Wind Composite Services Group/WindCom Introduction
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WindCom is an international wind turbine service company established in 2006 with headquarters in Houston, TX and offices in Spain and Brazil. They have over 75 service technicians across locations. The document discusses WindCom's blade fleet failure investigation process where they collect and analyze manufacturing and operational data from blade fleets to determine root causes of failures. They then develop standardized repairs and preventative measures to extend blade life. This is presented as a new approach to managing the life cycle of a critical asset to maximize value for owners.
Wind Composite Services Group/WindCom Introduction
- 1. Page 1Confidential and proprietary information of WindCom Wind Composite Services Group/WindCom Introduction
- 2. Page 2Confidential and proprietary information of WindCom Who We Are • Established in 2006 • Owned by Tecsis • Headquartersin 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
- 4. Page 4Confidential and proprietary information of WindCom Preferred Access Method 360° Suspended Platform
- 5. Page 5Confidential and proprietary information of WindCom Blade Fleet Failure Investigation Process
- 6. Page 6Confidential and proprietary information of WindCom Problem Aging blade fleets require solutions to emerging issues
- 7. Page 7Confidential and proprietary information of WindCom Objective To maximize the value of the rotor for the owner and minimize business risk
- 8. Page 8Confidential and proprietary information of WindCom 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.
- 9. Page 9Confidential and proprietary information of WindCom 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
- 10. Page 10Confidential and proprietary information of WindCom Example of How Data can be Assimilated Mass Mass Blade populations vary from design values differently during manufacturing sequence
- 11. Page 11Confidential and proprietary information of WindCom Different Blade Failure Modes are Categorized • Aft shell failure
- 12. Page 12Confidential and proprietary information of WindCom Several Blade Failure Modes are Evident • Aft shell failure
- 13. Page 13Confidential and proprietary information of WindCom Different Blade Failure Modes are Evident • Blade root cracking
- 14. Page 14Confidential and proprietary information of WindCom Different Blade Failure Modes are Evident • Trailing edge cracking
- 15. Page 15Confidential and proprietary information of WindCom Different Blade Failure Modes are Evident • Trailing edge cracking
- 16. Page 16Confidential and proprietary information of WindCom Different Blade Failure Modes are Evident • Surface Coating Failure
- 17. Page 17Confidential and proprietary information of WindCom 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
- 18. Page 18Confidential and proprietary information of WindCom 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
- 19. Page 19Confidential and proprietary information of WindCom Blade Life Cycle Management A New Approach to a Critical Asset Sandia Blade Workshop August 2016
- 20. Page 20Confidential and proprietary information of WindCom 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.
- 21. Page 21Confidential and proprietary information of WindCom 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 Lost Revenue and Expenses Annually Without Maintenance With Maintenace $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 Without Maintenance With Maintenance Expenses and lost revenue production over 20 years Loss of Production Erosion Loss of Production Repairs Cost or repairs Inspections LEP application Assumptions: • 200MW Wind Farm/ 100-2MW turbines in Midwest • 40% capacity factor PPA @ $25MW hour • Loss of revenue daily $60/summer and $420/winter • Average erosion which if left unattended would result in 5% loss of energy after 20 years (.25%/yr)• Lightening strikes (or other damage) effect 5 blades/year
- 22. Page 22Confidential and proprietary information of WindCom North America Houston – USA Sales 281-906-9572 T. +1 281 227 5130 F. +1 281 227 5192 Europe Madrid -Spain T. +34 91 241 10 02 F. +34 91 293 51 96 South America Sao Paulo - Brasil T. +55 15 2105 4800 F. +55 15 2102 4875 info@windcomservices.com | www.windcomservices.com For all your wind turbine composites servicing needs