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Ashwill - SNL Blade Workshop - Feb. 24, 2004
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• Thanks for Attending!!!• Workshop Staff
– Sam Gershin, Lenore Boulton– Lisa Sena-Henderson, Rachel Woodrum,
Shannon Clark• DOE Wind Technology Management Team
– DOE – Peter Goldman (Manager), Stan Calvert,Jack Cadogan, Phil Dougherty
– NREL – Bob Thresher (Director), Brian Smith,Mike Robinson, Dave Simms
– SNL – Paul Veers• DOE Albuquerque – Danny Sanchez
Ashwill - SNL Blade Workshop - Feb. 24, 2004
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Why a Blade Workshop
• Increasing interest in Wind Energy– Growth in worldwide capacity– New offshore projects in the U.S.
• Interest in blades– Increase in blade-related papers in conferences
(ASME Wind Energy Symposium)– Articles in non-wind-specific magazines
• Goals for further COE reduction– Heavily rely on blades/rotor
• Bring together those with common interests– Discuss issues associated with design & fabrication of
modern turbine blades
Ashwill - SNL Blade Workshop - Feb. 24, 2004
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Growth of Wind Energy Capacity Worldwide
Growth of Wind Energy Capacity Worldwide
0
10000
20000
30000
40000
50000
60000
90 91 92 93 94 95 96 97 98 99 '00 '01 '02 '03 '04 '05 '06 '07
Rest of World
Actual Projected
Rest of World
North America North America
Europe Europe
Jan 2003 Cumulative MW
Rest of World = 3,261
North America = 4,944
Europe = 23,832
MW
Inst
alle
d
Sources: BTM Consult Aps, March 2003AWEA/EWEA Press Release 3/3/03
0
10000
20000
30000
40000
50000
60000
90 91 92 93 94 95 96 97 98 99 '00 '01 '02 '03 '04 '05 '06 '07
Rest of World
Actual Projected
Rest of World
North America North America
Europe Europe
Rest of World
Actual Projected
Rest of World
North America North America
Europe Europe
Jan 2003 Cumulative MW
Rest of World = 3,261
North America = 4,944
Europe = 23,832
MW
Inst
alle
d
Sources: BTM Consult Aps, March 2003AWEA/EWEA Press Release 3/3/03
Ashwill - SNL Blade Workshop - Feb. 24, 2004
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MBOE/day
0
5
10
15
20
25
2000 2005 2010 2015 2020
Wind
Biomass power
Biofuels
Solar thermal
Geothermal
Solar PV
RE Growth PredictionsSource: Shell Global Scenarios
Ashwill - SNL Blade Workshop - Feb. 24, 2004
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Cost of Wind Energy is Falling
Increased Turbine Size - R&D Advances - Manufacturing Improvements
0
1000
2000
3000
4000
5000
6000
7000
1980 1983 1986 1989 1992 1995 1998 20010
102030405060708090
100
U.S
. Cum
ulat
ive
Cap
acity
(MW
)
Cos
t of E
nerg
y (c
ents
/kW
h*)
*Year 2000 dollars
Ashwill - SNL Blade Workshop - Feb. 24, 2004
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Current Wind Industry Market
• Size– 1.5-5.0 MW– Towers: 65-100
m– Blades: 34-50m– Weight: 150-
500t
• Costs– System <
$3/lb– Blades <
$5/lb– ~ $0.75/Watt– $0.04-
0.05/kWh
Ashwill - SNL Blade Workshop - Feb. 24, 2004
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Ashwill - SNL Blade Workshop - Feb. 24, 2004
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Ashwill - SNL Blade Workshop - Feb. 24, 2004
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How Do We Reduce the Cost of Energy from Wind Turbines?
(Thresher: 5/02)
Technology Improvements Estimated COE Improvement• Larger-scale 2 - 5MW - (rotors up to 120m) 0% ± 5%
• Advanced rotors and controls –(flexible, low-solidity, higher speed, hybrid carbon-glass -15% ± 7%and advanced and innovative designs)
• Advanced drive train concepts -(Hybrid drive trains with low-speed PM generators and -10% ± 7%other innovative designs including reduced cost PE)
• New tower concepts - (taller, modular, field assembled, -2% ± 5%load feedback control)
• Improved availability and reduced losses - (better controls, -5% ± 3%siting and improved availability)
• Manufacturing improvements - (new manufacturing methods, -7% ± 3%volume production and learning effects)
• Region and site tailored designs (tailoring of larger 100MW -5% ± 2%wind farm turbine designs to unique sites)
TOTAL -44% ± 32%
Ashwill - SNL Blade Workshop - Feb. 24, 2004
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Comparison of Weight Trends WindStats Data & Preliminary Designs
SAND2004-0074, Innovative Design Approaches for Large Wind Turbine Blades; Final Report, TPI
Ashwill - SNL Blade Workshop - Feb. 24, 2004
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Mass Growth for Commercial MW-scale Blades (primarily fiberglass)
0
5
10
15
20
25
20 30 40 50 60Rotor Radius (m)
Bla
de M
ass
(103
kg)
Commercial Blade DataLM 35.0 / 43.8 (Class 2)V66 / V80 (Class 1)Commercial Data Trendline
Commercial MassTrend - R2.30
SAND2004-0073, Blade System Design Studies Volume II: Preliminary Blade Designs and Recommended Test Matrix, GEC
Ashwill - SNL Blade Workshop - Feb. 24, 2004
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Design Process Trends
• Have matured significantly over the past 10 years
• Back-of-envelope calculations to in-house computational tools
• Now some codes available at labs and commercially– BLADED– ADAMS– FAST– FEM codes and preprocessors,
ANSYS/NuMAD
Ashwill - SNL Blade Workshop - Feb. 24, 2004
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Design Process Trends
• Load models continually upgraded to reflect improvements from research
• Certification & Standards GL, IEC, now UL– Designs enhanced by
consistent modeling practices to get certification
– Designers can use a set of commonly accepted load cases & not re-invent
Ashwill - SNL Blade Workshop - Feb. 24, 2004
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Design Advancement Opportunities
– Load alleviation • Passive - twist coupling
– Sweep twist• Active devices - microtabs
– Performance enhancement & control devices
• Pitch – collective & individual• Flaperons, ailerons• Active devices
– Efficient internal blade architecture• Anti-buckling concepts
– Slender blades– Integrated structural/aerodynamic design
• Thickened airfoils– Safety factor shakeouts
Ashwill - SNL Blade Workshop - Feb. 24, 2004
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Trends in Materials
• Continuation of material characterization– Data bases available to public –
DOE/MSU & FACT
DOE/MSU Fatigue Data Base•Material Properties (8800 Data Points for 158 Materials)
–Industry Materials (23)–Specialized Materials
•Expanded Programs–Spectral Loading–Matrix Materials–Carbon Fibers
•Updated Yearly - sandia.gov/wind/
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Trends in Materials
• Availability of new materials and new material forms– Traditional forms of glass
• Woven• Stitched• Bonded
– Carbon • Large tow & medium tow –
less expensive– Carbon-Hybrid– Pre-preg glass & carbon– 3D weave– New matrix materials
Ashwill - SNL Blade Workshop - Feb. 24, 2004
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Carbon & Carbon-Hybrids Provide Enhanced Strength for Less Weight
Large Tow Carbon FibersE-glass Fibers
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Additional Research in Materials• Continued characterization of new
or modified materials• Thin v. thick coupons v. full blade
properties (transfer function)– Determine properties in as-built
structure– More efficient composite design
• Understanding design details and substructures – Effect of defects, ply drops– Material combination (hybrids)
introduce strain concentrations– Carbon-glass interfaces– Concerns about waviness &
compressive strength
Failure of the Fiberlass Drives the Failure of the Hybrid Composite
Ashwill - SNL Blade Workshop - Feb. 24, 2004
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Manufacturing Process Trends
• Gone from hand lay-up to more automated processes– Pre-preg– Infusion – various forms– Re-emergence of wood-
carbon blades
Ashwill - SNL Blade Workshop - Feb. 24, 2004
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Manufacturing Process Trends
• Coupling of two or more processes– Pre-preg and infusion– Automated lay-up with
pre-preg or infusion– Incorporation of pultrusions
• MSU/Cairns• WindPACT
Studies/Zuteck
Ashwill - SNL Blade Workshop - Feb. 24, 2004
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Potential Improvements in Manufacturing
• Manufacturing processes– Process designed/optimized around
different forms • Modeling of process itself
– Material/resin combinations that infuse well to achieve desirable fiber content
– Pre-form use in thickened areas
• Increased reliability in general– Quality & repeatability (reduce
uncertainty)– More of test-validate-redesign cycle
• Automation– Tape laying– Pre-forms
5.0 mmCarbonlayers
Single exterior plydrop (symmetric)
to 3.0 mmcarbon layers
2x fiberglassouter plies
7.5 mmAdditionalfiberglass
3.0 mm Carbon layers
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