mem blade manufacturing assessment - ineel.mx · mem blade manufacturing assessment brian mcniff...
TRANSCRIPT
Outline
• Review objectives and goals
• Identify and describe required
skills and capabilities
• Survey capabilities of
collaborative partners
• Match in-country capabilities to
requirements - Identify gaps
• Propose how to augment
capabilities
• Weigh risks vs benefits to
manufacture in Mexico vs abroad
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From McNiff
MEM Project Objectives
• consolidate and advance skills and knowledge to
design MW wind turbines
• promote and strengthen a supply chain in Mexico for
wind energy related goods and services
• consolidate and advance local, high tech capabilities
needed to manufacture, assemble, test, certify,
install, operate and maintain MW scale turbines
• support the development of a 1.2 MW turbine for
distributed generation in Mexico and promote local
use by small power producers.
• Completion in 3 year period
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Nordex - 60 meter, 1.3 MW
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Gearbox
Generator
Main
Bearing
Tower
BLADES
Controller
from Nordex literature
5
Component costs
6
Uniquely
Loaded,
Complex
Structures
…but with
common,
manufacturing
elements
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Blade Molds – Similar to Boats
Sinovel
S46
factory
8
Complex
tooling
Skilled Labor
Industrial
Process
Knowledge
Requirements
Sinovel
S46
factory
Required Capabilities to Design
and Fabricate Blades (anywhere)
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1. Wind turbine blade design experience
2. High performance composite engineering
3. FRP manufacturing experience
4. Experience fabricating molds
5. Project planning & management
6. Quality & acceptance testing
7. Blade testing & certification
NREL
El diablo está en los detalles
• Geometric accuracy – airfoil performance
• Consistent laminates,
• Critical transitions & bond areas
• Minimize final finishing
• Handling & transportation issues
• Lightning protection – IEC 61400-24
• Blade structural testing – IEC 61400-23
• Blade manufacturing – IEC 61400-5 (draft)
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In-Country Capabilities
• Visits and survey of selected partners – Note: these were short visits over a narrow time period to
available nearby partners
• Many more organizations & companies
showing interest
• Research and follow up questions to
organizations aided the assessment
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In-Country Organizations Visited
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Organization Label Capabilities
Instituto Investigaciones
Electricas
IIE Electrical industry research and applied engineering;
developed initial MEM design; MEM project lead
Centro de Ingeniería y
Desarrollo Industrial,
CIDESI Industrial research center; applied research & broad
range of high tech services, e.g. developing unique
tooling and processes for manufacturing specific parts
Center for Advanced
Technology
CIATEQ Industrial research center; technical consulting in
manufacturing methods and materials; production
management, industrial & technical training
Autonomous University
of Querétaro
UAQ Advanced materials, graduate engineering research
center, built 7m blade using direct to mold CNC
Global Composites Manufacturer of large FRP parts for buses and other
applications, moving into aerospace industry
TEMACO FRP boat manufacturing, mature process & skilled
workers, skilled tooling and adapatable
Somerset Technologies Design and prototype engineering group (some WTG)
Dow Chemical Dow
Material knowledge; infusion methods & manufacturing
process advisory; quality systems,
Matched capabilities
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Item Required Critical Capabilities Organization Rating
1 Wind turbine blade design
1a – aerodynamic design and aero-elastic
modeling
IIE, CIDESI,
CIATEQ, UAQ
3
1b – planform design and structural integration
and analysis
IIE, CIDESI,
CIATEQ, UAQ
3
2 High performance composite engineering
2a – High strength/ weight, laminate knowledge CIDESI,
CIATEQ, Dow
5
2b – structural analysis, FEA modeling IIE, CIDESI,
CIATEQ
4
2c – use FRP material property & fatigue data 4
Rating: 5 is best, 1 is poor
Matched capabilities
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Item Required Critical Capabilities Organization Rating
3 Process manufacturing experience using
FRP
Global, TEMACO,
Dow
5
3a – RTM or other well developed laminate
system
Global, CIDESI,
CIATEQ, Dow
4
3b – workers experienced in FRP fabrication for
material cutting, layup, inspection and finish
Global, TEMACO 4
3c – Mature quality system (9001) Global, Dow,
CIATEQ
4
4 Experience fabricating molds & tooling Global, TEMACO 4
4a – Multiple elements, clam-shell molds,
compound curves, joints, blind bonding,
steep laminate transitions
4
4b – Plug, molds, substructures (root, spar,
beams)
Global, UAQ,
CIDESI
4
Rating: 5 is best, 1 is poor
Matched capabilities
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Item Required Critical Capabilities Organization Rating
5 Project management IIE, CIDESI, CIATEQ
5a – project planning, management and
execution
IIE, CIDESI, CIATEQ 5
5b – budgeting and resource management
planning
IIE, CIDESI, CIATEQ 5
6 Acceptance testing - manufacture
6a – As-built coupon strength and
composition tests,
CIATEQ, CIDESI 5
6b – Geometrical accuracy – airfoil &
planform
CIATEQ, CIDESI 3
6c – Inspections for poor bonds, voids,
laminate discontinuities, etc using NDT
Somerset (NDT),
CIATEQ, CIDESI
3
6d – Measuring weight and CG location,
stiffness, eigen-frequencies
Somerset?, need
WTG specific advice -
Rating: 5 is best, 1 is poor
Matched capabilities
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Item Required Critical Capabilities Organization Rating
7 Certification & Validation
7a – wind turbine blade testing experience 1
7b – experience in any product certification CIATEQ 2
7c – experience specific to wind turbine
certification
1
7d – lightning protection CIATEQ, CIDESI 1
Scenarios for Blade Procurement
1. buy a set of commercially available blades
- modify design of MEM around them
2. contract directly with a blade design/ fabrication group
- deliver the blades and /or molds
3. competitively bid the complete project (original IIE plan)
- to any worldwide entities
4. choose a Mexican group to lead the project organizing
and utilizing industrial partners in-country
- using in-country partners identified with the required skills.
- Write specifications for missing capabilities
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1. Buy a commercial blade
• None available from initial searches (of size)
• HT in China has one listed, but no evidence of
existing blades
• None of size listed as component certified
• Do not purchase uncertified
• May require re-evaluation of design loads
– Other components may need redesign
• Turbine certification requires all aerodynamic,
structural and material design details (IP?)
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2. Contract directly with design group
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• Groups that design all fabrication tooling and
process (- specialty)
• Will also provide, adapt, review design
• Different levels of sophistication and
knowledge of WTG (- careful selection required)
3. Competitively bid complete project
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• Open to consultancies, blade suppliers, plus
design/ fabrication companies & others
• IIE - TdR currently written this way
• Re-write to maximize in-country value-added
– Some use of in country skills and facilities
– Also require local training, technology share etc
• Careful selection and management required
4. Mexican group to lead project
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• Mexican group organizes and plans project
• Utilize partners in-country with required skills
– Maximize in country value added
– Experience accrues to Mexican companies
• Write specifications for missing capabilities
– Supplement the skills to fill identified gaps
– Require external consultant to train etc
• Re-write as MEM sub project
– Also require local training, technology share etc
External expertise Item Task Required activity Expertise
1a Aerodynamic
design
- Provide review, critical analysis &
recommendations to IIE aero design;
- perform independent aero analysis;
- Work collaboratively to converge
final design & design loads.
Extensive use of aero-
elastic codes and
standard engineering
design tools (CAD, FEA).
Thorough understanding
of root and root to airfoil
transitions areas
1b Structural
design
- Provide review, critical analysis &
design recommendations to IIE draft
structural design
- including complete laminate
schedule, internal structural elements,
blade bolt retention, root stiffness
transition, and lightning protection
system
understanding of high
strength FRP laminate
design, understanding of
unique elements of blade
structure – root,
transition, bonding, etc
3, 4 Manufacturin
g process
-Work collaboratively with team in
planning and detailing of all elements
of blade manufacturing
- including master mold and tooling,
selection of materials and process,
RTM manufacturing of
medium to large FRP
structures, closed mold
assembly, blind bonding 22
External expertise
Item Task Required activity Expertise
6 Acceptance - Advise on how to assure high quality is
maintained and verified throughout
manufacturing,
- contribute to developing final in-factory
acceptance testing of subcomponents and
complete blade
- to assure structural integrity and
manufacture consistency
Blade specific
experience
7c Certification - Advise on all elements of documentation
required for certification
Experience with
documentation for
design certification
7a Blade
structural
testing
- blade testing centers (NREL, CENER,
ECN, DNV/ DTU, etc) are experienced at
this, & requirements are well defined per
IEC 61400-23
best left to an
accredited blade test
lab (per IEC 17025)
that specializes
7 Lightning
protection
- good guidance in IEC 61400-24,
- should be supplemented. Testing not
required but will be soon
See report
recommendations 23
Evaluating and
Mitigating Risk of In-country Mfg
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Estimated In-Country
Manufacturing Schedule
Estimates from information provided in conversations with TEMACO (mold fabrication), Wetzel
Engineering (blade design and fabrication) , DNV-GL (certification) and NREL (testing).
Summary and Conclusions
• Sufficient capabilities exist in Mexico to
manufacture high quality MEM blades
• Risk of manufacturing in Mexico vs
abroad is not significantly different
• Achievable in less than 3 years based
on estimated realistic schedule
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