Download - 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
Stanford Composites Class, 11-September-2007, Paul Veers
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
Stanford Composites Class, 11-September-2007, Paul Veers
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Leadin Turbine Manufacturers
These four
suppliers
account for
75% of the
Gamesa (Spain)
world market
Vestas(Denmark)
Enercon
Stanford Composites Class, 11-September-2007, Paul Veers
(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
*
Stanford Composites Class, 11-September-2007, Paul Veers
,
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
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2006 costs are up over 50% Steel & copper
Currency exchange rate Limited Suppliers
Stanford Composites Class, 11-September-2007, Paul Veers
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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
Stanford Composites Class, 11-September-2007, Paul Veers
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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
Stanford Composites Class, 11-September-2007, Paul Veers
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
Stanford Composites Class, 11-September-2007, Paul Veers
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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
Stanford Composites Class, 11-September-2007, Paul Veers
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
Stanford Composites Class, 11-September-2007, Paul Veers
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Blade weight has dropped in
Use of Design Standards
Better manufacturing
Cubic
1995-2005Cubic
1985-1995 After 2005
Stanford Composites Class, 11-September-2007, Paul Veers
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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
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from wind tunnel tocoupon testing
Some larger blades
use carbon fiber n us on
manufacturingprocess
Stanford Composites Class, 11-September-2007, Paul Veers
Courtesy of LM Glassfiber
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with Mitsubishi - Vientek
Mostly glass fiber withglass/carbon hybrid in thespar caps
infusion technology formanufacturing
Stanford Composites Class, 11-September-2007, Paul Veers
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 $100,000 per MW
s s n e ne g or oo o , or aset of blades on a 1.5 MW machine
Blade strength and cost varies with the IEC
Standard Class of the site Class I is a high energy site with shorter, stronger blades
Class II is a lower wind site with longer blades and lowerdesign loads
Stanford Composites Class, 11-September-2007, Paul Veers
Class III is still lower wind speed and relaxed design loads.
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Turbine and Blade Market 2011 Forecast
The Global Wind Power M arket in US$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
Stanford Composites Class, 11-September-2007, Paul Veers
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$7B in 2011.
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Blade full-scale and material testin
Carbon Fiber
specimen failedin compression
Fatigue Test
Stanford Composites Class, 11-September-2007, Paul Veers
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
Stanford Composites Class, 11-September-2007, Paul Veers
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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%
Stanford Composites Class, 11-September-2007, Paul Veers
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Example of Fundamental Research findings
New Materials Carbon/Glass Hybrid-
Passive load reduction
a er a - ase
Geometry-based
Stanford Composites Class, 11-September-2007, Paul Veers
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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
)
Stanford Composites Class, 11-September-2007, Paul Veers
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
Stanford Composites Class, 11-September-2007, Paul Veers
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.
Stanford Composites Class, 11-September-2007, Paul Veers
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
Stanford Composites Class, 11-September-2007, Paul Veers
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
Stanford Composites Class, 11-September-2007, Paul Veers