الثلاثاء، 9 أكتوبر 2018

BLINKING SAIL WINDMILL A to Z


Blinking Sail Windmill
The Disrupter of Power Generation

BSW Windfarms ARE Coming to market

MASSIVE power without breaking the bank

The magic BSW will supply immense amount of power 

















Introduction:

The recent global growth in wind energy has been dramatic, prompting governments, utility companies and major energy corporations to invest billions of dollars in research and development as well as in creating massive windfarms on all continents.

Multiple research studies conducted by several wind energy organizations indicates that investment in this vital energy sector will rise dramatically in the next few decades due to high oil prices, drop in renewable energy prices and environmental concerns.

However, despite recent advances in wind turbine efficiency, prices of wind turbines are still very high. Current wind turbine prices range between 1-12 million US dollars and these prices are expected to rise steadily in the future due to production cost, complexity of new generations of wind turbines and high maintenance cost.

And yet despite their exorbitant prices conventional wind turbines, whether they have two or three rotating blades, are extremely inefficient and expensive for the following two reasons.

A-   All conventional wind windmills, whether they have 2 or 3 rotating blades, have extremely small surface area designed to be impacted by the blowing wind to create power.

This limitation of surface area, due primarily to the structure and shape of these wind turbines, reduces their ability to produce a huge amount of energy. To compensate for their limited active surface area, the area designed to be impacted by air, wind turbine manufacturers such as GE, Siemens and Mitsubishi and others, have increasingly manufactured extremely tall wind turbines with enormously long rotating blades. But these wind turbines produce a very small amount of power relative to their steep prices.


So, why is that? The diagram below shows the huge gaps of empty spaces between the long, thin rotating blades of a typical wind turbine. The total surface area of the three rotating blades impacted by the blowing wind is approximately 3% of the total radius area. Consequently, the air passing unhindered between the rotating blades represents a wasted potential energy; because the passing air does not impact a solid surface area, therefore, it will not produce any power.   





A- All conventional wind turbines are loaded with complex and very expensive gears and sophisticated components to achieve directional mobility:

To increase the efficiency of conventional wind turbines, whether they have 2 or 3 rotating blades, wind turbine manufacturers load their windmills with sophisticated and very expensive components, such as wind sensors and wind-direction mechanisms in order to shift the blades to an ideal position to be impacted with the maximum volume of air.




But the results are not always successful. There is a limit to the maximum degree of rotation that can be achieved by Yaw motors and Pitch motors to shift the wind turbine and the rotating blades to be at the right position at the right time to catch the blowing wind. Such failure is often seen as motionless wind turbines standing idle despite the blowing wind.



To further demonstrate the second inefficiency of conventional wind turbines, their inability to catch the blowing wind regardless of changes in wind direction, the above image of Spanish wind turbines illustrates in a stark and graphic fashion how wind farm operators hedge their bets by positioning their wind turbines to face different directions; as you can notice from the picture above, some of the wind turbines are facing left, some facing right, some facing north and some facing south.

Wind farm operators know very well that if wind turbines are positioned to face one direction only, the likelihood is that they will stay idle a big part of the day because their rotating blades will not be impacted by the blowing wind all the time; their solution is to deploy a large number of wind turbines and position them to face different directions, so that a percentage of the deployed wind turbines will catch the blowing wind while others will not. So, how do we overcome the twin problems of limited surface area and very expensive wind turbines? The simple answer is that we can’t. These twin problems are the direct results of structural design and will always be fundamental features of such conventional wind turbines.

But is there an alternative? Can these two problems be overcome?

The Blinking Sail Windmill
The Disrupter of Power Generation

The Blinking Sail Windmill, henceforward will be referred to as BSW, will solve these problems and provide a ground-breaking solution to overcome the afore-mentioned twin problems.
So, what are the main features of the BSW? How is it different than conventional wind turbines with rotating blades?
And how competitive is it in price and power output capacity?

This project involves two US patents issued by the US Patent and Trade Mark Office (USPTO). The two patents can be read by clicking on the two USPTO links below.
The first patent is titled “Blinking Sail Windmill” and was issued on 24/8/2010 numbered 7780416. The second patent is titled “Blinking Sail Windmill with Safety Control” and was issued on 22/04/2014 numbered 8702393
         BSW USPTO patent link
         Blinking Sail Windmill

         Blinking Sail Windmill with Safety Control

         This prospectus will also include several BSW links. These links      cover the two patents, animations, sketches, photos and          videos of original prototype construction in Kirkuk, Iraq, as well    as photos of conventional wind turbines.

You may view these videos and links in the two attachments entitled.
1-   BSW animations, clips and YouTube
2-   Gallery of BSW Construction in Kirkuk, Iraq

Jasim Saleh Al-Azzawi is the holder of the two above-        referenced patents

So, what makes the BSW so unique?
 The BSW has four unique and extraordinary features:
       The BSW’s surface area, designed to be impacted by wind, can be increased to an amazingly huge size, simply by increasing the height and width of its Spinning Frames.       The same certainly cannot be said about conventional wind turbines. Extending the length of their rotating blades to a massive degree does not produce a huge surface are; the result is often a minuscule increase in their surface area. 
       The BSW’s Spinning Frames are designed to be impacted by the blowing wind regardless of wind direction; the Spinning Frames will catch the blowing wind and create a huge amount of torque regardless of changes in wind direction. As wind direction changes the adjustment is instantaneous as which Spinning Frame will block wind. This instantaneous and automatic fine-tuned capability is a built-in feature of the BSW and no power generation is lost whatsoever. Conventional wind turbines have partial abilities to adjust the position of their rotating blades, but in no way they can change the position of the Nacelle 180 degrees or less to compensate for changes in wind direction. This inability results in loss or power generation capacity. 

       The BSW is maintenance-free, thus saving a huge amount of money. In sharp contrast, the cost of maintaining conventional wind turbines is huge, especially when deployed offshore.

       The BSW produces a huge amount of power relative to its extremely low production cost. For example, a BSW costing approximately $500K US dollars to manufacture will produce 7.6MW. Compare that with GE’s latest wind turbine with a price tag of $12 million US dollars and produces 8MW.

     What is a BSW and how does it work?
     For the purpose of this prospectus, a brief excerpt of the   patent describing the structure and function of the BSW can be        read in the paragraph below to provide a snapshot of its     fundamental features. As sated previously, the full text of the two patents can be accessed and read by clicking on the two      links on page 8.

“A vertical axis windmill comprising a set of frames attached via horizontal bars to a vertical axis of rotation, each frame comprising; two vertical side bars, a horizontal top bar, a horizontal bottom bar, and optional additional horizontal frame bars, a plurality of swinging windows, each swinging window comprising an upper horizontal bar, vertical side bars, and a plurality of additional horizontal bars; a plurality of sheets of lightweight material, wherein the upper edge of each sheet of lightweight material is fixed at one of said upper horizontal bars or at one of said optional additional horizontal frame bars, each of said sheets of lightweight material is allowed to move by pivoting or bending relative to the horizontal bar to which it is attached, and the remaining edges of said sheets of lightweight materials are not attached to any structural support; and gap control means to control the size of a variable gap between the bottom of said swinging windows and the frame of which it is a part; wherein said swinging windows stop said sheets of lightweight material from being blown to one side of said frames, said one side being on the same side of each frame relative to the direction of rotation of said vertical axis windmill; and wherein said swinging windows are movable toward said one side of said frame such that said variable gap allows part of the air to pass through in the downwind direction”. 

To flesh out the above patent text, composed in dry scientific language, and bring it to life, the two pictures below and subsequent 3 sketches will help readers visualize the structure and function of the BSW.



A BSW with four Spinning Frames, shown in red, hanging on long arms of a tower crane (shown in purple) and carried by an oil-rig-like derrick (shown in green) and anchored in concrete



A sketch showing a large BSW with four Spinning Frames but without   their corresponding blocking flaps. Notice the size of the palm tree  relative to the BSW


A sketch showing a large, anchored BSW with four Spinning Frames with their corresponding movable flaps



A sketch showing two Spinning Frames of  a BSW where one Frame is blocking the wind with its flaps and the other is  allowing the air to pass freely through it. The above three sketches are part of the granted patents.


         For further appreciation of the structure, function and uniqueness of the BSW, the following two short animations will provide added understanding.

         US patent 7780416 blinking sail windmill


         blinking sail windmill four layers desgine




         BSW Production:
Manufacturing BSWs does not require sophisticated,    cutting-edge machineries, expensive tools or high-end   engineering skills. BSWs can be manufactured in workshops equipped with cutting machines, welding equipment and   pneumatic presses. They are extremely inexpensive to manufacture, in comparison with high-priced conventional wind         turbines currently deployed worldwide.  

The generator is the only electro-mechanical component needed to be procured. All other necessary BSW parts will be manufactured or purchased domestically.

     A specialized production plant can be set up in a strategic location to mass produce specific sizes of BSWs for global export as well as for creating domestic wind farms in different parts of the country.

     Modular and scalable:
     The size of a BSW is dependent on whether it is used in homes, schools, hospitals or in commercial windfarms.
When a consumer version of the BSW is installed on roof tops, its height can range between 3-7m high with a Spinning Frame wingspan ranging between 3m x 3m to 5m x 5m or even wider, per customer needs.



The height of a large BSW manufactured to be deployed in commercial windfarms can be as tall as 100m, with a Spinning Frame wingspan ranging from 10m x 10m, 20m x 20m or 30m x 40m or even wider per power output needs and cost considerations. At a later stage, a final determination will be made what dimension BSWs the company will manufacture and for which market.

Large BSWs for deployment in wind farms:
Given the fact that a BSW is highly scalable, large size BSWs capable of generating enormous amount of power can easily be manufactured. Despite their large dimensions these BSWs cost a fraction of the price of conventional wind turbines with three rotating blades.

How to manufacture a BSW with 10m x 10m wide Spinning Frames?
This segment will explain in full details how to manufacture a BSW with 10m x 10m wide Spinning Frames and itemize all of its components. A great emphasis will be given to the production of the Double-Sided Unit (DSU), the basic building block of the BSW and its throbbing heart.

However, given the fact that if we wanted to build a BSW with 20m x 20m wide Spinning Frame or even 30m x 40m wide Spinning Frames the manufacturing process of the Spinning Frames would be exactly the same despite the increase in size dimensions. The only variable would be the increase in size. This is, however, unlike conventional wind turbines with rotating blades, where any increase in size needs careful aeronautic considerations and different manufacturing process resulting in an inevitable rise in production cost.

BSW Components:
Double-Sided Unit (DSU):

A BSW with 10m x 10m wide Spinning Frame will require 200 DSUs.

The colored image below represents the Double-Sided Unit, henceforth shall be referred to as DSU; it is the basic building block of BSW’s Spinning Frame.


Structure of Double-Sided Unit

The length and the width of the Spinning Frame will determine the number of the DSUs needed to build it; the bigger the Spinning Frame the larger the number of DSUs needed. For instance, to build a BSW with 10m x10m wide Spinning Frames 200 DSUs will be needed while 800 DSUs will be needed to build a BSW with 20m x 20m wide Spinning Frames.

In the picture below, you can see a BSW with four Spinning Frames shown in light yellow color while the DSUs are represented in orange as tiny rectangular shapes.                                      


A Gallery of 27 pictures of all the components necessary to assemble a DSU can be viewed in the attachment entitled: “Gallery of pictures showing DSU components”.

The four pictures below will give you a very good appreciation of the various components of the DSU.






Components of Double-Sided Unit (DSU):

DSU components, description and numbers, needed to construct a DSU.

1-   Four types of steel Angle Plates (A, B, C and D)
2-   Ball-bearings
3-   Steel Wire Mesh
4-   Synthetic or natural material to serve as Sail
5-   Hollow Shafts

A:                        Four steel Angle Plates, each 2m                       long,1.5 inch wide and 5mm thick

B:                        Four steel Angle Plates, each 1m long,              1.5in wide and 5mm thick

C:                        Two steel Angle Plates, each 0.4m
                           long, 1.5 inch wide and 5mm thick

D:                        Two steel Angle Plates, each 0.3m           long,1.5 inch wide and 5mm thick.
                                             (The four steel Angle Plates are in                                       yellow in the above DSU structure)
                 
                  Ball-bearings:       4
                                             (They can clearly be seen in yellow                                      color in the above DSU structure)

                  Wire Mesh:         One steel Wire Mesh
         (shown in green in the DSU structure)

Sail:                    Made from natural or synthetic material (shown in red color in the  DSU structure in the above DSU structure)
Shafts:                 Two hollow shafts, each 2m long     (They can clearly be seen in purple and red colors in the above DSU structure)
         Bolts:                  16

The four types of Angle Plates (A, B, C, D) needed to construct a single DSU will, for construction purposes, have various numbers of holes located at specific positions.

Since each Angle Plate has two sides, they will be       referred to as side X and side Y. Furthermore, each          Angle Plate will have different number of holes at       specific intervals between holes.

         Angle Plate A:
Angle Plate A will have one hole at each end of side X        and side Y. Furthermore, side X will also have 5 holes          at 30cm intervals, i.e. Angle Plate A will have a total  of 9 holes, seven on side X and two on side Y.



         Angle Plate B:
         Angle Plate B will have one hole at each end of side X         and 4 holes on side Y at 30 cm intervals, i.e. Angle Plate B will have a total of 6 holes, two on side X and  4 on side Y.


Angle Plate C:
         Angle Plate C will have one hole at each end of side X        and one hole at each end of side Y. Furthermore, side     X will have 4 more holes and side Y will also have 4 more holes, i.e. Angle Plate C will have a total of 12  holes, six holes on each side.



Angle Plate D:
         Angle Plate D will have one hole at each end of side X        as well as 2 holes on side Y and 2 holes on side Y at 10cm intervals i.e. Plate Angle D will have a total of 6   holes, 4 holes on side X and 2 holes on side Y.



The sketch below summarizes the above descriptions by showing the number and type of Angle Plates, number of holes on each Angle Plate, distances between holes and positions of holes on side X and Y.



Steel Angle Plates are universally available but their retail
prices differ from one country to another. Thus, it is important to find a good supplier to secure competitive prices. In the cost breakdown segment to work out the cost of manufacturing a 10m x 10m BSW we shall use Sharjah, UAE, retail prices.


The DSU below shows all four types of steel Angle Plates (A, B, C, D) of various sizes. The image also shows the perforated holes on each Angle Plate.


Below are images of steel Angle Plates of various lengths, widths and thicknesses.




Hollow Shafts: To build a BSW with 10m x 10m wide Spinning Frames 133 pieces of hollow shafts, each 6m long will be needed. The total number of hollow shaft pieces needed  to build a BSW with 10m x 10m wingspan Spinning Frame is 400 pieces.

Each piece has the following dimensions:
Length:      2M 
Diameter:   25mm


Next, 8mm holes will be made at each end of the 400 pieces. Via these holes the Hollow Shafts will be fixed on the Double-Sided Units (DSUs). 200 of the Swinging Windows Shafts, shown below in purple, will carry 200 Swinging Windows using 2 ball-bearings, while the other 200 Sail Shafts, shown below here in red, will carry the Sails, also by using 2 ball-bearings.   




A DSU showing two types of Hollow Shafts, a purple Swinging Windows Shaft and a red Sail Shaft. The structure also shows the green steel Wire Mesh, yellow steel Angle Plates and red Sail and yellow ball-bearings

 Ball-Bearings:

A BSW with 10m x 10m wide Spinning Frames will require 800 ball-bearings with 25mm inner diameter. As stated previously, each DSU has two shafts. A Swinging Windows Shaft (purple color) will carry the Swinging Window via two ball-bearings while the other shaft, the Sail Shaft (red color) will carry the Sail, also by using two ball-bearings. The two images below represent the kind of ball-bearings that can be used to build a DSU.

Steel Wire Mesh:

Each DSU will be fitted with a Steel Wire Mesh, 190cm long, 95cm wide and either 4mm or 5mm thick. The Steel Wire Mesh is designed to prevent the Sail from blowing over to the other side of the DSU. The Swinging Window is carried on the DSU shaft, shown below in purple, by two ball-bearings (seen in yellow).

















Below are pictures of Steel Wire Mesh that can be used to make Swinging Windows.







Sail:
Each DSU will require a Sail made of light and durable synthetic or natural material. The Sail will be 190cm long and 95cm wide. The Sail must be light enough for the blowing wind to move it and pass freely through the Swinging Window during the inactive phase, the phase where the wind is not blocked by the Sail. During the active phase, during which the wind is being blocked by the Sail and causing the Spinning Frame to spin, the Sail will prevent the wind from passing through the gaps of the Swinging Windows”.
The Sail is mounted on the Sail Shaft, shown in red on page 24, via two ball-bearings.
























 
 
















 Bolts:
The BSW with 10m x 10m wide Spinning Frames and 200 DSUs will require the following number of bolts:
       
        8400 bolts, 30mm long and 18mm in diameter
        3200 bolts will be used to assemble the DSUs
        5200 bolts will be used to connect the 200 DSUs together        to form the 4 Spinning Frames.



















Wires:
100 strong steel wires, with hooks at each end, will be needed to tightly connect the Spinning Frames to each other. A group of 25 wires will be used to connect together successive Spinning Frames. Thus, all four Spinning Frames will be strongly connected together producing one solid and strong rigid system where each Spinning Frame will support the other Spinning Frames during windy conditions.

Using the 100 steel wires will prevent the frames from wobbling; the net result is a solid, well-connected rigid steel structure.





Summary of parts used to manufacture a BSW with    10m x 10m wide Spinning Frames and 200 DSUs:

1.    800 Angle Plates 2m long (Type A)
2.    800 Angle Plates 1m long (Type B)
3.    400 Angle Plates 0.4m long (Type C)
4.    400 Angle Plates 0.3m long (Type D)
5.    800 Ball-bearings
6.    200 Steel Wire Mesh
7.    200 Sails
8.    400 Hollow Shafts 2m long
9.    3200 Bolts, to assemble the 200 DSU
10.           5200 Bolts to connect the 200 DSUs to 4 frames
11.           100 Strong steel wires with hocks at both ends
12.           500kW 250RPM 50 Hz 3 phase Vertical PMG Generator
13.           Central Post

Generator:
The 10m x 10m BSW prototype will use 500kW 250RPM      50 Hz Vertical 3 phase PMG Generator for Vertical Wind Turbine. A quoted price of $53,600 US dollars has been obtained from a Chinese supplier. Needless to say, prices of generators will vary, whether they are Chinese, German, US or Japanese made.

To integrate the generator with the BSW, the following items will be needed.

1-    One small pulley with four groves for the generator.
2-    One large pulley with four groves to be mounted on the lower casing of the Central Post.
3-    Sizes of pulleys will depend on the generator; 6 inches pulley for the generator and 12 inches pulley for the BSW.
4-    Strong belts, 22mm wide. Length of belts will be determined later, when the generator is fixed on the BSW.
5-    A strong seating platform for the generator extending from the Central Post with a sliding system to tighten the belts. This seating arrangement will be 2m above ground level.

        The Central Post:
        An important note:
        During the prototype phase, to avoid time-consuming             stress and expensive engineering efforts, the BSW’s  Central Post, designed to carry the four 10m x 10m wide Spinning Frames, should not specifically be manufactured to perform this job. This component can always be             manufactured later on since its role and function during the prototype phase is not very critical.

        Therefore, for economic reasons and to speed up the prototype phase, a ready-made construction tower crane, should either be built in a workshop or purchased from local suppliers.






The image above shows how the four 10m x 10m wide Spinning Frames (carrying rectangular red-colored DSUs) are hanged on four arms of a construction tower crane (purple) carried by a rig similar to derricks used in the oil industry (green)












Despite what was stated above, that for pragmatic and economic reasons, specifically engineered Central Post should not be manufactured for the BSW in the prototype phase, here is a general outline of how to manufacture the Central Post that can be used at later stages.

        Central Post:
        To manufacture a Central Post of the BSW we need, 14m long pipes of different diameters.
1-    2m long pipes with 12 inches diameter
2-    2m long pipes with 10 inches pipe diameter
3-    10m long pipes with 8 inches diameter

        The Central Post will be divided into 7 segments, or sections if      you will, each 2m long for ease of transportation.

        From the ground upward:
1-    The diameter of the first segment will be 12 inches
2-    The diameter of the second segment will be 10 inches
3-    The diameter of the subsequent segments, i.e. the third, fourth, fifth, sixth and seventh segments will be 8 inches in diameter.









Picture of Central Post segments with perforated flanges





Dimensions and components of Central Post:
1-    The steel Central Post is 10mm thick
2-    Flanges used with Central Post is 25mm.
3-    All flanges of the BSW’s Central Post have 10 holes
4-    The flange used with the foundation segment of the Central Post has two sets of 10 holes with two different circumferences i.e. the foundation flange will have 20 holes with 24mm bolts.
5-    The Central Post will require 80 bolts with 24mm diameter
6-    The Central Post will also require two 11 inches ball-bearings
7-    2 nine inches ball-bearings
8-    An upper and lower casing will house a total of 4 ball-bearings, where the lower casing will house the two 11 inches ball-bearings while the upper casing will house the two nine inches ball-bearings
9-    Each casing has four sides where each side is 40cm wide and 50cm long
10-                       Each side of the casing will have two rows of threaded holes, the distance between the two rows is 30cm. Each row has 12 threaded holes each is 24mm diameter and 30mm deep.
11-           The bottom side of the lower casing will have 12 threaded holes each 24mm in diameter and 30mm deep. These 12 holes will be used to fix the 12 inches pulley to the casing.
12-           8 Steel channels each 9m long, 3 inches wide and 8mm thick   will be bolted on the two casings. These 8 channels have as many     holes as the frames.
13-                       Two steel channels 9m long will be bolted on each side of the two casings, one channel will be bolted on the first row and the other will be bolted on the second row.
14-                       Finally, there is a four-sided channel 9m long rotating on the main post. Each frame will be fixed on one side which consists of two 9m channel where the positions of all the holes will match exactly the positions of the holes on the frames.


Foundation and stabilization requirement for BSW prototype

To securely protect the BSW against powerful windy conditions a strong and well-designed steel and concrete foundation is needed.

The depth of the concrete foundation will be 3m long and the length and width 2.5m and 2.5m respectively.  A copper extension at the top of the BSW will secure it against lightening.









How safe is the BSW in a powerful storm?
  The sketch below shows two Spinning Frames. The one on the right shows the three Swinging Windows are partially blocking the wind with their three shaded rectangular flaps. The left Spinning Frame shows how it is allowing all the air to pass  freely through the gaps of the Swinging Windows without       blocking it.








In normal wind conditions, however, the three Flaps of the      right Swinging Windows of the right Spinning Frame will stick     to the steel Wire Mesh of the Swinging Windows when it is   impacted by air and will block the air from passing through the gaps.

        But in this case a powerful wind is blowing and exerting an     enormous force, almost at hurricane level, on the three   Swinging Windows of the right Spinning Frame and forcing their Flaps to shift out of place and allow the bulk of the wind to pass freely through the gaps of the Swinging Windows; this is a built-in safety mechanism designed to protect the BSW        against destruction in hurricane and gale winds. The stronger the blowing wind the larger the gaps allowing the air to pass freely through them.

        Thus, it is critical to keep in mind that the BSW has an    ingenious built-in safety mechanism to protect it against destruction. When the wind speed is normal, the safety  mechanism will not be activated.
But when the speed of wind increases above a certain level the gape starts to open and as the speed of the wind increases the gap gets larger letting more wind to pass through active sail, so the BSW will be safe in all wind speeds but at the same time it generates power, while conventional wind turbines must stop at such high winds, if it does not stop it will be destroyed, while the BSW will generate power and work normally in such distractive wind speeds.





        The Actuator initiating the safety mechanism can either be    mechanical, where a spring can control the size of the  gaps on the active Spinning Frame, the Spinning Frame impacted by air,  or it can be a magnet controlled by a  controller capable of measuring the speed of wind and accordingly open the corresponding appropriate gap size for    the wind to pass freely though these gaps and thus protect the   BSW in powerful storms. Plus keeping the BSW generating power at high-speed winds where other wind turbines must stop.
        This safety mechanism is designed to reduce the active   Spinning Frame’s surface area impacted by the wind.
        As the wind gets stronger and stronger the area    impacted by the powerful wind will get smaller and         smaller.

        Accordingly, the BSW is capable of generating power even in   extreme windy conditions, unlike conventional wind turbines which must be stopped to avoid its inevitable destruction.

       
BSW power output calculations:

         The detailed calculations below will shed ample light on the    most crucial question concerning the BSW;
        how much power will the BSW generate?

        We shall use the universally accepted and used formula to       calculate power output by wind turbines:

          Power output (P) = 0.5 x air density at sea level (1.23) x swept area x   wind velocity cubed x efficiency (Cp)

          P = 0.5 × 1.23 × 2RH × V3  x   Cp

        Where:

        P =   Power output

0.5 = General efficiency of wind powered generators     

                1.23 = Air density at sea level      

        R=   In conventional wind turbine, R denotes the radius of the       rotating blades.


In the case of a BSW, R denotes  
 the distance between the Spinning
  Frame’s end column and the BSW’s Central Post       

         H =   Height of the vertical column of the active Spinning       Frame          
        V3 = The speed of wind cubed

          Cp = The efficiency rating assigned to wind turbines

        But before outlining the power output calculations in some      detail, and in order to understand and appreciate how these calculations are done, it is absolutely critical to highlight an Important feature of the BSW’s Spinning Frame’s structure which plays an important role in how to calculate the generated power.

        A BSW may have 3, 4, 5, or 6 Spinning Frames designed to spin,     block the blowing wind and generate power. Think of the BSW’s Spinning Frames as Microsoft Window’s Excel sheet consisting of multiple columns juxtaposition next to each other; a series of  parallel columns as if they are stitched together.
        BSWs of different sizes will have different number of    columns. The larger the BSW the greater number of    columns.

        For example:

A BSW with 10m x 10m wide Spinning Frames will have 5   columns, each 10m long.

A BSW with 20m x 20m wide Spinning Frames will have 10 columns, each 20m long.




A BSW with 30m x 40m wide Spinning Frames will have 30 columns, each 40m long.

        And just like the Excel sheet with multiple cells, each BSW       column will have multiple Double-Sided Units (DSUs). Each DSU       is 1m long and 2m wide.

        Different size BSWs will have different number of DSUs.
        A BSW with 10m x 10m wide = 200 DSUs
        A BSW with 20m x 20m wide = 800 DSUs
        A BSW with 30m x 40m wide = 2,400 DSUs

        Having briefly explained the general structure of                    the BSW’s Spinning Frames which is directly responsible for         generating power, it is crucial to explain an important feature        of the Spinning Frame which has an enormous and direct         impact on how much power is generated.


         A direct application and use of the aforementioned power      output Formula will give us a Conservative Power Output Figure. On the other hand, taking into consideration the        unique structure of the BSW’s Spinning Frame and how the         columns are arranged in parallel columns, the same BSW will   yield much higher Actual Power Output Figure

        For example, we can show that:

1-    BSW with 10m x 10m wide Spinning Frame can generate 98.4KW or 388.8 KW
2-    A BSW with 20m x 20m wide Spinning Frame can generate 295KW or 2MW
3-    A BSW with 30m x 40m wide Spinning Frame can generate 590KW or 7.6MW

·        But how can we explain this huge discrepancy in power output by the same BSW? As you can notice that the power discrepancy in a BSW with 10m x 10m wide Spinning Frame is huge, 98.4KW versus 388.8KW.

        When we used the power output formula (quoted above on    page 40) to calculate the lower power output figure of 98.4KW we simply aggregated the power produced by all five columns of the BSW i.e. we did not consider each column separately nor did we assign a unique and corresponding radius (R) to each individual column. Instead, we simply used one general figure as a radius for all 5 columns and applied it to the entire      Spinning Frame despite the obvious fact that each column has a unique and different radius of its own and produces its own specific amount of power which is directly corresponding to its unique radius.

        To explain the above point in more details, in the 2RH section of the power output calculation we simply used 20m to denote the radius (R) of the entire Spinning Frame, although each of the five columns has different radius of its own which is its distance from the Central Post of the BSW.

        In light of the above explanation, here is how we can get two sets of different power output figures to reflect the above-mentioned observation.

        To drive the above point home and make it absolutely crystal   clear three examples will be provided to show how we can get a low Conservative Power Output Figure and a much higher Actual Power Output Figure for the same BSW.

A:     So, let us begin with a BSW with 10m x 10m wide Spinning Frame, attached on 20m arm.
Our calculations can show that this BSW can generate either 98.4KW or 388.8 KW. But how?

         This Spinning Frame has 5 parallel columns, each column is   2m wide and 10m long. Despite the fact that the Spinning Frame has 5 parallel columns situated at different distances from the Central Post, when we assume that all 5 columns have the same radius of 20m, then these 5 parallel columns    will collectively generate only 98.4KW.

        We can simplify this matter even further by assigning specific letters to the 5 columns, A, B, C, D and E. All five lettered columns will have the same radius value of 20m.

        In the conservative method to calculate power generation we       do not calculate the power generated separately by each individual column. Instead the Spinning Frame will be considered as one integral Spinning Frame with 20m radius and 10m height. Thus:

        Conservative Power Output:
        P = 0.5 × 1.23 × 2RH × V3 x   Cp
        P = 0.5 x 1.23 x (2 x 20 x 10) x 103 x 0.4 = 98.4KW

        Now, let us calculate the Actual power generated by the same        BSW with 5 parallel columns. The power output figure will be a lot bigger. And the reason is that each of the 5 columns, A, B, C, D and E will generate its own unique amount of power corresponding directly to the value of its radius.

        Putting it in a nutshell as a general theory: 

“All other values of all 5 columns being equal, the value of their radius will determine the amount of power  they produce; the bigger the radius the larger the amount of power output”

        So how do we do that?
        Let us remember that each of the 5 lettered columns has its    own specific radius, reflecting its corresponding distance from the Central Post of the BSW. Remember that the five parallel columns are positioned in series.

        So, starting from the far-right end of the Spinning Frame and moving in a left direction towards the Central Post:

Column A:          is 20m away from the central Post of the BSW i.e. its radius is 20m
Column B:          is 18m away from the Central Post of the BSW i.e. its radius is 18m
Column C:          is 16m away from the Central Post of the BSW i.e. its radius is 16m
Column D:         is 14m away from the Central Post of the                       BSW i.e. its radius is 14m
Column E:          is 12m away from the Central Post of the BSW i.e. its radius is 12m

        Now we are in a position to calculate the power generated by each column, depending on its corresponding radius.


       
Actual Power Output
        Power produced by column A = 
0.5 x 1.23 x (2 x 20 x 10 x 103 x 0.4       98.4 KW 
        Power produced by column B =
0.5 x 1.23 x (2 x 18 x 10) x 103 x 0.4 =88 KW 
        Power produced by column C =
0.5 x 1.23 x (2 x 16 x 10) x 103 x 0.4 = 77.6 KW 
        Power produced by column D =
0.5 x 1.23 x (2 x 14 x 10) x 103 x 0.4 = 67.2 KW 

        Power produced by column E =
0.5 x 1.23 x (2 x 12 x 10) x 103 x 0.4 = 57.6 KW 
        Total power output = 388.8 KW

        By adding all the power generated by all 5 columns        the Actual (total) power generated by the same BSW is 388.8   KW; four times the value of the Conservative figure of 98.4 KW 

B:     In our second example we shall consider a BSW with 20m x 20m Spinning Frames, attached on 30m arm. The calculations below will show that this BSW can generate a Conservative power output of 295.2KW or an Actual power output of 2041KW (2MW).

        By applying the same method, we previously applied in   example A, here is a summary of all the critical information   needed to reach the two sets of power output figures, a low Conservative figure and a high Actual figure representing the total power generated by all 10 columns combined:

1.    A BSW with 20m x 20m wide Spinning Frame has 10 columns lettered A, B, C, D, E. F, G, H, I and J.

2.    Each column is 2m wide and 20m long

3.         Starting from the far-right end of the Spinning Frame and               moving in a left direction toward the Central Post of the          BSW, column A is the farthest from the Central Pole and column J is the closest; the radius values of the ten columns, from column A to column J, are as follow: 30m, 28m, 26m, 24m, 22m, 20m, 18m, 16m, 14m and 12m.

        Conservative Power Output Figure:
        In a Conservative power output calculation, the radius of   the arm is 30m and its height 20m.
        P = 0.5 x 1.23 x (2 x 30 x 20) x 103 x 0.4 =   295.2KW 

        Actual Power Output Figure:
        In an Actual power output calculation, we shall calculate the       power output of each column, a total of 10 columns. And    because each column produces different amount of power corresponding directly to the value of its radius, we shall calculate all ten power output values, add them up together    and reach the Actual power produced by a BSW with 20m x       20m wide Spinning Frame attached on 30m arm.

        Power produced by column A = 0.5 x 1.23 x (2 x 30 x 20) x     103 x 0.4 = 295KW     
        Power produced by column B = 0.5 x 1.23 x (2 x 28 x 20) x
        103 x 0.4 = 275KW     
        Power produced by column C = 0.5 x 1.23 x (2 x 26 x 20) x     103 x 0.4 = 255KW      
        Power produced by column D = 0.5 x 1.23 x (2 x 24 x 20) x     103 x 0.4 = 235KW      
        Power produced by column E = 0.5 x 1.23 x (2 x 22 x 20) x
        103 x 0.4 = 216KW      
        Power produced by column F = 0.5 x 1.23 x (2 x 20 x 20 x
        103 x 0.4 = 196KW    
        Power produced by column G = 0.5 x 1.23 x (2 x 18 x 20) x     103 x 0.4 = 176KW      
        Power produced by column H = 0.5 x 1.23 x (2 x 16 x 20) x     103 x 0.4 =   157KW    
        Power produced by column I = 0.5 x 1.23 x (2 x 14 x 20) x
        103 x 0.4 = 137KW    




Power produced by column J = 0.5 x 1.23 x (2 x 12 x 20) x
        103 x 0.4 = 99KW 

        Total Power = 2041KW (2MW)

        C:     In our third and final example we shall consider a         BSW with 30m x 40m wide Spinning Frame attached on 40m         arm. Our calculations will show that as Conservative calculations this BSW can generate 590KW and as an Actual calculation will         generate 7661KW or 7.6MW

        By applying the same method which we’ve applied in the        previous two examples, here is a summary of all the critical information needed to reach the two sets of power output figures, a low Conservative figure and a high Actual figure representing the total power generated by all columns combined:

            A BSW with 30m x 40m frame has 15 columns lettered A, B, C,                D, E. F, G, H, I, J, K, L, M, N and O. Each column is 2m wide and 20m long
   
            Starting from the far right-end of the Spinning Frame and               moving toward in a left direction to the Central Post of the BSW, column A is the farthest from the Central Post and J is the closest; the radius values of the columns from column A to column O are as follow: 40m, 38m, 36m, 34m, 32m, 30m, 28m, 26m, 24m, 22m, 20m, 18m, 16m, 14m, and 12m.






        Conservative Power output:

        In a Conservative power output calculation, the radius of the frame is 40m and its height 30m.

        P = 0.5 x 1.23 x (2 x 40 x 30) x103 x 0.4 =   590KW 

        Actual Power Output:
        In an Actual power output calculation, however, we shall       calculate the power output of each column, a total of 15 columns. And because each column generates different  amount of power corresponding directly to the value of its radius, we shall calculate all 15 power output values, add them up and reach the Actual power produced by a BSW with 30m    wide x 40m long frame, attached on 40m arm.

        Power produced by column A = 0.5 x 1.23 x (2 x 40 x 40) x     103 x 0.4 = 785KW 
        Power produced by column B = 0.5 x 1.23 x (2 x 38 x 40) x
        103 x 0.4 = 747KW 
        Power produced by column C = 0.5 x 1.23 x (2 x 36 x 40) x     103 x 0.4 = 708KW 
        Power produced by column D = 0.5 x 1.23 x (2 x 34 x 40) x     103 x 0.4 = 668KW 
        Power produced by column E = 0.5 x 1.23 x (2 x 32 x 40) x
        103 x 0.4 = 629KW 
        Power produced by column F = 0.5 x 1.23 x (2 x 30 x 40) x
        103 x 0.4 = 590KW 
        Power produced by column G = 0.5 x 1.23 x (2 x 28 x 40) x     103 x 0.4 = 550KW 
        Power produced by column H = 0.5 x 1.23 x (2 x 26 x 40) x     103 x 0.4 = 510KW 
        Power produced by column I = 0.5 x 1.23 x (2 x 24 x 40) x
        103 x 0.4 = 471KW 
        Power produced by column J = 0.5 x 1.23 x (2 x 22 x 40) x
        103 x 0.4 = 432KW 
        Power produced by column K = 0.5 x 1.23 x (2 x 20 x 40) x
        103 x 0.4 = 393KW 
        Power produced by column L = 0.5 x 1.23 x (2 x 18 x 40) x
        103 x 0.4 = 354KW 
        Power produced by column M = 0.5 x 1.23 x (2 x 16 x 40) x    103 x 0.4 = 314KW 
        Power produced by column N = 0.5 x 1.23 x (2 x 14 x 40) x     103 x 0.4 = 275KW 
        Power produced by column O = 0.5 x 1.23 x (2 x 12 x 40) x     103 x 0.4 = 235KW 

        Total Power Output = 7661KW or 7.6MW





Three phases of BSW

        The BSW project will go through three distinct phases.These phases will vary in duration due to various unpredictable   circumstances including production problems, evaluation method, potential governmental bureaucracy as well as   possible lack of funding.

        At this stage it is fair to say that the three phases    detailed     below, may last 12-18 months, at the most, if all critical segments of the project are professionally managed by highly qualified people. This time estimate    will certainly be shortened depending on early successes      achieved by the managing team.






           Three critical phases of the BSW project







        The Prototype Phase

        During the prototype phase a strong and visionary partner is needed to finance the manufacturing of world-class BSW prototypes. This phase will require the manufacturing of 3 BSW prototypes of different sizes.

        The ultimate goal is to    reach the final desired BSW dimensions and power output capacity.

        The ideal investor-partner would have the following essential qualifications.

1-  Sufficient funds to finance the manufacturing of the 3 BSW prototypes. It is absoulutely critical to secure a solid and binding comitmment from the partner that the agreed-upon funds will be readily available to finish the prototype and certification phases in order to complete these two crucial phase on time.

2-    Good grasp of the science and function of the wind turbine to be able to appreciate what the team is trying to achieve.

3-    A spirit of support and cooperation to back up the team and project to succeed.

Needless to say, if the partner is an industrialist with access to sophisticated cutting machineries, advanced welding tools, pneumatic presses and other vital machines, all under one roof and operated by highly skilled technicians, the time to start and finish the project will be considerably shorter.

        Notes on the prototype phase

        To follow tried and tested sceintific paths, a small BSW         prototype with 10m x 10m wide Spinning Frames will be the first prototype to be manufactured. This would be the smallest of the three prototypes to be manufactured.
        Manufacturing the first prototype will shed ample light on         several inter-related issues.

1-    It will give the team a very good idea about production cost and invalubale dollar and cents figures to budget for the second prototype.
2-    It will highlight production pitfalls and how to avoid them with the second prototype.
3-    It will give the team managing the project an invaluable experience that can be applied in manufacturing the second prototype.
4-    Major parts of the first protoype will be used in manufacturing the second prototype, thus saving money and reducing the overall production cost and time of the second prototype. For example, the tower crane as well as the 200 Double Sided Units (DSUs) of the first prototype can be used in manufacturing the second prototype. This represents a huge savings.
5-    Perhaps the most important information that will be gleaned from manufacturing the first prototype is the amount of power generated by this BSW; the prototype will confirm the projected power output and inject the team with a great dose of confidence that the project is resting on solid sceintic foundation and that the second prototype with 20m x 20m wide Spinning Frames will yield the projected power per the sceintific formula.
        Construction cost of a  BSW with 10m x 10m wide         Spinning Frames

        The following notes may shed some light on the cost of building a BSW with 10m x 10m wide four Spinning Frames. A potential partner-investor will be in a better position to complete the missing dollar figures, as the patent holder, Jasim Al-Azzawi, will currently not be able to provide exact figures of some of the items that will be itemized below. 

        The overall cost of building a BSW with 10m x 10m wide          Spinning Frames will include 4 vital parts.

    1-Spinning Frames consisting of 200 DSUs
2-Construction tower crane to hang the Spinning Frames on it
3-Generator
4-Foundation and stabalization of the BSW  

        Note:
        As component prices, labor and transportation cost and other         relevant figures related to manufacturing cost in specific country are currently not available, the manufacturing cost breakdown below is  based on Sharjah, UAE, prices. Prices between the two countries are approximately similar.
        The exchange rate of US dollar to UAE dirhams is $1 =         3.65dhm. The figure of $72 includes prices of all DSU components (steel angle plates, Hollow Shafts, ball-bearings,   steel mesh, sail and bolts). The cost of materials, however,   was based on retail, not wholesale, prices. Thus the overall material price can potentially be reduced considerably, if a wholesale supplier can provide competetive prices.


        Construction cost of one Double-Sided Unit (DSU)
        The DSU is the basic building block of the BSW. Different         sizes BSWs will have different number of DSUs. The bigger the BSW the larger number of DSUs. The DSU is the heart of the    BSW and as the size of the BSW increases the cost of manufacturing the corresponding number of DSUs will rise.

        A BSW with 10m x 10m wide 4 Spinning frames = 200 DSUs
        A BSW with 20m x 20m wide 4 Spinning Frames = 800 DSUs
        A BSW with 30m x 40m wide 4 Spinning Frames =  2,400         DSUs
        What is extremely important to realize is that power generation         is directly proportional to the increase in BSW size. The bigger the BSW the greater the power output.

        A BSW with 10m x 10m frame will generate =                388KW
        A BSW with 20m x 20m frame will generate =                2MW
        A BSW with 30m x 40m frame will generate =                7.6MW

        A single DSU consists of the following parts:
        Angle Plates:                      13    
        Shafts:                              4m shafts
        Ball-bearings:                     4
        Swinging Window:              1
        Flap:                                 1
        Bolts:                                8

        Angle Plates:                      4 dhm/meter (6m will cost                                                   25dhm)
                                                13 Angle plates x 4 = 52dhm

        Hollow Shaft (4m needed):  1m shaft cost 5dhm
                                                4 x 5 = 20dhm                  

        Ball-bearings:                     20dhm per ball-bearing
                                                4 x 20 = 80dhm

        Swinging Window:              40dhm

        Flap:                                 30dhm

        Bolts (8 are needed):          5dhm per bolt
                                                8 x 5 = 40dhm

        Total cost of components to build one DSU = 262dhm

        Total cost of components to build one DSU = $72
       
        Thus, the total cost of the 200 DSUs of a BSW with 10m x 10m wide four Spinning Frames capable of producing 388KW is:  $14,400 US dollars. The figure of $72 dollars does not take into   consideration labor cost, as no DSU has so far been         manufactured. During the period prior to start manufacturing    the BSW a better understanding of labor cost will be       investigated and factored in.

The BSW is modular and easily scalable, per customer needs and cost considerations; however, the cost of manufacturing a DSU is fixed, regardless of the BSW size. Thus, the dollar figures below provide good indications of manufacturing cost as the size of the BSW increases.

        A BSW with 10m x 10m wide 4 Spinning Frames capable of         producing 388KW:
        Number of DSUs = 200 DSUs
        Total cost of 200 DSUs = $14,400

        A BSW with 20m x 20m wide Spinning Frames capable of         producing 2MW:
        Number of DSUs = 800 DSUs
        Total cost of 800 DSUs = $72 x 800 = $57600

        A BSW with 30m x 40m wide Spinning Frames capable of         producing 7.6MW:
        Number of DSUs = 2400 DSUs
        Total cost of 2400 DSUs = $72 x 2400 = $172,800
        As precise cost of tower cranes, foundation and labor cost are    currently unavailable these figures will be estimated and         factored in prior to start manufacturing the prototypes.

        Spinning Frames
        Please bear in mind that the above figure of $72         dollars does not take into consideration labor cost, as     no DSU has so far been manufactured. During the period       prior to start manufacturing the BSW a better understanding of        labor cost will be investigated and added to this figure.

        The four Spinning Frames will hold 200 DSUs:
        $72 x 200 = $ 14,400 cost of 200 DSUs

        Tower crane with four intersected arms
        Since neither the cost of building a tall tower crane with two         perpendicularly-intersected arms to hang the four Spinning Frames nor the price of purchasing a second-hand tower crane from the local market and adapt/transform it to fulfill the same function, are currently not available to be included in this cost breakdown, it is advisable to go ahead now and survey the market to find out which option is preferrable and more cost competitive..

        As the current vision of the project is to manufacture three BSW prototypes of various dimensions (10m x 10m, 20m x 20m and 30m x 40m) we should explore and decide whether the lengths of the four arms of the tower crane should match the legths of the Spinning Frames for each BSW     prototype or should we use the same construction tower crane     for all three different sizes prototypes? 

        For the purpose of manufacturing the three BSW prototypes         here are three options to consider and explore the cost of each option.

1-  Use a tower crane with four perpendicularly-intersected arms each 30m long for all three BSWs to hang the Spinning Frames on them. We shall call this tower crane Type A.

2-  The lenghths of the four arms of each tower crane used for each of the three BSWs should match the lenghths of the Spinning Frames to maximize power outpu. We shall call this tower crane Type B.

3-  A flexible tower crane whose four arms can be extended and shortened to match the lenghths of the Spinning Frames of the three BSWs; a purpose-built specially designed and manufactured tower crane where 10m long segments can be extended or shortened from the four arms of such felxible tower crane. We shall call this tower crane Type C.

        So what US dollar amount should we assign to the tower crane        to be used with a BSW with 10m x 10m wingspan Spinning    Frames? The answer depends on which of the three types enumerated in the above paragraph we will use. While it is   extremely difficult to speculate on the cost of designing and manufacturing Type C it should be a lot easier to research the local market for a second-hand construction tower and  adapt/transfor it to be used either as type A and B.

        Having highlighted the three types of tower cranes that can         potentially be used with the BSW, for cost-saving purposes in      the prototype manufacturing phase of the three different sizes of BSWs, perhaps type A will be the logical choice for three main reasons.

1-    The same tower crane can be used with all three BSWs
2-     Such tower cranes are widely available worldwide.
3-    If the expected 7.6MW power generated by a BSW with 30m x 40m wingspan Spinning Frames is achieved then we can deduce that the expected power outpt of 388KW and 2MW of 20m x 20m and 10m x 10m respectively will also be achieved.

        Initial, cursory prices of tower cranes provided by         dealers of second-hand tower cranes ranged  between 30-40K US dollars. But as of this moment no actual specifications, dimension, transportation cost or the actual locations of such tower cranes have been confirmed. But   perhapt it is reasonable to assume that the cost is in the range quoted above.     

        Cost of stabilization and foundation:
          Unfortunately, at this stage it is rather difficult to estimate           the cost of securing and stabilizing the BSW against           hurricane and powerful winds, since labor and  transportation cost as well as price of raw materials, such as concrete and steel wires, are not available.

          Among the four major cost items, i.e. Spinning Frames, tower crane and generator, foundation and stabilization cost, the cost of the later item is the lowest and should not  exceed $10,000 US dollars.

        Generator:
        A generator is the only electro-mechanical purchased device needed for integration with the BSW; all other components will be manufactured or purchased locally. The   cost of the generator constitutes a major percentage of the overall pricetag of an installed BSW.

        It is critical to keep the following important point in         mind. As power output capacity of the BSW increases         with size the cost of the inegrated generator will also increase , while the cost of other vital componenets   (Spinning Frames, tower crane, foundation and stabilization) increases very modestly.

         For example: 
1-    The cost of 500kW 250RPM 50Hz vertical PMG generator used in 10m x 10m BSW is $52,600
2-    The cost of 2MW 500RPM 50Hz vertical PMG generator used in 20m x 20m BSW is $99,900
3-    The cost of 5MW 600RPM 50Hz Vertical PMG generator used in 30m x 40m BSW is $158,300

From the summary of power output capacities of the three BSWs in ascending size (10m x 10m, 20m x 20m and 30m x 40m), the coressponding expected power output of these BSWs is 388KW, 2MW and 7.6MW respectively.





       BSW Manufacturing Cost Breakdown

A-  Final manufacturing cost of BSW with 10m x 10m wide Spinning Frames using 500kW 250RPM 50Hz vertical PMG and producing 388KW

        Estimatede cost of manufacturing 4 Spinning Frames =  
        USD 14,400               
       
        Estimated cost of procuring the right tower crane =
        USD 30,000

        Estimated cost of procuring the generator =                 
        USD 52,600

        Estimated cost of foundation and stabilization =             
        USD 10,000

        Estimated cost of labor and transportation = 
        USD 20,000

        Total cost of manufacturing 10m x10m BSW = 127,000       
        US dollars

B-  Final manufacturing cost of BSW with 20m x 20m wide Spinning Frames using 2MW 500RPM 50Hz vertical PMG and producing 2MW

        Estimatede cost of manufacturing 4 Spinning Frames =  
        USD 57,600               
       
        Estimated cost of procuring the right tower crane =
        USD 30,000

        Estimated cost of procuring the generator =                 
        USD 99,900

        Estimated cost of foundation and stabilization =             
        USD 10,000

        Estimated cost of labor and transportation = 
        USD 20,000

        Total cost of manufacturing 20m x20m BSW =     
        $217,500 US dollars

C-  Final manufacturing cost of BSW with 30m x 40m wide Spinning Frames using 5MW 600RPM 50Hz vertical PMG and producing 5MW

        Estimatede cost of manufacturing 4 Spinning Frames =  
        USD 172,800             
       
        Estimated cost of procuring the right tower crane =
        USD 30,000

        Estimated cost of procuring the generator =                 
        USD 158,300

        Estimated cost of foundation and stabilization =             
        USD 10,000

        Estimated cost of labor and transportation = 
        USD 20,000

        Total cost of manufacturing 30m x40m BSW =     
        $301,100 US dollars


        BSW Cost comparison with well-known International   wind turbine brand names 

        The costs for a utility scale wind turbine range from        about $1.3 million to $2.2 million per MW of nameplate capacity installed. Most of the commercial-scale turbines installed today are 2 MW in size and cost roughly $3-$4 million installed.

Maximum Power Output
Typical Turbine Type
Project Cost
800 kW
Enercon E53/48/44
£1.4 million
900 kW
EWT DW61
£1.4 million
1.5 MW
GE 1.5sle
£2.7 million
2 – 3 MW1
Enercon E82
£3.1 million
There are economies of scale, so larger turbines cost less per KW-installed than smaller ones, and single turbine sites costing more per KW than multiple turbine sites. Having said that, the table below shows budget price for well-known international wind turbines.

Maximum Power Output
Typical Turbine Type
Project Cost
55 KW
Endurance E-3120
£320k
800 KW
Enercon E53/48/44
£1.4 million
900 KW
EWT DW61
£1.4 million
1.5 MW
GE 1.5sle
£2.7 million
2 – 3 MW1
Enercon E82
£3.1 million
   
Final Important Note:
By carefully examining the price of the last two turbines manufactured by GE and Enercon, £2.7 and £3.1 million British pounds to produce 1.5MW and 2-3MW respectively, and comparing them with the cost of manufacturing a 20m x 20m and 30m x 40m BSWs costing (approx) $300K and $400k US dollars we reach the following inescapable conclusions:

1-     For the price of one GE 1.5sle costing $3.5 million wind turbine we can manufacture 8 BSWs collectively capable of producing 40MWs.

2-    For the price of one Enercon E82 wind turbine costing $4.2 million we can manufacture 10 BSWs collectively capable of producing 50MWs.

Given the extreme low cost of manufacturing BSWs and the enormous amount of energy they can produce, an ideal partner is needed to execute this project.

 Executive Summary of Project Roadmap Guidelines

Phase one:
1-    Identify a strong and committed partner/investor
2-    Project is formally presented to the partner
3-    Secure a binding financing commitment from the investor
4-    A project leader is presented to the investor
5-    Create a managing team to supervise project execution
6-    Identify strong windy location to deploy prototypes
7-    Identify well-equipped workshop to manufacture prototypes
8-    Secure land rights to deploy prototypes
9-    Secure necessary permits to erect prototypes

Phase two:
1-    Place purchase orders for materials and parts
2-    Set specific time schedule to start and finish each phase
3-    Assign specific duties and responsibilities to section managers

Phase three:
1-    Build first BSW (10x 10xm)  
2-    Build second BSW (20m x 20m) 
3-    Third BSW (30x 40m) should be built with 5MW generator to show that this BSW can produce 5MW with fraction of the cost of very expensive turbines built by GE and Enercon.
4-    While running and observing the second BSW, communication should begin with companies authorized to issue certifications.
5-    The ultimate goal should be to secure three certified BSWs: (A) A BSW capable of producing less that 1MW (B) ABSW capable of producing between 1-2 MW and (C) A BSW capable of producing 5MW.          With these three BSWs the company will be able to cover various commercial and consumer markets.

Phase four:
1-    Upon securing the appropriate BSW certificates a professional feasibility study should be commissioned to cover all aspects of the project, including production, financing, marketing, creation of windfarms and identification of domestic and international suppliers of materials and generators.
2-    A company will be incorporated to launch this project.
3-    Simultaneously with exploring commercial aspects of the project, a world class advanced production facility should be built in a strategic location and staffed by highly skilled technicians.
4-    The Business Development Department should strive to secure and sign Power Purchasing Agreements (PPA) with various utilities, municipalities and governorates.
5-    Land rights necessary to establish windfarms must be secured as well as agreements with the relevant entities to feed the power generated by windfarms to the national grid.

Phase five:
1-    A year or two after launching the BSW project, the R&D department will strive to move to a higher plane by securing certification for BSW capable of producing 8MW and higher.    

        At this stage of writing this prospectus an investor has not been identified         and secured and consequently it is difficult to know if funds will be   extremely tight or readily available. Some of the guidelines highlighted    above assumes saving money is far more important than completing the   prototype and certification phase as quickly as possible. If on the other        hand availability of funds is not a concern and the most important goal is    to finish the project and secure certification ASAP then some of the above       recommendations can be ignored once we know who the investor is and   what sort of funds will be allocated to the project.

The End




kirkuk BSW prototype plus links to all videos of BSW on youtube














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