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Sandia 2014 Wind Turbine Blade Workshop- Coffey
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Blade Reliability Case Study
Sandia Wind Turbine Blade Workshop
August 26, 2014
David Coffey
2David Coffey
Overview
• Snapshot of Iberdrola Renewables
• Overview of blade failure data
• Failure modes & repair rates
• Examples of carbon spar damage
• Examples of large crack repair
• Conclusions
• Improvement Goals
Aug 26, 2014
3David Coffey
Iberdrola Renewables - North America
Aug 26, 2014
Iberdrola Renewables develops, owns and operates wind plants throughout the U.S.
• 3000+ turbines• 56 wind farms • 18 states• 6+ GW capacity• 6 different OEMs• Rotor dia. 47-102 m
O & M Engineering:• Performance & Reliability• Continuous Improvement• Root cause analysis• Reliability centered maintenance• Failure rate projections• Repair specifications
4David Coffey
Snapshot of Iberdrola Renewables Fleet
Aug 26, 2014
5David Coffey
Blade Reliability
Aug 26, 2014
“Repair required” blade damages by year:• 7+ years• ~ 2600 reports• includes end of
warranty inspections, FM, operations etc.
Typical types of damage:• Lightning• Cracks• Impact damage • Surface/gel coat• LE erosion
6David Coffey
Blade Reliability
Aug 26, 2014
Top 5 damage types:1. Lightning2. LE Erosion - Light/medium/heavy3. Cracks4. Gel coat damage5. “Undetermined”
includes:• Lightning• Ice• Moisture
intrusion
Damages can be broken down further by location on blade
Top 9 represent 80%
7David Coffey
Blade Reliability
Aug 26, 2014
• 94% reported damage is repairable
• Repair rates for lightning have improved
• Carbon spar damage is still problematic
• Structural cracks are less likely to be repairable
8David Coffey
Examples of carbon spar lightning damage
Repairable today Repairable tomorrow?
Aug 26, 2014
9David Coffey
Examples of large crack repair
Aug 26, 2014
Upper shell
Lower shell
• Testing feasibility of large crack repairs• Will the repairs last?• Is it economical?
10David Coffey
Blade Reliability
Conclusions:1. Overall blade damage rates are higher than expected
2. Lightning damage, LE erosion, Gel coat damage account for 80% of damage reported
3. 94% total repair rate for all blade damages– 6% replacement rate drives cost of ownership
4. Ongoing cost of ownership for carbon spar blades is higher than other blade types– Actively seeking improved protection and repair options.
Aug 26, 2014
11David Coffey
Improvement Goals:
1. Blade damage– Improved data reporting – standard method of damage categorization– Continue to refine and improve damage reporting data base
• Clear and consistent criteria for run vs. stop decisions• Clarify repair criteria
– Up tower repair – types and severity– Ground repair – economic feasibility of repairs
2. Lightning protection:– Design and test standards
• Improvements needed to IEC61400-24 lightning protection efficiency calculations
– LPS system enhancements
3. Large crack repair
4. Carbon spar repair
Aug 26, 2014
David Coffey 12
Thank You!