About this project:
Date:
August 2024
Project Information
Bladestar Renewables Ltd were tasked with conducting an initial investigation to a large span ways crack discovered on a blade. Once the team arrived on site, it was discovered that this blade defect was beyond reasonable repair and in its current state was not safe to lift.
Key Points
• 6m span ways crack in SPAR with various other chord ways fractures.
• Bladestar inhouse Senvion Limited Authorised Technicians.
• 75% of SPAR detached from the web foot.
• Customer kept in constant communication throughout repair and also access to our customer portal where live updates can be seen.
• Detailed repair report sent out to customer within 72 hours of completion.
• Bladestar inhouse Senvion Limited Authorised Technicians.
• 75% of SPAR detached from the web foot.
• Customer kept in constant communication throughout repair and also access to our customer portal where live updates can be seen.
• Detailed repair report sent out to customer within 72 hours of completion.
Investigation
Investigation was started by removing topcoat from the entire defect area. This allowed us to gain a better insight as to the severity of the defect. The SPAR had detached entirely from the web foot and was also cracked chord ways around 75% of the way through the SPAR. Due to the severity of the defect, the blade was deemed a total loss and not repairable. The blade in fact was not safe to lift due to the severity of the multiple cracks on the SPAR. Bladestar proposed a reinforcement plan in order to allow safe lifting of the blade to the ground and mitigate any further risk to the asset.
Reinforcement
Due to the severity of the SPAR defect, the blade required a substantial reinforcement in order for it to be lifted safely to the ground. Defective layers of laminate were removed in order to ensure a solid bind for the reinforcement laminate. In total, x20 layers of Uni-Directional laminate and x30 layers Biaxial laminate was applied to ensure integrity of the blade during lifting.
• In total, x50 layers of laminate added.
• Blade assessed and deemed safe for lifting.
• Root Cause Analysis instructed to determine failure.
• In total, x50 layers of laminate added.
• Blade assessed and deemed safe for lifting.
• Root Cause Analysis instructed to determine failure.
Root Cause Analysis
Following on from the safe removal of the blade from the turbine, Bladestar were instructed to conduct a Root Cause Analysis to determine the definitive failure cause. The blade was cut into multiple sections before being transported back to our warehouse to undergo further testing. During these tests, Bladestar were able to pinpoint the exact root cause of the failure and a detailed report was issued to the customer. During our findings, we also gained priceless knowledge on prevention of reoccurrence.
