blade maintenance: observations from the field and practical solutions
TRANSCRIPT
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q This webinar will be available afterwards at www.windpowerengineering.com & email
q Q&A at the end of the presentation q Hashtag for this webinar: #WindWebinar
Before We Start
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Introducing the Speakers
MODERATOR
FEATURED SPEAKER
FEATURED SPEAKER
FEATURED SPEAKER
Michelle Froese Senior Editor Windpower Engineering & Development
Kelly Miller Composite Report Manager EDF Renewable Services
Matt Sigala Area Technical Specialist EDF Renewable Services
Jon Salmon Senior Technical Services Manager EDF Renewable Services
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BLADE MAINTENANCE: observations from the field and practical solutions
Jon Salmon, P.E., Senior Technical Services Manager Kelly Miller, Composite Repair Manager Matt Sigala, Composite Specialist
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EDF Renewable Services
5
6.81 8.05
5.91 4.1
1.88 1.34 1.78 1.16 0.75 0.72 0.73
7.26 8.05 5.91
4.38 2.64 2.44 3.11
1.85 1.86 1.08 1.1
0 2 4 6 8
10
2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
Safety Performance 2005-2015
DART TRIR
TRIR: Total Recordable Incident Rate DART: Days Away, Restricted, or Transferred
30 years of expertise in renewable energy industry
Largest third-party provider of Operation and Maintenance (O&M) services in North America
Offer O&M, BOP, scheduled and unscheduled maintenance, blade inspections, blade repair and asset management
410 technicians and supervisors
Solutions customized to your specific projects needs
Company culture focused on safety
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Key Figures Across North America
6
10,723 7,782 6,703
4,094 3,840
0
2,000
4,000
6,000
8,000
10,000
12,000
Operations & Maintenance
Developed Put Into Service
Installed Capacity
Divested
EDF EN North America Activity
December 31, 2015
MW
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Blade Trends
3/22/16 Presentation Title 7
Larger rotors and longer,
heavier blades
Increased structural loading
Higher maintenance
costs
Turbine power ratings are increasing
Wind cost of energy
Least amount of
blade material
Lower design safety factors
Higher maintenanc
e costs
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Blade Trends
3/22/16 Presentation Title 8
Growing awareness of blade problems
Aging of flexible megawatt blades
The number of owners seeking blade maintenance services is increasing due to:
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Why is Blade Maintenance Important?
3/22/16 Presentation Title 9
Preserve the blade structure
Retain airfoil shape
Reduce AEP losses
Repair costs increase non-linearly as degradation progresses
Risk of complete blade loss
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Maintenance Factors
3/22/16 Presentation Title 10
Airborne erosive particles
• Water • Ice • Sand • Dust
Lightning frequency and intensity
Moisture ingestion
Freeze and thaw cycles
Blade design and manufacture
• Material erosion properties • Leading edge protection • Adhesive properties and processing • Workmanship
• Blade degradation rate varies greatly site to site • Some factors to consider at your site:
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Things to Consider
• Established blade and site maintenance plan
• Perform inspections early and often
• Owner budget
• Provider capabilities:
3/22/16 Presentation Title 11
Inspection techniques
Database to organize collected blade data
Maintenance and repair planning
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Things to Consider
3/22/16 Presentation Title 12
Modes of Inspection • Visual inspections • Binoculars • Cameras • Technicians on the blade • Drones
Ability to see fine details • High image resolution • Image effects: contrast, brightness • Zoom ability
Cost and productivity • Inspection • Data Management • Reporting
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Inspection Approach
3/22/16 EDF RS Blade Services 13
• The industry has multiple different inspection techniques putting the customer in control of their solution
• Blade maintenance needs can change depending on:
Turbine Age (construction vs. 10 years in)
Condition of Turbines
Climate
Customer Budget
Blade Design
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Basic Visual Inspection
• Visual inspection typically using binoculars • Technicians inspect each blade noting damage • Lowest cost option and often included with O&M contract
Photographic Inspection
• Inspection with a camera, typically including a telephoto lens • Technicians inspect each blade and are able to show owners
damage through photographs
Technicians on the blade
• Technicians are secured to the blade using ropes, cranes or a platform
• Visually inspect and take photos of blade noting any damage
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UAV Inspection
• Inspection with an unmanned aerial vehicle (UAV) or a drone • UAV takes up close photos or videos of each blade • Technicians then analyze data to see damage
Mosaic Image Mapping
• Inspection performed with a high powered telephoto lens • Photos are stitched together to form a mosaic image map • Owners are able to see each blade in single photograph
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Data Management Reporting Capabilities
3/22/16 Presentation Title 16
Basic Reporting • May include photographs • Detail recommended repairs • Paper or email form • Difficult to show yearly damage progression
Database • Central location to store reports from year to year • Difficult to note damage progression • Includes photos of every blade • Stored online or on computer
Website • Includes photos and may include mosaic image map photos • Online with 24/7 access • Easily see damage progression from year to year • Ability to filter and search through photos and blades
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Lightning Strikes
Leading Edge Erosion
Laminate Delamination
Moisture Ingestion
Freeze & Thaw Cycling
Manufacturer Defects
Common Blade Failures
3/22/16 EDF RS Blade Services 17
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#WindWebinar 3/22/16 EDF RS Blade Services 18
Lightning Damage Repair Progression
Removal of gel coat and NDT
Damage prep for repair
Repair laminate cured
Gel coat / LEP applied
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Lightning Damage Repair
3/22/16 EDF RS Blade Services 19
Specially trained technicians test and repair Lightning Protection Systems
Repair damaged laminate
Repair and replace lightning protection receptors
Delamination
Disbond
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Leading Edge Erosion Control and Repair
3/22/16 EDF Blade Services 20
Specially trained blade repair technicians inspect and repair erosion damage
Install and replace leading edge protection
Bond line repairs
Leading edge preventive maintenance
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#WindWebinar 3/22/16 EDF RS Blade Services 21
Costs of Not Repairing
A small problem one year can become a big problem the next
Leading edge erosion left untreated is more expensive to fix in the long term
Unrepaired damage can impact your plant performance
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Costs of Not Repairing • Over time, blade repair costs increase • Repair costs increase non-linearly as
degradation progresses • Erosion can cause significant AEP
reductions
*Data courtesy of 3M
Pits and gouges reduce AEP from 4% up to 10%
Delamination reduces AEP up to 20%
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Questions?
MODERATOR
FEATURED SPEAKER
FEATURED SPEAKER
FEATURED SPEAKER
Michelle Froese Senior Editor Windpower Engineering & Development [email protected]
Kelly Miller Composite Report Manager EDF Renewable Services [email protected]
Matt Sigala Area Technical Specialist EDF Renewable Services [email protected]
Jon Salmon Senior Technical Services Manager EDF Renewable Services [email protected]
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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 EngineeringExchange.com
Don’t Forget!
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