large blade for low-speed sites

NR65.5: CHALLENGES IN DESIGN, PRODUCTION AND LOGISTICS OF A VERY LARGE ONSHORE ROTOR BLADE

Stuttgart,

24.09.2015

Platform Strategy one platform … three turbines

New N131 Blade design, materials and manufacturing

XL Blade challenges in production and logistics

AGENDA

NR65.5: Challenges in design, production and logistics | Nordex Energy GmbH | Stuttgart | 24.09.2015 Vogl 2




AGENDA


4

NORDEX EVOLUTIONARY DEVELOPMENT

Generation Alpha N80/2500

Generation Beta N90/2500

Generation Gamma N80/2500 N90/2500

N100/2500 N117/2400

2000 2007 2010 2013

Generation Delta N100/3300 N117/3000 N131/3000 N131/3300

Global fleet availability in 2014 ~98 % Turbines under Nordex Service

15 years and

more than 10,000 MW*

*as of Sept.15

NR65.5: Challenges in design, production and logistics | Nordex Energy GmbH | Stuttgart | 24.09.2015 Vogl

Rotor diameter

131 m

117 m

100 m

90 m

6,0 6,5 7,0 7,5 8,0 8,5 9,0 9,5 10,0

Wind speed [m/s]

IEC 3a IEC 2a IEC 1a

NORDEX MULTI MW PLATFORM

5

N117/3000

N100/3300

N117/2400

N100/2500

N90/2500

Generation DELTA

Generation GAMMA

N131/3000





AGENDA


2014

0 m

20 m

40 m

60 m

80 m

100 m

120 m

140 m

Nordex Rotor Diameter

Industry Average Rotor

Diameter

1987

1997

Blade Specification

Blade Design

Blade Production

Blade Testing

Blade Installation

Blade Service

Lifecycle support

TURBINE BLADES - NORDEX CORE KNOW-HOW FOR OVER A DECADE

Source: iea 2014, technology roadmap

3D-CAD-Modelling Finite Element Calculation

3D-CFD-Calculation Blade Design Verification

Full scale test Quality assurance

7

27m

131m


NR65.5 – NEXT STAGE OF NORDEX BLADE EVOLUTION

8

NR 50

NR 58.5

NR 65.5

Performance-optimized root section

Max. chord moves further towards root to increase yield and limit loads

Introduction of yield-optimized Nordex flatback profiles

Sound & load-optimized tip section

More slender outboard section to optimize load and wake properties

Selection of proven family of profiles with superior sound power properties


NEW N131 BLADE success factors

9

NR50 NR58.5 NR65.5

WTG type N100 N117 N131

Length 48.8 m 57.3 m 64.4 m

Weight (1) 10,900 kg 10,200 kg 14,100 kg

Max. Chord 3700 mm 3496 mm 3938 mm

Pre-bend 2000 mm 2000 mm 3000 mm

Projected surface

116 m² 121 m² 153 m²

# of bolts 64 (M36) 64 (M36) 68 (M36)

Bolt circle diameter

2300 mm 2300 mm 2800 mm

Materials GRP GRP & CRP GRP & CRP

• Structural & aerodynamic design are based on the experiences of fully certified in-house developments NR45, NR50 and NR58.5

• Use of proven rotor blade design and carbon fiber composites (CFRP) in spar caps is key performance

• +12% of rotor diameter while adding 26 % to projected surface

• Development of manufacturing concept in cooperation with composite specialist Carbon Rotec

1 Without stud bolts but inclusive transverse bolts.


ROOT CAUSE success carbon blades

10

material supplier

Nordex blade

develop

spezial service

rotor blade

btp partner

Nordex lead

factory

btp partner

best

practi

ze s

harin

g

best

sim

& t

est

best

pro

perti

es


DESIGN CHALLENGES aeroelastic stability

11

Inertia Forces

Elastic

Forces

Aerodynamic

Forces

Dynamic

Aeroelastic

Static Aeroelastic

Flexible TurbineRigid Turbine

Collar-Triangle: classification of force interaction

Static Aeroelastics: • torsion divergence • optimal twist

Dynamic Aeroelastics: • Classical flutter • Limit cycle oscillations

Aeroservoelastics: • Controller interaction


light wind turbines more prone to aeroelastic stability problems

• cause of their slender form and

• different loads compared to strong wind turbines.

more accurate torsion stiffness calculation and validation

complete modal analysis

static aeroelastics in optimal blade shape (twist)

dynamic aeroelastics in defining stiffness properties

classical and non-classical flutter limits

DESIGN CHALLENGES aeroelastic stability

12

NR65.5

mode s

hapes


ANALYSING KEY COMPOSITES STRATEGIES AND CURRENT PRODUCTION METHODS

Costs of Energy / Costs per blade


Courte

sy o

f H. R

uckdaeschel, B

ASF S

E

ANALYSING KEY COMPOSITES STRATEGIES AND CURRENT PRODUCTION METHODS

Composites – Simulation as valuable tool to bridge length scales


length scale

pro

duct

matu

rity

nm mm m

fiber level

fabric level

application level

molecular level

mm

application level: turbine design blade weight efficiency

fiber level: virtual material characterization:

failure, degradation parametric studies:

voids, sizing, heterogeneities virtual single-fiber-experiments

fabric level: virtual experiments engineering constants first ply failure fiber dominated failure

Courte

sy o

f H. R

uckdaeschel, B

ASF S

E

COMPOSITE MATERIAL VS. DESIGN: WHICH COMES FIRST?

15 NR65.5: Challenges in design, production and logistics | Nordex Energy GmbH | Stuttgart | 24.09.2015 Vogl

innovations demand for holistic view – manufacture, design, performance, materials, etc.

Performance

Design Material

Process

final turbine

Courte

sy o

f H. R

uckdaeschel, B

ASF S

E

Comparing spare caps GFRP CFRP Comparable blade design , same design loads.

DEVELOPMENT OF A SLENDER ROTOR BLADE


Task: Development of a slender rotor blade to fit on an existing turbine • Existing turbine: N100/2500 (medium-wind turbine, IEC II class) • Goal: Turbine for low-wind sites, 117 m rotor diameter, 2400 kW

First try Second try

Carbon fiber No Yes (main spar cap)

Weight 14,4 tons 10,2 tons

Loads

Costs -

N131/3000

Rotor blade test NR65.5

• Static Tests (4 Directions)

• Dynamic Tests

• Edgewise Direction in progress

• Flapwise Direction

• Static Test (Post Fatigue)

Generation Delta

Test & measurement programme well on track





AGENDA


CHALLENGES IN PRODUCTION

19

Courtesy of Carbon Rotec



20




21



Transport from production site to windpark Janneby

• No transport permit over motorway

• ship transport necessary

• Increase of transport time and costs

Harbour time

Harbour cranes

• Less flexibility

• By the way: Blade transport on trucks does fit Elbe tunnel

LOGISTICAL CHALLENGES

22

Transport by ship Transport by truck


XL blades can be transported, but …

• it is time consuming

• it is more expensive than transporting smaller blades

• longer routes may apply

LOGISTICAL CHALLENGES – NEW TRANSPORT SOLUTIONS


LOGISTICAL CHALLENGES – NEW TRANSPORT SOLUTIONS


Logistic challenges: installation in forest

Optimized site management and single blade traverse make it possible


26

LOGISTICAL CHALLENGES – WE CAN DO IT


THANKS FOR YOUR ATTENTION.

Nordex Energy GmbH Langenhorner Chaussee 600, D-22419 Hamburg, Germany

Telephone +49 (40) 30030 1000

Fax +49 40 30030 1101

E-Mail [email protected]


large blade for low-speed sites

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