On November 28, 2006, TECO-Westinghouse Motor Company andDeWind, a European wind turbine manufacturer, signed a StrategicAlliance. This Alliance designatedthat TWMC’s Round Rock facilitywould be responsible for theassembly of DeWind’s wind tur-bine design in North America.

DeWind’s D8.2 wind turbine, a2.0 megawatt wind turbine, posesa significant advancement in tur-bine capabilities. TWMC’sPresident, Dr. H.C. Meng, explained, “For scale purposes, a 2.0 MW tur-bine is twice as large as serial production turbines manufactured just tenyears ago. The blade diameter (80 meters) is larger than a Boeing 747 air-craft.”

Dr. Meng added, “Although the D8.2 is new to the North American mar-ket, it has already attracted the attention of most major developers andusers.”

TORQUE REPORTINSIDE THIS ISSUE:INSIDE THIS ISSUE:

TORQUE REPORT 1

* US Navy Admiral Letter (Cont.) page 2 * New Product Release page 3* Round Rock Factory Ships Ball Mill Order page 3* TWMC Powers Local Semiconductor Facility page 3* TWMC Refurbishes Motors for Largest Mine page 4* TWMC Welcomes New Design Center Director page 4* TWMC Repairs MG Sets for Draglines page 4* More Horsepower for Steel page 5* Drivers in the Desert (Cont.) page 5* Wind Turbine Components (Cont.) page 5 * TWMC Hosts EPRI Seminar page 6

TORQUE REPORTOCTOBEROCTOBER 20072007

Getting WWindy: TTWWMMCC RRoouunndd RRoocckk FFaacciilliittyyttoo MMaannuuffaaccttuurree WWiinndd TTuurrbbiinnee CCoommppoonneennttss bbyy 44tthhQQuuaarrtteerr,, 22000077

The USS Enterprise (CVN-65), first commis-sioned in 1961, is the world's first nuclear-pow-ered aircraft carrier and longest naval vessel inthe world. The Enterprise, or the "Big E," is theeighth naval vessel in history to bear its nameand has an extensive military history, providingsupport in the Cuban Missile Crisis and theVietnam War. Most recently, the USSEnterprise was instrumental in providing airsupport to Operation Iraqi Freedom.In November of 2006, a coolant motor genera-

tor (#8) onboard the Enterprise began experi-encing a reduced voltage output. Unable to berepaired, a replacement CMG was ordered andinstalled in December, and final testing andacceptance were scheduled for January 2007.

USS Enterprise AdmiralCommends TWMC

Engineers

The USS Enterprise (CVN-65) is the eighth Navy shipto bear the Enterprise name and is the longest navalvessel in the world.

“Windy”continued on Page 5

“Admiral”continued on Page 2

Recent studies have revealed popula-tion increases along the Southwesternpart of the United States. According toU.S. Census Bureau figures, Arizonais the 2nd fastest growing state in thecountry with an estimated annualgrowth of 2.5% between the year2000 and 2030.

Such population shifts have a con-siderable impact on the demand foreveryday goods and services. Refinedproduct capacity is essential as newvehicles, with lower mpg, are added tothe streets along with heavy jet fuelconsumption at airports. To meet this demand, Kinder Morgan added 66 milesof 12" pipeline in Arizona, from Tucson to Phoenix, along with 160 miles oflooped 16" pipeline from El Paso, Texas to Tucson. These additions lead tocapacity increases from 70% to 100% Mbbls/d.

These seven 2500 HP induction motors drivingpipeline pumps provide additional refinedproduct capacity to the southwestern part ofthe United States.

New Demand Requires Driversin the Desert

“Drivers”continued on Page 5

TORQUE REPORT2

Editorial Statement: “Torque Report” is a periodical publication of TECO-Westinghouse Motor Company. Its editorial mission is to inform our readership in the areas of motor application industries,as well as business and world affairs that have an impact on our mutual concerns. Comments, inquiries and suggestions should be directed to: Torque Report, TECO-Westinghouse Motor Company,

5100 N. IH-35, Round Rock, TX 78681 USA. Phone: 1-800-451-8798. FAX: 512-244-5512. E-mail: torquereport@tecowestinghouse.com. Website: www.tecowestinghouse.com.

TWMC Acknowledged by US NavyAdmiral K.H. Donald

Before this testing could begin, the space containing twocoolant motor generators (#8 and #7) and an emergency dieselgenerator was inadvertently flooded. A TECO-WestinghouseService Engineer was sent to conduct extensive visual and elec-trical inspections of both motor generators.

It was quickly determined that the recently replaced CMG #8could be repaired, while CMG #7, an older unit, was too badlydamaged and would need to be replaced. Given the "Big E's"deployment schedule, the need for rapid turnaround was consid-erable.

TWMC engineers had to think and act quickly. It was decid-ed that the repairable unit (CMG #8) would be disassembledfrom its foundation and refurbished, as much as was practical, inthe space. The induction motor, induction rotor, DC exciter,synchronous rotor and synchronous stator were "cleaned andbaked." This CMG, once serviced, would replace CMG #7, whilea reconditioned unit (shipped from the TWMC factory) wouldserve as the new CMG #8. Once CMG #7 was disassembled andremoved from the space, the restored CMG #8 was installed inplace and tested. When the second unit arrived, it was reassem-bled in the space under the direct supervision of the TWMCengineer. Both units tested satisfactorily in February 2006.

The Enterprise was once again returned to workingorder. In response to the quick and successful action taken byTWMC, Admiral K.H. Donald of the US Navy, sent the follow-ing letter of commendation to Richard Fesmire, Director ofOperations, thanking all TWMC engineers and employeesinvolved in the project:

Mr. Richard Fesmire,

Your recent assistance in returning the USS Enterprise(CVN 65) to sea is greatly appreciated. The emergentneed to quickly replace one coolant motor generator

(CMG) and repair another was daunting, but the can-doattitude and flexibility of TECO personnel made all the

difference.

TECO's rapid acceleration of CMG inspection and refur-bishment efforts, as well as expert on-site repair, in sup-

port of this unplanned work exemplifies the Americanspirit. The Nation is fortunate to have such dedicated

employees supporting the Armed Forces. Please pass mythanks on to every TECO employee who contributed to

this success.

As we say in the Navy, Bravo Zulu - Well done!!

Sincerely,Admiral K. H. Donald

On May 4, 2007, TECO-Westinghouse Motor Companywas pleased to welcome two new members to itsLonghorn family. Willie andWinchester, both registeredTexas Longhorn steers, arrived attheir new home, in Round Rock,Texas, from the C&W Ranch inLampasas.

They can beseen in thefront pastureat the TECO-Westinghousefacility inRound Rock. Willie, 7 year old Longhorn steer

Winchester, 18 monthold Longhorn steer

New Longhorns Call TWMC Home

IP

Visually inspect all sleeve type bearingsduring routine motor service. The wearpattern between the shaft journal and bear-ing bore should measure at least 80% andthere should be no pitting or rusting onthese surfaces.

T E C O

TWMC distributor, Precision Drive and Control, suppliesTECO motor spares to the Ethanol Industry.

Badger State Ethanol, a premier Ethanol processing plant inWisconsin, receives TECO parts from Precision Drive andControl.

Ethanol:A Growing Industry

“Admiral” Continued from Page 1

TORQUE REPORT 3

TECO-Westinghouse has recently expanded itsAC Drives Product Line to include the EV andthe N3 series AC Drives.

The EV AC Drive is a din rail mountablemicro drive that is per-fect for OEM's thatpackage individual ormultiple lower HP ACdrives in a commonenclosure. The EV isavailable in 115V,230V, and 460V rat-ings from .25-3 HPwith dedicated singlephase and three phaseinput models. In addi-tion, the EV includes expanded features such asPID control, 8 preset speeds and a multi-functionanalog input/output.

The N3 AC Drive is a general purpose ACDrive designed to meetthe requirements ofmost constant and vari-able torque applica-tions. The PID controland sleep mode featureof the N3 makes thisAC drive a perfect fitfor fan and pumpapplications. Otherfeatures that make theN3 extremely flexibleare the keypad mounted speed potentiometer,configurable multi-functional digital and analoginput/outputs, and an optional LCD keypad thatallows the user to view programming parametersin English. The N3 is available in 230V ratingsfrom .5 - 40 HP and in 460V ratings from 1 - 75HP.

Many additional options are available for boththe EV and N3 series AC drives, including aremovable parameter copy unit, RS232 andRS485 communication interfaces, and the TECOLink programming software tool that allows theusers to configure programming paramaters,record trends, and set up PID control via a per-sonal computer.

Many industrial manufacturingfacilities employ circulating waterpumps to control indoor tempera-ture. Due to its higher density, watercan transmit heat over greater dis-tances with much less volumetricflow than air. Likewise, water has ahigher specific heat capacity andmore thermal conductivity than air,both of which reduce theamount of energy needed topower such a system.Cooling towers areoften used in conjunc-tion with these circu-lating water pumps tocool and re-circulatewater, while ejecting evapo-rated air into the atmosphere,reducing the facility's water andenergy consumption.

In November of last year, TWMCsupplied a number of Global-HDTEFC medium voltage motors and

Global-Plus TEFC NEMA PremiumEfficiency motors to TWMCDistributor, Advanced MechanicalSystems (AMS) in San Antonio foruse on their customer's circulatingwater pumps. Additionally, TWMCsold several Max- E2 NEMAPremium Efficiency motors, withmodified space heaters, to

Composite CoolingSolutions in Ft. Worth,

Texas. All motorswere then sold tothe same end-user,a semiconductor

manufacturer inAustin. The cus-

tomer, an importantcontributor to Austin's tech-

nology sector, has recently expandedthe size of its facility, which nowhouses many large cooling towersthat support these circulating waterpumps.

TWMC Provides Local Semi-Conductor Facility with Power

The Atacama Desert in Chile has one of the driest climates on Earth, expe-riencing an average rainfall of around 1 mm per year. As a result, the Atacamais rich in mineral deposits, including the world's largest natural supply of sodi-um nitrate. However, the desert’s climate and extremely high altitude providenumerous hurdles for mining.

Given these conditions, especially with regard to the grinding technologiesused in mining, motors employed must perform to very high standards. Of pri-mary importance is the capability of the motor to consume less energy, adaptto high altitude, and maintain constant speeds. Synchronous motors havecome to represent an effective means for controlling these factors, from man-aging currents to reducing slips and improving power factors in all miningapplications. Large synchronous motors are now the flagship motors for theMining Industry.

TECO-Westinghouse in Round Rock,Texas has recently completed produc-tion on two synchronous motors for aball mill OEM, whose customer's largeiron ore mine is located in the AtacamaDesert. These 111 frame, slow-speed(200 RPM), synchronous motors arrivedat the facility in February of 2007.

The two motors, both 5000 HP, repre-sent the Round Rock facility's capabilityto manufacture large synchronous millmotors to support the mining industry.

Round Rock Factory Ships OEM Orderfor Ball Mill Application

New Product Release:

TWMC Product Spotlight

In April of 2007, TWMC announced that David D.Parkinson would be the company’s Design Center Director.

David joins TWMC after a distinguished military and civil-ian career, holding positions from Senior Mechanical Engineerto Senior Vice President for leading companies in the rotatingmachinery industry. Additionally, David brings to TWMCadded experience gained during his parallel 28 year career as asenior officer in the Army Corps of Engineers.

In a recent “All Hands” meeting at TWMC, David elaborat-ed upon his vision for the Design Center and what his initialfocus will be. He stated “The TWMC Design Center acts as abridge between the front room (Sales and Marketing) and theback room (Operations and Sourcing). In professionally exe-cuting this function, the Design Center must be attentive,responsive, predictable, and globally-integrated as it supportsboth internal and external customers alike.”

He further stated that “it’s imperative that the Design Centerprovide the most competent and cost-effective solutions thefirst time, every time. This can only be accomplished by trulylistening to the customer and then developing the internal dis-cipline to efficiently meet customer needs.”

Additonally, David asserts, “Our primary initial goals are toimprove on-time delivery of services, minimizing errors, stan-

dardizing docu-mentation andprocedures, andexpanding para-metric designprinciples. Theenablers ofachieving andexceeding thesegoals will be theutilization ofcross-functionalteaming, theunderstanding and adoption of lean principles, and the empow-erment of personnel through the use of continuous improve-ment methodology.”

Long term, David envisions the TWMC Design Center lead-ing the charge toward global standards for product design andsourcing within TECO. He believes that global incorporationof “best practices” when coupled with an integrated sourcingnetwork is the key to cost effective design. David also sees anexpanded role for the Design Center in the strategic planningprocess of TWMC as it continues to diversify and to grow.

TORQUE REPORT4

Colonel (Ret.) David Parkinson brings grand vision forTWMC’s future as new Design Center Director.

New Director for TWMC Design Center

TWMC recently completed repair on the first ofseven 5500 HP, 180 RPM, 13,200 Volt synchronousmotors for Kennecott Utah Copper Corporation, amining, smelting, and refining company, whoseBingham Canyon Mine is considered the largestman-made excavation site in the world. All sevenof these large, 40 pole motors were originally man-ufactured at the Round Rock plant in 1986. Eachmotor will be serviced using the manufacturer'soriginal design schematics, reducing delivery timeand ensuringthe compati-bility of theupgrade andrepair.

Kennecottplans to haveT W M Crepair 1-2motors peryear, one at atime, until allseven motors are refurbished. The first of thesemotors shipped from Round Rock in April of thisyear. The next of these large synchronous motors iscurrently in house at TWMC.

This 40 pole synchronous motor isthe first of seven large motors thatwill be repaired for the BinghamCanyon Mine, the largest man-made excavation site in the world.

TWMC to Completely Refurbish Motors for Largest Man-MMade Mine

For nearly 100 years, Bucyrus has been a leading manufacturer ofdragline excavation equipment, introducing the first crawler mounteddragline, the "Class 14," in 1911. Today, Bucyrus continues to developadvanced excavation technologies and participate in some of the largestexcavation projects around the world. In late 2006, TWMC performed acomplete overhaul of two dragline motor generator sets for BucyrusInternational.

The MG sets were built at the Round Rock facility in the mid-1980'sand were in operation for nearly twenty years. Each motor generator setwas composed of six DC generators and one synchronous motor. EachDC generator's armature was completely rebuilt with new commutatorsand windings by the team at TWMC. In addition, the synchronous motorunits required both their respective stators and rotors be refurbished.

TWMC, as the original manufacturer of these MG sets, was in a uniqueposition to provide timely, cost-effective service and repair. Once com-pleted, a TWMC a fieldservice Engineer accompa-nied the MG sets toTurkey, overseeing theinstallation and startup ofthe equipment. The cus-tomer reports that bothmotor generator sets havebeen running without inci-dent since their installa-tion.

TWMC Repairs Motor Generator Sets forDragline Excavation Systems

TWMC recently received a large order from TATASteel for the upgrade of their Hot Strip Mill at theJamshedpur, India works.

With the completion of the order, the main drivemotors in the mill will produce a total of over 62,000combined HP. These, and other, changes will al lowthe mill to efficiently roll out the latest materials atan increased production rate.

Tata Steel, the first private Iron and Steel Companyin India, began production in Jamshedpur, India in1907. This plant remains the largest in Jamshedpurand accounts for a significant portion of the compa-ny's annual steel production. Westinghouse ElectricCorporation supplied the main drive motors for theoriginal mill and TECO-Westinghouse has continuedto provide main drive motors to new TATA Steel millsadded over the years.

In the early 1990's, a new Hot Strip Mill was builta t the complex in Jamshedpur, u t i l i z ing TECO-Westinghouse main drive motors built at the TWMCfacili ty in Round Rock, Texas. The HSM was original-ly designed for one mill ion tons/year of steel output.

R e f i n e m e n t swere made in1995 tha tinc luded theaddit ion of as ix th f in i sh-ing stand anddown coi le r,as well as theupgrade of thea u t o m a t i o nsystem. These changes doubled steel coil productioncapabili t ies.

Additional upgrades to the automation system,motor cooling refinements, and better maintenancepractices, among other things, resulted in the presentproduction rate of three t imes the original mill design.All of these production gains were made while st i l luti l izing the existing TWMC main drive DC motors.

Additionally, TWMC has continued to provided tech-nical guidance over the years to help make the millmore productive.

TORQUE REPORT 5

TWMC Provides More Horsepower for Steel

To move this product along, the pipeline pump stations with elec-tric motors, are generally added every 30 to 60 miles. For this proj-ect, (7) 2500 HP, 3600 RPM, dual voltage, squirrel cage inductionmotors were selected by the client. These motors were uniquebecause the user specified that the motors be designed to meet allpresent needs, as well as any future conditions. For example,although these motors were used in a constant speed application forthis project, the client requested "stiff-shaft" rotors in the event vari-able frequency drives were ever added to the system in the future.Furthermore, the motors were designed to start the pumps with anopen discharge valve while using a reduced auto-transformer starterwith only 65% terminal voltage. This was specified because olderlines and stations com-monly used auto-trans-formers as a method forreducing the inrush cur-rent during starting. Ifthe motors were relocat-ed to an existing loca-tion, the new motorswould be capable ofstarting the pump. Additonally, the motors were designed to function despite environ-mental conditions. As a portion of the pipeline is located in Arizona,the motors were constructed to perform at 4000 feet ASL, which is700 feet above standard elevation. Likewise, as the motors will besubjected to extreme changes in temperature, the design of themotors included specific features that make them suitable for manyconditions.

Drivers in the Desert MeetsIncreased Demand

According to the terms ofthe Alliance, TWMC willmanufacture both the nacelleand hub components for theD8.2. As the nacelle alonehouses 90% of turbine com-ponents, the construction ofboth the nacelle and the hubat the Round Rock facilityrepresents a significant por-tion of the manufacturingprocess.

Currently, the "D-Aisle" inTWMC's Round Rock facto-ry is being modified tobecome a state-of-the-artcell-based assembly line,which can be configured toproduce anywhere from onenacelle/hub per week to onenacelle/hub per day. “Theability to secure components(which we call supply-chainmanagement) will drive pro-duction output," said TWMCPresident Dr. H.C. Meng.“Based on the supply-chaincurrently in place, the first

units will ship from theRound Rock factory in 4thQuarter, 2007.”

Dr. Meng believes thisalliance will change thefuture of the wind turbinelandscape. “By combiningDeWind's design, jointTWMC and DeWind R&Defforts, and a successfulO&M joint venture,” Dr.Meng stated, “we believethere is no limit to what canbe accomplished."

Round Rock Facility toManufacture Wind TurbineComponents

“Drivers”continued from Page 1

“Windy”continued from Page 1

TTORQUEORQUE RREPORTEPORTOCTOBER 2007OCTOBER 2007

5100 N. IH-35Round Rock, TX 78681

1-800-451-8798

If you are interested in receiving futureissues of TTORQUEORQUE RREPORTEPORT, please visit

www.tecowestinghouse.com/torquereport.htmor send an e-mail to

torquereport@tecowestinghouse.com.

Watch for the TECO-Westinghouse Motor

Company Ethanol Ad in:

Ethanol Producer Magazineand

Ethanol Today Magazine

The EPRI Motor/Generator Rewind Seminar, hosted by TECO-Westinghouse MotorCompany, in conjunction with Electric Power Research Institute and JarscoEngineering Corporation, was held, for the fourth consecutive year, at the TWMC

facility in Round Rock, Texas. With fifty-fourattendees, this year’s three-and-a-half dayseminar was the largest to date.

Instructors Jim Oliver, Jim Michalec,Riccardo Covarrubias, and Elton Floyd ledthe seminar, covering many aspects of motorand generator repair and rewind, includinginduction motor design fundamentals, statorwinding insulation systems, stator coil com-ponents, coil manufacturing, motor efficien-cy, and much more. Designed to provideextensive information regarding motor orgenerator repairs and rewinds, this seminarattracted representatives from companiesacross the globe, including Voith-SiemensHydro, GenerationMayer Electric Supply,P&H Mine Pro Services, Tampa ArmatureWorks, Georgia Power Company, FMCCorp, Generating Authority of Thailand,NRG Texas, Precision Electric Coil, andmany others.

On Wednesday, TWMC employees led aguided tour of the 500,000 square foot motor and generator manufacturing and repairfacility. Likewise, several TWMC engineers and technicians gave presentations andfielded technical questions from seminar attendees.

According to the instructors and attendees, this year’s Motor/Generator RewindSeminar was a tremendous success.

EPRI Motor/Generator Rewind SeminarReaches Record Attendance

TWMC’s David Briggs and Brian Kruse(top) take EPRI attendees on a tour ofthe TWMC Round Rock facility. (Bottom) A class photo includes all 54attendees and three instructors.