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Manufacturing Blades for Turbine Reliability Reliability Sandia Wind Turbine Reliability Sandia Wind Turbine Reliability Workshop Albuquerque New Mexico Albuquerque, New Mexico 17 June, 2009 Presented by Gary Kanaby Presented by Gary Kanaby

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Page 1: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

Manufacturing Blades for Turbine ReliabilityReliability

Sandia Wind Turbine ReliabilitySandia Wind Turbine Reliability Workshop

Albuquerque New MexicoAlbuquerque, New Mexico17 June, 2009

Presented by Gary KanabyPresented by Gary Kanaby

Page 2: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

Overview• Review the major blade challenges facing turbine

reliabilityreliability.• Designing blades that can be built as designed• Building blades that survive• Building blades that survive• Design blades that reduce loads on the turbine

• Discuss possible areas for improvement• Discuss possible areas for improvement • Research opportunities

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Page 3: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

Ch llChallenges• DESIGN FOR MANUFACTURABILITY:

• How do we make sure that the blades can be built as designed?designed?

• BLADES BUILT TO SURVIVE:• How do we build reliability into the blade?

• REDUCE LOADS ON THE TURBINE:• How do we reduce blade mass and moment?• How does aero elastic tailoring reduce loads on the turbine?

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Page 4: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

Megawatt Class Turbinesg

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Page 5: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

25 Years of Blade Scaling25 Years of Blade Scaling

60 meter blades for a 5 MW turbine.

Source: Knight & Carver

9 meter blades on a 100 kW turbine.

5Source: Euros

Page 6: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

Designing for Manufacturabilityg g yMaterial

S l tiDesign

C t SelectionConcepts

Process Development

Feasibility Study Development

Design

Study

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Design Review

Page 7: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

IEC StandardsIEC Standards(International Electrotechnical Commission)

Blade design and testing requirements:• Blade design and testing requirements:• Blades along with the rest of the machine have

standardsstandards• Not detailed

Not prescriptive• Not prescriptive • All certified machines have testing

requirementsrequirements • All processes to be tested• Quality measures built into each process

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• Quality measures built into each process• Committee now writing new standards (TC-88)

Page 8: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

Design Development

Prove Process by Prototype

Design & Process

Development

IEC 61400-1IEC 61400-22

CertificationPrototype Fabrication

DevelopmentDesign Req.

Static testField testIEC 61400-13P t t T ti

IEC 61400-23

Fatigue Test

Prototype TestingLab Testing

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Fatigue Test

IEC 61400-23

Lab Testing

Page 9: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

Manufacturing to Surviveg• Major challenges facing megawatt-scale wind

turbine blade manufacturing:turbine blade manufacturing:• Material handling and placement• Resin InfusionResin Infusion• Bond assembly• Reducing variabilityReducing variability• Increasing repeatability• QC/QA

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• QC/QA

Page 10: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

Dry Material Placementy• Properly place 1000-

2000 kg of dry fabrics g yeach shell mold.

• Dry fabrics must remain i i i d iin position during vacuum bagging and infusioninfusion.

10Source: Siemens

Page 11: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

Resin Infusion• Must distribute

500-1000 kg of gresin throughout the mold. N d f ll i f• Need to fully infuse all fibers with resin.

• Must maintain• Must maintain vacuum over large surfaces.

11Source: Sandia National Laboratory

Page 12: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

Fiber Flatness & Straightnessg• Dry fibers can shift

during vacuumduring vacuum infusion.

• Waves and wrinkles degrade ultimate strength and fatigue life ofand fatigue life of the laminate.

12Source: Knight & Carver

Page 13: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

Dry Fibery• Defects in the

vacuum pressurevacuum pressure or the resin feed system can create dry spots in the blade laminate.

Source: Knight & Carver

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Source: Knight & Carver

Page 14: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

Bondline Control• Megawatt scale

blades may require y q200-300 meters of adhesive bond.B dli hi k• Bondline thickness is critical to blade structuralstructural performance.

14Source: LM Glasfiber

Page 15: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

Automation Increases Reliability • Blades do not vary due to human variability• Blades do not vary due to human variability.• Process is repeatable.

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Source: Composite Systems, Inc

Page 16: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

• Blades do not vary due to human variability• Blades do not vary due to human variability.• Process is Repeatable.

16Source: Composite Systems, Inc

Page 17: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

B ild i Q litBuild in Quality• ISO Quality Management System:

• A system that assures that you follow a y yquality system

• Does not include specific measuresDoes not include specific measures• Manufacturer determines the quality by

controlling important processescontrolling important processes, specifications and tolerances

Advanced Inspection Tools:17

• Advanced Inspection Tools:

Page 18: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

Identifying Defectsy g• Need to identify and repair defects

in the factory.• Ultrasound

I f d th h• Infrared thermography

18Source: Knight & Carver Source: Knight & Carver

Page 19: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

Load Reduction for the Turbine• Blade Mass & Moment:

• Better blade design tools and testing allows for the margin ofBetter blade design tools and testing allows for the margin of safety to be lessened.

• New materials can be used in smaller quantities.• New processes can reduce total material mass.

• Blades that shed loads by twisting• STAR® blade demonstrates load reduction• STAR blade demonstrates load reduction.• Sweep Twist Adaptive Rotor

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Page 20: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

3-D Navier-Stokes Modeling STAR® Bladeg

20Source: Knight & Carver

Page 21: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

STAR® T h lSTAR® TechnologyPl f i d t i t• Planform sweep induces twist.

• Blade twist sheds loads.L d d ti ll f l t hi h• Load reduction allows for a larger rotor which captures more energy.

• Load reduction allows for lighter components• Load reduction allows for lighter components.• Static, fatigue and field tests confirmed model

predictions. p• Field tests confirmed 8% energy capture gain with

loads comparable to baseline.

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Page 22: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

S l tiSolutions• Better IEC Standards• Assure that blades are built as designed. Eliminate “open

loop” manufacturing process changes.• Blade designs that manufacturing processes can achieve• Blade designs that manufacturing processes can achieve.• Perform extended testing of new blade designs: static,

fatigue and field.• Trial fit before bonding.• Blades can be bladder molded and/or infused in one piece

li i ti th b dieliminating the bonding process.• Fabrics can be pre-impregnated at the factory site.• Blades can be built out of smaller subcomponents• Blades can be built out of smaller subcomponents.• Build a two piece blade that can be shipped more easily.• Automation

Page 23: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

Research Possibilities• Rapid blade design tool incorporates:

• Performance, Structure, Materials and Manufacturing processes• Multi piece blade that is easier to build & transport• Multi piece blade that is easier to build & transport.• Advanced fabrics-better properties and easier to infuse.• Low cost S-glass and/or carbon fiber.• Component construction methods.• Automation of fiber placement working toward a fully automated

process.p• Automation of quality & manufacturing processes.• Automated inspection that may include x-ray or other techniques.

Condition monitoring and smart blades

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• Condition monitoring and smart blades.• Aero-elastic blade such as the STAR® Blade

Page 24: Manufacturing Blades for Turbine Reliability - Wind Energywindpower.sandia.gov/2009Reliability/PDFs/Day1-15-GaryKanaby.pdf · Manufacturing Blades for Turbine Reliability Sandia Wind

Knight & Carver Wind GroupGary Kanaby2423 Hoover Avenue4 3National City, Ca 91950B (619)‐791‐1050 x 111F (619)‐791‐1080gkanaby@kcwind com

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[email protected] Source: Knight & Carver