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Blade Assets – Extend Life and Reduce Risks with Proactive Maintenance

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This webinar will provide information on important steps you can take to implement a proactive blade maintenance program. Preventative maintenance and operations programs not only protect wind assets, they improve energy production and boost profitability.

Semi-Technical to technical professionals or anyone evaluating wind turbine blade asset management should attend. .

Business titles can include:

Structural Engineer
Asset Manager
Operations Manager/Director
Operations & Maintenance Manager/ Director
Corporate Purchasing Managers/Directors
What You'll Learn:

Overview of fundamental steps you can take to dramatically increase the lifecycle of blades and reduce down-time
Best practices for maintaining and enhancing blade performance and longevity
Critical questions all asset managers should ask themselves when considering benefits of proactive maintenance and operations programs to reduce costs

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Blade Assets – Extend Life and Reduce Risks with Proactive Maintenance

  1. 1. Blade Assets – Extend Life and Reduce Risks with Proactive Maintenance
  2. 2. Before We Start q  This webinar will be available at www.windpowerengineering.com & email q  Q&A at the end of the presentation q  Hashtag for this webinar: #WindWebinar
  3. 3. Moderator Presenter Paul Dvorak Windpower Engineering & Development Aaron Wahlstrom Broadwind Energy
  4. 4. © 2015 Broadwind Services, LLC All rights reserved. BLADE ASSETS – EXTEND LIFE AND REDUCE RISK WITH PROACTIVE MAINTENANCE
  5. 5. Our key topics §  Important steps you can take to implement a proactive blade maintenance program §  Dramatically increase the lifecycle of blades and reduce down time §  Common blade issues for all makes and models. §  Importance of routine blade inspections to identify issues early §  How impaired blades impact WTG reliability and performance §  Comparison of leading edge protection solutions Thinking  like  a  wind  farm  owner,  acting  as  your  partner. © 2015 Broadwind Services, LLC All rights reserved.
  6. 6. §  Most  comprehensive  proactive  GBX   maintenance  program §  Borescope  inspection §  4-­‐‑phase  oil  change §  Patent  pending  MW  class  GBX   rebuilds  executed  entirely  up-­‐‑ tower §  3-­‐‑year  rebuild  warranty We are the largest non-routine ISP in North America §  BladeHD  -­‐‑  a  stunning  full  profile  map   of  suspect  areas       §  BladenaTM  -­‐‑  strategic  alliance  to  install   D-­‐‑stringTM  technology       §  OEM  factory  support  &  authorized   service  provider           © 2015 Broadwind Services, LLC All rights reserved.
  7. 7. Awareness of blade damage is increasing © 2015 Broadwind Services, LLC All rights reserved.
  8. 8. Panel Breathing Induced by Gravity Trailing  edge  panel  breathing  induced  by   gravity  introduces  peeling  stresses  in  the     bond  lines Breathing  and  peeling  stresses  are  the  root   cause  for  cracks  in  the  trailing  edge  region  in   the  max  chord  area © 2015 Broadwind Services, LLC All rights reserved.
  9. 9. Turbines and blades are getting bigger! Gravity  forces  on  blades  are  cyclic §  Pull  down  as  the  blade  is  on  the  way  down §  Pull  in  the  opposite  direction  on  the  way  up This  causes  ‘breathing’ …  independent  of  wind  forces Blade  length  L:  from  20  m  to  ~100  m Gravity  forces  increase  with  L3 Bending  moment  increases  with  L4 e.g.  for  a  60  m  blade: §  Gravity  forces  are  27x  larger §  Bending  moment  is  81x  larger            …  than  for  a  20  m  blade  and              for  a  100  m  blade:  125x  /  625x Bigger  blades  =  more  risk © 2015 Broadwind Services, LLC All rights reserved.
  10. 10. Stronger blades – more energy Typical  12  D-­‐‑Strings  installed  in  max  chord  area Without   D-­‐‑Strings® installed With   D-­‐‑Strings® installed Red  =  high  peeling  stresses Blue  =  low  peeling  stresses   Damages  typically  seen  due  to  trailing  edge  panel  breathing  –  Eliminated  by  D-­‐‑String® Transverse  cracks  in  the   trailing  edge  panel Hairline  cracks  in the  trailing  edge Longitudinal  cracks  along the  bond  lines Peeling  stresses  removed  by  D-­‐‑String®
  11. 11. Simply stop breathing Blade  panel  deformations  induced  by  edgewise   gravity  loads  causes  panel  breathing Without     D-­‐‑Strings With   D-­‐‑Strings >D-­‐‑StringTM  –  simply  effective!
  12. 12. Identify issues early §  Prevent cosmetic issues from spiraling into structural damage §  Perform proactive planned maintenance at a fraction of the cost of blade replacement §  Reduce unscheduled maintenance costs §  Avoid media, insurance and community scrutiny © 2015 Broadwind Services, LLC All rights reserved.
  13. 13. Everyday sources of blade damage and wear © 2015 Broadwind Services, LLC All rights reserved.
  14. 14. Minor damage is the tip of the iceberg! Minor gel-coat crack Investigation process Repair preparation §  In-situ repair during inspection feasible §  Can be multi-day project © 2015 Broadwind Services, LLC All rights reserved.
  15. 15. §  Reduces energy capture §  In-situ repair during inspection feasible cuts into energy capture Moderate Edge Erosion w/ Structural Cracking Severe Edge Erosion Minor Edge Erosion © 2015 Broadwind Services, LLC All rights reserved.
  16. 16. Cracks and delamination on leading and trailing edges Severe edge damage can be catastrophic In-situ repair is feasible, however typically one week+ from date issue found to repair © 2015 Broadwind Services, LLC All rights reserved.
  17. 17. L/E Protection Tape /Paint PROs §  Longer lifespan in most cases §  Best on Polyester/Gelcoat blades §  Nearly same application time Considerations §  Cost §  Edge sealing §  Cutting, splicing §  Drag loss factor <1%* Factory Paint L/E Protection PROs §  Works for 1-1.5yrs on Epoxy Blades §  Inexpensive §  Bonds directly and wears predictably as original coating Considerations §  Polyester vs. Epoxy Construction §  Current level of erosion Several solutions - Pros & Cons © 2015 Broadwind Services, LLC All rights reserved.
  18. 18. Carbon Blade Construction Unidirectional Fiber spar cap and box type construction •  Prepreg fabric spar cap •  Pultruded square or sheet bonded spar cap bundle •  Carbon structure manufactured as separate component © 2015 Broadwind Services, LLC All rights reserved.
  19. 19. Lightning Strike Inspection In-process Investigation & Repair §  In-situ repair during annual inspection feasible §  Multi-day project © 2015 Broadwind Services, LLC All rights reserved.
  20. 20. Evaluation Process §  Damage assessment §  Repair feasibility §  Repair method §  Access method Considerations §  Standards §  Blade type §  Mfg. specs. Investigation Techniques §  Visual (ground or in-air) §  Acoustic §  Tap test §  Infrared imaging §  Thermography §  Ultra-sound §  Lightning system continuity check §  Bond line measurements Blade Damage Evaluation & Techniques © 2015 Broadwind Services, LLC All rights reserved.
  21. 21. ü Poor aerodynamics & pitch errors ü Reduced service life of gearbox due to blade vibrations ü Overloaded pitch control drive motors ü Shut down during icing & high winds ü Downtime waiting for repairs during peaks ü Overburdened lean onsite O&M teams ü Increased repair costs for crane access to repair blade ü Inflated cost of the needed repair Delayed maintenance impacts your bottom line! © 2015 Broadwind Services, LLC All rights reserved.
  22. 22. Proactive Blade Maintenance Checklist ü Scheduled periodic inspections during non-peak season ü Repairs are smaller and a fraction of cost of blade replacement ü Improved reliability and performance through aerodynamic efficiency ü No lost revenue due to down time waiting for unscheduled repair ü Build a blade performance database to project future costs Partner with a service provider who will customize a solution to meet your unique operating conditions. >Over 10,000 blades serviced. © 2015 Broadwind Services, LLC All rights reserved.
  23. 23. Questions? Paul Dvorak Windpower Engineering & Development pdvorak@wtwhmedia.com Twitter: @windpower_eng Aaron Wahlstrom Broadwind Energy Aaron.wahlstrom@bwen.com
  24. 24. Thank You q  This webinar will be available at www.windpowerengineering.com & email q  Tweet with hashtag #WindWebinar q  Connect with Windpower Engineering & Development q  Discuss this on the EngineeringExchange.com

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