Blade Life Cycle Management A New Approach to a Critical Asset

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Presentation transcript:

Blade Life Cycle Management A New Approach to a Critical Asset 07/12/2017 Blade Life Cycle Management A New Approach to a Critical Asset 2016

WindCom Vision To be recognized as the industry leader in maintaining blades by committing to the highest level of service and the customers’ overall success.

About WindCom Group 2nd Largest Blade Manufacturer Worldwide Worldwide Blade Services

WindCom Facts Servicing Blades Since 2006 servicing nearly 12,000 blades Has a database of over 18,000 blade service records Worldwide over 250 professionals to meet blade maintenance needs Advanced inspection, access and repair techniques Advanced blade composite engineering staff

Background Blades have often been overlooked as critical component of a wind turbine since they were perceived as product that was meant to last 20 or more years and was down the list as the most costly component relative to the operation costs of a wind farm. The perception has changed due to the fact that blades have been found to be wearing and small damages have later resulted in costly repairs or replacements and lengthy downtime. Blades, like no other component of the wind turbine is a combination of composites encompassing aerodynamic and structural features to capture the wind energy. Although maintenance teams at wind parks are skilled at keeping the turbine running, blades are a special challenge due to the complexities of the design, construction and materials. As an expert in wind blade maintenance, WindCom is offering a product that shifts the responsibility and risk of blade maintenance from the owner to WindCom where the blades will be maintained for peak performance and reduced downtime professionally managed.

Evolution of Blade Maintenance 1980-1995 1996-2005 2006-2015 2016 Blades heavy duty and design margins high Blades removed for repairs Blades easy to replace Spare blades available Preventive maintenance not considered As blade length grew design margins were reduced Blades becoming too large for inexpensive removal Production decreases due to erosion realised Blade repairs now uptower with incresed cost per incident Design margins low Owner designed maintenance programs without blade background LEP installed without data to support payback Repairs remain reactive Inspections at End of Warranty but few later Replacement blades not available Maintenance costs high BLCM Design margins understood Improved inspection methods allow increased frequency Database created and used to predict failure modes Preventative maintenance based on ROI Packaged product establishes maintenance costs in advance Blades heavy duty and design margins high Blades removed for repairs Blades easy to replace Spare blades available Preventive maintenance not considered As blade length grew design margins were reduced Blades becoming too large for inexpensive removal Production decreases due to erosion realised Blade repairs now uptower with incresed cost per incident Design margins low Owner designed maintenance programs without blade background LEP installed without data to support payback Repairs remain reactive Inspections at End of Warranty but few later Replacement blades not available

Blade Life Cycle Management Wind Farm owners and operators shift the responsibility of managing their blades to WindCom. Blade inspections without stopping the turbines. Predictive maintenance plan put in place based on WindCom and site data Preventative maintenance is performed at the right interval to maximize blade efficiency and limit downtime. Unscheduled maintenance is a priority to get the turbine back online quickly with incentives to react quickly or penalties for delays. Ability to negotiate insurance savings on premiums or deductibles. Blade replacement payment available.

Increased Profitability Blade Life Cycle Management Increased Profitability Prevenative Maintenance Plan Inspections Environmental Blade Construction Predictive Planning Blade History WindCom Data Blade Characteristics Site/Turbine Data Maintenance Leading Edge Protection LPS Verification Proactive Repairs Reactive Repairs Reduction in Repairs Blade Efficiency Reduced Downtime

Management Plan Preventative Maintenance Predictive Maintenance Blades are inspected annually using a high speed camera which does not require stopping the turbine Data is 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 depending on factors such as environmental conditions at the site. 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.

Management Plan Continued Reactive Maintenance Blade Life Cycle Management Options Unforeseen events such as lightning, hail & bird impacts can reduce the blade’s integrity and requires immediate attention. WindCom engineers will quickly determine if the turbine needs to be shut down and will offer advice as to the repair’s urgency. If necessary, an emergency repair crew will be dispatched to the site quickly to resolve the problem getting the turbine back on line quickly. Full Maintenance Contract Contract service period over 5 or more years WindCom will inspect blades and take preventative action to maintain blades Leading edge aerodynamics will be preserved for optimum performance Blade replacement deductible can be included and negotiated with your insurance company Customized Contract Pick from a menu of options that fits your needs/budget.

$ Full Service Contract One Price ffff Full Service Contract One Price per turbine annually for complete care of blades All risks to blades are assumed by WindCom WindCom will use database and knowledge of the turbine and its blades to provide a comprehensive maintenance plan guaranteed to lower annual maintenance costs and maximize performance of the blades Reward/penalty scheme will be agreed to as to the performance of the blades, repair costs and turbine downtime related to blades All blades will be inspected annually without stopping the turbine with options to stop the turbine for additional close-up inspection if required. Preventative maintenance such as leading edge protection will be used to insure optimum performance as required based upon site specifics. Maintenance will be scheduled to occur during off peak times to minimize downtime of the turbine. Reactive repairs will be carried out quickly to minimize downtime. Priority Service Will negotiate lowering insurance deductible for blade replacement. A proposed agreement will be presented to maintain the blades over time 24/7 Customer Service Hotline $

Customized Contract Price for Blade Life Cycle Management with options All blades will be inspected in predetermined intervals without stopping the turbine with options to stop the turbine for additional close-up inspections WindCom will use database and knowledge of the turbine and its blades to provide a comprehensive maintenance plan. Risks are shared between WindCom and owner/operator depending on degree of cooperation to the WindCom suggested plan After initial inspection we will meet to make a plan with upgrading the blades as required. 24/7 Customer Service Hotline $

Getting Started All data for the blades on site will be delivered to WindCom for review Previous inspections (if any) Repair reports of any blades serviced in the past Specifications/laminate schedule for the blades (if any) SKADA data on turbine performance and down time over the history of the site. Preliminary proposed plans will be presented All the blades onsite will be inspected There could be an upfront cost to get the blades back to proper service integrity A meeting with your insurance company to negotiate deductible reduction and deductible payment if a blade were to need replacement during the contract period. A proposed agreement will be presented to maintain the blades over time

Thank you. Questions?

For all your wind turbine composites servicing needs North America Houston - USA 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

Suggested Offer for Tecsis New Blade Customers Sign up for BLCM at time of new turbine purchase. (Deposit required) WindCom will be on site during construction (paid for by OEM). Blade database begun No hassle warranty work performed quickly (48hrs service?) Force majeure work completed with funds from deposit with warranty remaining intact (unless we offer a very low price for the first years during the warranty period???) End of warranty inspections at no cost. Unused portion of deposit will credit against BLCM contract after warranty period