Leading Edge Protection Lifetime Estimation. Jacques Nader and Drew Eisenberg March 1st, 2017
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1 Leading Edge Protection Lifetime Estimation Jacques Nader and Drew Eisenberg March 1st, 2017 Siemens.com/wind
2 Approach We will use laboratory erosion testing To predict erosion in the field over time To predict AEP Loss over time and develop new coating solutions Page AEP (%) 100 ~ Years Coating B Coating A
3 Outline of Leading Edge Protection Estimation Erosion model development Rain erosion testing Validation of model against field observations Categorizing Erosion Damage and Performance Loss Predict AEP loss over time due to erosion Summary Page
4 Erosion Model Development Erosion model we used is based on George Springer s Erosion by Liquid Impact Model Primary failure mode is fatigue due to rain s water hammer pressure Page
5 Surface Erosion Process Three main phases of erosion: 1. Incubation 2. Steady Material Loss 3. Coating Removed Depth of Damage Incubation Steady Material Loss Number of Rain Drop Impacts Coating Removed Incubation Steady Material Loss Coating Removed Slower 130m/s Less Impacts Less Force Page Area of appreciable power loss Faster 160m/s More Impacts More Force
6 Surface Erosion Model.. Larger drops cause more damage per impact d : Diameter of droplet S: Coating Strength P: Water Hammer Pressure Springer, G. S. and Yang, C. I. A model for the rain erosion of fiber reinforced composites. AIAA Journal, 13, (1975) C : Wave speed in material : Density V: Velocity Low density and low Young s modulus coating will reduce impact pressure : Poisson s ratio : Ultimate tensile strength b: Wöhler slope Erosion strength is primarily a function of ultimate tensile strength and Wöhler slope of the coating. Page
7 Outline of Leading Edge Protection Estimation Erosion model development Rain erosion testing Validation of model against field observations Categorizing Erosion Damage and Performance Loss Predict AEP loss over time due to erosion Summary Page
8 Measuring Surface Erosion Strength of Coatings Rain erosion testing performed in multiple helicopter tests with different water droplet sizes and speeds to determine erosion strength Number of droplet impacts until failure at different speeds are evaluated By adding high contrast to test sample photos, we can identify end of incubation Damage visible End of incubation period Faster Slower Page
9 Outline of Leading Edge Protection Estimation Erosion model development Rain erosion testing Validation of model against field observations Categorizing Erosion Damage and Performance Loss Predict AEP loss over time due to erosion Summary Page
10 Field Validation: Model Comparison Hundreds of turbines have been inspected. Evaluated over 6000 pictures of operational blades 61 turbines had identifiable locations of the beginning of erosion. Each turbine s expected erosion damage calculated using erosion model, operational RPM, and rainfall data Good correlation between observation and modeling Page Measured Radius of Erosion Initiation (m) Each dot represents an inspected turbine Calculated Radius of Erosion Initiation (m)
11 Outline of Leading Edge Protection Estimation Erosion model development Rain erosion testing Validation of model against field observations Categorizing Erosion Damage and Performance Loss Predict AEP loss over time due to erosion Summary Page
12 Categorizing Erosion Damage and Performance Loss Used published wind tunnel testing of wind turbine airfoils with differing stages of leading edge erosion* Defined 4 erosion damage levels that have been mapped to published research to apply deltas in lift and drag in performance Each damage condition has been simulated to evaluate sectional power loss due to erosion levels Erosion Level Same Blade Shown Sectional Power Loss [%] *Sareen, A, Sapre, C, Selig, M. Effects of leading edge erosion on wind turbine blade performance. Wind Energy. 2014; 17: Page
13 Outline of Leading Edge Protection Estimation Erosion model development Rain erosion testing Validation of model against field observations Categorizing Erosion Damage and Performance Loss Predict AEP loss over time due to erosion Summary Page
14 AEP Loss Forecasting Used erosion model to forecast depth of damage over time Apply sectional power loss over time to predict AEP loss Initially no power loss during coating incubation Soft shoulder due to initial damage not affecting power greatly AEP (%) 100 ~ Page Incubation Depth of Damage Initial erosion Years Incubation Steady Material Loss Number of Rain Drop Impacts Damage down to epoxy
15 Outline of Leading Edge Protection Estimation Erosion model development Rain erosion testing Validation of model against field observations Categorizing Erosion Damage and Performance Loss Predict AEP loss over time due to erosion Summary Page
16 Summary We used laboratory testing and analytical physics models to predict field erosion over time We used published wind tunnel testing of wind turbine airfoils with differing stages of leading edge erosion to predict AEP loss Erosion Testing Field Erosion AEP Loss 100 AEP (%) ~ Years We determined that best coatings have high ultimate tensile strength, good fatigue properties, low density and elastic modulus, and thicker than average droplet diameter We can accurately predict lifetime of leading edge protection with AEP loss estimation and forecast repair needs accordingly We are working with DNV-GL on certification of leading edge protection Page
17 PowerEdge Leading Edge Protection Page hours of rain erosion testing Using model, we know if tested materials will last 20+ years: PowerEdge will not erode on any of our turbines for 20+ years!
18 Thank You For Your Attention Jacques Nader Head of Global Blade Design 1050 Walnut st. Suite 303 Boulder, CO USA siemens.com/wind Page
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