TURKISH WIND ENERGY CONGRESS Innovative Blade Design. Istanbul November 2012

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1 TURKISH WIND ENERGY CONGRESS 2012 Innovative Blade Design Istanbul November 2012

2 ROTOR BLADES MADE BY NORDEX Rotor blade is a key component of a wind turbine main driver for energy production main driver for turbine loads Specifics: rotorblade is a composite part high level of vertical integration at Nordex Use of new technologies for the N117 blades; IEC3a turbine designed for low wind sites 2

3 ROTOR BLADES MADE BY NORDEX (2.X MW-PLATFORM) Turbine type N90-IEC1a N100-IEC2a N117-IEC3a Blade type NR45 NR50 NR58.5 Length 43.8 m 48.8 m 57.3 m Swept area m² m² m² Mass 10,300 kg 11,000 kg 10,500 kg Max. Chord 3220 mm 3700 mm 3496 mm Prebending 1500 mm 2000 mm 2000 mm Projected blade area 93 m² 116 m² 121 m² Number of bolts 64 (M36) 64 (M36) 64 (M36) bolt circle diameter 2300 mm 2300 mm 2300 mm Materials GRP GRP GRP and CRP 3

4 ROTOR BLADES MADE BY NORDEX Weight[kg] swept area [m²] X MWplatform MWplatform NR37.5 NR45 NR50 NR58.5 4

5 ROTOR BLADES MADE BY NORDEX Assistance, Quality Control and Documentation Blade Development 41 employees Technical Project Management System Department Blade System Department Processes Aerodynamics Additional Options Structural Mechanics Core Processes and Prototyping Material and Testing Design 5

6 ROTOR BLADES MADE BY NORDEX Generation of the outer shell 3D-CAD-Modelling Fenite Eelemt Calculation 3D-CFD-Calculation (Computational Fluid Dynamics) Determination of critical areas and calculation of the power curve Definition of the position of vortex generators 6

7 ROTOR BLADES MADE BY NORDEX Verification of the Blade Design Measurement at prototype blade 3D-CFD- Calculation Calculated position of the separation line is consistent with measurements (Picture on the right shows NR50 Blade) Extensive research into o o noise production and mitigation increasing aerodynamic performance Computer calculation and full scale tests Swift integration into production Separation line 7

8 ROTOR BLADES MADE BY NORDEX Use of Carbon Fibre for the Main Girders of the NR58.5 Blade Trailing Edge Girder Shell Pressure site Main Girders Trailing Edge Shear Web Main Shear Web Trailing Edge Girder Shell Suction site 8

9 ROTOR BLADES MADE BY NORDEX Lightning protection - certified according to IEC Lightning protection class I. Materials Reinforcement: Glass fibre/carbon fibre Epoxy resin Core Materials: Balsa and Foams (PET, PVC) Qualification of materials according to defined internal procedures Selected materials fulfil requirements of GL 2010 Tests are done according DIN/EN ISO standards Tests are performed in accredited labs 9

10 ROTOR BLADES MADE BY NORDEX Own test facility since 2010 Capacity: 3 blades Max. blade length: 65 m Max. moment: 20,000 knm Static test Dynamic tests Accelerated life tests 5,000,000 load cycles in edge and flap wise direction Duration: approx. 210 days Full scale tests according IEC NR45: static, dynamic tests finished NR50: static, dynamic tests finished NR58.5: static test completed, dynamic test in progress 10

11 ROTOR BLADES MADE BY NORDEX Quality Assurance Methods (routine tests): Material testing Fibre volume content Glass transition temperature visual inspections non-destructive testing: ultra-sonic Detection of wrinkles Inspections of bondlines Conclusion Closed-loop design process Simulation and validation on a high technological level Track record: production of blades in-house since 11 years All relevant certificates for blades available 11

12 NORDEX Anti Icing Sytem Istanbul November 2012

13 Anti Icing Option The Case In many regions of the world ice formation, especially on rotorblades, is possible during winter month. Beside North Europe and North America also in Turkey Temperatures can get very low in winter time. This leads to an inefficient operation and loss of energy production. Solving that issue, Nordex has developed an innovative Anti- Icing system. 13

14 Anti Icing Option The Nordex Solution Example pictures from wind turbines in Turkey in winter time 14

15 Anti Icing Option The Challenge Maintaining the highest possible level of power output during the winter season. Challenges: Prevention of ice on rotor blades: - No Rotor blade profile modification - No cost intensive downtime Reduction of ice throw Fast and safe detection of ice and energy-efficient de-icing Our answer ispro-active Anti-icing: Continuous monitoring of icing conditions Energy management with the focus on low internal turbine consumption Concentrated and localized heating of the aerodynamically relevant blade surface Reliable and lightweight electrical resistance heaters 15

16 Anti Icing Option The Reference/ NX Experience/ Track Record 2010: 4 WTGs (N100/2500 R100 CCV) in Jokkmokksliden 3 prototype Anti-Icing Systems (2 different systems) 1 reference turbine 2011: 2 AI-Prototypes to reference turbines +14 WTGs in Jokkmokksliden/Storliden + 2 WTGs Vårdkasen 2012: + 30 WTGs in Blaiken 2013: + 30 WTGs in Blaiken 2014: + 30 WTGs planned in Blaiken 16

17 Energy productin [MWh] Energy productin [MWh] Anti Icing Option Performance / Cost-benefit / In Detail Test evaluation of the system in Jokkmoksliden, Sweden: Winter 2010/2011 Yield increased In our first season we increased the yield in Dec by 126% in Jan by 43% in Feb by 83%. In the second season we increased the yield In Dec by 55% No Anti Icing With Anti Icing Dez days 0,9 3,4 5,2 Jan days Winter 2011/2012 Feb days In Jan by 82% In Feb by 45% To be on the safe side our flyer only promotes >25% for the months with icing conditions. This increases the annual production by more than 8% Ara 11 Oca 12 Şub 12 17

18 Daily Energy Production [MWh] Wind spped [m/s] Anti Icing Option Validation - performance during icing event Anti-Icing Performance (WEA3) Reference turbine Before Icing period Turbine with anti-icing system Mean wind speed Melting period

19 Anti Icing Option Validation - performance during icing event Webcam Observations 19

20 Anti Icing Option Validation - performance during icing event Icing period with heating Jan 22 nd 2012 Anti-Icing turbine, Jan 22nd, 2012 Reference turbine, Jan 22nd,

21 Anti Icing Option Validation - performance during icing event Melting period Feb 8 th 2012 Anti-Icing turbine, Feb 8th, 2012 Reference turbine, Feb 8th,

22 Anti Icing Option Benefits Benefits of the Nordex solution: Maximizing the energy output by reducing downtime Active prevention of ice formation on blades The system operates while the turbine is running: No downtime during de-icing process Minor energy consumption: Only aerodynamically relevant parts are heated, there are almost no losses, heating performance is variable and need-based System is robustly integrated in the blade-structure Reliable solution with integrated lightning-protection Detection and removal of ice even when the turbine comes to a standstill and before resuming energy production 22

23 Anti Icing Option Performance / Cost-benefit Test evaluation of the system in Jokkmoksliden, Sweden: Yield increased Increase of more than 8% AEP in the year 2011 in comparison to the reference turbine Increase of more than 25% EP in the frost period (December-April) Cost/Benefit The payback period of the system will typically be less than 5 years, based on only a few weeks of icing per year System consumption: The energy consumption of the system is negligible (<0.3% AEP) Nordex provides a reliable and efficient Anti-Icing System More production means more cash flow and the Nordex Anti-Icing system will recover the costs within a few years. 23

24 THANK YOU VERY MUCH FOR YOUR ATTENTION Nordex SE Langenhorner Chaussee 600, Hamburg, Deutschland Telefon Fax