Effective Ways to Prevent Wind Blade Erosion
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Transcript of 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
Ec Energy Components
Em Electronic Materials
Fc Flexible Converting & Packaging
Fe Flexible Electronics
Fs Filtration, Separation, Purification
Fi Films
Im Imaging
Fl Fluoromaterials
In Inspection & Measurement
Is Integrated Systems Design
Lm Light Management
Md Medical Data Management
Me Metal Matrix Composites
Mf Mechanical Fasteners
Mi Microbial Detection & Control
Mo Molding
Mr Microreplication
Pe Predictive Engineering & Modeling
Nt Nanotechnology
Nw Nonwoven Materials
Rp Radiation Processing
Se Sensors
Po Porous Materials & Membranes
Pm Polymer Melt Processing
Wo Wound Management
Vp Vapor Processing
Su Surface Modification
Sm Specialty Materials
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
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#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–PolyTechCompe<<veMaterials(SpecialLEPCoa<ngs)
TestSpecifica<ons:V<p[m/s]140,Rain[mm/h]30-35mm,DropletSize[mm]1-2mm
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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
TestSpecifica<ons:V<p[m/s]157,Rain[mm/h]30-35mm,DropletSize[mm]1-2mm
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RainErosionTests–PolyTech3MWindBladeProtec<onCoa<ngW4600
TestSpecifica<ons:V<p[m/s]157,Rain[mm/h]30-35mm,DropletSize[mm]1-2mm
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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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TestSpecifica<ons:V<p[m/s]157,Rain[mm/h]30-35mm,DropletSize[mm]1-2mm
RainErosionTestsofNextGenCoa<ng–PolyTech3MWindBladeProtec<onCoa<ngW4601curedat23°and85%r.H.
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Profile brushed, Cured at 23/50, two times (~ 400-500 µm)
TestSpecifica<ons:V<p[m/s]157,Rain[mm/h]30-35mm,DropletSize[mm]1-2mm
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Profile brushed, Cured at 23/50, four times (800-1000µm)
TestSpecifica<ons:V<p[m/s]157,Rain[mm/h]30-35mm,DropletSize[mm]1-2mm
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1mm PU Filler (W3610) underneath, Profile casted 1 time ,Cured at 23/50; (~350µm)
TestSpecifica<ons:V<p[m/s]157,Rain[mm/h]30-35mm,DropletSize[mm]1-2mm
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1mm PU Filler (W3610) underneath, Profile casted 3 times, Cured at 23/50; (~1000µm)
TestSpecifica<ons:V<p[m/s]157,Rain[mm/h]30-35mm,DropletSize[mm]1-2mm
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Profile casted one time (~350 µm); Cured at 23/80
TestSpecifica<ons:V<p[m/s]157,Rain[mm/h]30-35mm,DropletSize[mm]1-2mm
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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
q Tweet with hashtag #WindWebinar
q Connect with Windpower Engineering & Development
q Discuss this on EngineeringExchange.com
Don’t Forget!
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