Mass Megawatts- Morrison, Colorado Manufacturing Facility.
Vertical Axis Wind Turbine for Electricity
Vertical Axis Wind Turbine for Water Pumper
Our present facility has over 5600 sq. ft. of usage. On our property, which sits on 13 acres, we are planning a 20,000 sq. ft. expansion, to our current facility, to be built in the near future!
Water pump off the Grid system 2" Cylinder with 2-1/4" pipe can pump approx. 5-7 gallons per minute 220 ft. deep with only 18-20 mph winds. 2 3/4" Cylinder with 3" pipe can pump 30 gallons of water per minute at 220 ft. deep with the same wind speed.
Mass Megawatts Wind Systems are designed for efficient and safe, long-term operation. To achieve this, several protection mechanisms have been incorporated into the design. This includes over-speed protection with an electromagnetic braking system to protect the shaft and gearbox components.
WIND VELOCITY OVERSPEED PROTECTION
The generator rotation speed must be monitored electronically to ensure it is within the allowed range to prevent system damage. Our wind systems are programmed to constantly monitor this velocity by utilizing an RPM sensor attached to the rotor shaft. If the rotational speed exceeds the allowed range, the main relay is de-energized and a brake is applied. The microprocessor will reverse the process when PRM and wind velocity decreases. If the wind speed decreases below a specific RPM, the main relay is de-energized and the generator is allowed to turn until the wind increases enough to allow the generator to begin producing power again.
The torque force generated during operation of the wind turbine could easily damage the connecting shaft and gearbox when a brake is applied. To prevent this, our wind system has incorporated an electromagnetic braking system with clutch functions that allow slippage to occur. This provides for a more controlled action when the brake is applied. The electromagnetic brake also acts as an additional safety feature in the event of a power outage. The brake will be engaged to prevent damage to the generator and gearboxes during power outages related to high wind events. (The induction generators themselves would not send electricity to the grid during a power outage.)
ELECTRICAL GENERATOR DETAIL
In basic terms, our generator is an electric motor operating backwards. In our case, we have a three phase induction motor with a designed rotational speed of 1725 rpm. Induction generators and motors are also known as “squirrel cage motors” and are used as furnace blowers, pump motors, washing machines, and for various other functions. The operation is simple. The electric current flow in the stationary windings induces a magnetic field into the rotor. This magnetic field causes the rotor to chase the fields created by the stator windings. There is no physical connection between the rotor and stator windings. There are no bushings or slip rings. When the wind turbine causes the induction motor to rotate faster than the design speed, the motor begins to generate power back to the leads. The generator rotates slightly higher than the nameplate RPM and it remains locked into the same frequency as the utility grid. As the torque applied to the generator shaft is increased, the output current is also higher. More wind equals more power.
WIND POWERED WATER PUMP
Wind-powered water pumps are commonly used for agricultural applications across the USA and at remote locations throughout the world. The Mass Megawatts’ wind-powered water pump is an upgrade over the traditional windmill-style water pump, and provides a more cost-effective method for water delivery. With the patented design and Augmenter technology, the system will harness the wind’s energy more efficiently, with fewer components, to reduce capital and operational costs. When switching from other power sources, including natural gas and diesel generators, customers can realize a significant reduction in their energy bill. The savings are further enhanced when receiving qualified federal, state, and/or local incentives, including tax credits and grants. The unit has a life expectancy of 30 to 40+ years.
The traditional cylinder style pumps have a maximum stroke of 50 rpm and the cup leather needs to be replaced frequently. Our wind-powered water pump utilizes a 5 to 1 ratio helical gearbox with only eleven moving parts. In very high wind speed situations, we will not exceed the cylinder’s allowed 50 to 1 ratio. Traditional wind water pumps contain over 70 components including a standard gearbox with an 18 to 1 reduction ratio. Traditional wind water pumps also incur higher maintenance costs due to accelerated rotations at specific wind velocities. For example, the traditional wind-powered water pump rotates at 750 RPM at 24 miles per hour wind velocity while our unit rotates at only 150 RPM at the same wind speed.
The culmination of a 12 year R&D path has resulted in a wind power generation system that provides solid solutions to the two major wind project roadblocks: 'tower height' and 'lower wind resource.' With an overall unit height of 80 feet or less (most wind law zoning ordinances restrict towers above 100 feet), the Multi-Axis Turbo system (MAT) and MMW Augmenter (patent pending) combine to create a wind power generation technology that affords profitable electricity production at sites with lower wind speeds, while taking production at high wind sites to peak levels.
Our innovative Augmenter System is the key to our lower wind speed generation capability.
The underlying genius of the MAT technology is based on the concept that 'many small turbines' makes much more sense, from all perspectives, than 'one big turbine.'
This may seem counterintuitive. Yet, from a material standpoint alone, a 'tall tower' wind turbine uses over 10 times as much steel as a MAT unit of similar capabilities. A megawatt sized 'tall tower' has a hub (the 'nacelle') over 200 feet above ground level that contains, quite literally, many hundreds of moving parts. A MAT unit of the same power rating utilizes only a fraction of this number of moving parts. In addition, the MAT's geometrically simple configuration of small turbines arrayed on multiple axes dramatically reduces blade costs, while minimizing and dissipating forces of stress and vibration that quickly degrade large turbines and their generation equipment.
By positioning the MAT turbine blades in this proprietary arrangement, the harvesting of the mechanical power in the wind and its transfer to the generators is accomplished with tremendous efficiency, resulting in higher electricity production. This innovative design allows for all of the MAT's generation and electronic components to be situated close to ground level, reducing structural complexity, construction costs and slashing maintenance expenses.
Scalable from 10 kW 'home and farm' systems to multi megawatt utility installations, the MAT's versatility extends to two distinct turbine and generator configurations designed to address the unique requirements of both lower and higher wind speed sites. At lower wind speed sites, 'H' and 'C' rotor turbines are paired with lower rpm PMGs (permanent magnet generators). MAT's sited in higher-level wind resources are fitted with Darrieus type rotors that drive higher rpm induction motors. These specialized 'high and low' turbine and power drive designs enable the MAT to fully exploit the potential of both types of wind regimes.
The MMW Augmenter can be customized to address unique site characteristics, taking maximum advantage of each location's individual wind resource. From unit orientation and specialized structural adjustments, to spatial and relational ratios of the Augmenter's wind focusing chambers, each installation is crafted to extract the full energy potential from the site's wind stream. A proprietary aerodynamic software application 'places' a standard MAT unit on a computational model of the physical site and simulations are run, utilizing the site's historical wind data, to optimize the Augmenter's embodiment.
The MAT and MMW Augmenter are a 21st century wind technologies that combine to provide an innovative solution; a wind energy system that's easily sited where other vendor's equipment is either prohibited or will not operate profitably. For wind power developers facing 'project stopping' challenges, the MAT technology provides a new path to success and the promise of decades of productivity and profitability.
Mass Megawatts’ Wind Augmentation System
The augmentation system (prototype shown below) utilizes a simple and cost effective wind-focusing technique to increase the wind velocity directed at the turbine by an average of 70%. This accelerated wind speed results in a significant, three-fold increase in the electrical power generated by the turbine.
The augmentation effect is created by an inner cylinder that redirects and accelerates the incoming wind toward the turbine blades mounted on the side. Additionally, the blades are secured to a rotating shaft that adjusts to face the dominant wind direction. Our Charlton prototype can be viewed at http://www.youtube.com/watch?v=I__qE8YxPTE or by searching for “Charlton Future Renewables” at www.YouTube.com .
The augmentation system can be implemented with industry-standard, horizontal and vertical blade models, while reducing height and minimum wind-speed requirements. Since the augmenter system’s price is a fraction of the cost required to achieve the same level of energy production by adding larger and/or additional turbines, the return on a wind-energy investment is substantially increased.
The selling price of large scale wind power applications and its installation of Mass Megawatts augmenters with turbines can be less than $1,000 per rated kilowatt.
However, the cost of large scale application are traditionally more expensive that residential wind power due to economies of scale reasons. In an example of a more expensive residential wind application being more costly than a typical large scale commercial application, a retail 10 kilowatt residential, small turbine installation can cost $60,000. Using the Wind Augmentation System from Mass Megawatts, you can increase the power-output threefold, equaling that of a 30 kW system, with a total investment approaching $90,000. That’s a 50% increase in initial costs to realize a 300% increase in wind-energy production for the life of the augmented, wind-turbine system. While it depends on several factors, including wind speed and the price of electricity, the payback period for an augmented system can be realized in just a few years compared to more than a decade with a traditional, non-augmented system.
In addition to a significant reduction in material costs, the installation and maintenance are reduced as well. The augmented turbines can be mounted on a single, telephone pole or tower structure, and pairs of augmented turbines can be stacked upon the same tower. Also, in most cases, the maximum height will be less than 60 feet as the augmenter reduces the height requirements needed for effective operation, making lower wind-class sites economically viable.
The wind augmentation system is made from sturdy materials and requires no scheduled maintenance. Mass Megawatts backs their wind augmentation system with a full, 20 year warranty.
The Mass Megawatts’ augmentation system qualifies for the 30% Federal Production Tax Credit, and many states offer additional incentives as well. Additionally, businesses may be able to take advantage of favorable, accelerated depreciation methods, while USDA grants are available for farmers and ranchers.
- Do I have to use the turbine blades that Mass Megawatts recommends?
- No. Mass Megawatts can size and recommend the turbine models/vendors to use in your augmented wind system, but you can certainly select your own type as well.
- Who handles the installation and how long does it take?
- Mass Megawatts can handle the complete installation.
- While it depends on many factors, including total capacity being installed, in many cases, the full installation of an augmented system can be completed in a few days.
- What maintenance is required?
- There is no schedule maintenance for the augmentation structure itself. Depending on the turbine blade models selected, there may (or may not) be any schedule maintenance to perform.
- Is my property a good location for an augmented wind system?
- This depends on several site factors, including wind speed, price of electricity, zoning restrictions, and infrastructure requirements. In many cases, wind speed can be determined in a quick-fashion, avoiding lengthy evaluation periods. Also, your local county planning and zoning authority can tell you if there are any restrictions to placing a tower on your property. We’re happy to help you evaluate your site.
- How high will the augmented wind system be?
- Most installations will require a maximum height of 60 feet or less.
- How much does it cost?
- This depends on many factors, but you can expect a cost approaching $750 per rated kilowatt, which compares very favorably with traditional, non-augmented installation which typically costs between $1500 and $2000 per rated kilowatt.
- How long will it take to realize payback on my initial investment?
- Again, this depends on several factors, including the price of electricity and wind-speed at your location. However, in many cases, payback can be achieved in 2 to 5 years.
- What is the expected lifetime of the augmented wind system?
- 30 to 40+ years
- Where can I get more information about tax credits, grants, and accelerated depreciation?
- As a starting point, you can view information about the 30% Federal Renewable Energy Tax Credit at http://www.dsireusa.org/incentives/incentive.cfm?Incentive_Code=US37F&re=1&ee=1
- Information about accelerated depreciation, for businesses, can be found at http://www.dsireusa.org/incentives/incentive.cfm?Incentive_Code=US06F&re=1&ee=1
- Information about USDA grants for rural wind projects can be found at http://www.dsireusa.org/incentives/incentive.cfm?Incentive_Code=US06F&re=1&ee=1
- Information about state incentives can be found at http://www.dsireusa.org/ .
- What’s my next step?
- Please contact us at 1-508-751-5432 and/or through our corporate website at www.massmegawatts.com. It would be our pleasure to help you evaluate your site for an augmented wind system, and to fully explain the process.
water pump wind turbine
Another view of water pump wind turbine designed with a goal of reducing the cost of pumping water
Wind Tunnel Testing and Charlton Prototype
Mass Megawatts has constructed a wind tunnel for gathering data for power output of different blade designs and augmenters using a range of controlled wind speeds. Click on the photos below to view larger images of our wind tunnel testing facility and past project at field testing locations.