Upload
buibao
View
222
Download
4
Embed Size (px)
Citation preview
Managing Turbine Operating Costs Through Comprehensive and Targeted Rotor Blade Inspections
CanWEA – Operations and Maintenance Summit – February 26th & 27th, 2015 – Toronto, ON
Mike Jeffrey, Complete Wind Corporation
• A balanced design considering both Aerodynamic and Structural requirements
Rotor Blade 101
CanWEA – Operations and Maintenance Summit – February 26th & 27th, 2015 – Toronto, ON 2
• Rotor blades are very large, manually constructed composite structures serving as the primary driver • MW Class Rotor Blades: 34m – 83.5m +
1 – Wang , Brian (4/15/2011) . 20MW Wind Turbine Designs based on Modified Conventional Designs could be built by 2020, Retrieved: March 26, 2013, from http://nextbigfuture.com/2011/04/20-megawatt-wind-turbine-designs-based.html
1
• Rotor blades are generally made from Fibre Reinforced Plastic (FRP) with either a wood or plastic core
2
2 – Cho, James (7/14/2005). Airfoil, Retrieved: March 27, 2013, from http://en.wikipedia.org/wiki/Airfoil
Why Perform Rotor Blade Inspections? • Blades are typically designed for a 20 year
service life • Blades are WEAR components that require
routine inspection and repair • Insufficient inspection/service will lead to costly
blade repair and potential unplanned replacement
• Manufacturer variability – due diligence
3 CanWEA – Operations and Maintenance Summit – February 26th & 27th, 2015 – Toronto, ON
Critical Areas for Inspection
4
• Bond-lines: SW(s), LE and TE in particular Max Chord • Root and Flange Area • Tip (bottom 1/3 of LE) and Aerodynamic Elements • Main Structural Components • Sandwich Structure (in particular Max Chord)
CanWEA – Operations and Maintenance Summit – February 26th & 27th, 2015 – Toronto, ON
What is Involved? Inspection Type Frequency Primary Findings
Exterior From Ground Annually Exterior Wear/Operational defects, Lightning Strikes, Serious Manufacturing Anomalies
Up-tower Interior/Exterior Prior to End of Warranty, subsequent, every 3 – 5 years
Interior & Exterior Wear/Operational defects, Interior and Exterior Manufacturing Anomalies
Lightning Protection System
Following OEM or IEC 61400-24 recommendations
Confirmation of down conductor connection, receptor inspection
Dynamic Rotor Balancing At commissioning , subsequent tests every 3 - 5 years
Mass and Aerodynamic Imbalance
5 CanWEA – Operations and Maintenance Summit – February 26th & 27th, 2015 – Toronto, ON
What is a Wear Related Defect?
6
Some common wear/operational related defects: 1. LE Erosion 2. Cracking along Bondlines and/or Blade Shells 3. Lightning Strike Damage
CanWEA – Operations and Maintenance Summit – February 26th & 27th, 2015 – Toronto, ON
A wear/operational related defect is: • Resulting from the operation of the turbine • Resulting from Force Majeure
What is a Manufacturing Defect?
7 CanWEA – Operations and Maintenance Summit – February 26th & 27th, 2015 – Toronto, ON
A manufacturing defect is: • Resulting from the manufacturing process • Resulting from the rotor blade design
Some common Manufacturing defects: 1. Wrinkles 2. Dry Spots in Laminate 3. Bondline Voids
CWC Inspection Statistics
8
The findings of inspections performed between 2008 and the present were used to establish general inspection trends. • # of Blades in Sample Population: 4,860 • # of Turbine Manufacturers: 7 • Turbine Size: 0.66MW – 3.0MW • % of Population Identified with Defects: ~85% • Average number of defects per blade: ~10 • All statistics shown in charts are relative to number of blades affected not relative to defects per blade
CanWEA – Operations and Maintenance Summit – February 26th & 27th, 2015 – Toronto, ON
Defect Type Breakdown
9
Total # of Defects discovered through Inspections: 48,371
Defects were categorized by the following: 1. Manufacturer (~52%)
a. Fabrication b. Serial
2. Wear (~44%) 3. Transport/
Construction (~3%) 4. Other (~0%) CanWEA – Operations and Maintenance Summit – February 26th & 27th, 2015 – Toronto, ON
52% 44%
3%
0.26%
% Defects Mfg % Defect Wear % Defects Transport % Defects Other
Defect by Manufacturer
10
Inspections performed on 7 different Turbine Manufacturers:
CanWEA – Operations and Maintenance Summit – February 26th & 27th, 2015 – Toronto, ON
0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
70.00%
80.00%
90.00%
100.00%
No Defect TransportConstruction
Defects
Wear Defects FabricationDefects
Serial Defects Other
% of Blades
MFG A
MFG B
MFG C
MFG D
MFG E
MFG F
MFG G
Defect by Turbine Lifecycle
11 CanWEA – Operations and Maintenance Summit – February 26th & 27th, 2015 – Toronto, ON
0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
70.00%
80.00%
90.00%
100.00%
No Defect TransportConstruction
Defects
Wear Defects FabricationDefects
Serial Defects Other
% of Blades
Incoming
End of Warranty
Post Warranty
What are the Lessons Learned?
CanWEA – Operations and Maintenance Summit – February 26th & 27th, 2015 – Toronto, ON 12
End of Warranty Inspections: • End of Warranty Inspections are generally the last
opportunity the Owner and Operator has to place costs for repair on the Original Equipment Manufacturer
• >50% of rotor blades inspected at End of Warranty were found to have Manufacturing Related Fabrication Defects
• Most won’t complete thorough inspections on 100% of their wind farm It is imperative that inspections are timed to allow
for inspection of 100% of the Wind Farm in the event of serial defect discovery
What are the Lessons Learned?
CanWEA – Operations and Maintenance Summit – February 26th & 27th, 2015 – Toronto, ON 13
Wear Defects: • ~100% of rotor blades inspected Post Warranty were
found to have wear defects • >90% of rotor blades inspected at End of Warranty were
found to have wear defects • Almost all of the costs for repair of these defects will be the
responsibility of the Owner and Operators • Ensure that proper allowances are made for these costs
when planning and budgeting
What are the Lessons Learned?
CanWEA – Operations and Maintenance Summit – February 26th & 27th, 2015 – Toronto, ON 14
Transport and Construction: • ~25% of rotor blades inspected during incoming inspection
were found with transport and construction related defects • ~15% of rotor blades inspected at End of Warranty and
Post Warranty were found with transport and construction related defects
• Owner and operators must ensure that a representative is on site to inspect for and ensure proper completion of defect repair due to transport and construction
Conclusions
15
1. Owners and Operators must ensure that proper planning and budgeting is available to allow for inspection and maintenance of rotor blades.
2. Addressing defects requiring repair early allows for efficient scheduling of repairs allowing turbines to operate more safely and remain online longer.
3. It is imperative to work with in-house expertise, the OEM and 3rd Party ISP’s to develop and establish a long term inspection and maintenance program.
CanWEA – Operations and Maintenance Summit – February 26th & 27th, 2015 – Toronto, ON
Questions?
Thank you for your attention. Complete Wind’s Core Management group has: • Been active in the Wind Industry for 15+ years • Managed teams of technicians for repair, refurbishment and remediation of large scale wind turbine projects • Supported owner/operators in USA and Canada on Inspections, including but not limited to consultation with OEM • Worked collectively with owner/operators to develop a rotor blade preventative maintenance program for their own
Operations and Maintenance post warranty
16 CanWEA – Operations and Maintenance Summit – February 26th & 27th, 2015 – Toronto, ON