Effective Ways to Prevent Wind Blade Erosion

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q  This webinar will be available afterwards at www.windpowerengineering.com & email

q  Q&A at the end of the presentation q  Hashtag for this webinar: #WindWebinar

Before We Start

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Introducing the Featured Speakers

MODERATOR FEATURED SPEAKER Santhosh Chandrabalan Global Business Manager 3M Wind Energy

Paul Dvorak Editorial Director Windpower Engineering

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Latest Protection Methods Against Leading Edge Erosion For Increased Tip Speeds Santhosh K Chandrabalan Global Business Manager – Wind Energy 3M Renewable Energy Division

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3M Renewable Energy Division

#WindWebinar 6 © 3M 2014. All rights reserved.

§  3Menablesmoreefficientandmorereliablewindturbines,builtfasterandsafer§  Leveraging3M’scorecompetenciesinthefieldoffilms,adhesives,tapes,coa5ngsandtheinven<vepowerof40+addi<onalcorporatetechnologyplaAorms

Bi Biotech Ce Ceramics Dd Drug Delivery Di Display Do Dental & Orthodontic Materials

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Op Optoelectronics

Pd Particle & Dispersion Processing

Pr Process Design & Control

Pp Precision Processing

Tt Track and Trace

We Accelerated Weathering

Ab Abrasives Ac Acoustics Ad Adhesives Am Advanced Materials An Analytical

As Application Software

3MRenewableEnergyDivision–WindEnergy


#WindWebinar 7 © 3M 2014. All rights reserved.

Vortex Generators Aerodynamic Optimization of Installed Wind Turbines with

customized enhancement solutions

BladeBondingAdhesiveOfferinglongpotlifeands<ll50%faster

cure-addi<onallyincreasingcrackresistanceandfa<guebehavior

DryLayupAdhesiveRedcoloredsprayadhesivetoefficientlyfix

thefibermatsduringdrylayup

ErosionProtec5onSolu5onsTapes&Coa<ngofferingsuperiorerosionresistanceandprocess-advantagesinbladeproduc<on

§  Reducecycle<me§  Decreasevariability§  Increasebladethroughput§  Lowerprocesscost

§  Increasestrength§  Decreaseweight§  Enhancemechanicalproper<es§  Improvelaminatequality§  Lowerbladecost

§  Improveresistancetoerosion§  Improveaerodynamics§  EnableaTachmentstosurface§  Simplifymaintenance§  LowerO&Mcost

Rotorblade Surface

Rotorblade Structure

Rotorblade Process

Acrylic Foam Tapes For mess-free bonding applications

that require high durability and bonding strength while being mess-

free and fast to apply

WindFillersEasyandfasttoapplyfillerofferingsignificant<mesavingsbeforesanding

Sealants&AdhesivesHigh-performancesealingandbondingmaterialsforallareasoftheblade

3M`sWindPorAolio


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FieldPicturesofLeadingEdgeErosion

Source:WKA/GES&DRTS


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HigherRequirementsforSurfaceIntegrity§  Longerbladeswithhigher<pspeeds§  Offshoreinstalla<ons

§  Installa<onsinotherdemandingenvironments(e.g.desertsandcoldclimates)

§  Currentcommercialavailableproductsdonotmeeterosionresistancerequirements

Source:LMWindPower–IQPC&Sandia


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Erosion-Observa<onsfromtheField

§  Erosionisasevereproblemandcanbeseenonallblades§ …irrespec<veoftheturbineloca<on(Onshore,Offshore,Nearshore,Mountains)§ …irrespec<veofthehubheight(30m–110m).§ …irrespec<veofthepaint/coa<ngsystemused(Gelcoat,Topcoat)§ …irrespec<veofthebladelength(10m–45m).§ …irrespec<veoftheWindTurbineGeneratormanufacturer(AAlstom–ZZond)

§  Erosionisverymuchdependingon§ …theenvironmentalcondi<onsattheturbineloca<on§  ...thequalityofthebladestructureandthefinishing§ …theactual<pspeedoftheturbine

§  Acombina<onofhighpar<cleloadedairandrainhasasignificanterosionimpact


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EffectsofBladeLeadingEdgeErosiononWindTurbineOutput


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WindTunnelStudiesatUniversityofIllinois

§  TestLoca<on:§  UniversityofIllinoisAppliedAerodynamicsGroup

§  ProfMichaelSelig&AgrimSareen

§  Objec<ve:§  Determineimpactofleadingedgeerosiononaerodynamics(lijanddrag)atseveraldifferentReynoldsnumbers(hereRe1,850,000)onaDU96-W-180windturbineairfoilprofile

§  Es<matepoweroutput(AEP–AnnualEnergyProduc<on)foreachscenariousingPROPIDsojware


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ErosionCondi<onsEvaluated

§  CreatedsubscaleairfoilswithleadingedgedamageusingcomputergeneratedrandomGaussiandistribu<ons

§  3ofthe9levelsoferosionevaluatedarehighlightedinthispresenta<on

A2 – Moderate Pitting B3 – Pits + Gouges C4 – Pits, Gouges & Delamination

*Model cord length is 18 inches


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Leading Edge Status rDrag (Measured)

r Lift

(Measured)

rAEP (Simulated) rMWh / yr r€ / yr

A2 Erosion

Moderate Pitting �80%

�11%

�4.2% �166 �8,300€

B3 Erosion

Pits & Gouges �200%

�15%

�9.8% �386 �19,300€

C4 Erosion

Pits, Gouges & Delam �400%

�17%

�20.5% �808 �40,400€

Assumptions: 1.5 MW turbine, €50/ MWh, 30% capacity factor

EffectofLeadingEdgeErosiononTurbineOutputOnshore–1.5MW


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BenefitsofLeadingEdgeRepair&Protec<on

Source:LMWindPower–UWIGWindTurbineOpera<onsandMaintenanceUsersGroupMee<ng


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Products:

3MWindBladeProtec<onTapeFeatures&BenefitsofaProvenSolu<on

3MWindBladeProtec<onTapeFeatures

§  Highdurabilityensuringlonglife<me

§  Basedonover40yearsof3MProtec<onFilmexperienceinaircrajapplica<onsand

§  Morethan150,000protectedwindturbinerotorbladessince1994

§  Availableinvariouscolors(offeringsuperiorUVresistance)

3MWindBladeProtec<onTapeAdvantages

§  Significantreduc<onofleadingedgeerosion§  Extendedmaintenanceandserviceintervals

§  Fast&easeofapplica<oninOEMandMROenvironments

§  Broadapplica<onwindowenablinginstalla<onsalsounderharshenvironmentalcondi<ons(e.g.highhumiditylevels)


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BenefitsofLeadingEdgeRepair&Protec<onOnshore–1.5MW

Leading Edge Status rAEP Avg. Materials & Installation Cost per Blade

Downtime per Turbine (days)

Years of Service

ROI (months) NPV

A2 Erosion

- 4.2% 2,250 € 1 – 2 0.5 – 4 2.7 64,036 €

B3 Erosion

-9.8% 3,250 € 1.5 – 3 1 – 6 1.8 152,788 €

C4 Erosion

-20.5% 4,750 € 5 – 6 1.5 – 7 1.7 320.164 €

Example Calculation Assumption: 1.5 MW turbine, €50/ MWh, 30% capacity factor, NPV: straight line, 5 yr, 15% IRR


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Conclusion:Preven<onismoreefficientthanRepairErosionisasevereissueonalmostallrotorblades

ErosioncancausesignificantAEPreduc<ons

§  PitsandgougesreduceAEPfrom4%upto10%

§  Delamina<onreducesAEPupto20%

Preventa<vebladerepair&protec<onreducesdown<meandcosts

§  Repairoferosioncancostupto5.000EuroOnshore&44.000€Offshore

§  3MWindProtec<onTapeprovide5-10yearsofleadingedgeprotec<on

§  ROIsfromallscenariosstudiedwerelessthan5months


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Tes<ngMethodsforBladeLeadingEdgeErosiononWindTurbineOutput


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AdvancedRainErosionTestsMethodscansimulatewhattheBladeexperiencesinReal-Life

Source:LMWindPower–IQPC


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§  Shockwavesrunthoughsubstrateandwaterdroplet

§  Rayleighwavesrunoversubstrate

§ Wasserjetsrunoversubstratesurface

RainErosion-ImpactPhysics

§  “Hardmaterials”starttobreak/blister,i.e.materialsstarterodingearlier

§  “Elas<cmaterials”absorbenergy


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Source: http://www.poly-tech.dk

§  StandardTestParameters§  Rota<onalSpeed:125-157m/s§  Rain:25-35mm/h§  DropletSize:1-2mm§  Specimen:Leadingedgeprofile

HelicopterRainErosionTests

Source:UDRI&PolyTech


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RainErosionTests–PolyTechCompe<<veMaterials(SpecialLEPCoa<ngs)

TestSpecifica<ons:V<p[m/s]157,Rain[mm/h]30-35mm,DropletSize[mm]1-2mm


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RainErosionTests–PolyTech3MWindBladeProtec<onTapeW8607



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RainErosionTests–PolyTech3MWindBladeProtec<onCoa<ngW4600



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RainErosionTestsajerUVExposure–PolyTech3MWindBladeProtec<onCoa<ngW4600§  ErosionResistanceof3MWindBladeProtec<onCoa<ngW4600isnotsignificantlyinfluencedbyUVexposure

§ 

§  UVA-340lampsmatchthesolarUVspectrumwell,especiallyfrom295to370nm§  UVB-313lampsincludesignificantunnaturalradia<onbelowthesolarcut-offof295nm§  3MusesandrecommendsUVA-340lampsforacceleratedweatheringthatmakesuseofUVfluorescentlamps

Noinfluenceevenajer4000hUV


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Products:

IntroducingtheNextGenera<onLEPProtec<on3MWindBladeProtec<onCoa<ngW4601

§  W4601projectwasini<atedwiththefollowingobjec<ves

§  KeeptheleadingedgeperformanceofW4600andmakeitrobust§  Increasetheapplica<onwindowforW4600

§  Reducethecuring<meofexis<ngW4600

§  W4600formula<onwasthestar<ngpointofW4601§  Productrobustnesswasachievedbyadding3MProprietaryfluoropolymer

§  Thisaddi<veextendstheapplica<onwindowforW4601upto85%RHwithoutanylossinperformance

§  Theoriginalformula<onwasimprovedtoreducecuring<meto2hours


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IntroducingtheNextGenera<onLEPProtec<on3MWindBladeProtec<onCoa<ngW4601

Criteria W4600 W4601 Thixotropy/Sagging 300µm 350µm Curing Touch dry time ~ 1-1,5h,

Hard dry ~ 8 h, (cured at 23°C, 50% RH)

Touch dry time ~ 25 min, Hard dry ~ 1 h, (cured at 23°C, 50% RH)

Tensile ~900% Elongation at Break 27MPa Tensile Strength (cured at 23°C, 50% RH)

~700% Elongation at Break 30 Mpa Tensile Strength (cured at 23°C, 50% RH)

Application Window Loss in Rain Erosion Properties as humidity increases (similar to standard coatings)

RET shows no drop in performance after 18h RET at 85% RH

Applicability Brush and Casting Brush, Spray and Casting Mixing 1.5:1 3:1 (standard cartridges) Crysttalization If material is crystallized material

should be recovered by oven storing for 8h at 40°C

Material shows recovering properties, no oven storage needed


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KeyApplica<onFactorsInfluencingProductPerformance

Application Factor Theoritical Impact on Erosion Resistance

Coating Thickness below recommended level - Coating Thickness above recommended level + Humidty during Application & Cure - Surface Roughness - Toughness of LEP + Poor Adhesion between Surface Layers - Filler O / - Topcoat O / - Poor finish Quality (e.g. air entrapment) -

- + O neutral positive negative


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36+HourConsistentlyProvenPerformance

§  ProfilesBrushedwithW4601

§  Recommendedapplica<onthickness

§  2XRecommendedapplica<onthickness§  4XRecommendedapplica<onthickness

§  ProfileswithW4601+PUFiller

§  Recommendedapplica<onthickness§  3XRecommendedapplica<onthickness

§  ProfilesCasted

§  Recommendedapplica<onthickness§  3XRecommendedapplica<onthickness


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RainErosionTestsofNextGenCoa<ng–PolyTech3MWindBladeProtec<onCoa<ngW4601curedat23°and85%r.H.

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Profile brushed, Cured at 23/50, two times (~ 400-500 µm)


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Profile brushed, Cured at 23/50, four times (800-1000µm)


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1mm PU Filler (W3610) underneath, Profile casted 1 time ,Cured at 23/50; (~350µm)


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1mm PU Filler (W3610) underneath, Profile casted 3 times, Cured at 23/50; (~1000µm)


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Profile casted one time (~350 µm); Cured at 23/80



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KeyTake-Aways§  Erosion

§  Erosionisimpac<ngtheaerodynamicefficiencyofaturbine(upto20%)

§  BeTerTestStandardshavetobedeveloped§  RainErosion(Helicopter)Testsaretherightintermediatestep

§  UVAshouldbeusedtoagematerials

§  3Mistheleadingsupplieroferosionprotec<onsolu<ons§  3MWindBladeProtec<onTape

§  Morethan15yearsofexperienceinthewindindustry

§  S<llbenchmarkinregardtoerosionprotec<onofrotorblades§  Currentdevelopmentstoimproveease-of-applica<onanddurability

§  3MWindBladeProtec<onCoa<ngW4600andnowW4601

§  LiquidVOC-freealterna<vetoourWindTape§  EvenbeTerperformancethan3MWindProtec<onTapeinerosiontes<ng

§  Quickandeasytoapply-withnoneedforcapitalinvestment

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Questions?

Santhosh Chandrabalan Global Business Manager 3M Wind Energy [email protected] Tel: 651-733-7740

Paul Dvorak Editorial Director Windpower Engineering [email protected] @Windpower_Eng

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q  This webinar will be available at www.windpowerengineering.com & email

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