NR65.5: CHALLENGES IN DESIGN, PRODUCTION AND LOGISTICS OF A VERY LARGE ONSHORE ROTOR BLADE. Stuttgart,

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1 NR65.5: CHALLENGES IN DESIGN, PRODUCTION AND LOGISTICS OF A VERY LARGE ONSHORE ROTOR BLADE Stuttgart,

2 AGENDA Platform Strategy one platform three turbines New N131 Blade design, materials and manufacturing XL Blade challenges in production and logistics 2

3 AGENDA Platform Strategy one platform three turbines New N131 Blade design, materials and manufacturing XL Blade challenges in production and logistics 3

4 NORDEX EVOLUTIONARY DEVELOPMENT 15 years and more than 10,000 MW * *as of Sept.15 Generation Alpha N80/2500 Generation Beta N90/2500 Generation Gamma N80/2500 N90/2500 N100/2500 N117/2400 Generation Delta N100/3300 N117/3000 N131/3000 N131/3300 Global fleet availability in 2014 ~98 % Turbines under Nordex Service

5 NORDEX MULTI MW PLATFORM Rotor diameter 131 m N131/3000 Generation DELTA 117 m N117/2400 N117/ m Generation GAMMA N100/2500 N100/ m N90/2500 6,0 6,5 7,0 7,5 8,0 8,5 9,0 9,5 10,0 Wind speed [m/s] IEC 3a IEC 2a IEC 1a 5

6 AGENDA Platform Strategy one platform three turbines New N131 Blade design, materials and manufacturing XL Blade challenges in production and logistics 6

7 TURBINE BLADES - NORDEX CORE KNOW-HOW FOR OVER A DECADE 3D-CAD-Modelling Finite Element Calculation 3D-CFD-Calculation Blade Design Verification Quality assurance Full scale test Blade Specification 140 m m Blade Design Blade Production Blade Testing 120 m 100 m 80 m 60 m Blade Installation Blade Service Lifecycle support 40 m 20 m 0 m 27m Nordex Rotor Diameter Industry Average Rotor Diameter Source: iea 2014, technology roadmap 7

8 NR65.5 NEXT STAGE OF NORDEX BLADE EVOLUTION NR 50 NR 58.5 NR 65.5 Performance-optimized root section Max. chord moves further towards root to increase yield and limit loads Introduction of yield-optimized Nordex flatback profiles Sound & load-optimized tip section More slender outboard section to optimize load and wake properties Selection of proven family of profiles with superior sound power properties 8

9 NEW N131 BLADE success factors Structural & aerodynamic design are based on the experiences of fully certified in-house developments NR45, NR50 and NR58.5 Use of proven rotor blade design and carbon fiber composites (CFRP) in spar caps is key performance +12% of rotor diameter while adding 26 % to projected surface Development of manufacturing concept in cooperation with composite specialist Carbon Rotec NR50 NR58.5 NR65.5 WTG type N100 N117 N131 Length 48.8 m 57.3 m 64.4 m Weight (1) 10,900 kg 10,200 kg 14,100 kg Max. Chord 3700 mm 3496 mm 3938 mm Pre-bend 2000 mm 2000 mm 3000 mm Projected surface 116 m² 121 m² 153 m² # of bolts 64 (M36) 64 (M36) 68 (M36) Bolt circle diameter 2300 mm 2300 mm 2800 mm Materials GRP GRP & CRP GRP & CRP 1 Without stud bolts but inclusive transverse bolts. 9

10 best sim & test best properties best practize sharing ROOT CAUSE success carbon blades material supplier btp partner Nordex blade develop rotor blade Nordex lead factory spezial service btp partner 10

11 DESIGN CHALLENGES aeroelastic stability Elastic Forces Inertia Forces Dynamic Aeroelastic Static Aeroelastic Aerodynamic Forces Static Aeroelastics: torsion divergence optimal twist Dynamic Aeroelastics: Classical flutter Limit cycle oscillations Aeroservoelastics: Controller interaction Rigid Turbine Flexible Turbine Collar-Triangle: classification of force interaction 11

12 mode shapes DESIGN CHALLENGES aeroelastic stability light wind turbines more prone to aeroelastic stability problems cause of their slender form and different loads compared to strong wind turbines. more accurate torsion stiffness calculation and validation complete modal analysis NR65.5 static aeroelastics in optimal blade shape (twist) dynamic aeroelastics in defining stiffness properties classical and non-classical flutter limits 12

13 ANALYSING KEY COMPOSITES STRATEGIES AND CURRENT PRODUCTION METHODS Costs of Energy / Costs per blade Courtesy of H. Ruckdaeschel, BASF SE 13

14 ANALYSING KEY COMPOSITES STRATEGIES AND CURRENT PRODUCTION METHODS Composites Simulation as valuable tool to bridge length scales application level fabric level product maturity molecular level fiber level fabric level: virtual experiments engineering constants first ply failure fiber dominated failure fiber level: virtual material characterization: failure, degradation parametric studies: voids, sizing, heterogeneities virtual single-fiber-experiments application level: turbine design blade weight efficiency Courtesy of H. Ruckdaeschel, BASF SE nm mm mm m length scale 14

15 COMPOSITE MATERIAL VS. DESIGN: WHICH COMES FIRST? Process Performance Material final turbine Design Courtesy of H. Ruckdaeschel, BASF SE innovations demand for holistic view manufacture, design, performance, materials, etc. 15

16 DEVELOPMENT OF A SLENDER ROTOR BLADE Task: Development of a slender rotor blade to fit on an existing turbine Existing turbine: N100/2500 (medium-wind turbine, IEC II class) Goal: Turbine for low-wind sites, 117 m rotor diameter, 2400 kw Comparing spare caps First try Second try Carbon fiber No Yes (main spar cap) Weight 14,4 tons 10,2 tons Loads Costs - GFRP CFRP Comparable blade design, same design loads. 16

17 Generation Delta Test & measurement programme well on track N131/3000 Rotor blade test NR65.5 Static Tests (4 Directions) Dynamic Tests Edgewise Direction in progress Flapwise Direction Static Test (Post Fatigue) 17

18 AGENDA Platform Strategy one platform three turbines New N131 Blade design, materials and manufacturing XL Blade challenges in production and logistics 18

19 CHALLENGES IN PRODUCTION Courtesy of Carbon Rotec 19

20 CHALLENGES IN PRODUCTION Courtesy of Carbon Rotec 20

21 CHALLENGES IN PRODUCTION Courtesy of Carbon Rotec 21

22 LOGISTICAL CHALLENGES Transport from production site to windpark Janneby No transport permit over motorway ship transport necessary Increase of transport time and costs Harbour time Harbour cranes Less flexibility By the way: Blade transport on trucks does fit Elbe tunnel Transport by ship Transport by truck 22

23 LOGISTICAL CHALLENGES NEW TRANSPORT SOLUTIONS XL blades can be transported, but it is time consuming it is more expensive than transporting smaller blades longer routes may apply 23

24 LOGISTICAL CHALLENGES NEW TRANSPORT SOLUTIONS 24

25 Logistic challenges: installation in forest Optimized site management and single blade traverse make it possible 25

26 LOGISTICAL CHALLENGES WE CAN DO IT 26

27 THANKS FOR YOUR ATTENTION. Nordex Energy GmbH Langenhorner Chaussee 600, D Hamburg, Germany Telephone +49 (40) Fax