Manufacturing
flaws can cause problems during normal operation. For example, blades can
develop cracks at the edges, near the hub or at the tips . Fiberglass
rotor blades are regarded as the most
vulnerable components of a wind turbine.
Typical manufacturing flaws on
the blades may be summarized as delaminations , adhesive flaws and resin-poor areas. Here are some specific flaws at particular locations:
- Skin/adhesive: this is bad cohesion between the skin laminate and the
epoxy or the epoxy is missing.
- Adhesive/main spar: this is when there is no cohesion between the
adhesive and the main spar.
- De lamination in main spar laminate.
- High damping in skin or main spar laminate, which could be caused by
porosities or change of thickness of laminate.
Manufacturing flaws
on the tower
A tubular tower is made of a lot of sheets of iron
that are welded together.
A flange is welded onto each end of the sections. The welding is checked thoroughly using ultrasonic NDT.
NDT techniques at manufacture
Visual inspection
Relatively advanced NDT testing methods are used to examine rotor
blades. The methods employed include penetrant testing and visual inspection
with the use of miniature cameras or endoscopes.
At present, it appears that mechanical components
aren’t tested at manufacture but the cause of their damage can be determined. For example, endoscopes are
used for the visual inspection of planetary
gear transmissions. However, damaged components are usually examined in a
materials laboratory.
Ultrasonic NDT
An ultrasonic test can be carried out to investigate if any damage is
present in the wind turbine blade. Ultrasonic inspection reveals these flaws quickly, reliably
and effectively and is the most often used non-destructive composite inspection
method in industry. The main advantage of ultrasound
scanning is that it enables us to see
beneath the surface and check the laminate for
dry glass fibre and delamination.
Tap test
The tap test can be used to verify some of the results from the
ultrasonic test and it is also a good method to discover irregularities in the
structure. The method is based on the fact that the sound emitted when knocking
on the structure changes when the thickness or material type changes or when
porosities are present. It could also be caused when there is a dis bond between
the skin laminate and the main spar. There are three types of tap testing
equipment; a manual tapping hammer, the ‘Woodpecker’ portable bond tester and
the Computer Aided Tap Tester (CATT) system.
All the automated tap methods have the advantage
that they can produce a print of the damaged area, which is both useful and a
permanent record of the damage found. All the tapping methods work well for
thin laminates, honeycomb structures and other sandwich panels but are not so
effective on thicker parts.
Infrared thermography
The adhesive joints are critical points in the blade structure. That is
why they are inspected with particular care. Infrared (IR) scanners are used to
examine the blade throughout its length, measuring exactly the same points each
time. The scanner is able to see through the laminate and check the adhesive
joint. It records temperature differences in the adhesive, possibly identifying flaws, and takes a series of pictures. If there are any doubts, a point can be highlighted
and later analyzed using
electronic image processing. If flaws are found,
they can almost always be repaired immediately.
Flaws and NDT in-service
As the force of the wind is so irregular, the driving mechanism of a
wind turbine is subject to much greater dynamic loads. Virtually all components of a wind turbine are subject to
damage, including everything from the rotor blades to the generator,
transformer, nacelle, tower and foundation.Wind turbines do have regular maintenance schedules in
order to minimize failure. They undergo inspection every three months, and every six months a major maintenance
check-up is scheduled. This usually involves lubricating the moving parts and
checking the oil level in the gearbox. It is also possible for a worker to test
the electrical system on site and note any problems with the generator or hook-ups
Flaws on turbine
blades
In-service flaws have
been identified in the following report: Risø-R-1391(EN) ‘Identification of
Damage Types in Wind Turbine Blades Tested to Failure’ Christian P. Debel, AFM.
ISBN 87-550-3178-1; ISBN 87-550-3180-3 ISSN 0106-2840
Flaws on rotor
bearings
Cyclic stresses fatigue the blade, axle and bearing material, and were a
major cause of turbine failure for many years. When the turbine turns to face
the wind, the rotating blades act like a gyroscope. As it pivots, gyroscopic
precession tries to twist the turbine into a forward or backward somersault. For each blade on a wind generator’s turbine, precessive force is at a minimum when the blade is horizontal and
at a maximum when the blade is vertical. This
cyclic twisting can quickly fatigue and crack the blade roots, hub and axle of
the turbine.
Spalling (breaking up into fragments) of rotor
shaft bearings can result in cracked rings, and in some cases, revolution of
the inner rings around the shaft causes cracks in the shaft that can result in a total loss of the
turbine. illustrates what can happen when the
rotor bearings fail (in this case the blades landed 1 km away after having
crossed a road)
TESTING PROCEDURE
Acoustic emission
A substantial amount of work has gone on in AE since
1993. A fatigue test of a wind turbine blade which was
conducted at the National Renewable Energy Laboratory shows that fatigue tests
of large FRP wind turbine
blades can be monitored by AE techniques and that the monitoring can
produce useful information. AE testing procedures, developed during a laboratory
blade testing programme, have been
applied to an in-service wind turbine blade in 2003. In the Framework of the Non-Nuclear Energy
Programme, JOULE III from 1998 to 2002,
the partners successfully developed a methodology for the structural integrity
assessment of wind turbine
blades, either in-service, or during certification testing,
based on Acoustic Emission monitoring during static or fatigue loading. Within
the framework of JOULE III, specialized pattern recognition software for AE
data analysis and wind turbine automatic structural integrity assessment has
been developed
Full scale testing
of wind turbine blade to failure
A 25 m wind turbine blade was tested to failure when subjected to a flap wise load. With the test setup, it was
possible to test the blade to failure at three
different locations. The objective of these tests is to learn about how a wind
turbine blade fails when exposed to a large flap wise load and how failures
propagate. The report also shows results from the ultrasonic
scanning of the surface of the blade and it is seen to be very useful for the detection of flaws, especially in the layer between the skin laminate and the load carrying
main spar. AE was successfully used as sensor for the detection of damages in
the blade during the test.
Wireless detection of
internal delamination cracks in CFRP
In this study, a wireless system using a tiny oscillation circuit for
detecting delamination of carbon/epoxy composites is proposed. A tiny oscillation circuit is
attached to the composite component. When delamination of the component occurs,
electrical resistance changes, which causes a change in the oscillating
frequency of the circuit. Since this system uses the composite structure itself
as a sensor and the oscillating circuit is very small, it is applicable to
rotating components. The wireless method is found to successfully detect embedded delamination,
and to estimate the size of the delamination.
Structural health
monitoring techniques for wind turbine blades
These experiments indicate the feasibility of using piezoceramic
patches for excitation and a Scanning Laser Doppler Vibrometer or piezoceramic patches to measure
vibration to detect damage.
Further testing
of different smaller damages and types of damage is
needed to verify the sensitivity of the methods. The resonant comparison method
can be used for operational damage detection while the operational deflection
shape method produces non-symmetric contours that are an easily interpretable way to detect damage in a structure that is not moving.
Infrared thermography for
condition monitoring of composite wind turbine blades
Infrared thermography has the
potential for providing full-field non-contacting techniques for the inspection
of wind turbine blades(10).
For application to turbine blades, the sensitivity of the thermal
imaging has been shown to be suitable for non-destructive examination during fatigue testing; furthermore, it is thought that for
blades in situ, the wind loading conditions
may be sufficient to create effects detectable by
thermal imaging.