Wind Composite Services Group/WindCom Introduction

Confidential and proprietary information of WindCom

WindCompositeServicesGroup/WindComIntroduction


Who We Are

• Established in 2006• Owned by Tecsis• Headquarters in Houston, TX with offices in Spain &

Brazil• Over 75 Service Technicians in the USA• Safety Culture• Warehouse and training center (Houston)• Drug free workplace• Technically advanced


Preferred Access Method 360° Suspended Platform


BladeFleetFailureInvestigationProcess


Problem

Aging blade fleets require solutions to emerging issues


Objective

To maximize the value of the rotor for the owner and minimize business risk


The Idea• Compile and analyze original manufacturing data, operational experience, and

damage reports to determine the root cause(s) of the blade failures• Engineer and document standardized repairs and preventative measures to reliably

extend the life of the blades • WindCom will takes the role of the OEM to work with owners to find solutions. No

owner group is required. • WindCom retains data privacy for individual sites and owners, but aggregates

knowledge across the fleet.• Shares engineering results and critical findings to all owners without revealing any

detailed data provided by individual owners.


The Process

• Manufacturing data is collected from manufacturer or owners if possible• Owners are asked to provide data to the group• Blade numbers and at which site they have been operating• History of the blades- remediations, damage repairs, failures• Damage reports for different failure types and their frequency of occurrence

• The team will analyze data to determine trends and root cause(s) of damages


Example of How Data can be Assimilated

Mass Mass

Blade populations vary from design values differently during manufacturing sequence


Different Blade Failure Modes are Categorized

• Aft shell failure


Several Blade Failure Modes are Evident

• Aft shell failure


Different Blade Failure Modes are Evident

• Blade root cracking



• Trailing edge cracking



• Surface Coating Failure


DMAIC Approach

DEFINE Specify the goals of the blade remediation effort

MEASURE Obtain manufacturing, failure, & repair data for the fleet

ANALYZE Use forensic techniques to assess the root causes of failures

IMPROVE Develop solutions to address the root causes of failures

CONTROL Monitor remediation efforts to validate quality and longevity


Summary

• First document the failure types and frequency of occurrence for various failure types throughout the fleet

• Perform root cause analysis to understand why the blades are failing.• Develop engineered repairs for each specific failure mode and perform

tests to validate remediation methods• Prepare standardized repair procedures that are repeatable, have

documented engineering properties, and can be quoted using fixed cost• Develop statistical models that assist with our ability to predict failure rates• Develop preventative measures to lower risk and cost• Develop tools to estimate blade maintenance costs accurately and optimize

to control cost increases as the fleet ages over time


Blade Life Cycle Management A New Approach to a Critical Asset

Sandia Blade Workshop August 2016


Preventative Maintenance

• Blades are inspected at regular intervals• Data can be analysed using recognition software to

quickly categorize blade condition and to determine corrective actions

• Data is entered into the data base to monitor blade condition

• Decisions can be made to prevent wear and tear, damage progression or lightning damage

• Repairs are made during the low wind season with leading edge protection at planned intervals

Management Plan

Predictive Maintenance

• Using database and newly collected data future issues with the blade can be predicted

• Using the predictions a plan can be made to minimize future problems.

• Known failure modes can be investigated in further detail to prevent occurrences before they happen.

• Maintenance is not random but calculated to minimize downtime and repair expenses customized site and turbine specific.


Maintenance Plan vs Reactive only

$0

$100,000

$200,000

$300,000

$400,000

$500,000

$600,000

$700,000

$800,000

$900,000

$1,000,000

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

LostRevenueandExpensesAnnually

WithoutMaintenance WithMaintenace

$7,384,748

$87,600

$409,500

$23,400

$3,000,000

$1,500,000

0

$900,000

0

$1,950,000

$0.00

$2,000,000.00

$4,000,000.00

$6,000,000.00

$8,000,000.00

$10,000,000.00

$12,000,000.00

WithoutMaintenance WithMaintenance

Expenses andlostrevenueproductionover20years

LossofProductionErosion LossofProductionRepairs Costorrepairs Inspections LEPapplication

Assumptions:•200MWWind Farm/100-2MWturbines inMidwest•40%capacityfactorPPA@$25MWhour•Loss ofrevenuedaily$60/summer and$420/winter•Averageerosionwhichifleftunattendedwouldresultin5%loss ofenergyafter20years(.25%/yr)•Lighteningstrikes(orotherdamage)effect5blades/year


North America

Houston – USASales 281-906-9572T. +1 281 227 5130F. +1 281 227 5192

Europe

Madrid -SpainT. +34 91 241 10 02F. +34 91 293 51 96

South America

Sao Paulo - BrasilT. +55 15 2105 4800F. +55 15 2102 4875

[email protected] | www.windcomservices.com

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Wind Composite Services Group/WindCom Introduction

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