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Leading Edge Erosion: Protection, Costs, and Benefits

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This discussion will focus on the application of Wind Turbine Generator (WTG) Leading-Edge Blade Coatings to prevent blade degradation that decreases the performance of the WTG. We will explore the root causes of the blade erosion cycle and the effect of the leading edge erosion in the WTG performance output. Next, we will provide information on the WTG leading-edge blade coatings that offer protection against blade erosion and thereby increase both service life of the blade and maintain the original performance of the WTG.

Watch this webinar to learn:
1. What is leading edge erosion
2. What are the causes of leading edge erosion and buildup
3. The benefits of leading edge protection
4. Loss of turbine performance and revenue

Published in: Engineering
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Leading Edge Erosion: Protection, Costs, and Benefits

  1. 1. Leading Edge Erosion: Protection, Costs and Benefits
  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 Michelle Froese Windpower Engineering & Development Steven Elrod BS Rotor
  4. 4. BS ROTOR TECHNIC USA, LLC Presenter:   Steve  Elrod,  General  Manager
  5. 5. Why Surface Matters Blade length has increased overtime and has placed more demand on designs incorporating thinner and lighter materials.
  6. 6. Why Surface Matters •  Challenging environments (e.g. Offshore & Deserts)
  7. 7. Cause of Erosion Wear •  Higher tip speeds – because of increase length •  Location of turbine o  Operation in extreme/hostile environments (Deserts, Mountains, & Seas) o  Locations that have an abundance of sand, dust, bugs, rain, sleet, snow
  8. 8. Start of Erosion Cycle •  Loss of OEM Coating •  Minor Pitting Effects •  Damage Base Layer •  Severe Delamination •  Crack propagation
  9. 9. Leading Edge Erosion (Minor)
  10. 10. Leading Edge Erosion
  11. 11. Leading Edge Erosion (Major)
  12. 12. Leading Edge Erosion
  13. 13. Effect of LE Erosion on WTG Output (1.5 MW) •  Moderate pitting o  Increased Drag, Lower Lift – Loss $8,000 per year •  Pitts & Gauging o  Increased Drag, Lower Lift – Loss $16,000 per year •  Severe Pitting & De-lam o  Increased Drag, Lower Lift – Loss $32,000 per year  Source:  3M  Wind  Power  Blade  O&M  Forum
  14. 14. Effect of LE Erosion on WTG Output (5 MW) •  Moderate pitting o  Increased Drag, Lower Lift – Loss $120,000 per year •  Pitts & Gauging o  Increased Drag, Lower Lift – Loss $360,000 per year •  Severe Pitting & De-lam o  Increased Drag, Lower Lift – Loss $720,000 per year Source:  3M  Wind  Power  Blade  O&M  Forum
  15. 15. Proactive Leading Edge Protection •  Feature: Smooth Surface on leading edge •  Benefit: o  Higher lifts o  Improves Efficiency by 1 to 4% Source:    Infigen  Wind  Power  Blade  O  &  M  Forum
  16. 16. Effect on LE Protection on WTG Output on a typical 1.5 WT •  Payback in less than 6 months •  Increased revenue of $50K to $250,000 (over 5 years) Source:  LM  Wind  Power  UWIG  Wind  Turbine  Operations  and  Maintenance  User  Group  Meeting
  17. 17. Effect on LE Protection on WTG Output on a typical 5MW offshore WTG •  Payback in less than 8 months •  Increased revenue of $500K to $2,500,000 (over 5 years) Source:  LM  Wind  Power  UWIG  Wind  Turbine  Operations  and  Maintenance  User  Group  Meeting
  18. 18. Possible LEP Protection •  1. Flexible Poly Urethane Tape 14 Mil Thick •  2. Poly Urethane Coatings (2 Component Mix) 10-14 Mil Thick Layer. Applied by Rollers or Brush •  3. Wear Resistant Coatings 15-20 Mil thick applied by Rollers or Spay Gun.
  19. 19. Benefits of Various LEP Materials •  1. Poly Urethane Tape: 3M - New in the Market •  2. Poly Urethane Coatings: Duromar, Mankiewicz, Bergolin •  3. Wear Resistant Coatings
  20. 20. Conclusion – Pictures after 3 years of Service
  21. 21. Conclusion •  Erosion is going to occur on all blades •  Effects of Erosion can be controlled or limited •  LEP works and pays for itself
  22. 22. Questions? Michelle Froese Windpower Engineering & Development mfroese@wtwhmedia.com Steven Elrod BS Rotor selrod@bs-rotor.com
  23. 23. 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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