NuMAD Cost Tool: Summer Internship Summary

Transcription

1 NuMAD Cost Tool: Summer Internship Summary Rachel Koh Student Intern Mentor: Brian Naughton Manager: Dave Minster Sandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin Company, for the United States Department of Energy s National Nuclear Security Administration under contract DE-AC04-94AL85000.

2 Ph.D. Student, Univ. of Massachusetts Amherst Introduction Lab Affiliations: Wind Energy Center / Sustainable Building Materials Group Academic Thrust Areas: Materials Science and Wind Energy Dissertation Topic: Integration of Bio-based Materials into Megawatt-Scale Wind Turbine Blades

3 Project Goals Review and summarize existing blade manufacturing cost models Identify cost model requirements for integration with SNL design tools and adapt from existing design tools Modify NuMAD to integrate new cost model Do a blade cost study to demonstrate/validate tool

4 Summary of existing cost models Motivation/Development of NuMAD cost tool Tool Validation Demonstration: Parametric Analyses Future Work Presentation Outline

5 Existing Cost Models Tool/Model/Author Year public? fidelity scaling format strengths, limitations, notes manufacturing scaling and Report/ TPI trends analysis; somewhat WindPACT (SNL/TPI) 2003 Y low-med limited quotes outdated NREL Cost and Scaling 2006 Y low yes excel trends analysis; looks at entire turbine; very little detail non-us reference; automation analyses Fraunhofer IWES N med yes excel high- labor SNL / Johanns-Griffith 2013 Y med-materials yes excel high fidelity labor NREL / James- Goodrich 2013 N multi yes excel TPI / Nolet 2014 N med no excel NREL / Berry IP N high IP excel considers financing; labor based on SNL (2013) industry experience; current data; includes CAPEX very thorough materials analysis; other components currently unfinished

6 Cost Tool Priorities Integration with NuMAD Highly automated for optimization Medium-high fidelity Format to integrate with other blade design tools Low CPU time Minimal changes to existing NuMAD codes and interfaces

7 Aside: Current State of NuMAD prenumad: move to object-oriented programming motivations included incorporation of a cost tool improved ability to manage software complexity improved efficiency blade object properties, e.g. blade.sparcapwidth, blade.materials, blade.materials(6).density methods, e.g. blade.generatecost, blade.generatecostreport currently, blade object is defined manually or in excel input (xlsblade.m) and gets converted back to NuMAD

8 Integrated Blade Cost Tool

9 added fields: type cost cost unit waste rate resin infusion Cost Tool Input

10 Cost Tool Input

11 Integrated Blade Cost Tool

12 Cost Report Output SNL 5MW 61.5m Carbon Spar Total Manufacturing Cost 8% 2% 12% materials labor molds CAPEX 78%

13 Cost Report Output SNL 5MW 61.5m Carbon Spar 2% 9% Materials Cost 1% < 1% 2% 6% 11% Gelcoat E-LT-5500(UD) SNL(Triax) Saertex(DB) 13% FOAM Carbon(UD) Resin waste 15% Misc. Consumables 41%

14 Cost Report Output SNL 5MW 61.5m Carbon Spar 6% Labor Hours 8% 4% 6% 4% Spar Caps All Shear Webs TE Prefabs 7% 1% 2% Root Prefabs and Small Parts HP and LP Molds Infusion Prebond Assembly and Bond 11% Trim, Inspection, Wet Layup T-Bolts 9% Cure Edge Finishing Prep Paint and Paint Balance and Loading 13% 19% 10%

15 Cost Report Output SNL 5MW 61.5m Carbon Spar

16 Additional Functions / Features SNL materials library Adaptable to custom manufacturing process steps labor40_xls2mat.m update or define custom steps in excel Accepts many cost data input types cost in $/lb, $/m 2, etc. resin infusion by vol. fraction, areal spread < ¼ second CPU time extensive error handling

17 Model Validation many points of reference shown here: GLWN Manufacturing Competitiveness Study 5MW 61.5m design from SNL/NREL data from 8 factories in different regions 3 from USA manufacturers

18 Model Validation $300, Blade Materials Cost by Region $250, $200, $49, Auxiliary/Consumables LPS Hardware Adhesive $150, $100, $31, $32, $40, $41, $104, $35, $28, Epoxy Foams Gelcoat Saertex +/-45 Carbon-Uni ELT-5500 $50, $46, $61, $44, $46, CDB340 $- $25, $23, $17, $23, USA Germany China SNL Cost Tool

19 Model Validation 1600 Blade Manufacturing Process Labor Hours Finishing Steps Fabrication Steps Preparation Steps USA Germany China SNL

20 Model Validation $400, Total Blade Manufacturing Cost $350, $300, $250, $117, $29, $11, $200, $150, $78, $31, $39, $29, $37, Capex Labor Materials $247, $100, $147, $184, $157, $50, $- USA Germany China SNL Cost Tool

21 61.5m carbon spar blade single-parameter variation: carbon cost Parametric Analysis

22 Parametric Analysis 20$/kg 30$/kg 40$/kg Total Manufacturing Cost 8% 2% 13% Total Manufacturing Cost 7% 2% 12% Total Manufacturing Cost 7% 2% 11% 16% 3% 76% Total Cost: 199k Materials Cost < 1% 2% 11% 7% 31% < 1% 11% 18% 14% Total Cost: 227k materials 79% labor molds Materials Cost CAPEX 10% < 1% 2% 6% Gelcoat 3% E-LT-5500(UD) 11% SNL(Triax) 40% Saertex(DB) FOAM Carbon(UD) E-LT-5500(ISO) Resin waste Misc. Consumables < 1% 15% 12% 81% 2% Total Cost: 254k Materials Cost 8% < 1% 5% 47% Gelcoat 10% E-LT-5500(UD) SNL(Triax) Saertex(DB) FOAM 13% Carbon(UD) E-LT-5500(ISO) Resin < 1% waste Misc. Consumables materials labor molds CAPEX materials labor molds CAPEX Gelcoat E-LT-5500(UD) SNL(Triax) Saertex(DB) FOAM Carbon(UD) E-LT-5500(ISO) Resin waste Misc. Consumables

23 Future Work Optimization What do optimal blades look like when we optimize for cost? Tip Speed Study blades High-Modulus Carbon Fiber (properties-cost tradeoffs) Bio-based materials CAPEX/Factory Model Integration with AEP tool

24 Acknowledgements Mentor: Brian Naughton Design Codes: Jon Berg NRT: Brian Resor Supervisor: Dave Minster

25 Thank You