DELIVERING THE FUTURE OF COMPOSITE SOLUTIONS. UV Curing Composite Technology.

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1 DELIVERING THE FUTURE OF COMPOSITE SOLUTIONS UV Curing Composite Technology

2 RENUVO offers a fresh and novel approach to the manufacture, maintenance and repair of today s wind turbine blades. RENUVO uses UV light from specially-designed lamp equipment to achieve full cure in just a few minutes. RENUVO BLADE REPAIR RENUVO blade repair materials are designed to be handled at temperatures as low as +5ºC. This greatly widens the operating window for carrying out repairs and dramatically reduces the turbine downtime. RENUVO materials are easy to handle, requiring no mixing or awkward hand-impregnation of heavy glass fabrics. The RENUVO product range consists of two main types of material: RENUVO MPS: RENUVO MPS is a multi-purpose, single-component resin system supplied in a cartridge. For small maintenance repairs such as leading-edge erosion, small holes and other surface defects, RENUVO MPS can be used on its own. With its grease-like consistency it can be easily applied with small spreading tools and can be cured in just 90 seconds with the small, hand-held, RENUVO Neolectron lamp. RENUVO PP: For larger repairs, where the blade laminate itself needs to be replaced or reinforced, RENUVO prepreg (PP) is used. This consists of a biaxial or unidirectional fabric which is already impregnated with the RENUVO resin system. The material, which has a slight tack to it, can be easily cut to the desired patch size and can be used in single or multiple layers. Excellent bonding to the existing blade laminate is achieved through the use of the MPS resin acting as an interface. Full cure is obtained in as little as 180 seconds for repairs up to 3mm thick, using the large RENUVO LED 400F lamp. For large repairs, this lamp is indexed over the repair area using a specially designed lamp mounting system that ensures that each part of the patch receives the correct UV dose. Further details on the RENUVO products, ancillary RENUVO equipment and materials, are contained in this brochure. For full product details, instructional videos and how to guides, visit 1 2

3 THE PRODUCT RANGE PRODUCT DESCRIPTION TYPICAL APPLICATION PAGE MULTI-PURPOSE SYSTEM RENUVO MPS (+5 C to +30 C) Multi-Purpose System - single component resin for working conditions from +5 o C up to +30 o C Small surface maintenance repairs or as primer for structural repair. Cure with RENUVO Neolectron lamp 5 RENUVO PP BIAX (+5 C to +30 C) 600g BIAX Glass Prepreg for working conditions from +5 o C up to +30 o C Structural repair of turbine blades, where new laminate needs to be added 6 Use in combination with RENUVO MPS and cure with RENUVO LED 400F lamp PREPREG RENUVO PP UD (+5 C to +30 C) 600g Uni-directional Glass Prepreg for working conditions from +5 o C up to +30 o C LAMP TECHNOLOGY RENUVO Neolectron RENUVO LED - 400F Hand-held, 12V, battery operated, spot lamp suitable for small MPS repairs High intensity, large scale, 110/240V powered lamp, capable of curing RENUVO laminates Other leading UV lamp technology compatible with RENUVO Light repair and maintenance use, not requiring structural reinforcement. Can be used with rope access techniques Use whenever structural reinforcement has been added. Intended for use from work platforms 7 8 ANCILLARY EQUIPMENT RENUVO HVC (Heated Vacuum Consolidator) Ancillary Equipment Portable, +50ºC heated vacuum device for 240V power supply Range of equipment and materials to facilitate the repair procedure. UV blocking film, spreaders, cartridge guns, wipes and consumables Use to pre-consolidate more than one ply of RENUVO Prepreg for larger patches Most products can be used for both structural and maintenance repairs 9 3 4

4 MPS MULTI-PURPOSE SYSTEM PP BIAXIAL & UNI-DIRECTIONAL PREPREG Mono-component resin system Thixotropic paste consistency for ease of application Excellent handling through a wide temperature range Biaxial and UD material formats to enable close matching of the blade laminate Excellent drape and tack through a wide temperature range Suitable for use on polyester or epoxy substrates Compatible with current topcoat technology Cured with RENUVO Neolectron lamp in just 90 seconds +5 o C o C +41 o F o F Suitable for use on polyester or epoxy substrates Compatible with current topcoat technology Cured with RENUVO LED 400F lamp in just 180 seconds +5 o C o C +41 o F o F APPLICATION PROCESS RENUVO MPS is a multi-purpose UV curing resin system designed for use in wind turbine blade repair. The RENUVO MPS can be used on its own for repairs where laminate does not need to be replaced or added. This includes surface pitting and erosion, as well as small holes. RENUVO MPS is also used in combination with RENUVO prepregs as part of a structural repair. In this application it both acts as the interface to the substrate and can provide a smooth, easily sandable top surface to the final repair patch. APPLICATION PROCESS RENUVO MPS is a single component resin so requires no pre-mixing. The blade surface should first be lightly abraded and cleaned of dust and debris to ensure good adhesion. Special surface wipes are available to aid this process. The product should be dispensed using a standard cartridge gun and applied out of direct sunlight if possible, as this will extend the working time. Plastic spatulas can then be used to apply and spread the material and adding a layer of dry peel-ply over the repaired area helps to ensure that the material is evenly spread. Curing is achieved by using the RENUVO Neolectron hand-held lamp and after 90 seconds of cure the material can be sanded and painted. RENUVO PP is a range of UV curing prepregs designed for use in wind turbine blade repair. The prepreg format removes the need for manual weighing and mixing of wet resins and avoids the difficulty of hand-impregnation of heavy glass fabrics. The prepreg is clean to handle and eliminates the waste associated with mixing pots, spatulas, brushes and loose glass fibres. RENUVO prepregs can be used to both replace damaged laminate, or to add extra reinforcing layers on top of existing laminate. The conformability of the RENUVO prepregs makes them especially suitable for patches that need to wrap around and reinforce the leading and trailing edges of the blade. The RENUVO prepregs can be combined to make patches with multiple fibre orientations and with different thicknesses. This enables many different blade laminates to be replicated with just a few RENUVO prepreg types. RENUVO PP is supplied in 400mm wide, 20lm rolls in both biaxial and unidirectional formats. A 600g/sqm version of each is maintained as a standard product, although other fabric configurations may be possible in certain circumstances. The prepreg materials are cut to the shape of the required patch out of direct sunlight. If the patch consists of more than one layer of prepreg these are pre-consolidated using the portable RENUVO HVC equipment, or other heated vacuum table. This consolidates the individual prepreg layers into one, low-void patch that is then easy to apply to the blade. The blade surface should be lightly abraded and cleaned of dust and debris to ensure good adhesion. Special surface wipes are available to aid this process. The RENUVO MPS is then used to provide an interface between the prepreg and the blade surface, ensuring that excellent wet-out of the blade surface is achieved. Once the prepreg patch has been applied to the MPScoated blade surface, an additional layer of MPS can be applied on top of the reinforcement patch to achieve a smooth, easily sanded upper surface. The patch is then cured using the RENUVO LED 400F lamp. RENUVO PP should be applied out of direct sunlight to extend its working time. When combined with RENUVO MPS, a complete laminate repair up to 3mm thick can be cured in 180 seconds, with the use of the RENUVO LED 400F lamp. Patches that are larger in area than the lamp footprint are cured by indexing the lamp on a specially designed mounting system and curing in steps. See process notes for more details. 5 6

5 LAMP TECHNOLOGY LEADING UV LAMP TECHNOLOGY COMPATIBLE WITH RENUVO RENUVO Neolectron Handheld UV lamp for maintenance repair Sadechaf/ HID Mako lamp This product can provide a lower cost entry to using RENUVO for various applications both in field and in-factory. Simple 1 button operation Hotstrike - instant start/restart Standard battery pack Autosensing range finder The Sadechaf / HID Mako lamp is a lower cost 45min continuous use from fully charged Available exclusively through Gurit Lightweight handheld UV Lamp developed in partnership with Johnson and Allen for UV curing of RENUVO materials. The robust design is easy to operate and is convenient for use up turbine or in factory. The lamp must be used in combination with the correct PPE and should be held mm from the material substrate to ensure correct curing performance. Light repair use, can be used easily from rope access when not requiring structural reinforcement. To be used in combination with RENUVO MPS resin. Impact resistant case Low cost Off the shelf - ready to use HID UV has combined patented and proprietary technology to provide revolutionary UV curing. The continuous wave Xenon lamps, with high energy output can be turned on and off with no cool down or warm up periods. Reflector and irradiator designs produce up to 40% more energy than conventional systems. alternative for curing RENUVO materials both infactory and outdoors*. Faster curing is possible with some process control. *Gurit recommends that the manufacturer s guidelines for this product should be followed at all times. Neccesary precautions required when used outdoors. RENUVO LED - 400F Industrialised UV lamp for structural repair IP (54) Rated 54 Simple 1 button operation with timer 110V and 240V operation 180 second cure for combined MPS and PP repair Suction strap indexing system for controlled cure times up turbines The RENUVO LED 400F lamp has been designed in partnership with Sadechaf, a world leader in UV light technology, for use with RENUVO PP and MPS materials. It is simple to operate and can be used in harsh environments at the full temperature range of the RENUVO materials. The RENUVO LED 400F comes complete with a blade mounting device to correctly index the lamp for larger patches to ensure complete cure. The RENUVO LED 400F is designed for curing of repairs where RENUVO prepreg has been used. Through its high powered, patent-pending technology the RENUVO LED 400F lamp will complete a structural repair in a single cure step. Due to its size and weight it is primarily intended for use from work platforms, but can be used in-factory also. Phoseon FireFly High intensity SLM LED 395nm Consistent UV output overtime long life Very fast curing of RENUVO Products Instant on / off The Phoseon FireFly lamp has been designed to give superior performance, maximum UV energy and real world reliability. The compact solid state device provides low energy consumption as well as being environmentally friendly, with no ozone generation and UV LAMP TECHNOLOGY SUMMARY COST (EUR) CURE TIME (s) CURE AREA (mm) mercury free. The Phoseon FireFly can provide the cure speed required for large scale factory processing using RENUVO materials. The Phoseon FireFly lamp is a great candidate for fast in-factory curing of RENUVO. An outdoor solution could be devised with some additional cost*. Other cure areas sizes and options available. *Gurit recommends that the manufacturer s guidelines for this product should be followed at all times. CURE SPEED (min/m 2 ) LAMP TYPE WEIGHT (Kg) RENUVO Neolectron x 40 N/A** LED 2 4 RENUVO LED 400F x LED 30 4 HID Mako x Xenon 26 4 Phoseon FireFly x LED 5 8 OFF THE SHELF USE 7 **Not suited to large area repairs. 8

6 ANCILLARY EQUIPMENT TECHNICAL INFORMATION AND PRICING RENUVO HVC Up to 50ºC heating capability Portable device for repair patch size up to 600mm x 500mm Simple operation For more detailed information on RENUVO, as well as the complete Gurit product portfolio, please visit: to view the following: Product data sheets 'How to' videos News/case studies Composite guides Events schedules Representatives contact details Product brochures Corporate videos To simplify the application of RENUVO PP, Gurit has developed a portable heated vacuum consolidating device that can be used to pre-consolidate multiple For pricing or other enquiries, please contact gurit@gurit.com layers of material into a single, multi-ply patch. both sides of the prepreg, creating an envelope. The trimmed plastic envelope is then inserted into the RENUVO HVC to which a vacuum is applied Fig. 1 Fig. 2 Pre-consolidation of multiple layers of RENUVO PP from an external vacuum pump. The HVC heats the materials into a single, low void patch. materials to 50ºC for 15 minutes after which the patch APPLICATION PROCESS is consolidated and ready to be taken up the blade and applied. Individual plies of RENUVO PP are assembled onto a piece of UV blocking plastic, with the plastic covering RENUVO CONSUMABLES Product datasheets UV Filtering Film - extended working life of repair Rollers / Spreaders - flexible and efficient Peel-ply - protection and surface finish glasses, cartridge guns, surface wipes etc. The current To complement the primary RENUVO products and equipment, Gurit offers a range of ancillary tools and complete list of available ancillaries can be obtained from Gurit wind energy customer services. other products that can help complete a RENUVO Finally to finish the RENUVO repair operation, Gurit repair. These include spreaders for MPS, UV blocking can recommend suitably tested topcoats and paints for backer material, peel-ply, gloves, UV protective different weather conditions. Case studies 9 10

7 RENUVO BRO