Alternative Power Construction - 10 Oct 2009

For more information go to altpowerconstruction.com/info

For more information go to altpowerconstruction.com/info

V OLU ME 1

• • • • IS S U E 1

• • • • OC TO B E R

• • • • 2009

On the Cover:

12 Harnessing the Texan Sun

By Pam Stask

Gemini Solar Development Co. and Austin Energy team up for the construction of a 30-megawatt photovoltaic solar power plant — the largest in the United States.

Pg. 20

Features: 16 Beyond Price Point

By Loretta W. Prencipe

Understanding what matters in PV module purchasing.

20 Solar Power International 2009 Preview

By Pam Stask

The annual solar event heads to Anaheim, Calif., Oct. 27-29.

26 Generating Geothermal Power

By Karl Gawell and Leslie Blodgett

The Geothermal Energy Association offers insight into the U.S. market.

30 Finding the Perfect Spot

By Peter J. Comodeca

How site selection affects wind farm construction.

32 Renewable Opportunities

Pg. 35

By Pam Stask

MasTec Energy Group adds wind farm construction to its growing portfolio.

35 A Safe Descent

By William Wright

37 Meeting the Demand

By Ben McKelway



Selecting a rescue system for the wind energy industry.

A Pennsylvania hydroelectric power plant upgrades its much needed facilities.

Departments: 6 8 39 41 42 42

Editor’s Message News Product Showcase Power Play APC Advertisers Index Calendar

Alternative Power Construction is published bi-monthly. Copyright 2009, Benjamin Media, Inc., P.O. Box 190, Peninsula, OH 44264. All rights reserved. No part of this publication may be reproduced or transmitted by any means without written permission from the publisher. One-year subscription rates: complimentary in the United States and Canada, and $99.00 in other foreign countries. Single copy rate: $10.00. Subscriptions and classified advertising should be addressed to the Peninsula office. Periodical Postage Paid at Peninsula, Ohio and at additional mailing offices. POSTMASTER: send address changes to ALTERNATIVE POWER CONSTRUCTION, P.O. Box 190, Peninsula, OH 44264 USA. Canadian Subscriptions: Canada Post Agreement Number 40040393. Send change of address information and blocks of undeliverable copies to P.O. Box 1051, Fort Erie, ON L2A 6C7.

4 Alternative Power Construction • • • • October 2009

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Editor’s Message Constructing Power

Taking a Closer Look at Building America’s Energy Future Welcome to the inaugural issue of Alternative Power Construction — where we approach the renewable energy industry from the construction side of the business. Through a print publication, bi-weekly e-newsletter and informative Web site, we bring you the latest project stories, news and products relevant to the construction of sustainable energy facilities. With interest in using alternative energy sources — whether it’s wind, solar, water, etc. — rapidly growing among states, the demand for construction is high. Advantages such as tax incentives, a cleaner environment and less reliance on other resources are continuously pushing local governments, utilities and organizations to build these facilities. Thanks to funding through programs like the American Recovery and Reinvestment Act (ARRA), financing for the construction of facilities is becoming available — creating more jobs and paving the way for a cleaner energy future. Just last month, the Departments of Treasury and Energy announced $500 million in awards for clean energy projects (take a look at the News on page 8). This initial round of monetary awards will jumpstart 12 renewable energy projects spanning eight states. Energy Secretary Steven Chu exConstruction of renewable energy facilities is on plained, “These grants will help Amerthe rise and contractors are eager for the work. Companies like MasTec are diving into wind farm ica’s businesses launch clean energy installations to round out their project portfolios. projects, putting Americans back to Learn about MasTec’s transition to wind energy work in good construction and manuon page 32. facturing jobs. The initiative will help double our renewable energy capacity over the next few years and make sure America leads the world in creating the clean energy economy of the future.” With more money becoming available through stimulus packages, and utilities securing funding through partnerships, the renewable energy industry is looking up. Wind, solar, geothermal and biomass installations are all expected to increase throughout North America. As we move into the next year, there is an abundance of noteworthy projects to keep an eye on. For example, check out our cover story “Harnessing the Texan Sun” (on page 12) and learn all about the record-breaking solar farm installation in Austin, Texas. Built by Gemini Solar Development Co., the 30-megawatt solar power plant is expected to be operational by the end of 2010 and provide enough energy supply for 5,000 homes. At Alternative Power Construction, we look forward to promoting the industry and covering these projects over the next year. If you have any interesting project stories, products, press releases or news to share, feel free to send me an e-mail and be sure to stop by our Web site at www.altpowerconstruction.com. The road to decreasing our dependence on fossil fuels begins with building the facilities to capture renewable resources. With public interest, secured financing and proven technologies, meeting our energy goals can become a reality. Pam Stask Assistant Editor [email protected] 6 Alternative Power Construction • • • • October 2009

Publisher Bernard P. Krzys Associate Publisher Robert D. Krzys Editor James W. Rush Managing Editor Keith Gribbins Assistant Editor Pam Stask Contributing Staff Editors Sharon M. Bueno Bradley Kramer Jason Morgan Creative Director W.M. Conley Graphic Designers Sarah Hayes Chris Slogar Elizabeth Stull Marketing Manager Pete McNeil Regional Sales Representative Chris Johnson Circulation Manager Alexis R. Tarbet Web Manager Mark Gorman

Editorial & Advertising Offices 1770 Main St., P.O. Box 190 Peninsula, OH 44264 USA (330) 467-7588 • Fax: (330) 468-2289 www.altpowerconstruction.com e-mail: [email protected]

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News

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Green Costs Green

Treasury, Energy Announce $500 Million in Awards for Clean Energy Projects The evolution into a cleaner power infrastructure is going to take pushing, pulling and polishing with the help of clever government incentives. Marking a major milestone in the effort to spur private sector investments in clean energy and create new jobs for America’s workers, Treasury Secretary Tim Geithner and Energy Secretary Steven Chu announced on Sept. 1 $502 million in the first round of awards from an American Recovery and Reinvestment Act (Recovery Act) program that provides cash assistance to energy production companies in place of earned tax credits. The new funding creates additional upfront capital, enabling companies to create jobs and begin construction that may have been stalled until now. “The Recovery Act is investing in our long-term energy needs while creating jobs in communities around the country,” said Geithner. “This renewable energy program will spur the manufacture and development of clean energy in urban and rural America, allowing us to protect our environment, create good jobs and revitalize our nation’s economy.” Created under Section 1603 of the Recovery Act, the program is expected to provide more than $3 billion in financial support for clean energy projects by providing direct payments in lieu of tax credits. These payments will support an estimated 5,000 biomass, solar, wind 8 Alternative Power Construction • • • • October 2009

Payments delivered through the American Recovery and Reinvestment Act will support an estimated 5,000 renewable energy production facilities in all regions of the country over the life of the program. altpowerconstruction.com

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Energizing the West DOE Announces Transmission Project to Move Renewable Energy Resources to Market Creating employment and growth opportunities can revitalize a struggling economy — especially one plagued with a recession and countless layoffs. With the goal of bringing new jobs and green power to the West, Energy Secretary Steven Chu announced on Sept. 16 a large-scale transmission project to be financed using funding from the American Recovery and Reinvestment Act. The Western Area Power Administration will use borrowing authority under the Recovery Act to help build the $213 million Montana-Alberta Tie Limited (MATL) transmission project between Great Falls, Mont., and Lethbridge, Alberta. Almost two-thirds of the 214-mile transmission line will be located on U.S. soil, creating American jobs and allowing for the continued expansion of renewable energy production. “By integrating renewable energy sources into the electrical grid now, we are helping to shape America’s future economy, powered by clean, secure and affordable energy,” said Chu. “This project will help put Americans to work and build the transmission networks needed to bring renewable energy to consumers across the West.” Project construction will be completed by a Montana contractor and is expected to create dozens of jobs. Hundreds of additional jobs are expected for workers to build wind farms near Cut Bank, Mont., and across the region. Once energized, as early as 2010, the 230-kV transmission project will be capable of delivering 300 to 600 megawatts of clean, renewable wind energy — enough to power 150,000 to 300,000 homes. The MATL project will be funded through a public-private partnership between the Western Area Power Administration and Tonbridge Power Inc. with up to $161 million of the total project costs funded through Western’s Recovery Act borrowing authority. Construction is anticipated to begin by fall 2009 following the signing of agreements between Western and Tonbridge Power.

and other types of renewable energy production facilities in all regions of the country over the life of the program. As a result of this first round of funding, more than 2,000 Americans will have access to jobs in the renewable energy industry — both in construction and in manufacturing — while moving the nation closer to meeting the Administration’s goal of doubling renewable energy generation in the next few years. “These grants will help America’s businesses launch clean energy projects, putting Americans back to work in good construction and manufacturing jobs,” explained Chu.

“The initiative will help double our renewable energy capacity over the next few years and make sure America leads the world in creating the clean energy economy of the future.” The Treasury Department opened the application process for the 1603 program on July 31, 2009, and in early September made the first awards in half the statutorily mandated turnaround time of 60 days. The following is a chart of projects funded as part of today’s announcement. Additional awards under the program will be announced in the coming weeks.

STATE

PROJECT

LOCATION

AMOUNT

Colorado

Movement Gym PV System (Solar)

Boulder

$157,809

Connecticut

Solaire Development LLC

Danbury

$2,578,717

Maine

Evergreen Wind Power V LLC

Danforth

$40,441,471

Minnesota

Moraine II Wind Farm

Woodstock

$28,019,520

New York

Canadaigua Power Partners LLC (Wind)

Cohocton

$52,352,334

New York

Canadaigua Power Partners II LLC (Wind)

Cohocton

$22,296,494

Oregon

Wheat Field Wind Farm

Arlington

$47,717,155

Oregon

Hay Canyon Wind Farm

Moro

$47,092,555

Oregon

Pebble Springs Wind Farm

Arlington

$46,543,219

Pennsylvania

Highland Wind Farm

Salix

$42,204,562

Pennsylvania

Locust Ridge II LLC (Wind)

Shenandoah

$59,162,064

Texas

Penascal Wind Farm

Sarita

$114,071,646

Total altpowerconstruction.com

$502,637,546 October 2009 • • • • Alternative Power Construction 9

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Celebrate Solar Day with Dow Corning

Dow Corning is a captain of industry that specializes in silicon and silicon-based technologies, offering more than 7,000 products and services all over the world — from powders and primers to plastics and potting agents in industries as diverse as cosmetics, automotive and energy production. Promoting the latter, Dow Corning held an event called “Solar Day” in September where it announced the start of construction in Thomas Twp., Mich., of a manufacturing plant that will manufacture monosilane gas — a key material used to manufacture thin-film solar cells. Dow Corning will also unveil a solar panel installation and Solar Discovery Center at its corporate headquarters in Midland, Mich.

educate students and community leaders about how solar technology works as well as about the company’s critical role in solar technology.

Duke Energy to Build Ninth U.S. Wind Farm

Wind power offers an abundant, clean energy source for utilities looking to lessen their dependence on fossil fuels. With utilities and other energy providers realizing wind’s benefits, more farms are being requested to meet customers’ demands. Duke Energy continues to add to its renewable power portfolio with the announcement that it will build and operate a 200-megawatt (MW) wind energy project near Casper, Wyo. The Top of the World Windpower Project will be the company’s ninth U.S. wind farm and its fourth in Wyoming. Duke Energy will construct the Top of the World project on approximately 17,000 acres of private and public land it holds under long-term lease in Converse County. The project — expected to reach commercial operation by the end of 2010 — will generate enough electricity to power 50,000 to 60,000 homes on an annual basis. PacifiCorp, which operates as Rocky Mountain Power in Wyoming, will purchase all of the electricity generated by the Top of the World project and the associated renewable energy credits (RECs) as part of a 20-year power purchase agreement. PacifiCorp previously contracted to buy all of the output and RECs from Duke Energy’s nearby 99-MW Campbell Hill Windpower Project, scheduled to come on line later this year.

The solar panel installation at Dow Corning’s headquarters is the third the company has been involved with in Michigan. Others are at the Michigan site of Dow Corning’s joint venture the Hemlock Semiconductor Group, and at Dow Diamond in Midland, home of the minor league baseball’s Great Lakes Loons.

Located adjacent to Hemlock Semiconductor Group’s, Michigan polysilicon manufacturing site, the Dow Corning Monosilanes facility will manufacture high-purity monosilane, a key specialty gas used to manufacture thin-film solar cells and liquid crystal displays. The facility represents an investment of hundreds of millions of dollars and will initially employ approximately 30 people. The Dow Corning Monosilanes facility is expected to be completed in 2011. “This significant investment to become a leading supplier of monosilane for thin film solar technology will expand our feedstock offering and will further reinforce Dow Corning’s position as a material supplier across multiple solar technologies,” said Eric Peeters, global executive director, Dow Corning Solar Solutions. The solar installation at Dow Corning headquarters (mentioned above) features 136 solar panels and will produce approximately 30 kilowatt-hours of power — the amount of electricity consumed by approximately seven to 10 homes in a year. In addition to providing clean, alternative energy to the electrical grid, the solar installation serves as a testing ground for Dow Corning’s silicone encapsulation solution. Half of the solar panels in the installation are encapsulated with Dow Corning’s advanced silicone encapsulation solution to compare and test in real-life conditions, with the other half encapsulated using standard technology. Dow Corning constructed a Solar Discovery Center adjacent to the installation featuring interactive displays to educate visitors about solar technology. The Solar Discovery Center offers the company an opportunity to 10 Alternative Power Construction • • • • October 2009

The Top of the World Windpower Project, located near Casper, Wyo., will supply 200 megawatts (MW) of power to surrounding homes. Duke Energy also constructed the nearby 99-MW Campbell Hill Windpower Project (shown above). Photo courtesy of Duke Energy.

“We’ve always believed Duke Energy could become a major player in the wind power industry if we adhered to our strategy for organic, as well as opportunistic growth,” said Wouter van Kempen, president of Duke Energy Generation Services (DEGS), a business unit of Duke Energy that owns and develops renewable energy assets. “Including Top of the World — which will be our second-largest renewable energy facility — we’ll have committed to four new wind projects totaling more than 360 MW this year alone.” Duke Energy expects to start construction of the Top of the World project in late 2009 or early 2010, upon receipt of all necessary permits. Consistent with Gov. David Freudenthal’s executive order concerning the conservation of altpowerconstruction.com

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • greater sage grouse, Top of the World will be constructed outside of sensitive core areas. Duke Energy will use at least 66 G.E. turbines — each capable of producing 1.5 MW — at the Top of the World site. These units represent the balance of turbines Duke Energy arranged to purchase from G.E. in a procurement order announced in September 2008. Negotiations for the remainder of the wind turbine supply to be used are underway.

Cleantech America Breaks Ground on California PV Solar Project

Clean energy is a priority for states all across the country, especially in California. With strict standards set in place, the Golden State is determined to use renewable sources. Cleantech America broke ground on Aug. 24 on California’s first utility-scale photovoltaic (PV) solar project to be approved under the state’s Renewables Portfolio Standard (RPS) program. Named CalRENEW-1, the solar farm is located in the City of Mendota in California’s Central Valley and will provide 5 megawatts (MW) of emission-free solar electricity to PG&E under a long-term power purchase agreement. The facility is scheduled to begin operation before the end of the year, and when completed, will be one of the largest PV solar projects in California.

renewable energy and carbon reduction goals. Quanta Services will provide engineering, procurement and construction services for the project, which will utilize Sharp thin film modules, recently introduced in the United States.

Intersolar North America Draws More than 15,000 Attendees

Intersolar North America — an international businessto-business trade show for the global solar industry — welcomed a crowd of more than 15,000 attendees to the Moscone Center in San Francisco, July 14-16. The annual event served as an international platform for exchange, drawing in visitors from approximately 90 countries.

Intersolar North America welcomed a crowd of more than 15,000 attendees and attracted visitors from approximately 90 countries.

When completed, CalRENEW-1 will be one of the largest photovoltaic solar projects in California.

CalRENEW-1 represents a successful collaboration between the company, PG&E and the City of Mendota to create green jobs, improve air quality and demonstrate the viability of large-scale PV solar to help California meet its renewable energy goals. “As a zero emission solar facility, CalRENEW-1 will move the San Joaquin Valley one step closer toward cleaner air and create dozens of green jobs in a city embracing the new clean energy economy. It has taken the support and hard work of many dedicated individuals, and we are all extremely excited to be commencing construction,” said Bill Barnes, CEO of Cleantech America. Cleantech America was recently acquired by Meridian Energy Ltd., the largest electricity generator in New Zealand, which generates power entirely from renewable resources. CalRENEW-1 is the company’s first U.S solar project and is a model for its U.S growth strategy. CalRENEW-1 will be one of the most advanced PV solar facilities in the world, helping California meet its stringent altpowerconstruction.com

“We are extremely excited about the growth of Intersolar North America,” said Markus Elsaesser, CEO of Solar Promotion International GmbH, exhibition and conference organizer. “The U.S. solar market has incredible potential, and with the support of industry associations, including the SEMI PV Group, ASES and CALSEIA, we are creating an opportunity for solar professionals to come together and discuss continued development for the U.S. market.” More than 440 exhibitors (a 111 percent increase from 2008) filled the show floor to display their latest products, techniques and technologies. Intersolar North America drew in exhibitors and representatives from 23 countries — highlighting the internationality of the solar market. Once again, the conference and accompanying programs played a large role in Intersolar North America and attracted more than 2,000 attendees. The conference portion featured more than 170 speakers and 25 conference tracks with sessions like the “Solar Start-ups Forum” and “The Role of Public Policy in U.S. PV Market Development.” The “Solar Gigawatts Symposium” brought together leaders from both the European and American solar markets. The Symposium featured a debate between policy and industry leaders on the appropriate policy tools for sparking market growth. An additional panel also discussed the financing and residential installation trends in the United States, as well as perspectives on European and U.S. market growth. Intersolar North America 2010 will once again take place in San Francisco, July 13-15. For more information, visit www.intersolar.us. October 2009 • • • • Alternative Power Construction 11

Harnessing the Texan Sun Gemini Solar Development and Austin Energy Team Up for Record Solar Project By Pam Stask

E

verything’s bigger in Texas and the same holds true for its solar farms. With acres of open land ripe for construction and abundant sunshine beaming, the Lone Star state is an ideal place to reap the benefits of solar energy. And the City of Austin, Texas, will soon be taking advantage of this renewable resource as Gemini Solar Development Co. gears up for the construction of a 30-megawatt (MW) photovoltaic solar power plant — the largest in the United States. The solar power plant, which will be built for Austin Energy, is expected to be operational by the end of 2010. “This landmark solar power plant will be built on approximately 350 acres of city-owned land located approximately 25 miles east of Austin,” says Kristina Peterson, president of Gemini Solar Development and vice president of Suntech America. “The solar array will be operational by the end of 2010 and when completed, the solar-generated power will eliminate approximately 30,000 tons of CO2 per year and provide enough electricity to power 5,000 homes.” With the construction of this grand-scale solar farm, the City of Austin can continue its crusade for the use of renewable energy that it started more than five years ago. And Austin Energy will be able to deliver clean energy to its more than 397,000 customers.

12 Alternative Power Construction • • • • October 2009

Embracing Clean Energy

The road to renewable energy first began for the utility company in 2001, when it created a clean power program primarily based on wind generation. Under this program, Austin Energy has developed and contracted 439 MW of wind power with plans to increase generation to 1,000 MW by 2020. In 2003, the push for renewables became greater when the Austin City Council adopted a strategic energy policy. The plan called for the development and use of clean energy by Austin Energy, with goals of establishing 30 MW of solar power by 2010 and 100 MW by 2020. “Solar-generated power will be one of the predominate energy sources of the future,” says Roger Duncan, general manager of Austin Energy. “Solar also complements wind because in Texas the wind blows best overnight and is less active during summer days. Utilizing solar with wind, we are also able to maximize the use of transmission, which is a key consideration.” These energy goals became even more aggressive in 2007 after the Austin City Council launched its Climate Protection Plan. This initiative — which calls for 30 percent of the utility’s energy to be from renewable resources by 2020 — required Austin Energy to develop a more proactive energy conservation strategy. This led to the city council altpowerconstruction.com

and Austin Energy to the early planning stages of the 30MW solar farm, as a means to achieve the 30 percent goal. Then on March 5, the city council approved an agreement for Austin Energy to purchase all of the electricity produced over a 25-year term by a 30-MW solar project. Through the agreement, the solar farm was to be built on city-owned property located about 25 miles from downtown Austin and help the utility work toward meeting its renewable energy objectives. After edging out 14 other companies, Gemini Solar Development Co., a solar project financier and developer, was named the winning bidder to complete the massive project. Through this contract, Gemini will construct, own and manage the solar facility for Austin Energy. The facility will consist of photovoltaic solar panels and span approximately 350 acres, as well as produce enough energy each year to power approximately 5,000 homes. Under a 25-year power purchase agreement (PPA), Austin Energy will pay Gemini up to $10 million per year for the power. “By partnering with Gemini on this project, Austin Energy is demonstrating true vision when it comes to environmental sustainability,” says Tim Lasocki, vice president of Gemini Solar Development and Renewable Ventures. “Through a long-term power purchase agreement, Austin Energy will be able to deploy predictable solar power generation without altpowerconstruction.com

up-front installation cost or ongoing maintenance expenses. Customers will benefit from lower utility costs over the long term, as well as a cleaner environment.” With Gemini chosen, plans for the project are under way and construction is expected to commence in the first quarter of 2010 and be completed by the end of that year. But before any equipment can roll onto the jobsite, extensive research and permitting must be done and a team of trained personnel needs to be assembled for the build to begin.

Prepping the Project

Prior to selecting Gemini, Austin Energy conducted site surveys, archaeological analysis and environmental assessment beginning in 2008 and 2009. And with construction set to begin early next year, Gemini Solar Development has conducted a geotechnical analysis and full permitting review using a variety of specialized local engineering and consulting firms. As for site prep work and further ecological studies, Gemini has hired an environmental permitting firm to conduct this research and final findings are expected in fall 2009. “The environmental assessment of the property has identified some minor areas that will be addressed, including; several small abandoned structures with asbestos-containing material; several areas of discarded materials such as October 2009 • • • • Alternative Power Construction 13

Proactive Power Generation

Austin Energy Increases Its Renewable Energy Goals for Cleaner Electricity Ever since 2001, Austin Energy has actively pursued the use of renewable energy to serve its more than 397,000 customers. In addition to its past and current projects, the utility’s staff has recently presented recommendations to the Austin City Council to increase the amount of renewable energy to be provided by the utility from 30 to 35 percent by 2020. Proposals from the recommendation include: • Increasing the solar capacity goal from 100 to 200 MW by 2020. • Increasing the wind generating capacity to 1,000 MW by 2020. • Adding 50 MW of biomass to the utility’s renewable energy portfolio. Austin Energy has also contracted to buy all of the power produced from a 100-MW biomass plant to be built in east Texas. The plant is expected to be operational by 2013.

Austin Energy has developed and contracted 439 megawatts of wind power with plans to increase generation to 1,000 MW by 2020.

in Texas for the construction of the Austin project, and two full-time local operators will be needed onsite when the project is on line. “Management and 24/7 operational analysis will be overseen by three individuals located off site and dispatched to the project as required,” says Lasocki. “Maintenance of the facility will be conducted by local firms that will also be dispatched to the project as required.” As for the construction of the solar farm, the chosen contractor will use Suntech solar photovoltaic modules. Approximately 126,000 of these modules will be installed on tracking systems to optimize solar electricity production (see sidebar on page 15). Gemini expects to announce its selection for EPC and major component supply later this year. “Suntech is one of the largest solar PV crystalline panel manufacturers in the world and is capable of producing the large volumes of high-quality panels required by this project in the proposed time period,” says Peterson. “Suntech will also contribute 50 percent of sponsor equity in the project.” After the EPC is chosen in the fall, the equipment, anchor systems and site access for the project will be determined in its final design. And depending on the Construction of the Austin Energy solar project is expected to commence in the first quarter of final system design and layout, there will 2010 and be completed by the end of that year. When operational, the solar farm will provide enough be a combination of underground and electricity to power 5,000 homes. overhead lines with one substation and all power will go directly to the grid — readily available to Given the large scale of the project, an equally impressive crew is needed for its construction and completion. To seek Austin Energy’s customers. out an experienced and skilled group, Gemini has recently As for general upkeep of the 350-acre solar farm, electrical released a Request for Proposals (RFP) to solar engineering, maintenance of the inverters and substation is expected, as procurement and construction (EPC) companies for the well as mechanical maintenance of the tracking systems. build. Gemini predicts that about 600 people will be hired The solar PV panels will be washed periodically to ensure tires, household and farm debris; a buried butane tank will need to be removed; and other small areas that will require some cleanup,” says Kathleen Garrett, director of Austin Energy Environmental Care & Protection. “In addition, an in-depth archeological assessment is being conducted to meet requirements of the Texas Historical Commission and the National Historic Preservation Act.”

14 Alternative Power Construction • • • • October 2009

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peak efficiency, says Peterson, and spare PV panels will be kept on hand at the site. With 2009 dwindling away and construction anticipated to begin early next year, developments on the Austin solar farm are expected to hurry along in the next couple of months. Thanks to the combination of a proactive utility like Austin Energy and the resources of Gemini Solar Development, this record solar project will help diminish the city’s dependence on fossil fuels and continue the push toward utilizing renewable energy sources. “Austin Energy’s leadership in renewable energy is a great example for utilities across the country,” says Lasocki. “This project reflects the utility’s strong commitment to the increasing adoption of renewable energy and is a great step forward for Texas, a global energy industry leader. Solar is the new cost-effective energy source. We hope state policy makers build on Austin Energy’s decision and bring new jobs and clean energy to the state with long-term, supportive incentive policies.” Pam Stask is assistant editor of Alternative Power Construction.

Under a 25-year power purchase agreement, Austin Energy will pay Gemini Solar Development up to $10 million per year for the power generated at its 350-acre solar facility.

Capturing Energy

The Suntech STP270 Module Series Heads to Texas for Record Solar Project By Nick Allen

The 30-megawatt (MW) Austin Energy Solar Project will feature the Suntech STP270 Solar Module Series. These highefficiency modules — rated at 260, 270 and 280 watts per module — are ideal for utility-scale systems. The STP270 module series is currently deployed in many of the world’s largest photovoltaic (PV) systems, including approximately 180,000 modules at the 35-MW Elecnor Power Plant in Trujillo, Spain, and more than 25,000 modules at Nellis Air Force Base, the largest PV system in North America until the Austin Energy plant comes online in 2010. Suntech will deliver more than 126,000 modules for the Austin Energy Project. The Suntech STP270 module series is produced from high-grade polycrystalline silicon, a semiconducting material that converts light energy into usable electricity. During the solar cell manufacturing process, Suntech applies a proprietary surface texturing process to improve the number of photons captured by the cell. Suntech also employs a special chemical edge isolation process to optimize cells for solar conversion in low and indirect light, therefore increasing performance and energy generation. Suntech recently redesigned its module packaging to maximize shipping space efficiency. Innovative stacking and packaging materials have allowed the company to deliver more modules per shipping container. Module consolidation has a number of benefits, including reducing shipping cost, reducing onsite staging area requirements and eliminating cardboard waste. By choosing Suntech modules, Austin Energy minimizes its installation footprint. The Suntech STP270 module series is designed for durability and long-term energy delivery. The module’s unique frame features strategically placed drain- Approximately 126,000 Suntech solar photovoltaic modules are needed for the age holes to prevent corroding in wet conditions. Austin Energy project. These modules will be installed on tracking systems to optimize solar electricity production. The frame is designed with high-quality aluminum to ensure rigidity. Suntech modules are certified by the IEC, an international standards organization, to withstand winds of 85 miles per hour or more, and to support snow loads of up to 120 lbs per sq ft. For more information on Suntech products, visit www.suntech-power.com. Nick Allen is a senior at the University of California, Santa Barbara, with a double major in business-economics and environmental studies. He is the co-author of U.S. Electricity Policy 2009, an extensive report on the economic, social and environmental case for renewable electricity. altpowerconstruction.com

October 2009 • • • • Alternative Power Construction 15

Beyond Price Point Understanding What Matters in PV Module Purchasing By Loretta W. Prencipe

T

he change in the photovoltaic (PV) industry from early 2008 to today is remarkable. The credit crunch and an increasing number of panel manufacturers have brought about a new dynamic in the relationship among developers, distributors and module manufacturers — making purchasing a much more complex process. Last year, Borrego Solar, a San Diego-based PV system developer/integrator, bought panels from six different module manufacturers. Now, with a tighter financial market and more competing manufacturers in the PV industry, you would expect that Borrego Solar might broaden its module supplier base. But that’s not exactly the case. “In 2009, we are talking to other module manufacturers,” says Aaron Hall, president of Borrego Solar. “However, we want to reduce the number of suppliers and strengthen supplier relationships. We want to build up volume, credit and relationships with vendors.” Borrego Solar deployed approximately 10 megawatts (MW) in 2008. The company believes the strategy will strengthen offers from vendors and that suppliers will prioritize its needs — credit terms, product availability, type of product and engineering and sales support. This is important when a company is, according to Hall, “in a tight situation to win a competitive bid. ... A preferred vendor may give another few cents per watt to win a bid. Otherwise without a strong vendor relationship, you may not get any pricing support.” 16 Alternative Power Construction • • • • October 2009

Just over a year ago, buyers were competing aggressively to get panels, but today there’s a slowdown in obtaining financing for panel purchase and system development. These changes have definitely affected the purchasing process and what buyers look for when making their decision. “Over the last six months, the buyer feels more power than before,” says Paul Wormser, senior director of product development and systems solutions for Sharp Solar Energy Solutions Group, a manufacturer of roof modules for residential, commercial and utility-scale applications. “The one thing that influences behavior is price,” says Hall. “[Panels are] the most expensive part of an installation. Contractors that are bidding jobs are still heavily focused on price.”

Behind the Module

While the mantra of 2008 could have been “price, price, price,” experts point to a larger picture. “We all need to move away from module price as the exclusive metric,” says Wormser. “For most customers, the single most important metric is how much a kilowatt hour [kWh] costs over the life of the system. Module price is an element in this bigger question, but not the whole story.” “Every module has different power characteristics,” adds Al Velosa, solar industry analyst for Gartner, a research firm. “The purchase decision cannot be based simply upon the altpowerconstruction.com

“If you compare Factory Standard Test Conditions [STC] capacity perspective of price per watt. End customers are rating and PV USA Test Conditions [PTC], PTC rating is increasingly looking at the total cost to install, maintain less due to the higher solar cell temperature in the fields. and service a system over 20 or more years and comparing A higher PTC rating means more production,” says Sui. this with their utility’s price per kWh.” ET Solar, which has a manufacturing plant in Taizhou, ChiHall notes that buyers need to take a hard look at what na, produces panels with top-rated PTC ratings according to they are willing to spend. “The cost of an installation the California Energy Center listing (www.gosolarcalifornia. can easily have up to 100 line items,” he says. “Just the org/equipment/pvmodule.html). dimension of the module will impact the cost. A taller, With all the potential variances in output and design skinnier module will have a cheaper installation cost options, engineering should be involved in the buying than a square module because of racking. You have to decision from early on, recommends Steve Eng, an encompare that to what you’ll save on labor with a more ergy engineer for Enviro-Energy Technologies, which efficient module — calculating the spread is difficult and supports commercial and residential customers in the takes experience.” design, build and inspection of PV systems. “You need Other factors in the panel purchase decision include: to look beyond the nameplate rating and standard test panel engineering and estimated cost per kWh; panel conditions,” he says. supply availability and delivery; panel nameplate rating PV system designers and engineers review results from pilot vs. power tolerance; temperature coefficiency and light projects and long-term studies to have a better understandsensitivity; manufacturer financial health and the ability ing of how modules actually perform in certain construction to support warranties; and competitive quality assurance types, weather patterns and geographic conditions. procedures. Wormser points to what he calls a “cascading priority” for the buyer. “The admission ticket to be considered is Warranty vs. Power Tolerance satisfying the customer’s comfort level with quality and Power tolerance is No. 1 in importance on the spec being able to stand behind the product.” sheet and can be trumped by the warranty, explains Hall. “The entire process has changed,” says Mike Ross, vice Potential buyers must focus on the minimum power output president of corporate development and general counsel language. Warranties usually include the language based for Solar Semiconductor, a module manufacturer. “There upon the minimum power rating of the module. is more due diligence being conducted. Potential customers check on manufacturer certifications more and check on the long-term viability of the company. It has become a much different market. Buyers are trying to look behind the module.” Warranty trends are changing, both for manufacturers and installers. Solar energy customers are asking for five- to 10-year warranties on the project construction itself, says Hall. Borrego Solar offers a 10year warranty on system installation. “For crystalline modules, the standard warranty is 10 years with -10 percent degradation and 25 years with 20 percent degradation,” says Linhui Sui, vice president and chief strategy officer of ET Solar, which manufactures silicon ingots and wafers, PV modules and solar tracking systems. “A two- to five-year warranty on workmanship and defects is also an industry standard.” ET Solar offers 12 years with -10 percent power degradation and fiveyear workmanship warranty. While warranty terms are often boilerplate and often ignored, the power purchase agreement (PPA) model has some integrators asking whether the warranties are transferable. “We can sell the asset down The purchasing process goes far beyond just looking at the panel itself. Today, potential customers the road, but the warranty needs to be check on manufacturer certifications and the long-term viability of the company they are considering. transferrable,” says Hall. “It’s a huge value loss if it’s not.” The warranty needs to be read in essence as nominal power of the module and, says Hall, “subtract the power tolerance by 5 percent.” This is what your warranty is based Watt’s the Tolerance? upon. This is important for PPAs or if you are guaranteeing Leading module manufacturers invest in R&D to output, which can be a required component when respondimprove module power tolerances. Still, buyers need to ing to RFPs. Borrego Solar deploys solar under both buy/sell understand current tolerances and differences between and PPA models. test and field output. altpowerconstruction.com

October 2009 • • • • Alternative Power Construction 17

“You must look at the PTC variances of note,” adds Eng. “For instance, the difference between two brand name panels [in published reports] is 16 percent in the electricity produced over long-term testing.” Eng also reviews the specifications, third-party testing and pilot project output to understand the differences in standard test conditions on the panels, potential and actual output and which panels have the best temperature coefficients. Aesthetic design requirements aside, among the most important factors for Eng in designing a system — and thus a factor in module purchasing — are efficiency and temperature coefficient. “Efficiency will result in maximum power per fixed footprint,” says Eng. “Temperature coefficient will improve a panel’s efficiency. All panels decrease in efficiency as the temperature goes up. Certain panels are less susceptible to temperature than others. Usually better panels are slightly more expensive.”

Quality Assurance

Increasingly, buyers and distributors want to look beyond warranties and specifications for the assurances they need in large-scale buying. Ross says, “Buyers are asking what certifications do you have? What is your experience? What are your quality processes? How do they differ from other manufacturers?” Solar Semiconductor, for instance, carries out microcrack inspections during module manufacturing through an electroluminescent camera using advanced imaging techniques. “Micro-cracks degrade long-term performance of PV modules,” says Ross. “Micro-cracks are a result of the wafer manufacturing process and they can increase in size as the wafer is processed and converted to a module. If the micro-cracks become large enough, they will impact the module’s performance. If you are able to catch the weakest panel, that helps improve an array’s output.”

The company, which has worked with testing and certifying organization TUV Rheinland, also conducts other tests, including a test for electrical parameters done by using “Class A” pulsed type sun simulators with an accuracy of +/- 1 percent.

Installation and Support

Ease of installation is also important. Wormser notes that buyers should ask several questions throughout the purchasing process to determine how easily these units can be installed, as well as what’s needed for installation. Some questions include: • How do you ground the module? • What is the support structure? • How is the module packaged when it comes to my site? ET Solar provides engineering support to buyers. “Not many module manufacturers offer customers in-house engineering support,” says Sui. “Our engineers can help with annual kWh production estimations and offer assistance on how to maximize system output by selecting inverters, rack systems, installation tilt angles and even combiner boxes.” Hall adds, “If you are a new PV contractor, you should have someone recording as much data as possible and then constantly correcting assumptions and your pricing tool.” Panel pricing, system design and construction do not exist in a vacuum. The final desired outcome is long-term, reliable solar energy for the end-use customer. “A sophisticated customer should be asking to show how much are they paying per kWh over a period of time,” says Hall. “That is the rate to be measured.” Loretta W. Prencipe is a writer and energy consultant in Washington, D.C. She can be contacted at [email protected].

Buying Smart Ten Questions to Ask Module Manufacturers Throughout the Purchasing Process 1. Who pays for shipping? 2. Is the warranty transferrable? 3. What are the parameters and results of pilot project testing? 4. What is the financial health of the company? How long has the manufacturer been in existence? Are the warranty obligations insured? 5. What are the quality assurance procedures? 6. What is the panel failure rate? Is that certified by a third party? 7. What pricing support is available off the standard pricing list? 8. What engineering support is available? 9. What is the temperature coefficient? 10. Who are your current customers? How many projects? What’s the performance of the systems? 18 Alternative Power Construction • • • • October 2009

Warranties are an important part of purchasing solar modules. When buying, be sure to ask if the warranty is transferrable. In some cases, it can make or break a deal when selling the asset down the road. altpowerconstruction.com

For more information go to altpowerconstruction.com/info

Solar Power International 2009

The Annual Solar Event Heads to Anaheim, Calif.

A

rmed with new products, trends and insight, solar professionals from around the world are set to unite at Solar Power International 2009, the largest business-to-business solar event in North America, Oct. 27-29, at the Anaheim Convention Center in Anaheim, Calif. Co-sponsored by the Solar Electric Power Association (SEPA) and the Solar Energy Industries Association (SEIA), the annual trade show and conference offers solar professionals three days of valuable networking opportunities. “We’re focused on bringing businesses together to develop and strengthen relationships and partnerships,” says Julia Hamm, executive director of SEPA. “We also have a very strong focus on educational content, so we’re bringing all the parties involved in the solar industry together to learn about what’s happened over the past year and what key issues they need to be focusing on.” Through a wide range of educational sessions and exhibits, there’s something for everyone involved in the solar industry. The popular event gathers a variety of professionals under one roof in hopes to further the development of solar businesses throughout North America.

20 Alternative Power Construction • • • • October 2009

By Pam Stask “One main component of the show is that it’s just not the solar industry that participates — it’s everyone that has an interest in solar — whether it’s a business that is interested in installing solar at their facilities, electric utilities, policy makers, architects,” says Hamm. “It’s a very diverse group of individuals that participate, but all share a similar business interest.”

Meet and Greet

Established in 2004, Solar Power International is hosted by SEPA and SEIA — the two major non-profits working to expand solar markets in the United States. With such strong ties to two important associations, attendees and exhibitors can feel confident in how the money they invest in the show is spent throughout the year. “All of the proceeds from the show feed back into our activities to develop markets in the United States throughout the year,” says Hamm. “The industry knows that by supporting Solar Power International, they’re not just putting their money into a single week’s event, but they are putting their money into year-long activities that are going to benefit them.” altpowerconstruction.com

More than 25,000 people are expected to attend this year’s show, which offers attendees the opportunity to explore all of what the solar industry has to offer in one, convenient location. Through a diverse mix of exhibitors, attendees are able to get a broad understanding of the different companies, products and services that are available. “We have more than 900 exhibitors, so any vendor that you need to be talking to — whether it’s a panel manufacturer or a project financier — is here,” says Hamm. “Having a wide range of exhibitors allows attendees to make sure they are learning about what products are out there, as well as the specific companies that offer those products and services. Any type of business that has its hands in the solar industry is represented on the show floor.” This year’s floor plan is broken down into different technology types including: PV cell and module manufacturers; balance-of-system companies (inverters, mounting systems, etc.); manufacturing equipment; and solar thermal. There are also companies sprinkled throughout the show floor that concentrate on areas such as finance, utilities, engineering, construction and insurance. There is also a Public Night at the show, where the exhibit floor is open to the general public for three hours. This allows further networking opportunities and chances for attendees and exhibitors to strike up even more business connections. “The relationships and deals that are made at the conference are very significant,” explains Hamm. “We have a lot of people who come and actually do deals while they are at the show. It’s a great opportunity for people and businesses to meet with their clients in one location.”

to further support the detailed materials from the concurrent sessions offered throughout the conference program.” Solar Power International also offers an intensive list of pre- and post-conference workshops. For an additional fee, participants can take in sessions not available during normal conference hours. These extra educational opportunities are ideal for those attendees who are looking for a very general introduction to the solar industry, or for people wanting much more detail on specific topics that can not be covered in a normal, 90-minute session. Since networking plays a huge role in Solar Power International, SEPA and SEIA have included several opportunities for attendees and exhibitors to mingle outside of the event. On Monday, Oct. 26, the show is sponsoring an Opening Night Networking Reception at the convention center. This event will allow participants time to meet with other solar professionals prior to the opening of the trade show. The next night, Oct. 27, the show has partially bought out Disneyland and will host another networking party at the amusement park. “We’re excited for the Disneyland event,” says Hamm. “It will be a lot of fun, as well as offer a great networking opportunity for people in a much more casual setting.”

Industry Education

On top of roaming the exhibit hall, Solar Power International attendees can take in the show’s conference sessions. Designed for people looking to grow their business in the U.S. market, the conference content offers the insight of top experts in a wide range of topics. Conference sessions allow attendees to get up to speed on key issues in the industry in just a couple of days. This year, the conference program is broken down into six tracks — marketing, technology, policy, finance, crosscutting (topics that cross multiple tracks) and execution and implementation. “We really try to diversify the types of sessions that are offered,” says Hamm. “Some of the sessions are case studies, while others are presented in debate format or with single experts speaking on a single topic.” The execution and implementation track is brand new for 2009. The sessions in this track are focused on the issues that installers are facing on a day-to-day basis when trying to get projects off the ground. By adding the track, Hamm feels that the show has filled a gap in what was previously offered and will help installers with growing their businesses. Two CEO panels are scheduled on the mornings of Oct. 28 and 29. The first panel will focus on developing the utility market for solar electricity, including CEOs from utilities and solar providers. The second panel is on surviving the solar shakeout and how solar companies are getting through the current economic situation. This session, which will include solar manufacturers and installers, explores topics such as strategies that are being deployed to counteract the negative economic climate. “These CEO panels are very high-level discussions with big picture perspectives,” says Hamm. “The panels are designed altpowerconstruction.com

Networking plays a huge role in Solar Power International. The exhibit hall and other events offer attendees and exhibitors the opportunity to strike up even more business connections.

With strong numbers expected to attend the show, SEPA and SEIA are anticipating a successful event. As the economy begins to bounce back, confidence in the solar industry is building and more customers are looking to the energy source as a clean and affordable option. “I think we’re already starting to see signs that the solar industry is beginning to rebound well,” says Hamm. “As an industry, we’re beginning to see prices come down significantly which is a huge boost for market penetration. With prices coming down, we’re going to get a lot more interest from potential solar customers as it becomes a much more affordable option for everybody.” For more information on Solar Power International, visit www.solarpowerinternational.com. Pam Stask is assistant editor of Alternative Power Construction. October 2009 • • • • Alternative Power Construction 21

Solar Power International 2009 Adhesive Applications

For reliable, pressure-sensitive adhesive solutions in the manufacture, assembly and transport of photovoltaic products, Adhesive Applications offers a wide range of standard and custom high-performance products, including high/low temperature, low surface energy and UV-resistant adhesives. These products are available on a variety of substrates for mounting, gasketing, surface protection, masking, splicing, laminate attachment, reverse cell fixation, insulation and

The TrueSineWave Split-Phase Stackable Inverter, the Inverter Switchgear Module and the 80-amp MPPT charge controller integrate to become a complete off-grid system. The controller features a built-in battery state of charge meter. The entire system can be monitored via local computer net and/or the Internet via a communications gateway that can even provide data from sites without a landline via an optional GSM modem. The Apollo Solar System thus enables maximum solar energy harvest and verified performance. For more information, visit www.apollosolar.com.

ART TEC Solar wire wrapping. Film Tapes prevent damage during transport, keep cells secure during lamination and position laminate layers during fabrication. Double-sided foam tapes create a permanent element-sealed bond and provide a fixed bond for junction box placement. For more information, visit www.AdhesiveApps.com.

Advanced Energy

Designed for utility-scale or large commercial photovoltaic installations, the Solaron 500-kW inverter features a durable, transformerless, grid-tie design, converting raw DC power from solar-cell arrays to high-quality AC-grid electricity. With its robust controls and patented, soft-switching technology, the Solaron inverter achieves unbeatable 97.5 percent CEC efficiency and is NRTL-certified to UL 1741. A wide maximum power point (MPP) tracking window ensures maximum, daylong power processing. Both local and remote communications and data monitoring is always available via Advanced Energy’s Integrated Data System (IDS). Moreover, a comprehensive portfolio of service offerings — from installation assistance to long-term warranties and the company’s SafeGuard service program — allows integrators and power producers to continuously operate Solaron inverters at optimal performance for decades. For more information, visit www. advanced-energy.com.

Apollo Solar

Apollo Solar announces the availability of a complete system of off-grid photovoltaic (PV) power electronics, fully wired and factory tested, ready for quick installation with the industry’s smallest footprint. The installer needs only to connect the PV input, battery cables and AC load. 22 Alternative Power Construction • • • • October 2009

ART TEC Solar introduces a new solar differential controller designed to operate circulation pumps powered from solar panels or batteries. The DTC-AT includes adjustable differential temperature from 5 to 32 F. It also features an adjustable high temperature cut off or warning feature that either disables the circulation pump or simply shows a red warning light. The set point is adjustable from 80 to 200 F. Designed based on customer requests for a more fully featured controller, this new model is also very reasonably priced. For more information, visit www.ArtTecSolar.com.

Blue Sky Energy

The Solar Boost 3024i is a 12/24V MPPT type photovoltaic (PV) battery charge controller. The DUO-option diversion control upgrade converts the 3024i’s 20-amp auxiliary output into a separate 20-amp diversion type charge controller. The DUOoption diversion control upgrade allows a 3024i to provide diversion type charge control for hydroelectric, wind or similar generator type power sources while at the same time and within the same unit providing MPPT type PV charge control. A key aspect of the diversion control upgrade is its coordinated interaction with the PV charge control. This coordinated interaction allows the user to select whether maximum possible power is delivered to the dump load or minimum possible power is delivered to the dump load. For more information, visit www.blueskyenergyinc.com. altpowerconstruction.com

For more information go to altpowerconstruction.com/info

Bosch Rexroth Corp.

ET Solar

Carlisle Energy Service

long operational life at an attractive price. In the event of a high wind, the ET-S24/90 will move to a protective position. Mechanical stops provide further tracker protection under harsh weather conditions. The ET-S24/90 tracker has been put through detailed climatic, mechanical and electrical testing. This ensures a long operational life under harsh field conditions. The special design of the drive components allows self-lubrication, resulting in minimum maintenance throughout the project operation period. For more information, visit www.etsolar.com.

The Linear Motion and Assembly Technologies group from the Bosch Rexroth Corp. has developed a special transfer system that addresses the special demands of solar production. The TSsolar conveyor is designed with carefully-engineered features and materials to serve the unique manufacturing requirements of wafer-based solar cell modules or thinfilm technology modules. Solar power manufacturers are ramping up solar cell production across the globe. Waferbased and thinfilm solar module manufacturing processes are extremely complex and sensitive, demanding ultra-smooth, vibration-free material transport. Bosch Rexroth has incorporated high-friction belt technologies, special routing and handling devices and variable speed drives into the TSsolar conveyor line to help ensure a gentle material flow, an extremely clean, particulate-free operation and the ability to operate in the high-temperature environments (up to 200 degrees C) required for solar cell module manufacturing. For more information, visit www.boschrexroth.com. Carlisle Energy Service’s Spectro360 photovoltaic (PV) system combines Carlisle’s energy-star-qualified roofing membranes with Spectro360 cylindrical solar tubes. The Spectro360 PV system brings a third dimension to the rooftop PV world where up to 20 percent of the energy production is attributed to light that is reflected off the

roofing membrane onto the underside of the cylindrical tubes. Airflow between the Spectro360 cylindrical tubes results in operating temperatures lower than conventional flat-glass panels, improving energy output and reliability. Spectro360 PV panels are mounted horizontally with no angling or spacing required, allowing for more coverage of the roof area and producing more electricity per rooftop annually than conventional solar installations. Spectro360 requires half the labor and time at one-third the installation cost compared to a typical flat-glass PV panel system. This lightweight, self-ballasted and non-penetrating system was designed specifically for rooftop applications and eliminates the negative impact on roof life associated with traditional PV systems. For more information, visit www.carlisleenergy.com. 24 Alternative Power Construction • • • • October 2009

The ET-S24/90 is a state-of-art tilted single axis solar tracker, offering significant production advantages over fixed or non-tilted single axis trackers. The ET-S24/90 tracker can be ground-mounted on either precast pads or standard foundations. Electrical design flexibility allows use for off-grid, as well as grid-tied applications. The ET-S24/90 tracker is designed and configured to offer high performance and a

Sharp

Sharp launches its tandem amorphous-on-microcrystalline silicon thin film in the United States to meet the growing demand for utility-scale solar power plants. Thin film, with its strong performance and lower installed cost for large scale systems, is the preferred technology for multi-megawatt utility projects. Thin film delivers more megawatt-hours of energy per megawatt of power for the end-user, particularly in hot climates. Produced with only a fraction of the silicon used in crystalline solar cells, Sharp’s thin film modules offer high performance (128-W power output) and use less semiconductor material, thereby low-

ering the cost per kilowatt hour. With the addition of its innovative thin film technology platform and products, Sharp is one of the only manufacturers offering a full suite of solar solutions ideal for meeting the specific needs of every customer and application — residential, large commercial and utility-scale. For more information, visit www.solar.sharpusa.com. altpowerconstruction.com

For more information go to altpowerconstruction.com/info

Generating Geothermal Power The Geothermal Energy Association Offers Insight into the U.S. Market

Mapping Production

Despite the lagging economy, there continues to be strong growth in new geothermal power projects in 2009 and 2010. The Geothermal Energy Association (GEA) released its latest Industry Update in March 2009. The report showed a 25 percent increase in new geothermal projects from August 2008 and a 35 percent increase in overall power production potential of new geothermal projects. The GEA report identified 126 geothermal projects under development with the potential to put 5,500 megawatts 26 Alternative Power Construction • • • • October 2009

(MW) of new power capacity on line, providing enough power for 5.5 million California homes. New geothermal power projects were identified in 12 states — Alaska, Arizona, California, Colorado, Florida, Hawaii, Idaho, Nevada, New Mexico, Oregon, Utah and Washington. Nevada has the most production under development with 60 projects totaling 1,767.4 to 3,297.4 MW capacity. California is second with 28 projects and 1,056.6 to 1,365.6 MW capacity, followed by Idaho, Oregon, Utah and Alaska, respectively. Total Capacity in Development by State

MW Phase (I – IV)

G

eothermal power is a growing and important part of the energy supply mix in the western United States. A recent study from New York University showed that geothermal energy is one of the top renewable energy alternatives in the country, with greater efficiency and greater returns on research and development than most other options. Growing support shows it’s hard to compete with the limitless baseload supply of energy emanating from the center of the Earth. Grid-connected geothermal power plants provide reliable, baseload power today in California, Nevada, Utah and Idaho. Geothermal energy produced 4.5 percent of California’s total system power in 2007 and continues to grow. In addition, small geothermal power generators are operating in Alaska, Oregon, Wyoming and New Mexico. In the coming years, most western states are likely to have geothermal power generation on line.

By Karl Gawell and Leslie Blodgett

altpowerconstruction.com

The following chart displays the number of new geothermal projects and their power production potential by state: State

Total Projects/MW Power Potential

Alaska

5/60 to 100 MW

Arizona

2/2 to 20 MW

California

28/1,056.6 to 1,365.6 MW

Colorado

1/10 MW

Florida

1/0.2 to 1 MW

Hawaii

3/8 MW

Idaho

5/238 to 326 MW

Nevada

60/1,767.4 to 3,297.4 MW

New Mexico

1/10 MW

Oregon

12/292.4 to 318.4 MW

Utah

7/194 MW

Washington

1/Unspecified

Total

126 projects/3,638.6 to 5,650.4 MW

Stimulating Incentives

The American Recovery and Reinvestment Act (ARRA) of 2009 includes many provisions that will enhance the nation’s energy independence and create or save millions of jobs. The geothermal industry will be directly influenced through the development of new geothermal projects, as well as through advances in technology. altpowerconstruction.com

A key to recent growth in the geothermal power market has been the extension of the federal production tax credit (PTC) to include new geothermal power projects in the 2005 energy bill. The PTC was enacted in 1992 for wind projects and has demonstrated its effectiveness in providing an incentive for investors in the wind industry. The PTC provides a tax credit of roughly 2.0 cents per kilowatt hour (kWh) to new qualifying projects for every kWh produced in the first ten years of production. Since 2005, Congress has extended the PTC for wind, geothermal and other qualifying renewable technologies, but the stimulus bill took this incentive approach even further. Incentive provisions in ARRA of particular interest to geothermal power are: •A  three-year extension of the PTC, making geothermal power facilities placed in service by Dec. 31, 2013, eligible for the full credit. •E  xtension of the 30 percent investment tax credit (ITC) to new geothermal energy projects, in some cases allowing developers to apply for a cash grant in lieu of the ITC. •A  new 30 percent credit for companies manufacturing renewable/geothermal power equipment. •$  1.6 billion in new bonding authority for Clean Renewable Energy Bonds, used to finance new renewable power projects by public power, municipal and government entities. October 2009 • • • • Alternative Power Construction 27

• Up to $6 billion in loan guarantees for new renewable/ geothermal power projects, explicitly for commercial technologies.

electricity in otherwise untappable areas. While the long-term goal of EGS is to generate cost-competitive clean electricity, enabling research and development is needed to demonstrate the technology’s readiness in the near term. • I nnovative Exploration Techniques ($100 Million) — Funding will support projects that include exploration, siting, drilling and characterization of a series of exploration wells utilizing innovative exploration techniques. Funding the exploration of geothermal energy resources can carry a high upfront risk. By investing in and validating innovative exploration technologies and methods, the DOE can help reduce the level of upfront risk for the private sector, allowing

Together, these incentives provide a range of financial support for new geothermal projects intended to counter the difficult economic problems facing the economy and new investment. Once the provisions of the measures are fully implemented by the federal agencies, they are expected to create significant and lasting new project growth. In addition to the tax and loan incentives, the stimulus legislation provided $400 million in new funding for the U.S. Department of Energy’s (DOE) Geothermal Technologies Program (GTP) to implement a wide range of research, development, demonstration and deployment activities. The new funding provided through the DOE offers important and unique opportunities. The DOE GTP initiatives will spur new jobs, as well as the development and deployment of new technology and growth in new applications for the geothermal marketplace. The DOE announced a series of specific solicitations targeting key areas for short- and long-term industry and technolGrid-connected geothermal power plants provide reliable, baseload power today in California, Nevada, Utah and Idaho. ogy advancement. Through the Nevada has the most production under development with 60 projects totaling 1,767.4 to 3,297.4 MW capacity. stimulus bill, the DOE GTP will be funding: for increased investment and discovery of new geothermal resources. • Geothermal Demonstration Projects ($140 Million) — • National Geothermal Data System, Resource Assessment and Classification System ($30 Million) — The long-term sucFunding will support demonstrations of cutting-edge technologies to advance geothermal energy in new cess of geothermal energy technologies depends on a geographic areas, as well as geothermal energy prodetailed characterization of geothermal energy resources duction from oil and natural gas fields, geopressured nationwide. In 2008, the United States Geological Surfields and low- to moderate-temperature geothermal vey (USGS) conducted an assessment of high-temperresources. ature resource potential in the western United States. • Enhanced Geothermal Systems Technology Research and To fully leverage new low-temperature, geopressured, Development ($80 Million) — Funding will support co-production and EGS technologies, the DOE will support a nationwide assessment of geothermal resources, research of enhanced geothermal systems (EGS) techworking through the USGS and other partners. Second, nology to allow geothermal power generation across the DOE will support the development of a nationwide the country. Conventional geothermal energy sysdata system to make resource data available to academia, tems must be located near easily accessible geothermal researchers and the private sector. Finally, the DOE will water resources, limiting its nationwide use. EGS makes support the development of a geothermal resource clasuse of available heat resources by technologically sification system for use in determining site potential. engineering reservoirs so they are capable of producing

About the GEA The Geothermal Energy Association (GEA) is composed of over 150 member companies who are expanding

geothermal energy production in the United States and worldwide. Headquartered in Washington, D.C., the group works toward the increased knowledge and development of this clean, renewable, baseload energy industry through holding specialized workshops, publishing a newsletter and research reports and working with press and policymakers. GEA’s events cater to a variety of audiences and locations, spanning from New York City to the West Coast. The association also hosts the world’s largest annual geothermal show — the Geothermal Energy Expo (see sidebar on page 29). GEA’s latest reports include an overview called Geothermal 101: Basics of Geothermal Energy Production and Use and an industry production and development report that is updated twice a year. Other useful reports on technology, environment, economics and more are available at www.geo-energy.org/publications/reports.asp. GEA can assist professionals in networking with members of the industry and in accessing information on this valuable energy source. Geothermal has the potential to preserve the environment, create jobs and change lives across the country and around the world. For information on becoming a member of the Geothermal Energy Association, visit www.geo-energy.org/membership/membership.asp. 28 Alternative Power Construction • • • • October 2009

altpowerconstruction.com

Geothermal Energy Expo 2009 The Annual Event Offers Industry Professionals Educational and Networking Opportunities

Drillers, field researchers, equipment suppliers, financiers and everyone in between are set to unite at the Geothermal Energy Association’s (GEA’s) annual Geothermal Energy Expo, Oct. 4-7, 2009, in Reno, Nev. From experts to industry newcomers, people from around the world will share their expertise in geothermal resource exploration, characterization, development, production and management at the world’s largest geothermal energy event. It’s all part of turning today’s potential geothermal development into tomorrow’s reality. The Geothermal Energy Expo is the ideal event for individuals interested in alternative energy sources. The geothermal industry has picked up speed over the last couple of years and experts at the Expo will offer plenty of information and products to support that growth. Last year’s Geothermal Energy Expo drew in nearly A new addition to the annual Expo will be a Web cast presentation from the 1,800 attendees — an 80 percent increase from 2007. Expo floor. This will enable like-minded individuals who can’t make the trip to get the low-down on projects, equipment, services and state-of-the-art technology. The GEA is also bringing back last year’s popular Texas Hold ’Em Tournament. Last year nearly 1,800 people walked the Expo floor — an 80 percent increase over the previous year — and participants are expected to set records yet again. To learn more about exhibitors, events, sponsorships, guest information and to register, visit www.geothermalenergy2009.com. Alongside the Expo, the Geothermal Resources Council will hold their Annual Meeting of technical sessions. More information on the GRC Annual Meeting is available at www.geothermal.org. In total, the DOE ARRA funding is expected to support up to 90 new projects. The DOE will select up to 20 demonstration projects to bring 20 MW in new applications such as oil and gas co-production on line. They expect to select 30 new research and demonstration projects and will support exploration at 40 projects anticipated to involve up to 400 MW of new capacity. All of these developments will be in addition to the new projects GEA identified in its March Industry Update. The DOE hopes to complete an expedited review of the numerous applications it has received under these solicitations and expects to announce decisions by late summer or early fall 2009.

Facilitating Growth

A strong market, financial incentives and technology and deployment support are all important measures. But with roughly half of the geothermal power production taking place on public lands, federal agency leasing and permitting activities are also important for the industry’s future. Since changes in the federal geothermal leasing laws passed in 2005, the U.S. Bureau of Land Management (BLM) has been moving forward with a strong program intended to support geothermal production on appropriate public lands. The BLM held geothermal lease sales in December 2008 resulting in the sale of 194,410 acres of land and total revenue of almost $6.2 million. The lease sales took place in Oregon, Idaho and Utah and should result in an increase of geothermal projects in those areas. In 2009, a competitive Geothermal Lease Sale for parcels in California, Nevada and Utah took place July 14 in Reno, Nev. The sale generated $9,098,304 total in revenue for 255,354 acres leased. BLM has also completed and published a Programmatic Environmental Impact Statement for geothermal leasing on public lands. The plan allocates approximately 111 million acres of BLM lands and 79 million acres of National Forest System lands open for leasing. In addition, the plan allows pre-existing studies on specific lands to be used along with best management practices. The change should help reduce the processing time of future geothermal altpowerconstruction.com

power development. For more information on BLM’s plan, visit www.blm.gov/wo/st/en/info/newsroom/2008/december/ NR_12_18_2008.html.

Meeting State Goals

Some states with prime, undeveloped geothermal resources have set high goals for renewable power production through their state renewable portfolio standards. California and Nevada in particular both need new geothermal power production to meet their standards and maintain the reliability of their grids. Current transmission lines are insufficient for the nation’s growing renewable energy needs, but active transmission planning processes are reflecting these priorities in Nevada and California, where thousands of megawatts of undeveloped geothermal reserves have been identified. The GEA has been participating in transmission efforts that will make these reserves available and will make meeting these RPS goals possible. Federal stimulus legislation promises billions of dollars of support for transmission. Together, state renewable standards and transmission initiatives are supporting expansion of geothermal energy.

A Promising Outlook

Geothermal energy development continues to move forward and is expected to receive several boosts even before other solutions to current problems with the overall economy. New projects, new states and new technology will be the hallmarks of the geothermal industry in the coming years. Extrapolations of market trends show that with continued support from state and federal governments, geothermal growth rates could rise to meet or even exceed the peak levels seen during the industry’s boom period of the 1980s. Karl Gawell is executive director of the Geothermal Energy Association. Leslie Blodgett is the newsletter editor and outreach director of the Geothermal Energy Association. Photos courtesy of the Geothermal Energy Association October 2009 • • • • Alternative Power Construction 29

Finding the Perfect Spot How Site Selection Affects Wind Farm Construction By Peter J. Comodeca

Selecting a wind farm site is complex, time consuming and involves multiple disciplines working on parallel paths. Financing, government permits, meteorological studies, land use restrictions and design all have to be completed before a site is approved and construction can begin. However, it is imperative that construction experts be involved and consulted to achieve maximum use of the approved site. There are three principle sources of construction expertise generally participating in wind farm projects — the design team, the developer or construction manager and the wind turbine generator contractor. Wind farm developers should include an expert development team on their initial concept with knowledge in site design and wind farm construction, regardless of whether those people ultimately end up working throughout the building process. After conceptual approval and financing, expertise should be added to the team regarding the selection and operation of wind turbine generators. This expertise will allow the non-construction professionals on the project team to understand the limitations of various wind turbine designs, the site specific issues that may affect the layout and operation of the wind farm and the scheduling, civil engineering and electrical issues that will affect actual wind farm construction.

Site Searching

Wind is big and heavy. These two factors introduce unique considerations to the construction of a wind farm that differ from the construction of other power generation facilities. Big and heavy will contribute to the determination of an appropriate site and schedule for constructing the wind farm, as well as contribute additional costs to transportation, site preparation, construction and commissioning. When selecting the appropriate site for a wind farm, scheduling consideration should be given to accessing and constructing the site. Integral to both of these site selection concerns is the preoperational project schedule. Development of a wind farm generally takes about two to five years, with construction taking more or less than a year depending upon decisions made in the development phase. One of the key decisions that can affect the construction schedule 30 Alternative Power Construction • • • • October 2009

would be the lead time in ordering the wind turbine generators selected for the project. To the layperson, all wind turbines may look the same, but that is not reflective of reality. Turbine design, dimensions, weights and manufacturing locations all affect the construction of a wind farm. Another unique factor affecting project schedule and costs is the transportation and road system that exists between the wind turbine generator manufacturing point and the wind farm site. The excessive weight of a wind turbine nacelle and the excessive lengths of the wind turbine blades and tower segments require special attention when transporting the wind turbine generator to the jobsite. Special vehicles are required to transport wind turbine components. Roads have to be selected that can adequately bear the load of wind turbine parts. The transportation route has to be selected with adequate turning radii to accommodate the wind turbine part dimensions and with adequate vertical clearances to allow the parts to pass under bridges, signs, power lines and other overhead obstacles. These transportation concerns are generally addressed in the site selection and design process, and any associated roadway improvement costs are the equivalent of preparation costs often borne by the project owner or developer. The wind turbine generator manufacturer can provide assistance in analyzing the suitability of the transportation to the project site as can an engineering, procurement and construction (EPC) contractor. Site soil composition and the presence of rock are issues that will affect construction methods and costs. Site soil composition has to be reviewed to determine its tolerance for placement of tower foundations, roads and crane pads. Rock located on the wind farm site needs to be evaluated to determine if it is suitable for use as aggregate for foundations of roadways and crane pads on the site. The availability of aggregate onsite and the ability to quarry the aggregate for onsite construction purposes eliminates costs associated with both acquiring quarry from another location or entity and transporting that aggregate to the site. However, the location of suitable aggregate may otherwise impede construction by restricting or limiting access to the jobsite. Therefore, the soil condition and availability altpowerconstruction.com

of aggregate on a wind farm site may trigger construction costs of compensating for inadequate soil, purchasing necessary aggregate or overcoming potential delays or inefficiencies in the actual construction attributable to mining and moving aggregate onsite. Electrical issues are also different in the construction of a wind farm. An electrical substation is required to receive power from each tower and then increase the wind generated voltage to match the voltage in the power grid. Substation placement optimally should be central to the majority of the towers onsite and underground wiring should be used to connect each tower to the substation. The underground power systems should be designed to dissipate heat buildup to avoid damaging the cables or affecting their design life during transmission of the wind generated power to the substation. Also, cables to monitor individual tower performance and any other tower control cables should be trenched where possible between each tower and the wind farm operational control building. Site configuration will determine where to place the control building, but it is normally placed near the main entrance of the wind farm.

Building Relationships

During the construction process, it is important to distinguish the responsibilities of the wind turbine generator supplier and the civil and electrical works contractor. In the process, the supplier of the wind turbine generator is responsible for providing the tower, blades, hub, nose cone and power unit. The supplier is also usually responsible for the supervisory control and data acquisition (SCADA) system and can also be responsible for the provision of an initial spare part inventory and the possible design of any desired maintenance facilities. The wind turbine supplier is also usually responsible to commission the operation of the wind turbines to demonstrate achievement of the stated performance criteria. It is important to point out that there is no standard definition of commissioning except for what is provided by contract or by a technical data sheet provided by the supplier. However, the electrical infrastructure can be tested by reliance on standard electrical tests recognized in the industry or required by applicable codes. Commissioning is necessary to commence the wind turbine warranty. Warranties generally run from two to five years and cover lost revenue, downtime to correct faults and an evaluation of the power curve. A wind turbine power curve is a graph indicating the individual turbine’s electrical power output for operation at different wind speeds. The power curve is generally determined by local wind field measurements. Failure to achieve power curve standards is often addressed in a contract by the imposition of liquidated damages. The wind farm civil and electrical works are usually referred to as the balance of plant (BOP) and are provided by a contractor different from the wind turbine supplier. BOP civil engineering scopes of work include roads and drainage, crane pads, turbine foundation, meteorological mast foundations, buildings for electrical switch gear, SCADA equipment and a maintenance/spare parts facility. BOP electrical work scopes include: point of connection equipment to feed the wind farm’s power generation into the electrical grid; underground cable networks and overhead transmission lines; electrical switch gear to protect and/or disconnect turbines or other equipment from the system; transformers and switches for individual turbines unless located within the turbine and altpowerconstruction.com

provided by the turbine supplier; and grounding and connections for control rooms, maintenance facilities and any other buildings onsite. This difference in responsibility between the wind turbine supplier and the BOP contractor is the topic of some debate regarding selection of the proper project delivery system for a wind farm. Project developers generally use EPC contractors as the entity to design a wind farm project and manage construction through the commissioning phase. The EPC contractor would be responsible for contracting with the wind turbine supplier and any BOP contractors. However, this arrangement exposes the EPC contractor to damages should the wind turbine fail from a performance or delivery perspective. Additionally, the wind turbine generator represents a high percentage of project costs without provision of an appropriate markup available to the EPC contractor. That is because the wind turbine is commonly shipped, erected and commissioned by the wind turbine supplier and not by EPC contractor personnel. As a result, EPC contractors have begun to perceive a disproportionate risk/reward ratio in contracting with the supplier — encouraging some movement to a project delivery system where the developer contracts with the wind turbine supplier directly, instead of through the EPC contractor.

Other Considerations

Construction issues related to wind farm site selection are also affected Access and transportation to the site are by other issues unique two important factors to consider. to the selected parcel. Wind farm construction requires hefty components and equipment, such as Construction may be afcranes, which need ample space fected by land use restricto maneuver. tions or zoning issues such as hunting rights, grazing rights and cultural issues. Additionally, wildlife issues may restrict construction due to bird or bat migration, wildlife migration, spawning issues, wetlands and surface water issues. Lastly, noise or visual obstruction restrictions may affect placement of turbines or hours of construction operation. Construction of wind farms is greatly affected by site selection. Although these issues are relatively new in the United States, there are well developed practices within the wind turbine and wind farm industries adopted by other countries. Despite all of the publicity related to wind farm site selection regarding zoning, permitting, environmental concerns and community reaction, the construction industry is capable of constructing a wind farm in the face of multiple site specific issues. Peter J. Comodeca is a partner at Calfee, a law firm headquartered in Cleveland, Ohio. He is co-chair of the firm’s Energy Industry Team and chair of its Construction Practice Group. He can be reached at [email protected]. October 2009 • • • • Alternative Power Construction 31

Renewable Opportunities MasTec Energy Group Adds Wind Farm Construction to Its Growing Portfolio By Pam Stask

O

ver the past few years, the push for renewable energy has gained momentum as more states are looking to lessen their dependence on fossil fuels. With government incentives increasing, the popularity of using these resources is growing and opening a window of opportunity for contractors — especially in the wind energy industry. MasTec, an end-to-end telecommunications and energy infrastructure service provider, discovered the promise of this new venture and added wind farm installations to its range of services — exploring the new clients and contracts the alternative power market has to offer. “We believe renewable energy will remain a long-term national priority and with MasTec’s expertise in wind farm construction, natural gas and electric transmission, we will be a leading player in that effort,” says Jose Mas, president and CEO of MasTec. After recognizing the impact of renewable energy sources, MasTec chose to broaden its portfolio and provide electrical contracting services to wind farms throughout the United States. Today the company designs, builds, installs and maintains utility services for investor-owned utilities (IOUs), cooperatives, municipalities and government institutions such as military bases. Current and past projects include underground and overhead transmission and distribution, substation construction, balance of plant (BOP) for wind farms, duct bank construction, directional drilling, street lighting and emergency restoration. MasTec has more than 200 offices scattered across the United States, with its client base stretching from Texas, through the Gulf States and up the East Coast to Maine. The company is even experiencing interest and growth from areas west of the Mississippi. To accommodate its business and expansion, MasTec employs 9,000 people who are

32 Alternative Power Construction • • • • October 2009

split among the company’s four major divisions — energy, communication, satellite and broadband. Over the years, MasTec has acquired two companies in the wind energy industry — Wanzek Construction Inc. and Power Partners LLC (see sidebar on page 34). The company has also added 3 Phase Line Construction, which performs transmission and distribution work. With these partnerships, MasTec has built numerous wind projects, including the 150-megawatt (MW) Notrees Windfarm for Duke Energy Generation Services and the 150-MW Goat Mountain Wind Ranch project for Edison Mission Energy.

Understanding the Industry

Although MasTec has found success in the electrical utility and wind energy markets, the weakened economy has affected scheduled projects throughout the United States. Financing has become a serious obstacle for wind farm construction, leading to delays and even cancellations on some projects. However, there is promise that business will bounce back with more states interested in renewable energy sources. “The credit crunch in the fall of 2008 and the announcement of federal stimulus dollars has caused many wind farm projects to be delayed and in some cases cancelled,” says Walt MacFarland, president of MasTec’s Energy Group. “Financing has become much more difficult. Some companies are waiting to see how they can take advantage of stimulus dollars.” While financing is a definite hurdle for utilities, MacFarland still sees a push for wind energy among these customers. With Renewable Energy Standards (RES) established in individual states, utilities are trying to meet these guidelines in a timely manner. Additional business is expected as more states are looking to develop RES — leading to other contractors exploring the wind market for growth opportunities. altpowerconstruction.com

For more information go to altpowerconstruction.com/info

With more and more contractors eager to dive into the wind energy business, MasTec looks to its staff and industry know-how to stay competitive. MacFarland notes that holding on to the same entrepreneurial spirit that founded MasTec is an important part in the way the company operates today. “We try to stand out from other companies by maintaining a well-trained and experienced workforce,” explains MacFarland. “We strive to keep abreast of new technologies, equipment and software that can assist in efficiency or quality of work. For example, we use software like Project Management Systems, which is project management tracking software for larger projects.” One of the most important factors in the day-to-day operations of MasTec is safety. Since projects require working with electricity and heavy equipment, the company’s crews must keep safety in mind and be properly trained for the task at hand. Developing a safety program and thorough training courses has helped to ensure a healthy workplace for the company’s employees. “Safety is paramount, and we strive to make sure everyone comes home safely at the end of the day,” says MacFarland. “As a company, we have a well-defined safety program with a full-time safety director and several staff personnel to facilitate it. MasTec’s focus to ensure safety is treated as a culture, so it becomes second nature in every employee’s routine actions.” On top of adopting safety as a vital part of its operations, MasTec works to maintain a well-trained workforce, as well as provide proper equipment training and safety gear to its employees. Through combining strong job knowledge and the necessary tools for the job, the company can feel confident that it’s sending out prepared crews. “MasTec has a training department, facilities and a Department of Labor certified lineman training curriculum that enables employees to become certified journeyman lineman,” says MacFarland. “MasTec also has an extensive fleet of equipment and all the necessary tools to perform any electrical task safely and efficiently.”

And speaking of equipment, MasTec has an extensive fleet in order to perform various types of infrastructurerelated projects. For example, the company uses numerous buckets and diggers for transmission and distribution work, as well as various size cranes for erecting wind towers and installing turbine blades. Trenchers, backhoes, excavators, directional drilling equipment, augers and pressure diggers round out the diverse fleet.

MasTec works to maintain a well-trained workforce, as well as provide proper equipment training and safety gear to its employees.

As the United States continues to ride out the recession, MasTec relies on satisfied customers it has worked with in the past to draw in new clientele. MacFarland notes that a lot of new contacts come from word of mouth from previous customers, as well as engineering firms and conferences. By performing work at a high standard, MasTec paves the way for new patrons and opens the door to innovative and exciting projects. Pam Stask is assistant editor of Alternative Power Construction.

Joining Forces

A Look at MasTec’s Recent Acquisitions Wanzek

Wanzek Construction Inc. is a direct-hire contractor providing construction expertise to the wind and renewable energy, power and industrial process industries. Headquartered in Fargo, N.D., Wanzek has a strong résumé in the construction industry with hundreds of projects to its credit. The company has built more than 3,000 megawatts of wind energy projects for the most notable developers and owners in the industry. For more than 38 years, Wanzek has employed a proven planning and controls process for the benefit of both client and company. Today, Wanzek employs up to 1,200 skilled craftspeople and completes projects throughout the United States.

Power Partners

Power Partners is a leading contractor of wind power collection systems, substations and power system interconnection services for private developers, electric utilities and governments. Power Partners provides fast-track engineering, design, procurement and construction services throughout the United States. By relying on Power Partners to provide engineering services, the company minimizes delays and takes responsibility for completing projects on time and within budget. Power Partners has integrated its expertise in designing, building and maintaining traditional power systems with the new frontier of wind energy production.

3 Phase Line Construction

3 Phase Line Construction is a specialty contractor of overhead and underground transmission and distribution systems located in Farmington, N.H. The company’s goals focus on safe work procedures that minimize environmental disturbance and maximize efficiency and customer satisfaction. Its experienced project managers and environmental professionals work together to provide quality projects in any type of terrain. Capabilities include transmission line construction up to and including 500 kilovolts, reconductoring, OPGW installation, cell tower antennas (energized), maintenance programs, matting, barehand services and emergency restoration. 34 Alternative Power Construction • • • • October 2009

altpowerconstruction.com

A Safe Descent Selecting a Rescue System for the Wind Energy Industry By William Wright

B

uilding or maintaining a wind farm can be a tall order, especially when crew members need to scale soaring turbines. When working on a wind project, preparations should be made in the event a rescue situation occurs. A single rescue system cannot efficiently handle every scenario an authorized rescuer may encounter in the wind energy industry. One system may perform well for one application but not another. Some rescue systems are easy to use for one application, while others require more skill but can be adapted for use in multiple situations. Wind turbines in North America simply come in too many different styles and designs to have a one-unit-fixes-all rescue solution. In this way, rescue systems are analogous to vehicles; the basic function is similar, but depending on the road, some outperform others. Regardless of the turbine “road” you must travel, all turbines require technicians to climb them to perform maintenance. In the event of a fall, OSHA (1926.502(d) (20) of Subpart M) mandates a “prompt” rescue of the victim. Choosing a suitable rescue system for different types of turbines can be a daunting task for employers. Instead of asking, “What is the best rescue system for the wind industry?” consumers should ask, “What is the best rescue system for my turbine?” Regardless of your choice, the system you choose should have the ability to raise, lower, drag and evacuate. It should also be operational by one person because many turbine rescues will involve the rescuer and the rescue subject only. Examining the functions and capabilities of various rescue systems on the market, along with anchor point recommendations for these systems, is important in the selection process. The complexity of training required to operate a rescue system is also a factor. Regardless of the manufacturer, type, operation, color or construction method, the vast majority of rescue systems can be divided into two categories: automatic descent control devices and manual descent control devices. altpowerconstruction.com

Automatic Descent Control Devices

This family of automatic descent control devices is also known as rescue wheels. Tractel’s Derope Up E, SKYLOTEC’s MILAN, DBI-Sala’s Rollgliss R500 Descender and ResQ’s REDPro all fall into this category. These devices usually have a fixed mechanical advantage with a 4-to-1 lifting ratio. They are typically operated by turning a wheel toward the direction of travel intended, indicated by “Auf” and “Ab” stamps on the wheel, which simply mean “up” and “down,” respectively. Automatic descent control devices excel in scenarios where the evacuation and rescue is linear, so that there is always a line of sight to the anchor point. Simple to use and operate, the pre-loaded 3/8-in. rescue rope is strong enough to support one- or two-person descents from 300 to 1,300 ft. Automatic descent control devices allow an automatic descent rate between 2.8 and 5 ft per second, depending on the manufacturer. If overhead anchor points are available, automatic descent control devices are typically the quickest, most effective and simplest rescue devices on the market for emergency evacuation and rescue. The cost of these automatic descent control devices generally ranges from $1,300 to $3,200.

Manual Descent Control Devices

Manual descent control devices make up the second family of rescue systems. They usually include rope, pulleys and progress capturing devices. Some also have short haul systems used for lifting heavier loads. Manual descent control devices require a higher level of user participation from the rescuer. Unlike the automatic descent control devices used during self- or assisted-lowering where the user can rely on the automatic braking mechanism for descent control, the manual devices require an authorized rescuer to continually control the rate of descent. Manually operated rescue systems for the wind energy industry fall into one of two categories: block and tackle October 2009 • • • • Alternative Power Construction 35

training needs to be considered. Because a rescue event systems or pre-rigged rope systems. Products such as Miller’s creates a high level of anxiety and apprehension, the Series 70 universal rescue system, MSA’s Suretyman rescue rescue techniques should be effective, yet easy enough to utility system and DBI-Sala’s Rollgliss Top R350 are block remember. A rescue system is useless if the rescuer is unable and tackle systems. They generally operate in either a 2-to-1, to operate it. 3-to-1, 4-to-1 or 5-to-1 configuration and are only practical There is no magical equation to determine the approprifor distances under 100 ft. The higher lifting ratio allows for ate length of rescue system training. Competent rescuers easier lifting compared to automatic descent control devices. can begin to make this determinaHowever, they can require up to five tion during the initial rescue assesstimes the length of rope. They also rement when they identify all the posquire an overhead anchor point and do sible locations where a worker might not work well over edges. The advantage require rescue or evacuation. Identiof block and tackle rescue systems is that fying these locations will also help lifting and lowering are accomplished competent rescuers determine the necwithout an add-on pulley kit, reducessary functions of their rescue system. ing the possibility for user error when Rescue system training should instruct lifting — making it the likely choice the user on the system’s components when performing suspended pick-offs. and capabilities and include scenarThe cost for block and tackle systems ios that closely simulate the real-life ranges from $600 to $2,000 and is usurescue event. Training should always ally determined by the working length include an observation of performance. of the system and the lifting ratio. On average most rescue training lasts Pre-rigged rope systems are distinctbetween two and five days. The ANSI/ ly different from block and tackle sysASSE Z359.2 standard provides directems. They typically consist of a single tion on the content of authorized and rope used for lowering and a compatcompetent rescuer training. ible lowering device. Most systems of this variety have an additional short haul (pulley) add-on for an increased A Proactive Approach to Rescue mechanical advantage when lift- Pre-rigged rope systems, such as Gravitec’s G4 Wind Unlike emergency responders who Turbine Rescue and Evacuation System, typically ing. Unlike block and tackle systems, must react to the situation at hand, pre-rigged rope systems can navigate consist of a single rope used for lowering and a com- employers in the wind energy induspatible lowering device. The single line prevents rope corners more easily. The single line entanglement and length requirements are less than try have the opportunity to be proalso prevents rope entanglement and active if they engage in pre-planning those for a block and tackle system. length requirements are less than for rescue and evacuation. During the those for a block and tackle system. work planning phase, competent rescuers should perform Gravitec’s G4 Wind Turbine Rescue and Evacuation System detailed hazard surveys and write rescue procedures for is one of a handful of systems that use pre-rigged rope. those areas where hazards exist in an effort to address and These systems are an assemblage of components from a abate all fall hazards. This will give them the upper hand number of different manufacturers and may come equipped in a rescue event. with edge rollers or protectors for navigating rope over sharp The nature of the work, the anchor location, the workedges. They may also include descent devices with anti-panic ing load and limit and ease of use should be factors in features, industrial quality anchorage connectors and a host determining the appropriate rescue system. Relying on an of other accessories. This category of rescue systems generinternal competent rescuer to make an informed choice ally is the most versatile, lowest in price ($800 to $1,800) and based on these factors is a much more effective way to probest-equipped for more technical rescues. They do, however, tect workers than basing the decision on the purchasing require a higher level of training. habits of other consumers. There’s simply no such thing as the “best” rescue system for the wind energy industry. Individual companies should always select rescue systems Rescue System Training that best address their specific needs. Wind turbine technicians typically do not have the same caliber of training as an emergency rescue response team, William Wright is a training coordinator for Gravitec Systems Inc. therefore the duration and complexity of rescue system

A Comparison of Commonly Used Automatic Descent Control Devices Manufacturer

Model

Weight of Device (300 ft of Working Length)

Distance (1 Person/2 People)

Maximum User Weight

Lifting Ability

Descent Speed (ft/Second)

Approximate Cost with 300 ft of Rope

DBI-Sala

Rollgliss R500 Descender

30 lbs

305 m/100 m

550 lbs

Optional

3 ft

$2,100

Elk River Inc.

EZE-Man Auto Descent Device

33 lbs

500 m/250 m

550 lbs

Optional

3 ft

$2,400

Miller Fall Protection

SafEscape Controlled Descent/ Self-Rescue System

28 lbs

400 m/100 m

660 lbs

No

4.5 ft

$1,500

ResQ

REDPro

15 lbs

160 m/Max 2 People

440 lbs

Optional

2.6 ft

$1,387

SKYLOTEC

MILAN

33 lbs

500 m/250 m

550 lbs

Optional

2.9 ft

$2,400

Söll

AG 10 Hub B

25 lbs

400 m/150 m

500 lbs

Optional

2 ft

$1,500

Tractel Group

derope UP E

33 lbs

400 m/125 m

500 lbs

Optional

2 ft

$3,200

36 Alternative Power Construction • • • • October 2009

altpowerconstruction.com

Meeting the Demand A Pennsylvania Hydroelectric Power Plant Upgrades Its Much Needed Facilities By Ben McKelway

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ith a hydroelectric generating capacity of 1,100 megawatts (MW), the eight-generator Muddy Run Pumped Storage Facility in southeastern Pennsylvania helps the mid-Atlantic power grid meet peak demands. Although the local Amish families won’t use a single watt produced by the plant, the rest of area — packed with millions of electricity users — take it for granted with air conditioners, televisions and other appliances. Built in 1966, the plant is undergoing a major generator switchgear upgrade that is phased over several years to minimize the impact on output capacity. The Muddy Run plant boosts its output by drawing from its reservoir in peak periods and replenishing it off-peak. Four earthen dams form an 887-acre lake that holds up to 1.5 billion cu ft (11.4 billion gal) of water by containing the waters of the Muddy Run and a few other small tributaries that traverse Pennsylvania Dutch farmland on their way to the Susquehanna River. On the other side of the dams, at the river’s edge, sits the power plant. In the daytime, water from the reservoir falls 343 ft through four intake shafts, each 25 ft in diameter, and is shunted through eight tunnels to the turbines. Late at night and on weekends, when the demand for electricity is low, the turbines are reversed to pump water up to the reservoir from the river 400 ft below. Twenty hours of full-load operation causes the surface of the reservoir to drop 50 ft. altpowerconstruction.com

The owner of the facility, Exelon Power, is a division of Exelon Generation Co., which is a subsidiary of Exelon Corp., a Chicago-based energy giant with more than $19 billion in annual revenues. Exelon’s ability to boost its output as needed — especially on hot summer days when people typically turn up their air conditioners — is critical to meeting the region’s dynamic peak electricity demands. “The reservoir is like a giant battery,” explains Charles Tuttle Jr., the plant’s senior electrical engineer who is supervising the upgrade. By design, Muddy Run is not far (upstream and across the river) from the Peach Bottom Atomic Power Station — two nuclear reactors operated and partly owned by Exelon Generation. The nuclear plant runs all the time, so Muddy Run makes use of the excess power generated by the reactors at night to double its output the next day as needed. In service for about 40 years, the Muddy Run generator units, each of which includes a generator circuit breaker and a set of complicated switchgear, require two days of maintenance after every 500 operations (on/off cycles). Since the number of operations depends on the demand for electricity, there are days in the spring and fall when demand is low and some of the units are idle. But demand is higher in the winter and higher still in the summer, when it is not unusual for every unit to run at least twice a day. The facility’s eight 140-MW generators have already been replaced, but the aging switchgear is becoming expensive to maintain. October 2009 • • • • Alternative Power Construction 37

clearances or flame-retardant dielectric insulation between “The old switchgear is at the end of its life,” says Tuttle. certain components. “It is obsolete and has become very labor-intensive for us.” “Exelon put a lot of trust in us,” says Simo. “There was no The first of the eight replacement high-current switchway we were going to let them down.” gear units was commissioned in April 2007. Five more units The design for each cubicle also had to ensure that its have been commissioned since then, and the upgrade plan bus connections would line up perfectly with those of adcalls for the last two to be installed in spring 2010. jacent cubicles. After the assembly and individual testing Exelon’s multi-year contract for the eight sets of generaof each cubicle, Phoenix tested and measured each bus tor switchgear is with ABB Inc., one of the world’s largest connection between each manufacturers of high-voltindividual cubicle section to age equipment. At the heart verify proper alignments. of each replacement unit Last but not least, Phoenix is ABB’s state-of-the-art SF6 had to design the packaging high-current generator cirfor the cubicles, which had cuit breaker, manufactured to withstand the vibrations in Switzerland. For the rest of a 10-hour truck ride to of the gear — a veritable 3D Pennsylvania. maze of high-voltage switchWilliam Conley Jr., P.E., es, control systems and hundirector of contracts for ABB dreds of feet of copper cable Inc., had worked with Simo and buswork — ABB turns before on several projects. to its Boston-based supplier, In fact, ABB and Phoenix Phoenix Electric Corp. Electric have enjoyed a 30Phoenix Electric designed year partnership. Recently and is building eight of the the two men collaborated massive stacked switchgear on a project for the U.S. cubicles (six per generator) Army Corps of Engineers that house ABB’s circuit involving 109 generator cirbreakers, as well as the new cuit-breaker retrofits (each Phoenix gear. Each of the with customized Phoenix six-cubicle units is approxiswitchgear) for 11 hydromately 18 1/2 ft high x 20 ft electric dams in the Pacific x 7 1/2 ft and weighs about Northwest. The new units 15 tons. Each unit is rated for Muddy Run are more for 6,000 amps continuous than three times larger than duty at 15,000 volts and any in that project. is capable of interrupting “We knew Phoenix had 100,000 amps short-circuit the expertise and capabil— among the highest-rated ity to produce high-qualiequipment of its kind in Among the highest-rated equipment of its kind in the world, the new, more the world. When each unit powerful switchgear cubicles for the Muddy Run Pumped Storage Facility are ty product on time,” says is completed, it is shipped rated 20 percent higher than the ones they replaced, yet fit in the same space. Conley, who is based in North Carolina. “We’ve alfrom Phoenix’s Massachuways had a good relationship with them, and we also setts assembly plant to Pennsylvania in three sections know they provide great customer support. It has been a strapped to semitrailer flatbed trucks. strong team effort.” Phoenix Electric has no “off the shelf” products; all of “We’re quite pleased with the way things are going — the the company’s work is custom. The design/development phase, in which Exelon, ABB and Phoenix engineers worked entire process to this point has been very smooth,” adds together, took thousands of hours of design, calculations Tuttle, who looks forward to completing the long upgrade and testing to ensure the new equipment would interface project. Tuttle anticipates the new switchgear units will last properly with the ABB breakers and the generators. another 40 years, but Conley thinks they may actually last “These are the largest units we have ever built, and they are longer. All of the original Muddy Run circuit breakers are rated 20 percent higher than the units they replace,” notes General Electric air-blast models. Conley points out that Stephen Simo, vice president of Phoenix Electric. “The combecause the new ABB SF6 breakers use newer, more reliable plexity of what Exelon needed, combined with the challenge gas-insulation technology, they are rated for 40,000 on/off of fitting more powerful switchgear into the limited available cycles with minimal maintenance — more than 54 years of space, was a true engineering challenge. This project represervice at two cycles per day. sents the culmination of all our capabilities.” Thanks to the Muddy Run plant and its upgrade, much To speed up and simplify the design of the units, Phoenix needed power will be available for customers who are engineers used new 3D software. They knew there was no accustomed to a more energy-dependent lifestyle. With a room to spare; the new, higher-capacity cubicles had to be thoughtful design and a team of industry professionals, the the same size as the old ones. The software made it easier hydroelectric power plant can continue serving customers for the engineers to visualize not only the components, but with its 1,100-MW output. the spacing between them. Positioning the components precisely within each cubiThis article was submitted on behalf of Phoenix Electric Corp. For more cle was key to fitting them all in. Pertinent codes specified information, visit www.pec-usa.biz or e-mail [email protected]. 38 Alternative Power Construction • • • • October 2009

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Product Showcase Vermeer HG8000TX Horizontal Grinder

Vermeer Corp., a leading manufacturer of wood-waste recycling equipment, has expanded its line of grinders with the addition of the Vermeer HG8000TX horizontal grinder with a track undercarriage. The Vermeer HG8000TX is a fully mobile horizontal grinder that allows the operator to efficiently move the machine around jobsites, whether it is for land clearing, compost processing or forest thinning. The tracks provide increased traction in unstable ground conditions, providing access to remote areas or transport across obstacles such as shallow creeks or ditches, soft sandy or wet soil conditions and moderate inclines. Equipped with 28-in. double- or triple-grouser track pads, the HG8000TX produces only 12 psi of pressure in soft ground conditions. The undercarriage features a rigid-mounted, reinforced boxed track frame and the idlers are sealed for life, providing maintenance-free rollers that are sealed from possible contamination. Powered by a 1,050-hp engine, the HG8000TX horizontal grinder features a millbox opening measuring 50 in. high x 71.5 in. wide — the largest infeed opening of any horizontal grinder on the market. The infeed opening on the HG8000TX allows operators to process a higher volume of raw materials and grind materials usually reserved for a tub grinder. The HG8000TX features the Vermeer-exclusive AutoFeed system, which stops and reverses material from feeding into the patented duplex drum when engine rpm drops below an efficient operating range. Reversible hammers and cutter blocks on the Series II duplex drum offer nearly double the life of single-sided designs. Three preset automatic feed settings can be used in 90 percent of grinding situations, saving operators time. A fourth customizable setting is available for specialized situations. Other features include: an anvil accessible from the ground level, making it easy to maintain or replace; a one-piece belly and discharge conveyor that eliminates the transition area which can cause spillage; and the Thrown Object Deflector (TOD), which is designed to reduce the distance and quantity of thrown material debris to allow operation in smaller and controlled worksites. The HG8000TX is controlled by a multifunction, wireless remote control that allows the operator to control most operating functions from a maximum operating distance of 300 ft. This feature enhances jobsite productivity by allowing the operator to control machine functions from the loader vehicle while performing other functions.

Lincoln Electric’s Lincolnweld WTX

Welding is one of the factors that play a key role in wind tower construction. With that in mind, Lincoln Electric, a leading manufacturer of welding technology, is concentrating efforts to help grow wind tower production worldwide with various products tailored to the industry’s needs, including a new line of welding flux and electrodes. Lincolnweld, the product line of submerged arc welding flux and electrodes, allows companies to increase manufacturing efficiency and produce towers that meet requirements necessary to withstand years of exposure in extreme environmental conditions. The company’s Lincolnweld family of consumables has more than 10 flux and electrode combinations designed to provide consistent performance in wind tower welding applications. Within this family is a new submerged arc flux, Lincolnweld WTX, designed specifically for submerged arc welding on wind tower bases and door frames. As a neutral flux, this consumable can be paired with a variety of electrodes for multi-pass circumferential and longitudinal welding. As with most welding applications in the wind power industry, Lincoln recommends a specific combination of consumables for different application and procedure requirements. Fabricators must determine which welding flux and wire combination produces weld deposits that meet the strict mechanical property requirements of their job. Lincoln Electric recommends using Lincolnweld WTX, in combination with Lincolnweld L-61, a low carbon, medium manganese, low silicon general purpose submerged arc electrode. This combination of flux is ideal for longitudinal and circumferential seam welds and meets the F7A8-EM12K-H8 AWS classification, which allows welds to exceed the demanding mechanical property requirements specified for cold weather wind tower applications. altpowerconstruction.com

October 2009 • • • • Alternative Power Construction 39

Astec EarthPro Geothermal Drill Rigs

The new Astec EarthPro Geothermal 4550 (truck-mounted) and 4550X (track-mounted) drill rigs are designed to meet the specialized demands of geothermal system installations. Their superior field mobility, power and state-of-the-art technology make them ideally suited for high-production drilling applications. During development, Astec Underground engineers conducted extensive field studies with geothermal system installers and incorporated suggestions by veteran drillers into the design of the EarthPro Geothermal drills. Adapted from Astec horizontal directional drilling units, this proven design ensures dependable service. There are no chains, cables or hydraulic cylinders to replace. All rack-and-pinion components are covered by a five-year warranty. The three-speed drive motors allow quick trip times with strong 45,000 lbs pull up and 22,000 lbs pull down. It provides safe, precise operation and features locking motors to prevent carriage free falls. A single operator can drill and trip out up to 600 ft of pipe without winch assistance. Its pipe basket can hold up to 30 pieces of 20-ft pipe in 3 1/2-, 4- or 4-1/2 in. diameter. The distinctive table design features a vise breakout system on top for strength, versatility and safety. The key is located on the bottom for added safety and increases security for downhole tooling. Dual multifunction joystick controls are mounted on a console, which is adjustable for height and angle to reduce operator fatigue. The multi-function LCD display provides information on drill operation in easy-to-understand terms. The unit carries a 1,050cfm Sullair compressor with a maximum pressure of 350 psi to drill deeper and faster and to operate larger hammers. The drill is powered by a Caterpillar C15 ACERT turbocharged diesel Tier 3 Stage IIIA engine that develops 580 hp at 2,100 rpm and 1,953 ft-lbs of torque at 1,400 rpm. All filters, fluid checks and fill points are located on the same side of the drill near ground level to make monitoring and maintenance quick and easy.

ELT Lifting Fixtures

Engineered Lifting Technologies (ELT), located in Orchard Park, N.Y., specializes in the design and fabrication of belowthe-hook lifting fixtures. These fixtures range from small ergonomic devices up to large capacity lifters. All of the fixtures are designed and tested in accordance with ASME B30.20 and BTH-1. ELT has developed a wind turbine tower erection system that is relatively light weight, easily mounted and designed to dramatically reduce the stress on tower flanges. The system uses a four-bracket approach (two tailing and two lifting) and does not require the use of snatch blocks or spreader bars. In most cases, all tower sections can be placed using the same brackets and rigging hardware. To accommodate the various diameters and bolt spacing on the towers, an eccentric is used at the bolt holes — offering several advantages over multiple holes or slots. One advantage is that it allows for a tighter fitting hole, reducing stress on the bolts and flange. The system uses three bolts for the lifting brackets and two bolts for the tailing brackets. The brackets are flame sprayed with zinc and the eccentrics are nickel plated for corrosion resistance in severe conditions. The system also uses synthetic slings for its lightweight use and resistance to stretching. Due to the relatively light weight of the system, it is possible to mount the lifting brackets without the use of heavy equipment. This allows the towers to be staged closer to the foundation, making it possible to pick and place all tower sections. The system can be installed prior to the arrival of the crane to the tower site, reducing necessary crane time and overall total cost to the job. All system components are available with embedded RFID technology for tracking of all the equipment. ELT also can design and fabricate other lifting fixtures that will allow the contractors to perform their work safer and faster. A rental program may be available for smaller projects or for system evaluation. 40 Alternative Power Construction • • • • October 2009

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Power Play Solar’s Future: Your Voice Counts The solar industry is doing more than just generating clean, reliable energy — it is creating economic opportunities and jobs across America. At the heart of our country’s economic crossroads is Michigan. The decline of the auto industry and traditional manufacturing has left the state with an unemployment rate of over 15 percent for June — among the nation’s highest. Greenville, Mich., for instance, was hit hard when the local refrigerator factory that employed so many closed in early 2006. Economic opportunity returned when thin-film photovoltaic (PV) solar manufacturer United Solar Ovonic opened two facilities in the town. According to plant controller Norice Thorlund Rasmussen, “The doors didn’t shut on Greenville when Electrolux left, United Solar made sure of that.” East of Greenville, in Hemlock, Hemlock Semiconductor Group is manufacturing polycrystalline silicon, a core component of many solar panels. Workers who spent their careers in the automotive industry, including Richard Stuedemann, have been able to use their skills in the emerging clean energy economy. After 23 years in engineering and project leadership in the auto industry, Stuedemann is now responsible for manufacturing, maintaining and tracking of high-quality polycrystalline silicon at Hemlock. Employment opportunities in the solar industry extend across the supply chain with jobs for manufacturers, installers, electricians, plumbers, project developers, sales and construction workers. These are skilled jobs that pay a good wage. Others in the solar industry talk about the pride in their new careers. One person told me that his children are proud to tell other kids at school that their dad is helping to fight pollution. Enterprising Americans have an opportunity now to do something our country has done for generations — combine ingenuity, innovation and entrepreneurship to create a powerhouse industry that is the envy of the world. It’s happening now with leaders such as Dan Leary, who wrote his business plan while serving in Iraq. He has seen his Massachusetts-based clean energy and energy efficient solutions company, Nexamp, grow from 26 to 36 employees this year alone. Blake Jones founded Namaste Solar Electric in 2004 and hosted President Barack Obama and Vice President Joe Biden in Colorado for the signing of the American Recovery and Reinvestment Act in February. Since 2004, the company has grown from three employees to 55 and installed more than 650 PV solar energy systems on roofs across the state. These are just some of the stories that illustrate the tremendous growth of the solar industry. In 2008, gridtied PV (solar electric) installations grew by 81 percent, while domestic PV cell manufacturing grew by 65 percent. Meanwhile, solar water heating installations grew by 50 percent. And we expect to see 440,000 permanent jobs created by the solar industry by 2016. altpowerconstruction.com

By Rhone Resch

What’s Next for Solar?

While the past year has been a challenge for every industry in the United States, solar can and will continue to grow. It is critical that we seize the opportunity to be the leader in this fledgling global industry. Our opportunity to lead requires the right policies to promote innovation and ingenuity. These policies include a national renewable electricity standard that requires a certain percentage of the nation’s electricity to be generated by renewable sources like solar by a certain date. President Obama has a bold goal — 25 percent of America’s electricity to be generated by renewable sources by 2025. This is possible — with the right policies. The solar industry is up to the task. Establishing a national interconnection standard is another important policy that will break down barriers to solar. Countless people have told me about installing solar panels on their roofs, but not being able to connect to the electric grid because of cumbersome, lengthy and expensive procedures. It’s like a dishwasher manufacturer having to make 50 different models to meet different kitchen hook-up standards for each of the 50 states. It doesn’t make sense. Adopting a single, nationwide standard will allow for a streamlined approval process for homeowners and businesses and will provide a uniform technical standard for interconnection equipment. While the Solar Energy Industries Association (SEIA) continues work to advance pro-solar policies at the federal level, we must continue to hear from the voices of those already creating green jobs. Joining SEIA is one way to make sure that your views are brought to the table as Congress prepares to debate energy and climate change legislation this fall. Opponents of developing a clean energy economy are ready — they’ve already prepared talking points for the upcoming debate. We must be heard and continue to support our industry’s potential. You can help through attending town hall meetings and writing letters to your local newspaper. The most effective communicator of our message are people like you — the people already growing their businesses, creating green jobs and installing pollution-free solar energy on homes and businesses across the country. Amidst the sobering realities of the economy, wildly fluctuating fossil fuel prices and concerns about our deteriorating atmosphere, the solar industry is providing an opportunity to do something about these problems with a reliable, affordable energy option. In fact, solar energy is ready now to lead the clean energy economy, diversify our energy portfolio and help reduce our dependence on imported energy sources. Everyone should encourage their lawmakers to grab onto that opportunity now. Rhone Resch is president and CEO of the Solar Energy Industries Association (www.seia.org) in Washington, D.C. Learn more about projected solar jobs in each state at www.seia.org/cs/solar_jobs_ map. October 2009 • • • • Alternative Power Construction 41

Calendar 2009

December

October

2-3 Offshore Wind Project Workshop, Boston, AWEA, Web: www.awea.org

19-21 Biomass Summit, Washington, D.C., Web: www.infocastinc.com

8-10 Power-Gen International, Las Vegas, Web: www.power-gen.com

27-29 Solar Power International 2009, Anaheim, Calif., SEPA and SEIA, Web: www.solarpowerinternational.com

November

2010

4-6 World Energy Engineering Congress, Washington, D.C., AEE, Web: www.energycongress.com

January 20-21 Solar Power Generation USA, Las Vegas, Web: www.solarpowercongress.com

11-13 Advanced BioEnergy 2009, Sacramento, Calif., Web: www.advancedbioenergyconference.com

February

18-20 AWEA Wind Energy Fall Symposium, Orlando, Fla., AWEA, Web: www.awea.org

3-5 RETech 2010, Washington, D.C., Acore, Web: www.retech2010.com

Advertisers Index Advertiser......................................................... Page#........................................................ Web site APRS World....................................................... 25.........................................www.aprsworld.com Astec Underground....................................... 3......................... www.astecunderground.com AWEA...........................................................................33.....www.smallandcommunitywindexpo.org Benjamin Media Educational Webinars......43.............www.benjaminmedia.com/webinars Boldt . ................................................................. 19...................................... www.boldt.com/wind

Advertiser......................................................... Page#........................................................ Web site Engineered Lifting Technologies.............. 23.................................................. www.eltlift.com Hatch Energy.................................................... 2........................................................www.hatch.ca HPM..................................................................... 7..................................... www.hpmamerica.com Suntech.............................................................. 5.................................www.suntech-power.com Townsend.......................................................... 44.........................www.thetownsendcorp.com

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The Key to Predicting Your Business Future BMI Educational Webinar Series Presenter: Brad Dawson, Managing Director of LTV Dynamics Date: October 20, 2009 Time: 2 p.m. EST Registration: www.benjaminmedia.com/webinars Sponsored by Alternative Power Construction

Cost: FREE

Strategic planning has become an annual administrative rite. Every year, contractors brush off last year’s plans and doggedly seek to update their strategies. Once completed, the task, like filing tax returns and conducting employee reviews, is checked off for another year. What value do you really get from that sort of current planning process? When done correctly, strategic planning is a dynamic and invigorating process. New market opportunities are explored and competitive threats vanquished. A true strategic plan however is not an annual event. It is an activity that is tied to your business cycle – a period for contractors that extends for approximately 5 years. Brad Dawson, Managing Director of LTV Dynamics, gazes into his crystal ball to provide participants with a clear explanation of the five phases of the natural business cycle and pinpoints the exact location their business is in with regards to this cycle. Now is the time for growth.

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