Blades are the most critical components of wind turbines, and the manufacturing process is intricate and predominantly manual, with roughly 250 people involved in producing each blade. This labour-intensive approach stems from the industry's rapid pace of innovation, which sees new products launched every three to five years without fully consolidating previous production methods. Models are continually updated, blades are lengthened, aerodynamic innovations are explored, and more aggressive structural designs are pursued in a relentless quest for optimal blade productivity. However, this constant drive for innovation often undermines the very efficiency it aims to enhance.
The blade production process can be divided into five stages: the initial stage involves preparing the fibres and the accessories; the second, is the chemical stage, where resin is injected and infusion occurs; then the mechanical stage, where the two halves of the blade are joined and adhered; the fourth stage includes finishing touches such as painting and lightning protection; and the final stage encompasses logistics.
Each stage presents unique challenges that vary with the blade model being produced and minor deviations or errors at any stage can result in catastrophic failures.
Quality challenges
For the past two decades, maintaining the quality of wind turbine blade manufacturing has posed a consistent challenge. Far from becoming rarer, images of massive blades crumpled like paper, scorched by lightning, or showing delamination and deterioration at the leading edge have become increasingly frequent as the turbine fleet ages.
, the successor to Tecsis – a former top-three global blade manufacturer – has reinvented itself with a commitment to developing new processes that enhance energy generation efficiency and address structural issues that extend the lifespan of existing blades. The paradox is that this approach does not seek to create a groundbreaking new product; rather, it focuses on the meticulous task of correcting flaws that arise from the relentless pursuit of the next big innovation.
The drive to prolong blade longevity not only generates economic value but also enables environmental benefits by delaying blade disposal and, consequently, extending carbon sequestration. Among all wind turbine components, blades present a unique challenge due to inadequate recycling options and end-of-life disposal methods. Although some alternative solutions are being explored, the prevailing approach involves dismantling the blades and relegating them to landfills, a solution that remains far from satisfactory.
Root replacement
One recurring issue across various blade models involves manufacturing defects at the blade’s root, such as wrinkles, severe delamination, or loosening at the joints that attach the blades to the turbines, known as inserts. These are metal components incorporated into several blade models and vary in number based on the model and primarily the diameter of the root. The failure typically starts with a millimetric movement of an insert from the blade laminate, which triggers a domino effect, in many cases leading to the blade detaching from the turbine.
Currently, the standard solution for loose inserts is to replace the entire blade. The Adcomp-Tecsis innovative development involves replacing only the blade root when the metallic inserts become loose. This is an unprecedented solution and this procedure has already been successfully implemented by Adcomp-Tecsis on the 1.65MW rotor model.
Root replacement for 2MW turbine model
Adcomp-Tecsis and Echoenergia have partnered to develop the root replacement solution for the 2MW turbine. Within this partnership Echoenergia provided financial support and supplied data and inputs for Adcomp-Tecsis analysis and project development. Additionally, Echoenergia contributed a blade with loose inserts from its turbine fleet for prototype development.
In collaboration with Wetzel Wind, an American blade design firm, Adcomp/Tecsis developed a specialised1 project aimed at manufacturing a new root and securely attaching it to the existing blade. The initial phase of the project involved a thorough RCA that examined both the blade design and the manufacturing process. Based on these insights, the next step involved designing the project and implementing a new production process: a comprehensive review of approximately 20 different micro and macro processes for the root manufacture, and the removal of the existing root and replacing it with the new one. After the new documentation was in place, production started.
The final product, engineered to meet the safety and durability standards of a new blade, underwent extensive static and fatigue testing at Adcomp-Tecsis's facilities. It has a projected operational lifespan of 20 years, confirming its robustness and reliability.
Final thoughts
This solution requires a smaller investment than completely replacing a blade, offering significant financial benefits. Not only that, but this solution is also more sustainable, delivering a significant reduction in carbon emissions—around 88% less CO2—and an 85% reduction in landfill disposal.
As of May this year, the solution, currently undergoing the patenting process and certification, has already been successfully implemented on approximately 175 blades for 1.65 MW and 2.0 MW rotors.
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