Kanaby sandia august 2016 windcom

1. Page 1Confidential and proprietary information of WindCom
Wind Composite Services Group/WindCom
Introduction

2. Page 2Confidential and proprietary information of WindCom
Who We Are
• Established in 2006
• Owned by Tecsis
• Headquartersin Houston, TX with offices in Spain &
Brazil
• Over 75 Service Technicians in the USA
• Safety Culture
• Warehouse and training center (Houston)
• Drug free workplace
• Technically advanced

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Preferred Access Method 360° Suspended Platform

5. Page 5Confidential and proprietary information of WindCom
Blade Fleet Failure Investigation Process

6. Page 6Confidential and proprietary information of WindCom
Problem
Aging blade fleets require
solutions to emerging issues

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Objective
To maximize the value of the
rotor for the owner and
minimize business risk

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The Idea
• Compile and analyze original manufacturing data, operational experience, and
damage reports to determine the root cause(s) of the blade failures
• Engineer and document standardized repairs and preventative measures to reliably
extend the life of the blades
• WindCom will takes the role of the OEM to work with owners to find solutions. No
owner group is required.
• WindCom retains data privacy for individual sites and owners, but aggregates
knowledge across the fleet.
• Shares engineering results and critical findings to all owners without revealing any
detailed data provided by individual owners.

9. Page 9Confidential and proprietary information of WindCom
The Process
• Manufacturing data is collected from manufacturer or owners if possible
• Owners are asked to provide data to the group
• Blade numbers and at which site they have been operating
• History of the blades- remediations, damage repairs, failures
• Damage reports for different failure types and their frequency of occurrence
• The team will analyze data to determine trends and root cause(s) of damages

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Example of How Data can be Assimilated
Mass Mass
Blade populations vary from design values differently during manufacturing sequence

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Different Blade Failure Modes are Categorized
• Aft shell failure

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Several Blade Failure Modes are Evident
• Aft shell failure

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Different Blade Failure Modes are Evident
• Blade root cracking

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Different Blade Failure Modes are Evident
• Trailing edge cracking

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Different Blade Failure Modes are Evident
• Trailing edge cracking

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Different Blade Failure Modes are Evident
• Surface Coating Failure

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DMAIC Approach
DEFINE Specify the goals of the blade remediation effort
MEASURE Obtain manufacturing, failure, & repair data for the fleet
ANALYZE Use forensic techniques to assess the root causes of failures
IMPROVE Develop solutions to address the root causes of failures
CONTROL Monitor remediation efforts to validate quality and longevity

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Summary
• First document the failure types and frequency of occurrence for various
failure types throughout the fleet
• Perform root cause analysis to understand why the blades are failing.
• Develop engineered repairs for each specific failure mode and perform
tests to validate remediation methods
• Prepare standardized repair procedures that are repeatable, have
documented engineering properties, and can be quoted using fixed cost
• Develop statistical models that assist with our ability to predict failure rates
• Develop preventative measures to lower risk and cost
• Develop tools to estimate blade maintenance costs accurately and optimize
to control cost increases as the fleet ages over time

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Blade Life Cycle Management
A New Approach to a Critical Asset
Sandia Blade Workshop August 2016

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Preventative Maintenance
• Blades are inspected at regular intervals
• Data can be analysed using recognition software to
quickly categorize blade condition and to determine
corrective actions
• Data is entered into the data base to monitor blade
condition
• Decisions can be made to prevent wear and tear,
damage progression or lightning damage
• Repairs are made during the low wind season with
leading edge protection at planned intervals
Management Plan
Predictive Maintenance
• Using database and newly collected data future issues
with the blade can be predicted
• Using the predictions a plan can be made to minimize
future problems.
• Known failure modes can be investigated in further
detail to prevent occurrences before they happen.
• Maintenance is not random but calculated to minimize
downtime and repair expenses customized site and
turbine specific.

21. Page 21Confidential and proprietary information of WindCom
Maintenance Plan vs Reactive only
$0
$100,000
$200,000
$300,000
$400,000
$500,000
$600,000
$700,000
$800,000
$900,000
$1,000,000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Lost Revenue and Expenses Annually
Without Maintenance With Maintenace
$7,384,748
$87,600
$409,500
$23,400
$3,000,000
$1,500,000
0
$900,000
0
$1,950,000
$0.00
$2,000,000.00
$4,000,000.00
$6,000,000.00
$8,000,000.00
$10,000,000.00
$12,000,000.00
Without Maintenance With Maintenance
Expenses and lost revenue production over 20 years
Loss of Production Erosion Loss of Production Repairs Cost or repairs Inspections LEP application
Assumptions:
• 200MW Wind Farm/ 100-2MW turbines in Midwest • 40%
capacity factor PPA @ $25MW hour • Loss of revenue daily
$60/summer and $420/winter
• Average erosion which if left unattended would result in 5%
loss of energy after 20 years (.25%/yr)• Lightening strikes (or
other damage) effect 5 blades/year

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North America
Houston – USA
Sales 281-906-9572
T. +1 281 227 5130
F. +1 281 227 5192
Europe
Madrid -Spain
T. +34 91 241 10 02
F. +34 91 293 51 96
South America
Sao Paulo - Brasil
T. +55 15 2105 4800
F. +55 15 2102 4875
info@windcomservices.com | www.windcomservices.com
For all your wind turbine composites servicing needs