Wind Composite Services Group/WindCom...

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Wind Composite Services Group/WindCom

Introduction


Who We Are

• Established in 2006

• Owned by Tecsis

• Headquarters in 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

• Three full time engineers


Preferred Access Method 360° Suspended Platform


Sub-zero 360° Suspended Platform

Sub-zero 360° Suspended Platform available for immediate mobilization to your project.


Using Data and Engineering Principles To Implement Effective Standardization Measures:

Blade Fleet Failure Investigation Process

1 November, 2016


Problem

Aging blade fleets require

solutions to emerging issues


Objective

To maximize the value of the

rotor for the owner and

minimize business risk


Case Study 2016


Who We Are - The Team

• Tecsis

• Rodolfo M. Meleiro Head of Engineering and team

• WindCom

• Gary Kanaby – Project Manager

• Ricardo Silva – Senior Engineer and team

• WINDProve

• Kevin Jackson, Ph.D. – Engineering Manager

• Mike Zuteck – Composite Structures

• Rick Santos, Ph.D. – Loads and Dynamics

• Owners


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.


Goals

• First document the failure types and frequency of occurrence

• Develop engineered repairs

• Prepare standardized repair procedures

• Repeatable,

• Documented engineering properties

• Can be quoted using fixed cost

• Perform tests to validate remediation methods

• Perform tests to validate remediation methods

• Develop statistical models to predict future failures

• Develop preventative measures

• Develop tools to estimate blade maintenance costs accurately to control

cost increases as the fleet ages over time


Different Blade Failure Modes are Categorized

• Aft shell failure


Several Blade Failure Modes are Evident

• Aft shell failure


Different Blade Failure Modes are Evident

• Blade root cracking


Different Blade Failure Modes are Evident

• Trailing edge cracking


Focus-Prevention of this


Example of How Data can be Assimilated

Mass Mass

Blade populations vary from design values differently during manufacturing sequence


Trailing Edge Strain Under Static Loads

• There is substantial variability in the blade fleet

• The weight and the gravity bending moment exceed the

original design value in all of the blades

• Blade mass distribution will affect rotor frequencies

• Blade weight will affect tower fore-aft and side-side

frequencies

• Higher blade moment will increase TE strain range and

reduce edgewise fatigue life



Categorized the radial

position of fifty-two trailing

edge cracks.

68% of TE cracks occurred

between R20 and R25


inboard of R20


between R25 and R35



Based on the original Blade Edgewise Static Load Test

Maximum Spanwise Strain was located near R16 in this test


Most cracks occur near the TE spline spreading transition region at R23m

Next most cracks occur at R20m, which is likely highest TE strain

A minimum spanwise extent of repair from R16m to R24m seems likely

Spanwise Extent of Repairs

Drawing removed-Call Gary Kanaby to discuss


Field Verification• WindCom crews are currently performing

repairs on these blades for customers

• Photos and other data are being collected from

field sites

• One use of the data is to verify the accuracy of

the laminate drawing set

• The example photo shown here has 17 UD plys

in a location that can then be compeered to

laminate schedule (previous slide)

• We want to accurately know as-built properties

and how they vary across the fleet


Preliminary Results

• Increased mass and moment induce

high strains on trailing edge

• Spar cap uni drops and “spreading”

varies

• Trailing edge laminates have reached

fatigue life


Solutions

• Preventative: Replace TE unis with new

materials/laminate schedule

• Repairs: Go well beyond the damaged

area adding strength the TE.

• Ultimate solution: Replace large section

of TE with new.


Challenges• Adding additional laminates can increase the

moment and mass thus increasing the loads on the

TE.

• Use of laminates with different properties can

change frequencies & stiffness and must be

modeled

• Length of replacement laminates determined by

where “good” laminates remain.

• Solutions must make since financially. ROI must be

considered.

• Solutions need to be able to be performed up tower


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

[email protected] | www.windcomservices.com

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