About this project:
Client:
EDF Renewables
Windfarm:
Rusholme
Address:
Selby, England
Date:
June 2024
Duration:
20 hours
Access Method:
Internal Repair
Project Information
Bladestar Renewables Ltd were tasked with repairing a Cat 4 repair to a blade in the Selby, England. Following on from a routine internal inspection, a chord ways crack was found on the pressure side shell. 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 defect was located 12m from the root.
Key Points
• Repair time = 20 hours incl. Internal setup/isolations etc.
• Bladestar inhouse Senvion Limited AT’s.
• All internal layers including core affected.
• Common issue found across all LM blade types.
• Detailed repair report sent out to customer within 72 hours of completion.
• Bladestar inhouse Senvion Limited AT’s.
• All internal layers including core affected.
• Common issue found across all LM blade types.
• Detailed repair report sent out to customer within 72 hours of completion.
Investigation
N/A
Repair
Internal Repair
The internal crack was found during a routine internal inspection, highlighting the importance of internal blade inspections. The defect was a chord ways crack measuring approx. 300mm.
The team setup an internal habitat to allow safe working conditions and also to contain any dust being returned to the hub. The internal laminate was removed to reveal that the core was also compromised. Defective core was removed and new core bonded into position. Core was then profiled and surrounding laminate chamfered in preparation for new laminate. New laminate was then laminated over core to complete.
• x1 core replacement completed.
• Internal Biaxial laminations completed across an area of approx. 0.6m2.
• Quick interaction resulted in mitigating defect from propagating into SPAR.
• x1 core replacement completed.
• Internal Biaxial laminations completed across an area of approx. 0.6m2.
• Quick interaction resulted in mitigating defect from propagating into SPAR.
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