W E L I S T E N .

Services and upgrades for your Gamesa® G47, G5x, G8x and G9x WTGs.

GAMESA®

Solutions with perspective.

‘Gamesa’ is a registered trademark of Gamesa Corporación Technológica, S.A., Spain.

Contents Page

Aluminium ring examination 04

Generator support diagnosis 05

BGV A3 inspection 07

Fire protection system 07

Remote monitoring for Gamesa® WTGs 08

Generator 2 MW 08

Base frame maintenance 11

Main bearing examination 11

LED beacon light 12

Arc sensor 13

Permanent lubrication system (yaw gear rings) 14

Access monitoring 15

"We may not speak Spanish, but we certainly understand the technology."

'Aerogeneradores' means wind turbine generators. Even if I have to admit to not being able to speak any Spanish, my team and I understand the technology behind the 'Aerogeneradores' very well indeed.

After all, we have been consistently working with the turbine technology from the Spanish manufacturer Gamesa® for a long time. And that is why we are so familiar with the field. In our competence centre in Hamburg we are developing our own upgrades and other solutions that, above all, meet the requirements of our customers.

And when Gamesa® G47, G5x, G8x and G9x wind turbine generators start to get a bit long in the tooth, it doesn't necessarily mean the end of good yields. For us, this is the beginning of a new task. And it is one we solve almost as quickly as we realise it. There are several examples for this on the following pages.

And if a little more Spanish is required: my colleague Michael Richter not only knows the meaning of 'Aerogeneradores', he also speaks Spanish fluently. And as the Global Sales Manager, he knows all about the most varied details and contract concepts for Gamesa® turbines. His contact details can be found on the back page of this brochure.

Kind regards,

Olaf Kleesch(Director Global Technical Support and Engineering)

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Problem:The rotor blades of wind turbine generators (WTGs) are subject to enormous loads during operation. As the rotor blades are held in place by an aluminium ring, these also have to carry great forces. This great stress can lead to machine fatigue and therefore cracking. If these damages aren't discovered ahead of time, in the worst case, a blade could even break off.

Solution:Together with the experts at WPT-Nord GmbH, Availon has many years of experience and expertise in the area of non-destructive material testing at its disposal. This allows possible sources of danger to be determined ahead of time and, if necessary, resolved. All this whilst upholding nationally and internationally recognised certifications.

Aluminium ring examination.

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Overview of benefits and features of aluminium ring examinations:

• Maintains WTG’s operational reliability• Inspection and diagnosis of aluminium rings and damage repair • Certified repair procedure without having to remove the blades• Short downtimes• Non-destructive material testing • Ultrasound and dye penetration testing• Damage repair via welding procedure in accordance with DIN EN ISO 14175 I1• Prevention and/or delay of recurrent crack formation in components under dynamic loads• Lifetime service concepts• For G47 turbines

Overview of benefits and features of diagnosis of generator support:

• Maintains WTG’s operational reliability

• Inspection and diagnosis of generator support and damage repair

• Non-destructively material testing using a magnetic pulse process

• Abolition of cracks using MAG, E and WIG welding procedures

• Prevention and/or delay of recurrent crack formation in components under dynamic loads

• For G8x and G9x turbines

Problem:Over the lifetime of a WTG, enormous mechanical loads act upon its components. The seams of welded generator supports represent a weak point in this. Similarly to welded base frames, abnormalities were detected in the weld seam connections. What begins slowly, can, if left undiscovered, end in long downtimes and high costs.

Solution:As with the aluminium ring examination, Availon can also rely on the many years of experience and the knowledge of the WPT-Nord experts in this case. A magnetic pulse process is used to non-destructively examine 30 or, if necessary, more test areas and determine whether cracks have occurred and, if so, where. Of course, nationally and internationally recognised certifications are upheld.

Generator support diagnosis.

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BGV A3 check.*

Problem:The consistent checking of the complex electronics of a WTG has not yet been established, even though it has been a legal requirement for several years now. And rightly so, as electrical accidents lead to serious burns and, in the worst case, death.

Problem:Aside from the mechanical components, it is above all the installed electronics which pose the danger of fire breaking out in a WTG. This not only leads to higher insurance premiums and stricter building regulations. In the event of a fire, there is a risk not only of the write-off of the WTG, but, in the worst case, even a risk to the life of people present.

Solution:Together with ABO Wind, Availon has developed the first BGV A3 testing especially for WTGs. Taking into account the various WTG types, every use follows its own, turbine-specific plan. Over 150 measurement points and kilometres of cables are responsibly tested, taking into account all legal requirements.

Solution:The fire safety solution by Availon is made up of smoke detection and a fire extinguishing system. The detection of smoke is takes place quickly and uses dual detector dependency to prevent false alarms. The generation of smoke is immediately forwarded as an alarm notification to the monitoring system of the WTG. But if a fire still manages to break out, the fine-spray extinguisher automatically activates, thanks to the thermopneumatic sensors, and effectively puts out the fire.

Fire protection system.

Overview of benefits and features of BGV A3 testing:

• Upholds the safety of the electrical equipment in WTGs

• According to the requirements of BGV A3, DIN VDE 0105-100 and VDS clause 3602

• Avoids accidents with serious consequences due to electrical faults

• Reduces the liability risk for operators

• First BGV A3 testing process especially for WTGs

• Seamless documentation including detailed description and, if necessary, photos

• Implementation recommended every four years, for mobile devices: annually

07

Overview of benefits and features of fire safety systems:

• Maintains WTG’s operational reliability

• Almost maintenance-free

• No external energy source is necessary

• Only minimal space is necessary

• Fire detection without false alarms

• Works even in extreme conditions (up to -30°C)

• For G8x and G9x turbines

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geprüft nach BGV A3Nächster Prüftermin

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* Performance exclusively applies to Germany and is based on German legal principles and guidelines.

Problem:Over the course of a WTG's service life, turbine damages can occur from time to time that affect major components. For example, the generator. Alongside unwanted turbine downtimes and yield losses, in the worst case scenario, this can lead to the total failure of the entire major component.

Solution:The 2 MW generator is a joint development. The optimised effectiveness is just one of many advantages. Alongside high speed variability, this also includes manufacturer-independent compatibility. Furthermore, the design of the generator 2 MW according to heating class F also leads to an extended service life.

Generator 2 MW.

Overview of benefits and features of the generator 2 MW:

• Compatible with generators of other manufacturers

• High speed variability

• Consistent output for many years

• High thermal loading capacity

• Optimised effectiveness

• Efficient cooling system

• For G8x and G9x turbines

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Overview of benefits and features of remote monitoring for Gamesa® WTGs:

• Remote troubleshooting (if conditions permit)

• User-specific visualization of all open data points

• Collection of statistical fault frequencies

• Permanent surveillance of your WTGs (24/7)

• Immediate processing of incoming fault messages (also on Sundays and public holidays)

• Read-out and preparation of production figures

• Manufacturer-independent remote monitoring

Problem:The possibility of remotely observing a WTG allows the read-out of production and condition data of the system as well as the rectification of problems without having to be on-site. Unfortunately, until now, this has only been possible via the remote monitoring of the OEM, creating a certain level of dependency.

Solution:Together with renowned partners, Availon has developed a system that makes it possible to read out data from your wind park. Almost all open data points of the system are available and the rectification of faults can be done online. In addition, Availon is available to the operator by phone for any technical questions. Overall, this creates an independent and efficient remote monitoring of your wind park.

Remote monitoring for Gamesa® WTGs.

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Problem:As the main bearing housings are under major loads in WTGs, cracks are often formed in this area. This is probably down to too much stress. And this problem occurs more often than you might think: crack formations were observed in 80 out of 100 turbines examined. If these damages are not recognised ahead of time, high costs and long downtimes are often the consequence.

Solution:In this case, Availon can once again rely on the expertise and many years of experience of WPT-Nord. The experts for non-destructive material testing have the know-how required to determine possible sources of danger in and around the main bearing and, if necessary, to rectify them. This allows the quality of the main bearing to be secured for the long term. As usual whilst upholding nationally and internationally recognised certifications.

Overview of benefits and features of main bearing examinations:

• Maintains WTG’s operational reliability

• Inspection and diagnosis of main bearing and damage repair

• Non-destructive material testing

• Application of proven magnetic particle testing

• Radii relieve small cracks

• Prevention and/or delay of recurrent crack formation

• For G8x and G9x turbines

Main bearing examination.

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Problem:A good wind location brings with it many challenges for materials and technology. Above all, the base frame, the backbone of the WTG, is subject to enormous traction and bending torque. The result can be cracks and unstable weld seams and can lead to particularly costly and time-consuming repairs.

Solution:Together with WPT-Nord, the experts in non-destructive material testing, Availon has many years of experience and the expertise to secure the quality of base frames. All this whilst upholding nationally and internationally recognised certifications.

Base frame maintenance.

Overview of benefits and features of base frame maintenance:

• Maintains WTG’s operational reliability

• Inspection and diagnosis of the base frame as well as rectification of damage in cooperation with renowned partners

• Non-destructive material testing technology

• Roentgen, ultrasound and surface crack tests

• Abolition of cracks using MAG, E and WIG welding procedures

• Welding and sanding preventative measures with the removal of tension peaks

• Prevention and/or delay of recurrent crack formation in steel components under dynamic loads

Problem:Wind turbine generators are getting taller and taller. But they are also intruding on an area critical for air traffic. WTGs must therefore be identified from a total height of 100 m. The beacon light plays an important role in this, but is exposed to adverse weather conditions.

Solution:Availon has a tested LED beacon light system for WTGs on offer. LEDs are unbeatable when it comes to efficiency and reliability. This low maintenance and wear system ensures a higher level of safety and makes the costly replacement of conventional bulbs and other components redundant.

Overview of benefits and features of LED navigation lighting:

• Plug & play: works as soon as the power supply provided

• Highly efficient LED system

• Minimal maintenance and wear

• Hard-wearing, even in adverse weather conditions

• Increases the safety of the WTG

• For G8x and G9x turbines

LED beacon light.

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Overview of benefits and features of the additional arc sensor:

• Permanent monitoring of copper rail main distribution

• Additional third sensor directly in control cabinet next to circuit breaker

• Save deactivation of SF6 medium voltage switchgear within milliseconds

• Prevents serious fires and total loss

• For G8x and G9x turbines

Problem:Experience shows that arcs can also occur in the control cabinet of the circuit breaker and even cause fatal fires. Arcs occurring in this way are not recognised by the two available arc sensors.

Solution:A third arc sensor is installed in close proximity to the circuit breaker to monitor the copper rail main distribution. If an arc occurs there, the turbine is immediately taken off the grid.

Arc sensor.

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Problem:Maintenance of the yaw gear is very laborious. Particularly if the yaw pinion is lubricated manually, as even experienced service engineers cannot guarantee an even lubrication film. This can result in excess grease and have a negative effect on wear and corrosive protection.

Solution:The central lubricant pump with a grease container and lubrication pinion guarantees a perfectly even lubrication film and thereby ensures better corrosive protection and less wear. The grease container has to be replaced once per year. The maintenance work required is reduced to a minimum.

Overview of benefits and features of permanent lubrication systems:

• Constant lubrication of yaw pinions and gear teeth

• Avoidance of excess grease

• Prevents corrosion and wear

• Permanent, even lubrication film on gears

• Increases operational reliability

• Reduces maintenance and repair costs

• The grease container has to be replaced just once per year

• For G8x turbines

Permanent lubrication system (yaw gear rings).

Problem:If thieves tamper with WTGs, they often do so with little expertise, but great criminal energy. Possible consequences: major damage due to stolen copper cables and destroyed WTG installations.

Solution:Possible defence: Availon access monitoring. As those who ignore the warning sign on the WTG set off more than they might think: along with the acoustic alarm directly in the WTG, a message is immediately sent to the remote monitoring. They are able to listen via an acoustic sensor on the inside of the WTG. If nothing can be heard and there is no longer anybody in the entry area, the warning alarm switches off. Otherwise, the police are immediately informed.

Access monitoring.

Overview of benefits and features of access monitoring:

• Solution independent of WTG control

• Movement sensor and remote monitoring are directly connected via GSM modem

• Immediate alarm and reaction to break in attempts

• Acoustic alarm directly in the turbine

• Acoustic sensor on the inside (optional: monitoring camera)

• Prevents damage, downtimes and yield cuts

• Can also be used for transformer or transfer stations

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Availon GmbH | Jacksonring 2 | 48429 Rheine | Germany | www.availon.eu

My name is Michael Richter. Thank you for taking the time to look at our solutions for Gamesa® WTGs. In turn, I would be happy to take the time to work with you to determine which contract concept makes sense for your WTG and how you can benefit from it. I look forward to your call.

All the best,

Michael Richter

Michael RichterManager Global Sales

michael.richter@availon.eu

Phone +49 (0) 40 181313-532

Mobile +49 (0) 173 8780908

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¡Buenos días! And hello!