turbine and solar panel manufacturers arestarting to develop factories in the U.S. to produce wind turbinegenerators and solar panels, they are still largely produced inforeign countries. In light of our immediate and future needs tocreate jobs here in America, what should be done to encouragethese manufacturers to invest in the U.S. economy?

Denise Bode: U.S. wind manufacturing has increased from lessthan 25 percent of turbine value a few years ago to nearly 50percent today. Since 2004, domestic wind manufacturingcapabilities have increased 12 times over. In 2008 alone, the U.S.brought online, announced or expanded over 55 manufacturing

Setting the Hub and Blades at a Wind Farm near Roscoe, Texas. Photo credit: Randy Hunter



facilities. The wind industry believes that the policy changesoutlined here, such as a renewable electricity standard and newprocedures for approving transmission, will stimulate demand sothat more wind manufacturing facilities are located in the UnitedStates and an even greater percentage of the components are madehere. Already, almost every turbine manufacturer that has installedturbines in the U.S. has manufacturing facilities currently online inthe U.S. or has a facility planned here. We have two U.S.-basedmanufacturers and seven foreign-based manufacturers with existingU.S. facilities, and at least six foreign and domestic manufacturerswith announced U.S. facilities. Manufacturing investments takefive to 10 or more years to pay off, so the key is for the U.S. tomake a long-term commitment to wind and other renewables tosignal to the manufacturers to add more facilities and build outtheir supply chain for subcomponents in the U.S. A strong RES isone of the only policies that would provide the long-term and stablemarket needed to attract more manufacturing investments.

Gov. Rick Perry: Wind turbine and solar manufacturers areinherently energy intensive businesses, and Washington’s commitmentto policies that will make energy more expensive sends the wrongsignal to businesses ready to invest and risk their own capital.

In Texas, we are using our Texas Enterprise and EmergingTechnology Funds to attract renewable energy manufacturers in thesolar, wind power and non-food-based biofuels industries, and alsocoordinate with our local communities. Just last year, we invested$945,000 from the Texas Enterprise Fund (TEF) in MartiferEnergy Systems LLC for 225 new jobs in the San Angelo area anda projected $40 million in capital investment. This Portuguese-owned company located its wind energy tower manufacturing plant

in Texas as a result of the TEF investment.We also collaborate closely with industry andhigher education institutions to ensure we canprovide emerging technology companies with aneducated workforce, research and developmentfacilities and commercialization opportunities.

Gov. Mike Rounds: The U.S. needs to promoteits manufacturing and technological know-howand pro-business environment. In South Dakota,Molded Fiberglass Inc., in Aberdeen, and Knightand Carver, in Howard, operate wind-bladeproduction facilities. These innovative firms choseour state because of its pro-business environment.In South Dakota, we have no corporate incometax, no personal income tax, and no businessinventory tax. We also do our best to expeditesiting requests as well as cut the red tape fordevelopment efforts.

Rhone Resch: The U.S. is losing the global race for solarmanufacturing jobs. As recently as a decade ago, the U.S. accountedfor more than 40 percent of global solar photovoltaic (PV) cellproduction. In 2008, the U.S. produced only five percent of theworld’s solar cells, with Europe and Asia leading global production.It’s clear that we need to do something now.

The American Recovery and Reinvestment Act included acompetitive tax credit for advanced energy manufacturing projects.It’s a good start, but we need to enact the Solar Manufacturing JobsCreation Act to improve this tax credit and create long-term growthopportunities that incentivize job creation in U.S. factories.

Since making an investment is based largely on confidence of apredictable return, trust can be gained by offering reliable financingoptions to growing companies, long-term tax relief and assurancesfrom government leaders for future assistance, if it is needed.

Creating a hospitable environment that encourages a predictabledemand and return on solar and other renewable technologies iskey in attracting and keeping the attention of investors.

TEC: As an entrepreneurial country, where do you see thebiggest opportunities for small business growth in therenewable energy sector of our economy?

Denise Bode: We see opportunities all along the wind energy valuechain. A wind turbine has 8,000 components, and each has to bemanufactured. We are working hard to match the opportunitieswith potential manufacturers, many of them small businesses, allover the United States. In addition to manufacturing, there arethousands of U.S. job opportunities in wind farm design,construction, transportation, operations and maintenance. The

Nacel Control Cabinet, Stephenville, Texas



transportation and logistics of the many large components is acritical and significant part of our industry and can account for 20percent of the cost of wind turbine. After wind projects areconstructed, there are many skilled job opportunities for operationsand maintenance of the turbine fleet, ensuring componentreliability and maximum performance. Already, the wind industryhas produced more than 85,000 American jobs. With the rightpolicies in place, the U.S. Department of Energy estimates theindustry will support hundreds of thousands of new American jobs.

Gov. Rick Perry: Small businesses have always played a vital role inmaintaining Texas’ status as an energy leader, with hundreds ofthousands of Texans working in the energy industry that fuels ournation. We’re already seeing some of these businesses meeting growingdemand in areas such as wind turbine installation and maintenance,solar panel installation and remodeling efforts to maximize energyefficiency. The federal government would be remiss if they didn’t takea page from Texas’ playbook and create a business friendlyenvironment in this country that encourages innovation, creates jobs,improves the quality of living for its citizens and propels our economyforward in an increasingly competitive global marketplace.

Gov. Mike Rounds: Renewable energy offers an enormousopportunity for innovation, which is what this country thrives on.There are more than 8,000 parts in a wind turbine, meaning 8,000parts that can be improved, produced faster and at lower cost,assembled more efficiently, and better maintained. The U.S.

became a global leader in business and commerce throughinnovation, and that is how it can maintain its position in theworld. At the federal level, Congress has to once again focus onallowing private businesses to not only survive but flourish.Constant government intervention costs this country jobs that weshould be keeping here for the next generation.

Rhone Resch: There are tremendous growth opportunities forentrepreneurs in solar energy. These aren’t just the jobs you typicallythink of with solar, like the installers you see putting panels onrooftops. They are across the supply chain. From manufacturingand installing to electricians and plumbers, there are growingopportunities in the solar industry. These are good jobs with goodbenefits. And, they are bringing a sense of pride back to theAmerican worker.

The solar industry has also seen the emergence of innovative newbusiness models that have contributed to the robust growth of theindustry. For instance, residential and commercial power purchaseagreements have allowed home and business owners theopportunity to enjoy the benefits of solar without having to putdown the upfront cost. Also, the Property Assessed Clean Energy(PACE) financing model allows homeowners to take a loan fromtheir locality for the cost of a new solar system, which is then paidback by the owner through an addition to their property tax billover 15 to 20 years. Combined with effective state and federalpolicies, it is innovative new business models like these that willallow more and more Americans to go solar.

Photovoltaic Solar Array

CASPER WIND PROJECT


Challenges ResolvedCasper Wind Project

Chevron Wind Farm near Casper, Wyo.


ummings Electrical was awardedthe contract for the electricalconstruction of the Casper Wind

Project for Chevron in Casper, Wyo. Theproject began in August 2009 and wascompleted December 1, 2009. The scope ofwork covered by the initial contract was theunderground collection system, mediumvoltage terminations and VLF (Very LowFrequency) testing of the 35kV cables. Theinstallation of .7 miles of OH distributionline and the substations for both the CasperWind Farm and the local utility weresubsequently added.

During the initial safety orientation andproject kick-off meeting conducted at thesite, it was clear that Cummings’ normalopen trenching methods for cableinstallation for the underground collectionsystem was not the best option for thisproject. The soil was 100 percent sand andtherefore not safe for traditional methodsof trenching or the use of a backhoe.The solution was to use cable plowtechnology that allows for a safermovement through unusual soil conditions.Cummings Electrical was able to install theunderground collection system onschedule, accident-free and with minimaldisturbance of the natural habitat.

The land on which the wind farm was tobe built had once been the location of anoil refinery. As a result, much of the areawas classified as “Hazwop (HazardousWaste Operations),” which presented achallenge during the installation of the OHDistribution line. Working in this type ofclassification requires special safety trainingand precautions per OSHA (OccupationalSafety and Health Administration)Standard 1910.120, “Hazardous WasteOperations and Emergency Response.”Personnel certified in the appropriatetraining resolved the issue.

The construction of the substationspresented several challenges as well.Approximately 80 percent into the scheduledwork, a flaw in one of the steel structures wasdiscovered. The structure had been damagedand repaired at the factory. However, whenthe flaw was discovered, it was decided thatthe structure should be replaced.Unfortunately, the structure supported partof the incoming 115kV OH distributionline. Working in conjunction with MSEPower, a new structure was installed withoutremoving the existing OH Distribution lines.

Cummings Electrical encountered anotherchallenge when a leak was discovered in one ofthe CT/VTs (Current Transformer/VoltageTransformer) during installation. Immediateprecautions were taken to contain the spill. Theunit was shipped back to the manufacturer forinspection. It was decided that an independ-ent consultant would be used to inspect thewelds to determine the cause of the leak. Theconsultant subsequently determined that thewelds were faulty.While all the testswere being con-ducted, replacementequipment wasshipped to the siteand installed. Thisadditional work wascompleted in orderto ensure the substa-tions could beenergized on time.

Because of thehard work of ourrenewable energygroup, we wereable to deliver aquality project toChevron, accident-free, on time andon budget.

CASPER WIND PROJECT

C

Cummings was able to install the underground

collection system on schedule, accident-free and

with minimal disturbance of the natural habitat.


Cummings’ Renewable Energy LabIs a small wind turbine a good investment for you?

1 KW SWEA Horizontal Axis Turbine

ENERGY LAB

ENERGY LAB


ne area in renewable energy thatseems to have the most confusionassociated with it is the small

wind turbine (SWT). Most everyone wantsto go “green.” One of the ways that seemsto be the most obvious is the small windturbine. However, as we have found out inour research, that isn’t necessarily so.

Many inquiries for a SWT start with thequestion, “Do you know what your averagewind speed is for your specific turbinelocation?” More often than not, theresponse is, “No, but I know it is goodbecause the wind blows here all the time.”That statement can be the beginning of avery expensive lesson in wind energy.

What most people do not realize is the cut-in speed on an SWT usually ranges between6 and 10 mph. At these speeds the turbine’soutput is minimal—often less than 100watts. The name plate output is not obtaineduntil the conditions approach the rated windspeed. This is often between 20 and 30 mph.A very small portion of the county hasaverage wind speeds in this range.

This does not mean installing an SWT tooffset one’s power requirements on theirhome or business is a bad idea. But it doesmean they need to have a very realistic ideaof what they are buying and the return on

investment it will yield.Cummings Electrical recently completed

Phase I of its Renewable Energy Lab.It consists of three SWTs—differentmanufacturers, different configurationsand different sizes. The Lab also has a windvane and an anemometer. The outputs ofthe SWTs and monitoring equipment aretracked and recorded in graph form sothe effects of the various wind speeds,gusts and changes in wind direction canbe monitored.

The Lab currently has a SWEA 1 KWtraditional, 3-bladed Horizontal Axis WindTurbine (HAWT), a Mariah PowerWindspire 1.2 KW Vertical Axis WindTurbine (VAWT) Giromill and a Hi-Energy Technology 3 KW VAWT“Eggbeater.” Research is under way onother new designs. The ones with the mostpotential will be added to the Lab as theybecome commercially available.

Potential customers of an SWT areencouraged to visit the Lab and see,firsthand, what they look and sound like inoperation. They can also compareperformance at their specific locationusing average wind speeds from variousInternet sites and power curve informationfrom the manufacturers.

Said Tim Cummings, President ofCummings Electrical, “The purchase of asmall wind turbine is an excellentinvestment for many parts of the state, butthe customer needs to have a realistic ideaof the ROI and power it will generate toavoid unreasonably high expectations.”

To arrange for a tour of the CummingsElectrical Renewable Energy Lab call JimThompson, Sales and Marketing ManagerRenewable Energy Division. The direct phonenumber is 817-355-5337.

O

Cummings Electrical, Inc. Renewable Energy Lab at the Fort Worth office 1.2 KW Mariah Power Windspire Turbine

3 KW Hi-Energy Technology DS 3000 Turbine

Cummings Electrical, Inc.14900 Grand River Road, Suite 124Fort Worth, TX 76155

coghlin perspective v3i1

Documents

wind farms cummings

sustainable energy

renewable energy laboratory

renewable energy projects

nations energy supply

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theelectrical connection

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