David Brown Wind Energy is a supplier of transmission solutions for renewable energy applications such as wind and tidal. It has over 150 years of experience designing critical solutions. It serves the wind, hydro, solar, and tidal renewable sectors globally. It has facilities and supply chains worldwide to support offshore wind customers. It is establishing itself as a trusted partner for offshore wind customers by offering innovative gearbox designs tailored for multi-MW turbines with a focus on reliability, maintainability, and lowest cost of energy. It has experience developing and deploying tidal energy solutions as well.

1. David Brown Wind Energy
Servicing the Supply Chain for
Offshore Environment
28th February 2012
Alfonso Garcia
Business Development Manager – Renewable Energy
agarcia@davidbrown.com
Company confidential © DB Gear Systems Limited 1

2. 150 Years of Assurance Critical Solutions
‘To provide customised transmission solutions for
applications where customers demand absolute assurance’
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3. Renewable Sectors Served
Wind Hydro
Solar Tidal
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4. A Worldwide Capability
UK France Eastern Europe
• Land defence transmissions • Renewables – wind, hydro • Sales office
• Naval applications • Rubber & tyre industries
• Renewables – wind, tidal • Cement, metals & mining
• High speed drives – oil & gas • Overhaul & upgrade
• Custom designed ‘low speed,
China JV
• Rail
high torque’ drives
• Renewables - wind
• Rail
USA
• Precision ‘double Indonesia
enveloping’ worm drive
• Sales Office
• Renewables - solar, wind
• Packaging/food & beverage
• Machine tools, medical and
high precision applications
• Mining, steel & energy
Chile Australia
• Mining • Overland conveyor &
• Service ,repair and Port handling
upgrade systems
• Mining
• Renewables – wind
• Power generation
(coal)
Brazil • Sugar processing
• Sales office South Africa Dubai • Service contracting
• Girth gear and mill drives • Oil & gas, power, metals, • Rail
• Mining cement, port handling India
• Power generation (coal) • Spares manufacture • Business & design centre
• Overhaul & upgrade programmes • Service, repair and • JV with Bharat Forge
• Heavy duty conveying systems upgrade
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5. Products & Services
David Brown Gear Systems Product Groups
Renewable Industrial Industrial Land & Naval
Energy Engineered Aftermarket Defence
Product
Wind Mill Drives & Girth Specialist Spares Tracked/wheeled
Gears transmission New
Build
Tidal High Speed & Rail High Integrity Repair Tracked transmission
& Overhaul upgrade programmes
Solar Low Speed, High Site Services High Integrity Naval
Torque Drives
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6. Wind Energy – Activities & Progress
Since 2009…
• Aftermarket Services – Globally
 European repair contract with Vestas
 25% UK market share in gearbox services
 UK Wind Service & Upgrade Research Facility announced
 Wind Service operating on 5 continents
• New Build Onshore – Joint Venture, China
 1.5MW gearbox in production, 3MW in development
 State-of-the-art manufacturing facility with 550 staff
• New Build Offshore
 Selected as gearbox partner for 2 Wind Turbine OEM
Programmes for UK Round 3
 Product development 7-10MW
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7. Wind Research & Development
• Existing technology – Total Life Cost • Gearbox Bearing Technology
• Condition Monitoring • Permanent Magnet / Hybrid Technology
• Wave Energy
Feasibility analysis for geared solutions.
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8. Offshore Wind – A New Challenge
• New paradigm - Offshore wind is a different
challenge to onshore
– New entrants can take a leading role
• Offshore wind demands new & innovative
thinking
– Environment is harsh – safety considerations
are paramount
– Development costs are very high – a
different model for investment is required
– Operators need to know that their turbines
are reliable - exacting testing standards are
required
– Deployment is challenging – standardisation
& simplified logistics required
– Reactive offshore maintenance is expensive
& prohibitive
– Planned interventions require predictive
technology
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9. Imperative for change
Existing GBX performance
• Most of the problems with the current fleet of wind turbine gearboxes
are generic in nature, meaning that the problems are not specific to
a single gear manufacturer or turbine model. Over the years, most
wind turbine gearbox designs have converged to a similar
architecture with only a few exceptions. (*)
• The majority of wind turbine gearbox failures appear to initiate in the
bearings. (*)
• Problems that manifested themselves in the earlier 500kW to
1000kW, still exist in many of the larger 1 to 2 MW gearboxes being
built today with the same architecture. (*)
• Many of the gearbox problems are the direct result of institutional
barriers that hinder communication and feedback during the design,
operation, and maintenance of turbines. Hence, a collaborative is
needed to bring together the various portions of the design process,
and to share information needed to address the problems.
(*) Musial W., and Butterfield S. “Improving Wind Turbine Gearbox Reliability “. National Renewable Energy Laboratory , 2007
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10. Imperative for change
Existing offerings in the market
• Normally, GBXs are manufactured in different facilities and locations.
Then, they are sent Nacelle assembly plant.
• Existing fix warranty periods for WTG components (normally 2 years).
• Maintenance is currently done by WTG manufacturers. Wind Turbine
technicians basically perform simple visual inspections every six
months. Lack of GBXs specialists on site.
• There are sporadic GBX assistances on site, performed by GBX
manufacturers, when it is specifically required by WTG manufacturers
or wind farm owners.
• When a GBX is damaged, it must be replaced completely in most of the
times.
• Condition Monitoring Systems are rarely installed and, in those cases
where it is, there is not a proper data analysis performed by operators
at the remote control centre. Lack of knowledge.
• GBX manufactures are reluctant to share data about performance and
failure analysis.
• Reactive response way of working with WTG OEMs and final users.
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11. David Brown approach to Offshore
‘Assured’ UK Gearbox Design & Supply Chain Partner to
OEM’s looking to UK Round 3 development:
• UK presence & established supply chain. David
Brown is the only British company with the know-how &
immediate capability to engineer, source, handle,
manufacture & assemble the large components and
functionally test very large MW gear units.
• Product Innovation. Modular design for reliability and in
nacelle maintenance. Gearbox flexible designs for 6 to
10MW wind turbine generators. Scope includes design,
verification, manufacture and testing
• Rapid Prototyping capability. Already prepared to meet
2012/13 Demonstrator sites.
• High degree of engineering capability. DB has a long
history in delivering mission critical solutions where the
consequences of failure are extremely high; defence,
marine, airspace and offshore oil & gas.
• Willing to invest in the necessary facilities/assets.
Company confidential © DB Gear Systems Limited 11 11

12. Technical differentiation for assurance
Discrete,
Planet gear & 2ndstage
All removable 1st
stage integrated rotor
flexpin assembly annulus components annulus bearings
<10T
2nd stage
sun pinion
shaft
1st stage sun
pinion shaft
Individual planet gears
1st stage carrier & fixed & flexpin assemblies
2nd stage carrier & fixed
pin assembly pin assembly
MANTAINABILITY DIFERENTATION
Example of Wind Gearbox that can be completely disassembled from downwind end
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13. Tidal Energy
• In December 2011, the 1MW Hammerfest Strøm
HS1000 tidal turbine (1 MW) was successfully
deployed in the North Sea, signaling a major step
forward for the global marine renewable energy
industry.
• The HS1000 tidal turbine is fitted with a three
stage David Brown gearbox which was designed,
manufactured and tested at our Huddersfield
facility and delivered in April last year.
• Following successful load testing, the turbine was
installed at the European Marine Energy Centre
(EMEC) in Orkney. The HS1000 device will now
enter a test period to confirm its performance and
reliability, in preparation for larger scale production
and deployment.
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14. David Brown Summary
• David Brown is rapidly establishing itself as a trusted Supply Partner
in Renewable Energy
• R&D programmes give significant innovation in products and services
• Collaborative approach ensures OEMs get a gearbox specifically
designed for multi MW wind turbine applications with lowest cost of
energy
– Reduced transmission weight and length from structurally efficient
architecture
– High reliability from reduced component count
– Innovative design for up-tower maintenance
• Global supply chain in place for multi MW gearbox components
• Facilities in the UK and China and supply chain investments make it an
ideal partner for supplying the Northern European and Asian Markets
– Wind
– Tidal
– Any other technical solution (Waves)
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15. Thank you for your
time and kind
attention
Company confidential © DB Gear Systems Limited 15