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  • How a Wind Farm is Born: Celada Fusion

    • Renewable energy
    Join the tour and discover step by step how a wind farm is built. Check out the video and picture gallery full of fascinating revelations about such a project, in this case Celada Fusion wind farm, helping us move the world without harming the planet.
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    The birth of a human being is the happy result of nine months of gestation and lots more of shared illusions, expectations and decisions. The supportive and enthusiastic collaboration of many family and friends is the best guarantee that everything will turn out fine. Something similar happens with a wind farm, only over a much longer period.

    In 2022, we commissioned the Celada Fusion wind farm in the region of Valles del Cerrato in Palencia (Spain). This was also the product of many years of study, procedures, discussions, reports and calculations to which was added 15 months of works until the newborn emerged, destined to help us move the world without damaging the planet. We have prepared the following picture gallery and video to record the most significant milestones during this journey, similar to that of many others we strive to create every day.

    Join the tour and discover step by step how a wind farm is built.

    • WHERE THE WIND LIVES

      The creation of a wind farm is conditioned by the existence of wind with sufficient intensity and frequency. For this, it is essential to have a large volume of prior data, measured over years, to be able to predict how much, when and in which direction it will blow over a certain location.

    • PROJECT ENGINEERING

      Based on an exhaustive prior knowledge of the wind resources and the rest of the physical and technical conditions of a site (access, connection to the electricity grid, geotechnics, etc.) the engineering project is drawn up describing in detail the features of the future facility.

    • SELECTING THE WIND TURBINES

      The wind turbine generators represent 70% of the investment in a wind farm. It is vital to select the best model for the conditions at each location. The close collaboration between ACCIONA Energía and Nordex, our preferred supplier, allows the design to be adapted and the performance optimized for each facility.

    • THE NACELLE, THE TURBINE HEART

      The nacelle houses the main components of the wind turbine generator, such as the power train, responsible for transmitting the energy produced by the turning blades to the generator which converts it into electricity. The model at Celada Fusion is a Nordex N149/4.8, the numbers referring to a 149-meter-diameter rotor with an output of 4.8 MW.

    • IMPORTANCE OF THE MATERIALS

      The blades capture the wind energy for the turbine generator. They are manufactured with glass or carbon fiber, impregnated with epoxy resin, materials which confer them with the ideal relationship between weight and flexibility in order to optimize their function. The N149/4.8 turbine blades each measure 72,9 meters in length.

    • BLADE MANUFACTURE, A SMITH’S TRADE

      The production of a wind turbine blade has a highly artisanal part to it. The glass fiber fabrics are stretched manually one by one over the molds with the care taken by a master smith.

    • MAGIC HAPPENS IN THE MOLD

      Once the manual assembly of the blade shells is complete, each of the blade faces are brought together in a mold. This is one of the most spectacular operations in the turbine blade manufacturing process.

    • AN IMPECCABLE FINISH

      Once the blade is assembled in the mold, it is subjected to a meticulous finishing process in which the surface is prepared for painting. After the painting process, the turbine blade will be readied for transporting to the wind farm, a huge logistical challenge.

    • TRANSPORT TO THE WIND FARM

      Transport of the turbine components requires the prior obtention of several permits due to the size of the task. The route is studied beforehand to detect any possible obstacles. During the mainly night-time journey, the load-carrying vehicles are escorted by an impressive convoy to ensure maximum safety.

    • THE LOGISTICAL CHALLENGE OF REACHING THE FACILITY

      Each turbine arrives at the wind farm in its separate components: sections of the tower, blades and nacelle. The delivery represents a significant challenge and has to be perfectly coordinated with the construction schedule. Before the turbines are installed, significant civil engineering works must be performed: preparation of the ground, foundations, cabling, etc.

    • THE TOWER RISES TO THE SKY

      The wind power tower, the column supporting a turbine, arrives at the facility in several sections. As such, it is necessary to assemble it in situ with the help of cranes that can reach the necessary height, 125 meters in the case of Celada Fusion.

    • ALOFT WITH THE NACELLE

      There are several procedures that have to be adhered to when installing the head of the wind turbine generator on the tower, depending on its size and weight. At Celada Fusion, the nacelle is raised first, then the power train, to be assembled at height. A labor of love that demands maximum technical rigor and an enormous degree of precision.

    • THE ARMS THAT THE WIND MOVES

      Once the nacelle is installed, the hub is raised and assembled. The hub is the component that joins the blades with the power train. After this, it only remains to hoist each of the blades and successively attached them to the faces on the hub.

    • COMMISSIONING

      Once the installation is finished, it will be time to connect the turbine to electrical control panels, internal cabling and the rest of the components needed to start up the machine. But many technical tests will still need to be performed before the plant is finally powered up.

    • PERSONNEL AND THEIR SAFETY

      The installation of a wind turbine generator is a task that requires qualified personnel with the highest technical level. People are always behind the most complex technical processes. Ensuring that they can carry out their work in the safest possible conditions comes before anything else.

    • A POSITIVE IMPACT ON SOCIETY AND THE PLANET

      A wind farm is a facility that aims to generate a positive impact on society and the planet. It produces clean energy that boosts development while contributing to halting global warming. The Celada Fusion Wind Farm has already produced, in just nine months, all the energy that was needed for its construction.

    • SOME DATA ABOUT CELADA FUSION

      And it will continue to produce energy for another 40 or 50 years! Every year this will avoid the emission of 60,000 tonnes of CO2 to the atmosphere, while the facility will supply clean electricity equivalent to demand from 27,000 homes. As a measure of the circular economy, ash from our biomass plant in Briviesca (Burgos, Spain) was used in the construction of the access roads to Celada Fusion.

    • The Celada Fusion Wind Farm has already produced, in just nine months, all the energy that was needed for its construction.

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