Retrofitting Wind Turbines - improve your return on investment

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1 Retrofitting Wind Turbines - improve your return on investment

2 Retrofitting What is a Vortex Generator? Today, the wind turbine industry is able to benefit from the aircraft industry by utilizing the well-known vortex generator technology and improve aerodynamic performance of ageing wind turbines. When installed on aircrafts, vortex generators significantly increase both the stability and the efficiency of the aircraft wing. Now, wind turbines across the world benefit from the same technology. Postponing the Stall Point Each vortex generator has a triangular wing with a sharp leading edge. They are fabricated in pairs and integrated on a base plate, suitable for adhesive attachment on the blade surface. Each pair is symmetrically opposed in order to generate counter-rotating and interacting vortexes that force the airflow to stay on the blade. As a result, the stall point, which is where the airflow is separated from the blade surface due to age-related blade surface roughness, is postponed. When correctly designed and positioned on the blade, vortex generators will make the wind flow stay attached on the blade surface for a longer time, thus reinstalling lost lift and regaining the expected electrical output of the wind turbine generator. Design and Installation If the vortex generators are not designed or positioned correctly, an increase of the wind turbine electricity output may fail to appear. For that reason, it is important to always work closely with experts when utilizing the effect of vortex generators. 2 POWER CURVE

3 Retrofitting Increase Power Output With up to 10 % Retrofitting is the intelligent way to make the most of your investments and maximize the profitability of ageing equipment. As wind turbines age, they gradually lose energy efficiency. Thousands of the +250,000 wind turbines across the globe are not performing their outmost, mostly due to blade surface and leading edge degradation. As a result, the demand for optimizing wind turbine blade performance to regain lost efficiency is rapidly growing. Regain Lost Efficiency The Power Curve solution is a simple, low-risk and inexpensive add-on solution that increases turbine annual energy production efficiency with up to 10 %*. This improvement of wind turbine energy performance is based on the vortex generator technology and consists of relatively small add-on devices that enable the wind flow to stay attached to the blade surface for a longer time, thus enhancing blade lift and generator energy output. World-Class Aerodynamics The Power Curve solution has been developed by some of the world s best within the field of aerodynamics. Consequently, we are able to offer specially designed vortex generators which are: researched, designed and validated by world-leading wind research centres (DTU Risø) made from high-quality, environmentally robust materials manufactured by experienced sub-contractors to the global wind industry installed by skilled and trusted lifting and handling companies Together, we make the world more efficient, one turn at a time. * The increase in AEP depends on several factors such as actual blade surface damage level, wind climate and already installed performance enhancement devices. In most cases, the AEP increase will be in the range from 2 % to 6 %. POWER CURVE 3

4 Case Story Turnkey Solution for Wind Turbine Operator A European-based operator recently installed a Power Curve turnkey solution on an MW turbine. The project included all steps in the Power Curve process, from assessment to complete installation and evaluation. Technical Assessment and Specification In the initial turnkey project phase, a technical assessment and identification of airfoil characteristics were performed. In most cases, the airfoil geometry must be reengineered by 3D measurement, but in this case the client had full access to airfoil data. With these data, Power Curve performed advanced flow simulations of relevant blade sections to determine the optimal vortex size and position on the blades. In cooperation with the client, a vortex design was specified including simulation of the expected power increase. When all specifications were set and agreed to, the vortex generators were put into production. Installation and Validation Installation was carried out on-site by a local third party installation supplier, trained and supervised by the Power Curve experts. After installation, an evaluation and validation period followed with a final report at project closure. This turnkey project was completed during the autumn of 2013.

5 Your Benefits Low-Cost Technology As a rule of thumb, the repayment period (ROI) is as low as 12 months, making the Power Curve solution an inexpensive investment and the older the blade, the higher the ROI you can expect from your Power Curve solution. Other benefits include: Flexible Solutions There is always a Power Curve solution which matches your needs, from turnkey to do-it-yourself. Whether you want the Power Curve experts to handle the complete installation or if you have the necessary capacity and knowhow to install the Power Curve technology in-house, blade performance enhancement has never been easier. risk is introduced by the Power Curve solutions. Based on the underlying physics of stall and pitch controlled turbines, the Power Curve solutions are solely designed for pitch turbines. Quality Products and Services The Power Curve concept is created by a team of experts and together they represent world-class specialists within: Customized for Your Wind Turbines The range of wind turbine blade designs is wide, and so each Power Curve solution requires complex and carefully calculated fitting procedures. At Power Curve, we make sure that you receive a customized add-on solution, optimized for your wind turbines. Thoroughly Validated and Low-Risk Solution Designed to reinstall lost performance, the effect of the vortex generator technology is thoroughly validated, and no structural the application of passive blade enhancements for wind turbines scientific wind power research and engineering plastic injection moulding, shaping and installation lifting, handling and installation of complex components to the wind turbine industry POWER CURVE 5

6 Products and Packages The Choice is Yours The Power Curve packages have been specifically designed to match different customer needs and capacity. We recommend a turnkey solution which includes complete installation from assessment analyses and add-on fitting to installation and performance reports. However, should you prefer to have your own expert team install Power Curve, this is also an option. Wind Turbine Feasibility Assessment To evaluate the potential benefits of applying a Power Curve solution, an initial wind turbine feasibility assessment is made in collaboration with the customer and preferably based on wind turbine production data. If required, the Power Curve team can mount tufts on strategically chosen areas of the blades to visualise the airflow before and after application of the Power Curve solution. Blade Add-On Enhancement Device The Power Curve solution includes the application of vortex generators, gurney flaps, root shells and other suitable aerodynamic performance enhancing devices, depending on the given project. Power Curve add-on devices are manufactured with high precision and in a long-life, high grade material, and are supplied with adhesive systems suitable for harsh application conditions. Data Sheets and Documentation (for the Add-On Device) Data sheets and documentation information are supplied. They enable the customer to install the add-on solution in blade production according to own positioning specifications, choice of adhesive and cleaning system, and work instructions. Technology Installation Instructions An aerodynamic analysis is made to ensure optimal add-on placement and combinations of add-on devices. This analysis is based on advanced, empirical engineering models developed and verified by DTU Risø, a globally recognized leading research institution within wind turbine aerodynamics. Wind Turbine Blade Inspection A thorough blade inspection determines and potentially suggests relevant blade repair measures. Independently of the potential need for blade repair, the blade inspection gives critical input to the installation team with regards to surface treatment in the specified adhesive area. Installation of Blade Add-On Enhancement Device Installation is performed from a mobile blade platform or by rope access. The turbine down time during installation is typically 1 day, depending on factors such as blade size and required repair work. The installation process is documented with key characteristics, and during the installation phase, all technical, environmental and safe & health requirements are met. Pre-Fitted Adhesion Technology Power Curve specifies and delivers the adhesive and cleaning system suitable for the project. Based on many years of experience, Power Curve has developed various adhesive solutions from combinations of tape and resin. Our adhesive program combines practical installation experience and material compatibility with superior bonding strength. Performance Report To document the effect of a Power Curve solution, different measures can be applied depending on data availability and client validation ambition. The ultimate documentation level is a beforeand-after certified Power Curve measurement, but more pragmatic and less costly measures are often applied. As data sharing can be proprietary, the precise validation process is always discussed and agreed to with the customer. For further details about the individual services, please visit our website 6 POWER CURVE

7 Products and Packages Turnkey: Kit: Basic: A complete Power Curve solution for both large and small operators A pre-packed Power Curve kit, ready for installation by your own professional fitters Power Curve add-ons with no additional equipment, intented for large operators and OEMs Wind turbine feasibility assessment Wind turbine feasibility assessment Wind turbine feasibility assessment Blade add-on enhancement device Blade add-on enhancement device Blade add-on enhancement device Data sheets and documentation Data sheets and documentation Data sheets and documentation + Pre-fitted adhesion technology + Pre-fitted adhesion technology + Technology installation instructions Wind turbine blade inspections Installation of blade add-on enhancement device Performance report Technology installation instructions POWER CURVE 7

8 Global Locations Denmark Power Curve (head office) Stationsmestervej Aalborg SV P: (+45) E: Spain P: (+34) Avenida San Bartolome Portal N 1, Piso 2 A Baracaldo C.P China P: (+86) (22) E4C-103, Binhai Finance Zone 3rd Avenue, TEDA Tianjin, Germany P: (+49) (40) Papenreye , Hamburg USA P: (+1) N Michigan Ave, suite 3950 Chicago, Illinois