1. Increasing Reliability Through
The Blade’s Lifecycle
Wind Project Profitability and Reliability Workshop
January 2010
San Diego
Presented by Gary Kanaby

2. Overview Reliability can be affected throughout a blade’s lifecycle.
Blade must be designed right, built right, installed right and maintained properly.
An owner/operator must be involved in the blades from their birth to decommissioning.

3. Get Involved Upfront Ask Questions
What condition monitoring is available?
Is there a Lightning protection system?
Where are your blades coming from?
Are IEC standards met?
What Certifications do you have?
Hire an ISP as a representative to visit factory
Review production process and quality system
Learn inspection processes
Get familiar with the blade structure
Source: LM Glasfiber

4. Get Blade Right Before Installation
Inspection at off-loading sites
Repairs initiated and documented
Documentation starts here
If remediation required, get an ISP to review and plan.

5. Last Chance… Second inspection before flying rotor Blade database
Blade damage
Correct Pitch
Correct tension
Blade database

6. During Warranty Know maintenance schedule Look & listen
Bolt tensioning
Inspection
Look & listen
Special attention after storms
Contact OEM immediately with issue
Document services provided
End of Warranty Inspection

7. Inspect at End of Warranty
Verify condition at end of warranty with ISP
Damage report is prepared
Warranty repairs are completed before hand off
Non-warranty repairs can also be completed at the time of inspection

8. Lost Revenue
Reduced energy as result of poor aerodynamics & pitch errors
Blade vibrations damage gearbox
Reduced energy for shut down during icing & high winds
Lost revenue due to turbine non-operation while waiting for repairs to be completed
Access to the blade using crane/lift
Actual cost of the needed repair

9. Benefits of Scheduled Maintenance
Increased availability.
Reduced crane/mobilization cost.
Reduce/eliminate large repairs and replacements.
Increased aerodynamic efficiency.
Leading edge erosion
Correct Pitch Angle

10. Blade Monitoring is Essential
Follow European Example
People Monitoring
Continuous Inspection from ground with binoculars and camera
Annual inspections
Condition Monitoring
Photo from the ground

11. Condition Monitoring Active Condition Monitoring
“Smart” blades send information to the controller
If strains are too high, angle of attack can be adjusted
Detection of major degradation of laminate or bond can shutdown machine
Fiber- optic strain gauges run span wise
Shutdown and start up during icing is controlled, minimizing downtime
Sensors in root detect imbalance

12. Condition Monitoring (cont.)
Passive monitoring
Collects data
Mass imbalance or aerodynamic imbalance can be detected
Steps can be taken before large problems occur

13. Common Damage
Lightning damage
Leading edge erosion

14. Summary
The cost of the repair itself is a small fraction of the total revenue lost due to blade problems.
Total cost must include loss of energy production, damage to other components plus increased mobilization and repair costs.
Scheduling maintenance increases productivity and decreases the total repair costs.
A number of useful tools are available to inspect and monitor blades in the field.

15. MFG automated spray booth South Dakota
Wind Energy Services Company
Gary Kanaby
MFG automated spray booth South Dakota