Wind Turbine Blades Overview

8/3/2019 Wind Turbine Blades Overview

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Technology

Paul VeersWind Energy Technology

Sandia National Laboratories

psveers san a.gov

Stanford Composites Class, 11-September-2007, Paul Veers


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verv ew o w n energy ec no ogy

Overview on the wind ener businessPerspective of wind turbine blades

a e manu ac ur ngBlade research

Critical issues for advanced technology es gn

Materials


m e e ev ces an sensors


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Current Blade

All com osite withsteel bolt circle to

attach to the pitch

34 - 61.5 meters

5 - 18 tonnesCourtesy of LM Glassfiber

Fiberglass Small amounts of

some blades

Size limited byoverlandtransportation



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Leadin Turbine Manufacturers

These four

suppliers

account for

75% of the

Gamesa (Spain)

world market

Vestas(Denmark)

Enercon


(Germany)

34% of themarket


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Growth of Wind Energy

End of 2006 Cumulative = 74,306 MW

Rest of World = 12 102 MW

North America = 13,577 MW

Europe = 48,627 MW

100000Rest of World

Actual Projected

Rest of World

North America North America

60000

urope urope

20000

40000

00000

90 91 92 93 94 95 96 97 98 99 '00 '01 '02 '03 '04 '05 '06 '07 '08 '09 '10 '11

*


,

US = 11,698 (~22% incr.)


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Wind Industry Trends &

Recent Costs (2003)

ze 1.5-5.0 MW

Towers: 65-100

~

Blades ~$5/lb

~ $1000/KiloWattmeters

Blades: 34-60 meters

Weight: 150-500 tons

-

2006 costs are up over 50% Steel & copper

Currency exchange rate Limited Suppliers



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Installed capacity has tripled in the last six years

Global Wind Power Status

Cumulative MW by end of 2000, 2003 & 200650,000

35,000

40,000

45,000

20,000

25,00030,000

5,000

10,000

15,000

0

Europe USA Asia Rest of World

2000 18 449 MW 2003 40 301 MW 2006 74 306 MWSource: BTM Consult ApS - March 2007



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2001 and 2016 Forecasts

Global Wind Power Projectionsumu a ve - orecas re c on

160,000

200,000

80,000

120,000

to double in the next five years(to 2011)

0

,

Europe North America Asia Rest of World

2011 (203,151 MW) 2016 (455,852 MW)Source: BTM Consult ApS - March 2007

Global Wind Power ForecastCumulative MW by end of 2006 & Forecast 2011

120,000

and double again inthe following five

60,000

80,000

100,000

0

20,000

40,000


Europe USA Asia Rest of World

2006 (74,306 MW ) 2011 (203,151 MW )Source: BTM Consult ApS - March 2007


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Gear Box

c ys em

Yaw System

BladeTower



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0.3balsa-core skins

0.1

0.2

scaled to 30% t/c

0.0y/c s ar ca s

-0.2

-0.1aft shear web

forward

-0.3

0.0 0.2 0.4 0.6 0.8 1.0


x/c


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Wind Turbine Blade Development

System analysis identifies researchinitiatives with increasing industryinvolvement as it gets closer to the

commercial product



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Blade weight has dropped in

Use of Design Standards

Better manufacturing

Cubic

1995-2005Cubic

1985-1995 After 2005



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Blade Manufacturers: A sampling

LM Glasfiber: the largestsupplier of wind turbine

TPI Composites: Partner withMitsubishi (Vientek) and with

research initiatives

Stanford Composites Class, 11-September-2007, Paul VeersCourtesy of TPI Composites


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The leading world-

supplier of windturbine blades

Six countries

Three continents

-

from wind tunnel tocoupon testing

Some larger blades

use carbon fiber n us on

manufacturingprocess


Courtesy of LM Glassfiber


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with Mitsubishi - Vientek

Mostly glass fiber withglass/carbon hybrid in thespar caps

infusion technology formanufacturing


Courtesy of TPI Composites


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.weight is about 10,000 kg per MW of power

output. At current cost levels of about $10-12/kg,

blades cost over $100,000 per MW

s s n e ne g or oo o , or aset of blades on a 1.5 MW machine

Blade strength and cost varies with the IEC

Standard Class of the site Class I is a high energy site with shorter, stronger blades

Class II is a lower wind site with longer blades and lowerdesign loads


Class III is still lower wind speed and relaxed design loads.


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Turbine and Blade Market 2011 Forecast

The Global Wind Power M arket in US$Expected development 2007-2011

40,000

45,000

,

160,000

180,000

,

25,000

30,000

35,000

ill.US$

100,000

120,000

140,000

tivemill.US$

10,000

15,000

20,000

40,000

60,000

80,000

Cum

ula

0

5,000

2006 2007 2008 2009 2010 2011

0

20,000

Forec as t of fs hore Of f shore 2006 Ons hore 2006Source: BTM Consult ApS - March 2007

Forecast onshore Cumulative market


.

$7B in 2011.


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Blade full-scale and material testin

Carbon Fiber

specimen failedin compression

Fatigue Test


Courtesy of LM Glassfiber

Static Test to Failure


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Video courtesy of LM Glassfiber

Static test to failure of a 42.5 meter blade



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Rotor study results:

Blades are 15% of total s stem cost

Blades generate all the energy

Blades can be designed to reduce the loads passedroug o e res o e s ruc ure

Grow the rotor diameter with adaptive blades:

Energy capture increases

Cost increases mar inall or with careful desi n not at all.

System return on investment increases 10-20%



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Example of Fundamental Research findings

New Materials Carbon/Glass Hybrid-

Passive load reduction

a er a - ase

Geometry-based



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Example of sub-scale development projects

Partnerships with TPI Composites andKnight & Carver

3

4

Weight

600

700

800

5

0

100

200

300

400

500

lbs

Carbon Fiber area in Blue

Design Generation

Blade Strength

100

150

200

250

ailureMoment

(kN-m

)


Carbon is used to make longer,stronger, adaptive, and lighter blades.0

50

1 2 3 4 5

Design Generation

R

oot


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Example of full-scale

27.1m swept blade

Replacement blades Zond 750 5-10% increased energy capture


Continuing Partnership with Knight & Carver in the Developmentof Passive-Bend Twist Coupled Swept Blade


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Noise that originates with

mechanical equipment

it is radiated into theenvironment.

Noise that originates dueto blade aerodynamics isradiated already and can

only be mitigated by

uieter blade desi ns.


AWEA


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Important Research Issues

Special airfoils

Aeroelastic tailoring uc ng res stant es gns

Strategies for location of expensive fibers(e.g. carbon)

ower we g t

Quieter tips

Manufacturing Automation

Processes for very large sizes

Qualit control and ins ection Joining both seams and mid-span

Embedding devices and sensors


Courtesy of TPI Composites


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we could generate up to 20% of our

e ec r c y nee s roug w n

President George W. Bush - February 21, 2006

Thank You


Wind Turbine Blades Overview

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