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.
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
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
Summary of existing cost models Motivation/Development of NuMAD cost tool Tool Validation Demonstration: Parametric Analyses Future Work Presentation Outline
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notes manufacturing scaling and Report/ TPI trends analysis; somewhat WindPACT (SNL/TPI) 2003 Y low-med limited quotes outdated NREL Cost and Scaling 2006 Y low yes excel trends analysis; looks at entire turbine; very little detail non-us reference; automation analyses Fraunhofer IWES N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
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
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
Integrated Blade Cost Tool
added fields: type cost cost unit waste rate resin infusion Cost Tool Input
Cost Tool Input
Integrated Blade Cost Tool
Cost Report Output SNL 5MW 61.5m Carbon Spar Total Manufacturing Cost 8% 2% 12% materials labor molds CAPEX 78%
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%
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%
Cost Report Output SNL 5MW 61.5m Carbon Spar
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
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
Model Validation $300,000.00 Blade Materials Cost by Region $250,000.00 $200,000.00 $49,395.00 Auxiliary/Consumables LPS Hardware Adhesive $150,000.00 $100,000.00 $31,560.00 $32,860.00 $40,210.00 $41,345.00 $104,494.00 $35,499.00 $28,902.00 Epoxy Foams Gelcoat Saertex +/-45 Carbon-Uni ELT-5500 $50,000.00 $46,698.00 $61,600.00 $44,942.00 $46,981.87 CDB340 $- $25,982.00 $23,359.00 $17,708.00 $23,199.19 USA Germany China SNL Cost Tool
Model Validation 1600 Blade Manufacturing Process Labor Hours 1400 1200 399.3 282 1000 272.6 382 800 Finishing Steps Fabrication Steps 600 768.8 828.7 Preparation Steps 400 841.1 768.3 200 0 201.3 194.7 43.1 0 USA Germany China SNL
Model Validation $400,000.00 Total Blade Manufacturing Cost $350,000.00 $300,000.00 $250,000.00 $117,430.00 $29,003.00 $11,103.00 $200,000.00 $150,000.00 $78,762.00 $31,300.00 $39,912.00 $29,560.00 $37,660.00 Capex Labor Materials $247,028.00 $100,000.00 $147,825.00 $184,084.00 $157,050.00 $50,000.00 $- USA Germany China SNL Cost Tool
61.5m carbon spar blade single-parameter variation: carbon cost Parametric Analysis
Parametric Analysis 20$/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
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
Acknowledgements Mentor: Brian Naughton Design Codes: Jon Berg NRT: Brian Resor Supervisor: Dave Minster
Thank You