1. Wind Composite Services Group/WindCom
18/04/2018
Wind Composite Services Group/WindCom
Introduction

2. 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

4. Preferred Access Method 360° Suspended Platform

5. Blade Fleet Failure Investigation Process
18/04/2018
Blade Fleet Failure Investigation Process

6. Problem
Aging blade fleets require solutions to emerging issues

7. Objective
To maximize the value of the rotor for the owner and minimize business risk

8. 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.

9. The Process
Manufacturing data is collected from manufacturer or owners if possible
Owners are asked to provide data to the group
Blade numbers and at which site they have been operating
History of the blades- remediations, damage repairs, failures
Damage reports for different failure types and their frequency of occurrence
The team will analyze data to determine trends and root cause(s) of damages

10. Example of How Data can be Assimilated
Blade populations vary from design values differently during manufacturing sequence
Static Moment
Mass
Mass

11. Different Blade Failure Modes are Categorized
Aft shell failure

12. Several Blade Failure Modes are Evident
Aft shell failure

13. Different Blade Failure Modes are Evident
Blade root cracking

14. Different Blade Failure Modes are Evident
Trailing edge cracking

15. Different Blade Failure Modes are Evident
Trailing edge cracking

16. Different Blade Failure Modes are Evident
Surface Coating Failure

17. DMAIC Approach
DEFINE Specify the goals of the blade remediation effort
MEASURE Obtain manufacturing, failure, & repair data for the fleet
ANALYZE Use forensic techniques to assess the root causes of failures
IMPROVE Develop solutions to address the root causes of failures
CONTROL Monitor remediation efforts to validate quality and longevity

18. Summary
First document the failure types and frequency of occurrence for various failure types throughout the fleet
Perform root cause analysis to understand why the blades are failing.
Develop engineered repairs for each specific failure mode and perform tests to validate remediation methods
Prepare standardized repair procedures that are repeatable, have documented engineering properties, and can be quoted using fixed cost
Develop statistical models that assist with our ability to predict failure rates
Develop preventative measures to lower risk and cost
Develop tools to estimate blade maintenance costs accurately and optimize to control cost increases as the fleet ages over time

19. Maintenance Plan vs Reactive only
Assumptions:
• 200MW Wind Farm/ 100-2MW turbines in Midwest • 40% capacity factor $25MW hour • Loss of revenue daily $60/summer and $420/winter
• Average erosion which if left unattended would result in 5% loss of energy after 20 years (.25%/yr)• Lightening strikes (or other damage) effect 5 blades/year

20. For all your wind turbine composites servicing needs
North America
Houston – USA
Sales
T   F
Europe
  Madrid -Spain
T F
South America
Sao Paulo - Brasil
T F |

21. Step 1: Define
DEFINE Specify the goals of the blade remediation effort
VALUE Maximize the value of the blades to the owner
LIFETIME What is the goal for the design lifetime of repaired blades?
1 year, 5 years, 10 years, 20 years
MODES What failure modes have occurred in the fleet? What is the observed risk for each mode of failure?
How do modes affect WTG performance & safety?

22. Step 2: Measure
MEASURE Obtain manufacturing, failure, & repair data for the fleet
DESIGN Design manufacturing drawings and work instructions
PRODUCTION Blade weight and balance values, dates of manufacturing
HISTORY Operational and blade remediation history
CONDITION Photography and non-destructive testing results

23. Step 3: Analyze
ANALYZE Use forensic techniques to assess the root causes of failures
IEC LOADS Perform calculations for IEC fatigue and extreme conditions
DYNAMICS Assess the structural dynamic response across the fleet
STRUCTURAL Evaluate the structural impacts for ultimate and fatigue cases

24. Step 4: Improve
IMPROVE Implement solutions to address the root causes of failures
DIAGNOSTICS Create procedures to identify blade issues before remediation
REMEDIATION Document existing condition and perform remediation

25. Step 5: Control
CONTROL Monitor remediation efforts to validate quality and longevity
QUALITY Review the remediation process to assess field implementation
LONGEVITY Implement processes quantify the remediated blade longevity

26. Blade Life Cycle Management A New Approach to a Critical Asset
18/04/2018
Blade Life Cycle Management
A New Approach to a Critical Asset
Sandia Blade Workshop August 2016

27. Management Plan Preventative Maintenance Predictive Maintenance
Blades are inspected at regular intervals
Data can be 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
Repairs are made during the low wind season with leading edge protection at planned intervals
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.