17 Large Wind Turbine Drivetrain Testing Facility

8/13/2019 17 Large Wind Turbine Drivetrain Testing Facility

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8/3/2009 Wind and Hydropower Technologies Program 2

Webinar outline

Background information

Facility requirements

Application process

Questions and answers (18 Q&As)


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Definitions

Funding Opportunity Announcement (FOA) is a publicly

available document by which a Federal agency makes known itsintentions to award discretionary grants or cooperative agreements,usually as a result of competition for funds.

"Application" means the documentation submitted in response to aFunding Opportunity Announcement.

FedConnect refers to the electronic system used by applicants tosubmit applications to DOE. Note: FedConnect registration process can take up to 21 days

"Financial Assistance" means the transfer of money or property toan Applicant or Participant to accomplish a public purpose ofsupport authorized by Federal statute through Grants or Cooperative

Agreements and sub-awards.


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American Recovery and Reinvestment Act of2009 (ARRA)

The Recovery Acts purposes are to stimulate the economy and to

create and retain jobs. The Act gives preference to activities thatcan be started and completed expeditiously. Accordingly, specialconsideration will be given to projects that promote and enhance theobjectives of the Act, particularly job creation, preservation andeconomic recovery, in a timely manner.


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FOA Overview

Objective: Development and construction of a wind turbine

drivetrain test facility Independently certified to test 5 15 MW drivetrains

Self-sustaining operations and maintenance without future DOE funding

Funding: ~$45 million in Recovery Act funds

FedConnect Opportunity Number: DE-FOA-0000112

Letters of Intent were required from Prime Applicants on July 22,

2009 (partnering still possible); DOE does not assist in formingteams or partnerships

Close date for full application: August 13, 2009


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Additional Requirements

Preparation rooms for assembly, disassembly and instrumentation check-

out of test articles are required. Separate from the test bays

Data acquisition systems to enable verification of instrumentation prior toinstallation in the test bays

Overhead cranes, access doors, and other facility infrastructure foraccommodating associated components and equipment

Sufficient office space for permanent staff and visiting users

Conference rooms, lunch room, restrooms, computer stations, etc.

Can be new construction or involve the design and modification of anexisting building

Consideration will be given to geographical location relative to sea port and

rail access


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Application Requirements

Application must include:

Organizational participants from a state(s) and university(ies) - primeapplicant must be a State or Local Government, University or non-profit

Applicants must demonstrate capabilities and experience in:

Drivetrain testing

Business management and operation of industrial facilities

Ability to develop a self-sustaining, end-user facility for the benefit of the nation Plan for achieving long term sustainable operation and maintenance and

funding without future DOE assistance

Plan for disposition of equipment and real property

Plan for allowing users to access the facility

Plan for the disposition of intellectual property arising from testing at thefacility

Applicant must have submitted a Letter of Intent by the due date set forth in theFOA in order to submit a final application


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Other Requirements

Cost share: at least 35% of the total allowable costs of the project

(or at least 25% of the total allowable costs of the project with formaljustification)

Leveraging DOEs investment through applicant cost sharing will be afactor considered in the selection of applications

Potential end users of the facility may not partner due to conflict ofinterest

National Labs and/or private industry are permitted to participate asa partner


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Application Process Overview

The Applicant completes necessary registrations to submit anApplication (see next slide for details). COMPLETED

The Applicant submits Letter of Intent (LOI) and Final Application bythe due dates specified in the FOA. LOI COMPLETED

The Final Application will go through an Initial Review to ensure thatits compliant with the requirements of the FOA. Those Applicantswho do not pass the Initial Review will be notified in writing.

Compliant Applications will be sent to the Technical Merit ReviewCommittee composed of a panel of experts who will comment on,score, and rank each Application according to Merit Review Criteria.

The consensus comments and scores from the Technical MeritReview will be submitted to a team at DOE Headquarters (HQ) forthe Program Policy Factor Review.

Upon completion of the reviews, all information from each review willbe submitted to the Selection Official (SO) at DOE HQ. The SO willselect certain Applications for negotiation of award. All Applicantswill be notified in writing regarding the decision of the SO and willreceive Merit Review comments on their strengths and weaknesses.


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Registration Process

1. Obtain a Data Universal Number System (DUNS) number: Ifyour organization is located in the United States, you can requestand register for a DUNS number by calling 1-866-705-5711. If yourorganization is located outside of the United States, you can requestand register for a DUNS number online via web registration or callyour local Dun & Bradstreet office.

2. Register in Central Contract Registration (CCR): Go tohttp://www.ccr.gov orhttp://www.ccr.gov/Start.aspx and follow theinstructions, or contact the CCR Assistance Center at 888-227-2423.

3. Register in FedConnect: Go tohttps://www.fedconnect.net/FedConnect/PublicPages/FedConnect_

Ready_Set_Go.pdf

4. Please begin the registration process as soon as possiblebecause this process can take up to 21 days to complete.
http://www.dnb.com/ccr/register.htmlhttp://www.grants.gov/assets/D&B%20International%20CRC%20Phone%20Numbers.dochttp://www.ccr.gov/http://www.ccr.gov/Start.aspxhttps://www.fedconnect.net/FedConnect/PublicPages/FedConnect_Ready_Set_Go.pdfhttps://www.fedconnect.net/FedConnect/PublicPages/FedConnect_Ready_Set_Go.pdfhttps://www.fedconnect.net/FedConnect/PublicPages/FedConnect_Ready_Set_Go.pdfhttps://www.fedconnect.net/FedConnect/PublicPages/FedConnect_Ready_Set_Go.pdfhttp://www.ccr.gov/Start.aspxhttp://www.ccr.gov/http://www.grants.gov/assets/D&B%20International%20CRC%20Phone%20Numbers.dochttp://www.dnb.com/ccr/register.html


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Questions and Answers: 1

Q. Please discuss the role wind power can play in world energy.

A. The DOE Wind Program is responding to the challenges setforth in the "20% Wind Energy by 2030" report and PresidentObama's energy strategy. The ultimate role of wind power inworld energy production will be directly affected by DOE's

success in addressing those challenges.


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Q. Given the large scope of the project, will DOE consider anextension of the grant application date?

A. Due to the urgency of placing funding to accomplish the goalsof the American Recovery and Reinvestment Act, DOE doesnot antic ipate extending the application due date at this t ime.


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Q. Will the bidder's list be available?

A. DOE will not be providing a bidders' l ist for this FundingOpportunity Announcement.


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Q. Please address Cost Principles for a Subawardee planning toprovide hardware and services.

A. Assuming the question regards a contractor (vendor)providing off-the-shelf goods or services to the project, asopposed to a true subcontractor (subawardee or subgrantee)

who is participating substantially in the direction of the project,10 CFR 600 is the applicable guidance that governs how aprime recipient is to conduct procurement and issuesubawards: 10 CFR 600.140-148 applies to a prime recipientthat is an Institut ion of Higher Education or a non-prof it; and 10CFR 600.236 applies to a prime recipient that is a State or Localgovernment. Please note that allowability of costs for a

subawardee is determined according to the type of enti ty it is.For example, if the subawardee is a for-profit , the for-profit costprinciples apply even if the prime is a state, university or non-profit.

Q


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Q. Are there restrictions on profit? If so, what would they be?

If there are restrictions, is overhead an allowable cost?

A. Per 10 CFR 600, no fee or profit may be paid to a recipient orsubrecipient under a DOE award or subaward. A fee or profit

may be paid to a contractor providing a goods or servicesunder a contract with a recipient or subrecipient.

Overhead is generally an allowable cost. Please see theapplicable OMB Circulars or Federal Acquisition Regulation(FAR). The applicable guidance depends on the type of

recipient. OMB Circulars can be reviewed atwww.whitehouse.gov/OMB/circulars/index.html and the FARcan be viewed at http://www.arnet.gov/far/.

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Q. Over what time frame does the cost sharing need to occur?

A. Evidence of cost sharing commitments must be provided withthe application. Timing of cost sharing contributions shouldbe planned with the understanding that cost sharing must befully contributed by the end of the five year project period forthis effort, and the recipient should make every effort tomaintain a pro rata share of its cost share contribution (i.e., to"keep up" with its required contr ibution) as the projectproceeds. For addit ional guidance, please review FOA

Appendix C - Cost Share Information.

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Q. From Page 8: "Appl icants will also be required to set forth aplan for disposition of equipment and real property,..." - Canyou please elaborate/clarify this posit ion?

A. This project anticipates construction of a large dynamometerfacility, and as described in the FOA, a considerable amountequipment and real property may potentially be acquired by therecipient in support of the effort. In accordance with 10 CFR600.130-137 (for prime recipient that is an Institut ion of HigherEducation or a Non-profit) or 10 CFR 600.230-232 (for a primerecipient that is a State/Local Government), applicants are toprovide a plan for disposing of the equipment and real propertyat the conclusion of the project period.

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Q. From Page 8: "...a plan for allowing users to access the facili ty(e.g., peer review of user applications)..." - Can you pleaseelaborate/clarify - will this subject potential users to peerreview of their products/plans?

A. The primary purpose of this project is to develop a nationalfacility that will provide a unique test capability for w ind turbinedrivetrains. A plan permitting fair and equal access to allpotential users is required. An independent peer reviewprocess is one possible means to achieve this goal.

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Q. Can you please give an estimate of the size and weight of thegear-box units?

A. As a reference, literature shows the weight of a typical 2.1 MWnacelle and a typical 5 MW nacelle is around 160,000 lbs and440,000 lbs, respectively. For more information, please contacta wind turbine original equipment manufacturer (OEM).

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Q. Since the current wind turbine is between 1 to 5 MW range, andif the 15MW drivetrain never materialize, the hefty cost shareputs the applicant at very high financial risk. Can you explainthe rationale why the requirement jump to such high power sosoon?

A. Greater than 10MW designs are already in progress. Theexpectation for of fshore wind turbines is cont inued growthbeyond 10MW.

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Q. Are the two 7.5MW drivetrain test bay arrangement mandatoryor just recommendations?

A. A two-bay facility is not mandatory; however, DOE's preferenceis for a facility with multiple test bays. Consideration of thiselement will be given in the Merit Review Process.

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Q. What is the correlation between 20 MW dynamometer powerrequirement and the 15 MW wind turbine testingrequirement? Specif ically, should the 20 MW requirement beinterpreted as overload torque only or a transient capabili tythat best represents variation of the blade root moment?

A. The 20MW power requirement is necessary to conduct HighlyAccelerated Life Testing - it should not be considered atransient load.

Although not a DOE requirement, some wind turbine dr ivetrainmanufacturers have expressed interest in the addit ional abilityto test to twice the rated power as a transient (30MW for a15MW rated turbine).



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Q. Currently proposed high power (>7) MW wind turbine designshave an integrated gearbox/generator design or do away withthe gearbox altogether. Based on this trend, is it practical toinclude within the scope of supply the capability to dogenerator simulation above 7.5 MW?

A. The DOE has not asked for generator s imulation. Thissolicitation requires the facili ty to have the abili ty to test directdrive generators in addition to traditional gearbox/generatorsystems at the requested power.



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Q. Are there any specific temperature conditioningrequirements? Specifically, is the abili ty to cold soak a samplebefore the start of a test suff icient or is the capability tomaintain a set temperature during testing required?

A. Environmental chamber capabilities are not required; however,such capabili ty would be desirable.



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Q. Does the facili ty need to be able run the 15MW of power whenit opens or can that be upgraded over time?

A. The facility should be independently accredited to conductcertification testing of 15MW drivetrains by the end of thisproject. By the time this facility is commissioned it is expectedthat there wil l be demand to use the ful l capacity of the system.



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Q. How many separate test programs has the 2.5 MWdynamometer at the National Wind Technology Center (NWTC)

run? How many dif ferent gear boxes? Approximately howmuch does the facility charge? What is the annual revenue ofthe dynamometer facility?

A. DOE's NWTC 2.5MW dynamometer was commissioned inAugust 1999. It has not been operated as a publically-available user facil ity. DOE/ NREL custom-designed and bui ltthe facility to provide specialized wind turbine drivetrain R&Dtest capabili ty to support DOE technology developmentpartnerships with industry.

Over the last two years, the facili ty has been predominantlyoccupied by the "Gearbox Reliabili ty Collaborative" which is aDOE-funded R&D effort to understand fundamental root-causegearbox issues plaguing the wind industry. Directly comparingthe NWTC to this new facili ty is not relevant.


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Q. Does the grid simulation capability requirement imply also aneed to simulate change in grid frequency? Does the facility

need to accommodate 50 Hz generators to meet the FOArequirements?

A. The ability to test at 50 Hz is desirable though not arequirement; however, it will be taken into consideration duringthe Merit Review Process.


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The DOE Wind and HydropowerTechnologies Program thanks you for yourinterest

http://www1.eere.energy.gov/windandhydro/
http://www1.eere.energy.gov/windandhydro/http://www1.eere.energy.gov/windandhydro/

17 Large Wind Turbine Drivetrain Testing Facility

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