Small Wind Energy Solutions

OFF-GRID
SYSTEMS GUIDE

UNRIVALED
PERFORMANCE
 Small Wind Energy Solutions
INTRODUCTION TO
OFF-GRID SOLUTIONS
Why Choose An Off-Grid Solution from Kingspan Wind?
Kingspan Wind is a global market leader in the design,
manufacture, supply and installation of small scale off-grid
energy systems. Born as the result of over 30 years’ research,
development and innovation, Kingspan Wind offers unrivaled wind
power solutions the world over - with over 5,000 installations in
over 70 countries and on every continent.
Whether for business solutions, domestic applications, offshore
developments, community power stations or remote stand
alone systems, our track record is unrivaled. Kingspan has been
supplying off-grid solutions around the globe with many of our
early systems now entering their third decade of operation.
17% of the global population is currently without electricity -
that’s over 1.26 billion people! For some this is a lifestyle decision,
opting to live beyond the grid for electricity. For the majority this
is not through choice. Approximately 87% of the people without
electricity live in rural or remote areas, or locations with low
population. It’s in these locations where the provision of national
grids isn’t possible, whether due to technical challenges, high cost
or a lack of local government investment.
17% of the global
population is currently
without electricity -
that’s over 1.26 billion
people!
2
WORLD’S
MOST RELIABLE
Small Wind Turbines
Kingspan Wind provides reliable, efficient and affordable off-grid
energy solutions through our small scale wind turbines, often
combined as hybrid systems with Solar PV or diesel back-up
generators. Our solutions are compatible for integration into
existing off-grid systems that may require additional power
expansion or as an alternative ‘clean’ technology to replace high
polluting and expensive to operate diesel gensets.
Off-grid systems are adaptable, can be expanded easily to
accommodate change in use or load demand and can provide
uninterrupted power 24/7.
The requirement for power demand will differ from site to site and
one size does not fit all when it comes to designing an off-grid
system, which is why our ‘Guide to Off-Grid Systems’ has been
created to help you understand the various options available, the
key technical considerations and to demonstrate the wide range
of existing off-grid customers, system sizes and configurations
already providing robust, reliable off-grid power around the globe.
If you need help in designing the most appropriate off-grid energy
solution for your needs, contact our expert team today!
 KINGSPAN WIND
BUILT ON EXPERTISE

AVAILABLE SYSTEM
TYPES
Stand Alone
Wind turbine is the sole source of
power, connected to a battery storage
to provide constant supply of energy.
Hybrid
Wind turbine integrated with solar PV
panels, battery storage and/or diesel
generators to provide uninterrupted
power 24/7.
Mini-Grid
Multiple wind turbines and
alternative renewable technologies
interconnected to create a distributed
energy network.
CONTENTS
❱❱Introduction 2
❱❱System Types 3
❱❱Worldwide Installations 4
❱❱Kingspan Turbines
Technical Specification 6
❱❱System Sizing & Load
Demand 8
❱❱Domestic Hybrid System 10
❱❱Remote Island Mini-Grid
System 12
❱❱Telecoms Hybrid System 14
❱❱Rural Electrification 16
❱❱Cold Climate 18
❱❱Offshore & Hazardous
Environments 20
❱❱Battery Selection 22

Smart Grid ❱❱Towers 24

A type of mini-grid that prioritises ❱❱Foundations 25
energy demand and allocates energy
to users based on real time availability. ❱❱Additional System
Components 26

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 Small Wind Energy Solutions

KINGSPAN WIND OFF-GRID

INSTALLATIONS AROUND
THE WORLD

RURAL DOMESTIC
Alaska
3 x KW6 wind turbines RURAL DOMESTIC
installed to power a England
house and business in The hybrid system
cold temperatures. including 2 x KW6 wind
turbines provides the
full electrical, hot water
and heating demand of
the smallholding and
business premises.

30+
YEARS
OPERATION
AROUND TELECOM BASE
STATION
THE GLOBE Namibia
The base station serves
telecommunication
power to around 1,500
people living in the
village of Dorbadis and
to farming communities
over 30km away. The
hybrid energy solution
ensures that the base
station provides clean,
green and continuous
RURAL energy day and night.
ELECTRIFICATION
Falkland Islands
90% of rural electricity
generated in the Falklands
comes from KW3 and
KW6 wind turbines.

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 KINGSPAN WIND
BUILT ON EXPERTISE

OVER 5,000
INSTALLED IN
MORE THAN
70 COUNTRIES

REMOTE
COMMUNITY
Isle of Eigg
Isle of Eigg’s electricity
was powered by diesel
generators until they
installed 4 x KW6 – This
is the first time in its
history that Eigg has
operated a power grid.
OFFSHORE
North Sea
The robust KW3 wind
turbines provide reliable
power to unmanned gas
platforms in the North
Sea.
VISITOR CENTER
Korea
2 KW6 units installed in
2007 as part of hybrid
package along with
Solar PV Panels. The
system is used to power
the visitor center.

TELECOM BASE GAS LABORATORY

STATION Japan
Saudi Arabia 2 x KW6 generating
The installation of power for Tokyo
wind turbines provided Gas Laboratory in
a cost-effective Yokohama.
alternative to a
diesel generator that
would have involved
subsequent costly
refuelling trips and
regular maintenance.

TELECOM BASE
STATION
Rabi Island Fiji
As the only wind turbine
on the island, the
Kingspan Wind turbine
is producing far more
than the expected
annual energy output
RESEARCH STATION thanks to the great wind
Antarctica regime on the site and
the unique design of
9 x KW6 generating wind turbine.
power for research into
climate change.

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 Small Wind Energy Solutions

UNIQUE
DOWNWIND
DESIGN
TECHNICAL PRODUCT
SPECIFICATIONS

SELF REGULATING

MINIMAL VISUAL IMPACT

NO GEAR BOX

ANTI OVER-SPEED CONTROL

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 KINGSPAN WIND
BUILT ON EXPERTISE

UNRIVALED
WIND ENERGY
SOLUTIONS

PRODUCT SPECIFICATION PRODUCT SPECIFICATION

Peak Power 3.2kW Peak Power 6kW

Telecoms, Offshore Oil & Gas Platforms, Remote Rural Domestic, Small Holdings, Commercial,
Applications Applications
Islands, Domestic Telecoms, Public Sector, Remote Islands

Solutions Battery Charge, 24V, 48V, 300V Solutions Battery Charge, 48V, 120V, 300V

Architecture Downwind, 3 Bladed, Self Regulating Architecture Downwind, 3 Bladed, Self Regulating

Rotor 3.9m Diameter (maximum 300 RPM) Rotor 5.6m Diameter (maximum 200 RPM)

Blade Material Glass Thermoplastic Composite Blade Material Glass Thermoplastic Composite

Generator Brushless Direct Drive Permanent Magnet Generator Brushless Direct Drive Permanent Magnet

Tower Height Options 6.5m / 11m Taperfit Monopole - Hydraulic Tower Options 9m / 11m / 15m / 20m Taperfit Monopole - Hydraulic

Tower Specification Class 1 Rated / Galvanised Steel Tower Specification Class 1 Rated / Galvanised Steel

Foundation Options Pad / Root / Rock Anchor Foundation Options Pad / Root / Rock Anchor

Cut In Speed 2.5m/s Cut In Speed 2.5m/s

Cut Out Speed None - Continuos Operation Cut Out Speed None - Continuos Operation

Survival Wind Speed Designed to Class 1 (70m/s) Survival Wind Speed Designed to Class 1 (70m/s)

Warranty 5-Year Parts & Labour Warranty 5-Year Parts & Labour

Cold Climate Options Available on Request Cold Climate Options Available on Request

Colour Options White (RAL9003) Black (RAL9005) Colour Options White (RAL9003) Black (RAL9005)

KW3 ANNUAL ENERGY PRODUCTION KW6 ANNUAL ENERGY PRODUCTION

Annual Energy Production (kWh)

35,000
Annual Energy Production (kWh)

14,000
12,000 30,000
10,000 25,000
8,000 20,000
6,000 15,000
4,000 10,000
2,000 5,000
0 0
4.0 5.0 6.0 7.0 8.0 9.0 10.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0
Annual Average Wind Speed (m/s) Annual Average Wind Speed (m/s)

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 Small Wind Energy Solutions

CUSTOM
DESIGNED
SYSTEM
SYSTEM SIZING TO SUIT NEEDS OF
YOUR APPLICATION

& LOAD DEMAND

Our expert team can help you choose which system

size and type is best to suit your load demand and
provide uninterrupted power supply 24/7.

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 KINGSPAN WIND
BUILT ON EXPERTISE

UNRIVALED
WIND ENERGY
SOLUTIONS

OUR TEAM CAN

SIZING YOUR SYSTEM ASSIST WITH
There are many factors to consider when it comes to designing an off-grid system. ❱❱ Site feasibility including
load demand assessment
Kingspan recommends that Load Demand is the first consideration to review and
understand before deciding which system type is best for your needs. ❱❱ System sizing, design
and specification
Understanding load demand, when peak demand is required, environmental considerations
and the rate of battery discharge will help you establish the size of system you require. ❱❱ Supply & installation

The power and energy consumption of the loads is of significant importance in off-grid ❱❱ Planning & grid support
systems. The main points to consider: ❱❱ Commissioning & registration
❱W
 hich electrical loads are to be supplied by the off-grid system? ❱❱ Servicing contracts
❱H
 ow high will the energy consumption be per day or annually? ❱❱ Data monitoring
❱W
 hat will be the maximum peak power requirement in a day? ❱❱ Funding applications &
incentive schemes, i.e. Feed-In
Kingspan has a number of sizing calculators to assist with the design stage and our team
Tariffs
of experts are on hand to advise which method is the best to suit your application.
❱❱ Legislation compliance,
Once the load demand and system rating has been established, Kingspan will then
i.e. CRC Energy Efficiency
recommend if a stand-alone, hybrid or mini-grid system is the most practical to your
Scheme, ESOS – Energy
demands and also the operating voltage of your system.
Savings Opportunity Scheme
Depending on your geographic location and availability of space, we will also recommend
whether supporting technologies such as Solar PV or a diesel generator should be
integrated within your system to help compliment the wind turbine or provide back up.

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 Small Wind Energy Solutions

SYSTEM
TYPE:
WIND & DIESEL
HYBRID
DOMESTIC
HYBRID SYSTEM

95% 24/7
ANNUAL ENERGY PRODUCED UNINTERRUPTED
BY THE WIND TURBINES OFF-GRID POWER SUPPLY

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 KINGSPAN WIND
BUILT ON EXPERTISE

UNRIVALED
WIND ENERGY
SOLUTIONS
LIVING
OFF
GRID

SYSTEM
SPECIFICATION
THE CHALLENGE
A smallholding and business premises that is located in rural Yorkshire, England, is a great ❱K  ingspan KW6 (300V) x 2 (12kW)
example of living off the grid. When the owners purchased and developed the property ❱S  MA Mini-Grid Inverters
to become their new home and business premises, the property was not connected to ❱R  ectifier Protection Controller
the national grid. This was due to the rural location of the property which is in one of the ❱B  attery Bank 720 AMPH
highest points in the Yorkshire countryside. ❱ 1 0kVA 3 Cylinder Diesel Generator
❱E  WP Hot Water Diversion Control
The owners originally enquired about connecting the property to the national grid, however,
due to the remote location, they decided the costs to connect to the grid and then still
require purchasing electricity was not cost effective so opted to explore the alternatives. KEY COMPONENTS
THE SOLUTION
The location has a good wind resource, is well exposed and has plenty of space, so the
WIND TURBINE
obvious solution was to install a small scale wind turbine. In 1992, the owners installed their
first wind turbine as part of a hybrid system with a diesel generator as back up.
As the power demand of the property increased with business and office premises, the
system has been expanded to cover demand and now has 2 x Kingspan KW6 wind turbines,
CONTROLLER
back up diesel generator and battery bank. When the battery is fully charged, any surplus
energy produced from the wind turbines is diverted into hot water storage with a unique
diversion control system. This ensures all of the renewable energy produced is utilised
across the domestic premises, office and outbuildings.
The hybrid system provides the full electrical, hot water and heating demand INVERTER
of the site.

SYSTEM BENEFITS
HOT WATER
Turbines annual average output 21,500kWh
DIVERSION
Diesel annual average output 1,315kWh
Annual energy used for hot water & heating 13,980kWh
Annual energy used for electricity 8,835kWh DIESEL
Annual energy produced by the wind turbines 95% GENERATOR
Annual energy produced by the diesel generator 5%

COMPARISON ANNUAL RUNNING COSTS

GRID INVERTER
To power this application without the off grid wind turbine system would have an annual
average cost of:
£5,375.00
Annual running cost if powered solely on diesel
BATTERY BANK
£3,422.25**
Annual running cost if electricity was purchased from grid
*at 0.25p per kWh of energy produced by a diesel generator
**at an electricity purchase rate of 0.15p per kWh

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 Small Wind Energy Solutions

SYSTEM
TYPE:
WIND, SOLAR PV,
HYDRO & DIESEL
REMOTE ISLAND MINI-GRID

MINI-GRID SYSTEM

96% 100%
REDUCTION IN DIESEL COMMUNITY POWER
CONSUMPTION AVAILABILITY

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 KINGSPAN WIND
BUILT ON EXPERTISE

UNRIVALED
WIND ENERGY
SOLUTIONS
WIND
POWERED
COMMUNITY

SYSTEM
SPECIFICATION
THE CHALLENGE
The Isle of Eigg is a remote island of the West Coast of Scotland with a population of 90 ❱K  ingspan KW6 (300V) x 4 (24kW)
residents, 45 households, 26 businesses and 6 community buildings. As the island was ❱S  olar PV Panels (55kWp)
some 16km from the mainland, the cost to connect the island to the mainland grid was not ❱H  ydro Generators x 3 (110kW)
economical. Residents relied on expensive diesel generators and in some cases had no ❱S  MA Mini-Grid Inverters
power at night and even relied on candles for light. ❱R  ectifier Protection Controller
❱4  8V Battery Bank 720 AMPH
Through extensive research, the Isle of Eigg Electrification Programme was created to help
❱ 1 0kVA 3 Cylinder Diesel Generator
find potential solutions to providing a reliable and cost effective source of power for the
island and its residents.
A medium voltage grid design was required and due to the inconsistent weather regimes
KEY COMPONENTS
experienced on the islands, this design had to have a combination of technologies to ensure
a consistent supply of power was available through all seasons.
WIND TURBINE
THE SOLUTION
The Island has a plentiful supply of wind, rain and sunshine throughout the year, so a
system that could benefit from all of these elements was designed whilst also taking into
CONTROLLER
consideration the load demand of the islanders – day and night.
4 x 6kW wind turbines (KW6) were installed, providing a peak output of 24kW whilst forming
part of a mini-grid with 110kW of Hydro and 55kWp of Solar PV. The mini-grid was designed
to incorporate a diesel generator as back-up.
INVERTER
The Kingspan wind turbines were chosen due to their ability to produce renewable energy
through all the seasons and not require to be shut down in high winds, which are often
encountered on the island.
The system is a distributed medium voltage grid with modular AC coupling. This HYDROPOWER
incorporates the KW6 (300V) wind turbines with a grid inverter system and large battery SYSTEM
bank. The entire system is monitored and controlled by this inverter system which can
power balance the mini-grid automatically.
As a result of this pioneering community mini-grid, new properties are being developed SOLAR PV
on the island. The mini-grid can easily be expanded with additional renewable technologies SYSTEM
being integrated to provide greater coverage.
The Isle of Eigg is a great example of what is achievable with proven technology and a
combination of renewable energy sources to maximise the benefits from wind, rain and sun. DIESEL
GENERATOR
COMMUNITY BENEFITS SYSTEM BENEFITS
❱E
 lectricity available 24 hours a day ❱S  ignificantly reduced running costs
❱E
 ach household has 5kW of daily power compared to diesel
GRID INVERTER
❱E
 ach business has 10kW of daily power ❱C  ontrol of distributed generation
❱P
 opulation & income now on the ❱ Intelligent load control
increase ❱L  ow maintenance costs
❱O
 ver 96% annual energy produced ❱M  odular concept allows expansion
BATTERY BANK
by renewables upgrades

13
 Small Wind Energy Solutions

SYSTEM
TYPE:
WIND & SOLAR PV
HYBRID
TELECOMS
HYBRID SYSTEM

12,000kWh £19,000
AVERAGE ANNUAL OUTPUT ANNUAL SAVINGS COMPARED
FROM KW6 WIND TURBINE TO DIESEL*

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 KINGSPAN WIND
BUILT ON EXPERTISE

UNRIVALED
WIND ENERGY
SOLUTIONS

24/7
POWER
SUPPLY

SYSTEM
SPECIFICATION
THE CHALLENGE
Saudi Aramco required an additional energy source to power its RS10 telecom base station ❱K  ingspan KW6 (48V)
in Saudi Arabia. The base station was solely powered by solar photovoltaic (PV) panels; ❱S  olar PV Panels (6kW)
however, an additional energy source was required to provide extra power to supplement ❱D  C-DC charge controller
an increased load. ❱ 1 690Amp Battery Bank

The base station is in a remote location and is miles from a grid connection. It provides
a service to the public and therefore cannot be shut down for long periods of time.
The extreme climate in Saudi Arabia also demands an energy solution that works in all KEY COMPONENTS
weather conditions.

THE SOLUTION
To meet all the above requirements, the company opted for a battery charge Kingspan KW6 WIND TURBINE
wind turbine. The hybrid solution improved the availability, performance and reliability of
the power supplied. The extra energy production capabilities will also allow for an increase
in load in the future, without the need for any additional energy source.
The installation of the wind turbine provided a cost-effective alternative to a diesel CONTROLLER
generator that would have involved subsequent costly refueling trips and regular
maintenance. As the turbine and solar panels are producing more than required, the base
station always has a backup of energy.
The KW6 wind turbine was successfully installed in January 2005 as a battery charging SOLAR PV
configuration and has been 100% operational since. The turbine produces on average SYSTEM
12,000kWh of electricity annually which currently exceeds the base station’s requirements.

SYSTEM BENEFITS BATTERY BANK

❱2
 4/7 uninterrupted power supply
❱S
 upplies all electricity requirements of the base station
❱S
 ignificantly reduced running costs compared to diesel generator
(up to £19,000* per annum)
❱L
 ow maintenance costs

*at 0.25p per kWh of energy produced by a diesel generator, and including
refuelling trips and labour costs

15
 Small Wind Energy Solutions

SYSTEM
TYPES:
STAND ALONE,
HYBRID & MINI-GRID
RURAL
ELECTRIFICATION

90% 130
ELECTRICITY REQUIREMENTS KINGSPAN WIND TURBINES
SUPPLIED BY WIND TURBINES INSTALLED ON THE ISLANDS TO DATE

16
 KINGSPAN WIND
BUILT ON EXPERTISE

UNRIVALED
WIND ENERGY
SOLUTIONS
WORLD’S
LARGEST
OFF-GRID
FLEET

SYSTEMS UTILISED
STAND ALONE & HYBRID
THE CHALLENGE • Kingspan KW3 (24V)
March 1996 and an initiative to support the uptake of Off-Grid Renewable Energy has just • Kingspan KW3 (48V)
been initiated in one of the most remote areas of the world – The Falkland Islands, South • Kingspan KW6 (24V)
Atlantic. With a land mass covering 4,700 square miles and a population of over 2900, • Kingspan KW6 (48V)
Falkland Islands Development Corporation (FIDC) had a vision to introduce renewable MICRO-GRID
energy to support the economic growth within the rural community but more importantly • Kingspan KW6 (300V)
to ensure rural life on the islands could continue.
Residents on the Islands relied solely on diesel generators for power as there was no grid
KEY COMPONENTS
network available. The cost of transporting the diesel was unsustainable and damaging
to the sensitive environment on the islands.

THE SOLUTION WIND TURBINE

The potential for harnessing ‘small scale’ wind power was realised with a 50% grant made
available with funding through FIDC.
The initial concept tried a number of manufacturers, many of which were not capable of
withstanding the harsh weather regimes on the islands. After a 12 month pilot trial, FIDC CONTROLLER
opted for a reliable, robust and easily maintainable wind turbine, the Kingspan KW3. These
are available on tower heights from 6m to 20m.
21 years on from the first installation, Kingspan Wind continues to supply the 3kW and
6kW Small Turbines, most of which are stand-alone systems in 24V, 48V and 300V
configurations and have recently introduced micro-grids, designed to power remote villages INVERTER
and communities. These systems have integrated multiple 6kW turbines, utilising battery
storage and a back-up diesel generator for the very rare occasions the wind doesn’t blow.
90% of the rural population now has 24-hour power thanks to Kingspan Small Wind
Turbines! With over 130 turbines on the islands, Kingspan has what is believed to be the GRID INVERTER
largest off grid turbine fleet in the world. Our success in the Falklands is a great example
of what can be achieved with Small Wind and Rural Electrification.

SYSTEM BENEFITS BATTERY BANK

❱2
 4/7 uninterrupted power supply
❱9
 0% electricity requirements of the rural community supplied by wind turbines
❱S
 ignificantly reduced running costs compared to diesel generator
❱E
 liminates the need for expensive fuel deliveries to remote islands
❱L
 ow maintenance costs
❱E
 xcess power diverted to heat the homes

17
 Small Wind Energy Solutions

SYSTEM
TYPE:
WIND & SOLAR PV
MINI-GRID /
COLD SMART GRID

CLIMATE

1st -40°C
ZERO EMISSIONS POLAR OPERATING TEMPERATURE
RESEARCH STATION CAPABILITY

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 KINGSPAN WIND
BUILT ON EXPERTISE

UNRIVALED
WIND ENERGY
SOLUTIONS
POWER
SUPPLY
DOWN TO
-40°C

SYSTEM
SPECIFICATION
THE CHALLENGE
In such a remote region of the world, the costs of powering a scientific research facility ❱K
 ingspan KW6 x 9 (300V)
with diesel generators was simply not an option. This was not only due to the challenging ❱S
 olar PV Panels
logistics of diesel transportation but most importantly, to allow the scientific research ❱S
 olar Thermal Panels
facility to achieve a Zero Emissions status which was fundamental to its existence. ❱S
 MA Mini-Grid Inverters
❱R
 ectifier Protection Controller
Two of the most omnipresent features of Antarctic weather (during the Austral summer) ❱B
 attery Bank
are the wind and the sun. Two renewable sources that provide free energy to the “zero
emission” Princess Elisabeth Antarctica. KEY COMPONENTS
While the sun never sets in Antarctica for one half of the year, it never rises for the other
half. This means that, in order to function properly during the Antarctic winter, the Princess
Elisabeth Station needed a second source of energy that would be available all winter long.
WIND TURBINE
Coupled with the challenges of extreme winds and periods of no sunshine, the area also
required a technology that had the capability to withstand -40°C temperatures.

THE SOLUTION
CONTROLLER
The katabatic winds on the Antarctic continent provided the answer to the issue, as the
wind gusts from the plateau are as fierce in the winter as they are in the summer. With
these factors in mind, the most obvious solution was Kingspan.
9 x Kingspan KW6 were installed due to their ability to withstand the two most extreme
elements on Antarctica – high winds & cold climate. Ease of Installation and Low INVERTER
Maintenance were also key considerations in establishing the best fit for small scale wind
and an alternative energy source.
The energy-producing solutions implemented at the Princess Elisabeth Station are
incredibly efficient, so much so that solutions had to be foreseen for storage of any SOLAR PV
excess energy. SYSTEM
A room full of classic lead-acid batteries enables the station to store energy for times when
demand exceeds the current energy production.
In the future, the station’s engineering team plans to install hydrogen fuel cells as an
GRID INVERTER
additional intermediary backup system.

SYSTEM BENEFITS
❱C
 ontinuous power supply all year round BATTERY BANK
❱E
 nergy generation in all weather conditions - operational down to -40°C
❱S
 upplies all electricity requirements of the research station
❱S
 ignificantly reduced running costs compared to diesel generator
❱L
 ow maintenance costs SOLAR THERMAL
❱Z
 ero CO2 emissions energy system SYSTEM

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 Small Wind Energy Solutions

SYSTEM
TYPE:
WIND & SOLAR PV
HYBRID
OFFSHORE
& HAZARDOUS
ENVIRONMENTS

2-Year 96%
INTERVAL FOR SERVICING OPEX REDUCTION
REQUIREMENT

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 KINGSPAN WIND
BUILT ON EXPERTISE

UNRIVALED
WIND ENERGY
ONLY SOLUTIONS
ATEX
APPROVED
SMALL WIND
TURBINE

SYSTEM
SPECIFICATION
THE CHALLENGE
Unmanned Oil & Gas platforms require a source of energy to help power remote operations. ❱K  ingspan KW3EX (24V)
In most cases these platforms are powered by diesel generators which require almost ❱E  X-rated Solar PV Panels
constant maintenance and are subject to excessive corrosion as a result of the inclement ❱E  nclosed Charge Controller
weather conditions experienced offshore. ❱2  4V Battery Bank 3400 APMH
❱M  arinised Components
All refuelling and maintenance trips to these platforms are via helicopter or sea vessel ❱ INCONEL upgraded rotor control
which incurs significant costs and has the added complexity of requiring favourable weather
conditions to ensure safety is maintained at all times. These are all incredibly challenging
elements in ensuring a power source is available and maintained to guarantee ongoing
KEY COMPONENTS
operations.

THE SOLUTION
WIND TURBINE
Kingspan Wind has delivered the world’s first and only ATEX approved small wind turbine.
Our unique design ensures low maintenance (every 24 months) therefore reducing the
requirement for mobilisation to these unmanned platforms.
With Zone 2 Certification our EX approved KW3 is helping to establish safety alongside CONTROLLER
innovation in the Oil & Gas sector and other Hazardous Environments.
The integration of the EX approved wind and solar PV hybrid system will allow for
significant OPEX reduction by offsetting runtime of diesel generators which are expensive
to operate and maintain whilst at the same time providing a tried and tested source of SOLAR PV
renewable energy. Recent installations have demonstrated a 96% OPEX reduction, further SYSTEM
highlighting the capability of the Kingspan range.
This specialist system has been operating successfully in the North Sea for over a decade
and with an increasing portfolio around the world in the Oil & Gas sector, our ATEX
approved solutions are now being recognised as the leading alternative to diesel generators BATTERY BANK
in specialist sectors around the globe.
With the ability to reduce frequent visits via helicopter to these platforms some of these
Kingspan KW3EX installations have paid for themselves in less than 1 day when compared
to alternative generators and the methods required to operate and maintain them.

SYSTEM BENEFITS
❱A
 TEX approval
❱9
 6% OPEX reduction
❱S
 ervicing required only every 2 years
❱C
 ontinuous energy generation 24/7
❱R
 eliable, uninterrupted power supply, even in the harshest
weather conditions
❱L
 ow servicing requirements, which lowers the need for
dangerous and costly helicopter journeys
❱R
 educed running costs comparing to diesel generators

21
 Small Wind Energy Solutions

24/7
UNINTERRUPTED
POWER SUPPLY

BATTERY SELECTION

As with most forms of technology, one size does not fit all and in the case KEY FACTORS
of a battery system, where they are being used and most importantly the
rate of expected discharge are the most important factors to consider when There are various approaches to
selecting the best battery for your installation. what has been described as the
‘black art’ of battery selection, sizing
and design, although, there are some
BATTERY SIZING key considerations:

A battery has two main specifications: voltage and capacity. Multiplying these two ❱ Is the battery fit for purpose - rated
values will calculate the watt-hours of energy storage. for its duties?

Adding cells in series will allow you to build up to 12, 24, 48, 120 or any voltage. ❱D
 oes it have an adequate storage
capacity and cycle life?
Capacity is measured in Amp hours (Ah). A string of 800Ah cells makes a 800Ah
battery. More amp hours can be gained by connecting more strings in parallel. ❱ Is a sealed or vented battery more
appropriate for the particular
Your system designer will apply these basic principles when designing your off-grid installation?
system.
❱W
 ill the battery be made up of
series cells or parallel banks?
CHOOSING YOUR BATTERY All of these elements will be
There are typically three main types of battery that are used on renewable energy considered by your system
off grid systems – Lead Acid Battery, Lithium Ion Battery and Salt Water Battery. designer dependent on the needs
Alternative new designs are reaching the market and Kingspan advises that all of your application, location and
specifications should be considered depending on your location, system design and energy demand.
usage requirements.

For those who are entirely off grid, Kingspan recommends the following:
❱L
 ead acid battery
❱L
 ithium ion battery
❱S
 alt water battery

22
 KINGSPAN WIND
BUILT ON EXPERTISE

UNRIVALED
WIND ENERGY
SOLUTIONS

LEAD ACID BATTERY

A key factor to consider with a Lead Acid Battery is the deeper the battery gets
discharged on a daily basis, the less cycles it will achieve through its expected
lifespan. How to eliminate this concern and ensure you are getting the maximum
number of cycles and efficiency from the battery is to size the battery system so
that your average daily demand never takes the discharge below 50%. Where you
are using a Lead Acid Battery on a grid inverter system, the inverter will ensure the
discharge rate is maintained not to drop below this threshold.

Lead Acid remains the most cost effective as the capital investment is considerably
cheaper than an alternative battery.

LITHIUM ION BATTERY

The main benefit to Lithium Ion Batteries is their ability to discharge up to 100%
of the stated capacity which makes them a better option for those who have a high
or fast energy usage and the battery are likely to be discharged quickly.

An additional benefit is they are very low maintenance compared to an alternative

battery; however, the additional upfront capital cost is higher. A Lithium Ion battery
is lighter with less space required for housing.

SALT WATER BATTERY

A Salt Water Battery contains no heavy metals or toxic chemicals; they are also
non-flammable and non-explosive, making them amongst the safest in the world.
This type of battery is designed for stationary long-duration daily cycling applications
such as off grid, micro-grid and domestic applications.

They are easily connected in series or parallel. Wide operating temperature range
and a high cycle life are two of the main benefits of this type of battery.

Note: Examples given for illustration purposes only.

23
 Small Wind Energy Solutions

DESIGNED &
CERTIFIED TO THE
HIGHEST
STANDARDS

TOWERS

Kingspan recognises the integrity of supporting structures is as critical as

the wind turbines themselves, which is why our towers are designed and
classified to the highest standard available.
With a full range of hydraulic masts available from 6m to 20 heights, the location of
your project will establish which tower height is the most suitable for your application.
Kingspan recommends the highest tower height possible at your location, to ensure
optimum outputs are achieved. As the wind speed increases with height, consideration
should be made to ensure your wind turbine is free from surrounding obstructions and
is well exposed to the prevailing wind direction.

Hydraulic towers offer many benefits with the most obvious being the raising and
lowering of the turbine for servicing purposes is achieved over a shorter duration, 20 min.
therefore, minimising downtime for service inspections. The Kingspan wind turbines on RAISING &
hydraulic masts can be lowered and raised in as little as 20 minutes which ensures the
turbine can be serviced at ground level without the need for expensive cranes or plant
LOWERING TIME
equipment for both installation and servicing.

Our turbines are designed to Class 1 standards which guarantee the supporting
structure is as robust as the turbine itself.

24
 KINGSPAN WIND
BUILT ON EXPERTISE

UNRIVALED
WIND ENERGY
SOLUTIONS

FOUNDATIONS

Kingspan offer a variety of foundation designs, each of which is available

to support the integration of your turbine in all types of ground conditions.
Options available include:

❱ PAD FOUNDATION ❱ GROUND MOUNTED (AFS)

The most commonly used at 3.5m x 3.5m with a 0.8m depth. Commonly used in locations where digging or transportation of
Can be landscaped over once foundation has cured. Utilises a concrete isn’t possible. Also a practical solution for mobility and
reinforcing cage. relocation if required such as humanitarian aid or disaster relief.
Concrete Volume = 11.02m3
❱ ROCK ANCHOR
❱ ROOT FOUNDATION Can be designed to fit the needs of the application. Commonly
Popular in rural locations which can achieve a depth up to 3m. used in areas of high rock density or mountainous regions.
Can be landscaped over once foundation has cured. Utilises a
reinforcing cage.
Concrete Volume = 3.52m3

25
 Small Wind Energy Solutions

COMPLETE
SOLUTION
TO SUIT YOUR
PROJECT
ADDITIONAL SYSTEM
COMPONENTS

SOLAR PV
Solar Photovoltaics compliments Small Wind Turbines very well and in particular can
offer a seasonal back up benefit for periods of no wind or for applications that require
a full renewable hybrid solution – day and night.

Kingspan can supply Solar PV panels as part of a Hybrid Solution, which can be
designed into the off grid system at time of installation or as a retro-fit upgrade should
energy demand increase at site.

The recommended Solar PV panel will depend on your location and weather regime.
Your system designer will advise the best solution at the point of enquiry.

DIESEL GENERATORS
Whilst Kingspan specialise in off grid systems as an alternative to diesel generators,
in some cases a generator is required as a back-up power source to compliment a
renewable off grid system, typically, for the rare occasions there has been no wind
or where the battery has discharged beyond your load demand and until they have
re-charged.

The integration of a diesel generator is to provide back-up which is only required on

average 5% of the time when a hybrid system is sized appropriately to your load
demand requirements.

DATA LOGGING
Kingspan can tailor data logging and energy monitoring to the specific needs of any
project and specialise in the integration of remote telemetry for the purposes of
energy management, recording performance outputs, wind speed etc.

Dashboards to record all elements of performance characteristics can be customised

with alerts, charting and data comparison. In addition, Kingspan can integrate
anemometry with our data logging systems.

26
Contact us

If you need help in designing the most appropriate

off-grid energy solution for your needs, contact
our expert team today!

T: +44(0) 1560 486 570

E: wind@kingspan.com
Global Head Office
Wardhead Park, Stewarton
Ayrshire, Scotland KA3 5LH
Tel. +44(0) 1560 486 570
Email: wind@kingspan.com

www.kingspanwind.com