Large Wind Turbine Drivetrain Testing Facility Funding Opportunity Webinar

July 30, 2009

Wind and Hydropower Technologies Program Office of Energy Efficiency and Renewable Energy U. S. Department of Energy

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 its intentions to award discretionary grants or cooperative agreements, usually as a result of competition for funds. "Application" means the documentation submitted in response to a Funding Opportunity Announcement. FedConnect refers to the electronic system used by applicants to submit applications to DOE.
Note: FedConnect registration process can take up to 21 days

"Financial Assistance" means the transfer of money or property to an Applicant or Participant to accomplish a public purpose of support authorized by Federal statute through Grants or Cooperative Agreements and sub-awards.
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American Recovery and Reinvestment Act of 2009 (ARRA) The Recovery Acts purposes are to stimulate the economy and to create and retain jobs. The Act gives preference to activities that can be started and completed expeditiously. Accordingly, special consideration will be given to projects that promote and enhance the objectives of the Act, particularly job creation, preservation and economic 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 forming teams or partnerships Close date for full application: August 13, 2009
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Need for Drivetrain Testing

Ultimate goals:
Improve the countrys competitiveness in wind energy technology Lower energy costs for consumers Maintain rapid growth of wind energy deployment

Need for drivetrain testing:

Verify the long-term reliability of current megawatt-scale drivetrains through testing to improve performance, durability and reliability Facilitate research and development of next-generation, lower-weight and lower-cost turbines

Drivetrain testing allows the wind industry to:

Demonstrate compliance with wind turbine design standards Reduce wind turbine costs Secure product financing Reduce the technical and financial risk of deploying mass-produced wind turbine models
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Facility Requirements
Large dynamometer facility for testing 5 to 15 MW rated wind turbine drivetrains
Multiple test bays, permitting simultaneous, independent testing of two 7.5MW rated drivetrains
Test bay dynamometers able to be coupled to obtain a single test capability of up to 15MW rated drivetrains

Capacity to perform Highly Accelerated Life Testing (HALT) of large drivetrains and generators
Minimum dynamometer capacity of 20MW to support testing of a 15MW rated drivetrain

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Capacity to accommodate large direct drive generators in addition to generator/gearbox configurations Capability to simultaneously impart dynamic and steady off-axis loads to the low speed shaft of the test article Electrical infrastructure to permit interconnection of the test article at all common system operating voltages Capable of testing generator system response to grid anomalies and for grid code compliance
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Additional Requirements

Preparation rooms for assembly, disassembly and instrumentation checkout of test articles are required.
Separate from the test bays Data acquisition systems to enable verification of instrumentation prior to installation in the test bays

Overhead cranes, access doors, and other facility infrastructure for accommodating 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 an existing 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) - prime applicant 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 the facility
Applicant must have submitted a Letter of Intent by the due date set forth in the FOA 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 formal justification)
Leveraging DOEs investment through applicant cost sharing will be a factor considered in the selection of applications

Potential end users of the facility may not partner due to conflict of interest National Labs and/or private industry are permitted to participate as a partner

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Application Process Overview

The Applicant completes necessary registrations to submit an Application (see next slide for details). COMPLETED The Applicant submits Letter of Intent (LOI) and Final Application by the due dates specified in the FOA. LOI COMPLETED The Final Application will go through an Initial Review to ensure that its compliant with the requirements of the FOA. Those Applicants who do not pass the Initial Review will be notified in writing. Compliant Applications will be sent to the Technical Merit Review Committee 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 Merit Review will be submitted to a team at DOE Headquarters (HQ) for the Program Policy Factor Review. Upon completion of the reviews, all information from each review will be submitted to the Selection Official (SO) at DOE HQ. The SO will select certain Applications for negotiation of award. All Applicants will be notified in writing regarding the decision of the SO and will receive Merit Review comments on their strengths and weaknesses.
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Registration Process
1. Obtain a Data Universal Number System (DUNS) number: If your organization is located in the United States, you can request and register for a DUNS number by calling 1-866-705-5711. If your organization is located outside of the United States, you can request and register for a DUNS number online via web registration or call your local Dun & Bradstreet office. 2. Register in Central Contract Registration (CCR): Go to http://www.ccr.gov or http://www.ccr.gov/Start.aspx and follow the instructions, or contact the CCR Assistance Center at 888-2272423. 3. Register in FedConnect: Go to https://www.fedconnect.net/FedConnect/PublicPages/FedConnect_ Ready_Set_Go.pdf 4. Please begin the registration process as soon as possible because this process can take up to 21 days to complete.
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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 set forth in the "20% Wind Energy by 2030" report and President Obama's energy strategy. The ultimate role of wind power in world energy production will be directly affected by DOE's success in addressing those challenges.

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Questions and Answers: 2

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

A. Due to the urgency of placing funding to accomplish the goals of the American Recovery and Reinvestment Act, DOE does not anticipate extending the application due date at this time.

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Questions and Answers: 3

Q. Will the bidder's list be available?

A. DOE will not be providing a bidders' list for this Funding Opportunity Announcement.

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Questions and Answers: 4

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

A. Assuming the question regards a contractor (vendor) providing off-the-shelf goods or services to the project, as opposed 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 a prime recipient is to conduct procurement and issue subawards: 10 CFR 600.140-148 applies to a prime recipient that is an Institution of Higher Education or a non-profit; and 10 CFR 600.236 applies to a prime recipient that is a State or Local government. Please note that allowability of costs for a subawardee is determined according to the type of entity it is. For example, if the subawardee is a for-profit, the for-profit cost principles apply even if the prime is a state, university or nonprofit.

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Questions and Answers: 5

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 or subrecipient under a DOE award or subaward. A fee or profit may be paid to a contractor providing a goods or services under a contract with a recipient or subrecipient. Overhead is generally an allowable cost. Please see the applicable OMB Circulars or Federal Acquisition Regulation (FAR). The applicable guidance depends on the type of recipient. OMB Circulars can be reviewed at www.whitehouse.gov/OMB/circulars/index.html and the FAR can be viewed at http://www.arnet.gov/far/.

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Questions and Answers: 6

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

A. Evidence of cost sharing commitments must be provided with the application. Timing of cost sharing contributions should be planned with the understanding that cost sharing must be fully contributed by the end of the five year project period for this effort, and the recipient should make every effort to maintain a pro rata share of its cost share contribution (i.e., to "keep up" with its required contribution) as the project proceeds. For additional guidance, please review FOA Appendix C - Cost Share Information.

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Questions and Answers: 7

Q. From Page 8: "Applicants will also be required to set forth a plan for disposition of equipment and real property,..." - Can you please elaborate/clarify this position?

A. This project anticipates construction of a large dynamometer facility, and as described in the FOA, a considerable amount equipment and real property may potentially be acquired by the recipient in support of the effort. In accordance with 10 CFR 600.130-137 (for prime recipient that is an Institution of Higher Education or a Non-profit) or 10 CFR 600.230-232 (for a prime recipient that is a State/Local Government), applicants are to provide a plan for disposing of the equipment and real property at the conclusion of the project period.

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Questions and Answers: 8

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

A. The primary purpose of this project is to develop a national facility that will provide a unique test capability for wind turbine drivetrains. A plan permitting fair and equal access to all potential users is required. An independent peer review process is one possible means to achieve this goal.

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Questions and Answers: 9

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

A. As a reference, literature shows the weight of a typical 2.1 MW nacelle and a typical 5 MW nacelle is around 160,000 lbs and 440,000 lbs, respectively. For more information, please contact a wind turbine original equipment manufacturer (OEM).

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Questions and Answers: 10

Q. Since the current wind turbine is between 1 to 5 MW range, and if the 15MW drivetrain never materialize, the hefty cost share puts the applicant at very high financial risk. Can you explain the rationale why the requirement jump to such high power so soon?

A. Greater than 10MW designs are already in progress. The expectation for offshore wind turbines is continued growth beyond 10MW.

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Questions and Answers: 11

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

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

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Questions and Answers: 12

Q. What is the correlation between 20 MW dynamometer power requirement and the 15 MW wind turbine testing requirement? Specifically, should the 20 MW requirement be interpreted as overload torque only or a transient capability that best represents variation of the blade root moment?

A. The 20MW power requirement is necessary to conduct Highly Accelerated Life Testing - it should not be considered a transient load. Although not a DOE requirement, some wind turbine drivetrain manufacturers have expressed interest in the additional ability to test to twice the rated power as a transient (30MW for a 15MW rated turbine).

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Questions and Answers: 13

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

A. The DOE has not asked for generator simulation. This solicitation requires the facility to have the ability to test direct drive generators in addition to traditional gearbox/generator systems at the requested power.

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Questions and Answers: 14

Q. Are there any specific temperature conditioning requirements? Specifically, is the ability to cold soak a sample before the start of a test sufficient or is the capability to maintain a set temperature during testing required?

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

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Questions and Answers: 15

Q. Does the facility need to be able run the 15MW of power when it opens or can that be upgraded over time?

A. The facility should be independently accredited to conduct certification testing of 15MW drivetrains by the end of this project. By the time this facility is commissioned it is expected that there will be demand to use the full capacity of the system.

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Questions and Answers: 16

Q. How many separate test programs has the 2.5 MW dynamometer at the National Wind Technology Center (NWTC) run? How many different gear boxes? Approximately how much does the facility charge? What is the annual revenue of the dynamometer facility?

A. DOE's NWTC 2.5MW dynamometer was commissioned in August 1999. It has not been operated as a publicallyavailable user facility. DOE/ NREL custom-designed and built the facility to provide specialized wind turbine drivetrain R&D test capability to support DOE technology development partnerships with industry. Over the last two years, the facility has been predominantly occupied by the "Gearbox Reliability Collaborative" which is a DOE-funded R&D effort to understand fundamental root-cause gearbox issues plaguing the wind industry. Directly comparing the NWTC to this new facility is not relevant.
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Questions and Answers: 17

Q. What are maximum speed and torque ratings to which the 15 MW wind turbine is expected to be tested?

A. Please contact wind turbine OEMs to discuss the future specifications for the accelerated life testing of a 15 MW unit. Highly Accelerated life testing involves operating the test specimen at some minimum percentage above rated torque at various speeds.

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Questions and Answers: 18

Q. Does the grid simulation capability requirement imply also a need to simulate change in grid frequency? Does the facility need to accommodate 50 Hz generators to meet the FOA requirements?

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

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The DOE Wind and Hydropower Technologies Program thanks you for your interest
http://www1.eere.energy.gov/windandhydro/

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