GE Renewable Energy and Keystone Tower Systems have installed a commercial spiral-welded wind tower on a GE turbine.
The installation for the 2.8MW turbine is the result of a multi-year collaboration between Keystone and GE to design and produce spiral-welded towers for GE wind turbines.
The tower was manufactured at Keystone’s factory in Pampa, Texas, located in the Texas Panhandle.
The brownfield factory was built at an idled facility that formerly made drilling equipment for the oil and gas industry and will ultimately bring back nearly 200 manufacturing jobs to the region.
When at full capacity the factory will be capable of producing approximately 1GW of towers per year.
This increase in domestic manufacturing capacity is coming online at a critical time with a significant expansion in need for wind turbine components driven by the passage of the Inflation Reduction Act.
Keystone’s tapered spiral welding process brings the speed, quality, and consistency of automated manufacturing to wind tower manufacturing.
Keystone designs and builds its own custom spiral welding manufacturing equipment.
The manufacturing process is designed to use coil steel, enabling a new segment of highly efficient domestic steel mills to supply into the wind industry.
While this first factory is in a fixed location, Keystone is also developing mobile factories capable of building taller towers directly at the wind site, as detailed in the US Department of Energy’s May 2022 publication, “How Spiral Welding is Revolutionizing Wind Turbine Manufacturing.”
Keystone is now ramping up production of spiral welded towers, with additional deliveries targeted for early 2023.
The first product is an 89-metre tall spiral welded tower for the GE 2.8-127 turbine, designed to be used interchangeably with GE’s conventional 89 metre tall tower.
The spiral tower has received a component certification from TÜV NORD for a 40-year lifetime. Keystone and GE have also collaborated on a tower design for the GE’s 3MW turbine platform and have signed a multi-year supply agreement for spiral towers from Keystone’s Pampa factory.
“This is the culmination of a dream we had to bring advanced manufacturing to the tower industry to help drive down the cost of wind energy and expand where wind is competitive into new regions,” said Eric Smith, Keystone’s co-founder and CTO.
“I’m very proud of the years of hard work our team has invested in developing and scaling up tapered spiral welding.”