About this project:
Client:
EDF Renewables
Windfarm:
Long Park
Address:
Galashiels, Scotland
Date:
August 2024
Duration:
90 hours
Access Method:
Rope Access
Project Information
Bladestar Renewables Ltd were tasked with repairing a Cat 5 repair to a blade in the Scottish Borders. A team of complex repair specialists were deployed to complete the repair. Utilising our own inhouse Limited Authorised technicians we were able to work self-sufficiently. This enabled us to handle the repair from start to finish without any external support from the customer. The blade had suffered a transverse crack measuring at 1050mm at the bottom of the spoiler. Poor quality spoiler removal techniques were a factor in the crack due to moisture ingression on the spoiler screw holes.
Key Points
• Repair time = 90 hours via rope access
• Bladestar inhouse Senvion Limited AT’s.
• All layers from external to internal affected.
• Poor spoiler removal techniques by third party affected integrity of core material allowing moisture ingression.
• Detailed repair report sent out to customer within 72 hours of completion.
• Bladestar inhouse Senvion Limited AT’s.
• All layers from external to internal affected.
• Poor spoiler removal techniques by third party affected integrity of core material allowing moisture ingression.
• Detailed repair report sent out to customer within 72 hours of completion.
Investigation
Investigation was started by removing surrounding topcoat to further expose the defect. External Uni-directional and Biaxial layers were found to be cracked. As a result the balsa was also affected and would require replacement. Upon further investigation and core removal, internal laminate layers were also found to be defective.
Repair
External Repair: Defective layers of Biax and UD fiberglass were removed to expose a crack and moisture within the balsa.
As a result of this, several core replacements were completed due to the direction of travel of the defect. Defective balsa was removed and internal laminate of the blade checked. Upon removal of the core, internal laminate was also found to be defective. In total, 3 core replacements were completed externally.
New core was profiled and surround laminate chamfered in preparation for new external laminate. UD/Biax laminations were completed in order to return the blades structural integrity. New laminate then profiled, filled, sanded and painted to complete.
• External repair completed via rope access.
• X3 External core replacements completed.
• Uni-directional and Biaxial laminations completed across an area of approx. 1m2.
Internal Repair: Due to discovering internal laminate had been affected, an internal repair was mandatory. The team setup a repair habitat within the blade and set to work on rectifying the internal issues. A further x2 core replacements were required upon removing defective internal laminate. Core profiled and surrounding laminate chamfered in preparation for new laminate. Cover laminations were completed and the blade was now back to full structural integrity.
• External repair completed via rope access.
• X3 External core replacements completed.
• Uni-directional and Biaxial laminations completed across an area of approx. 1m2.
Internal Repair: Due to discovering internal laminate had been affected, an internal repair was mandatory. The team setup a repair habitat within the blade and set to work on rectifying the internal issues. A further x2 core replacements were required upon removing defective internal laminate. Core profiled and surrounding laminate chamfered in preparation for new laminate. Cover laminations were completed and the blade was now back to full structural integrity.
What the client had to say...
EDF has a wide and varied fleet of wind turbines which generates One Gigawatt of renewable energy. This sizeable fleet requires constant maintenance from specialist personnel and contractors in order to maintain the highest possible efficiency, one of those contractors is Bladestar Blade Repair.
EDF chose to work with Bladestar due to their expertise in blade internal and external inspections, structural repairs and Root Cause Assessment of faults.
Throughout the time EDF have worked with Bladestar they have found them to be highly skilled, approachable and professional. Their work ethic is second-to-none and they are willing to go above and beyond in order to achieve our goal.
Both Chris and Joe are stand out in their abilities and they have contributed to EDF’s values and mission towards net zero.
I can highly recommend Bladestar for any blade repair work or inspections and EDF will be collaborating with them going forward.
Mark Haggerston
Blade Engineer