2023风电叶片运维如何实现最佳产能

风电叶片运维如何实现最佳产能Content

目录WhoWe

AreScopeof

ServicesCooperation

ModelSampleapplications

andcustomer

benefitsConclusions公司简介服务范围合作模式技术应用案例及客户利益结论Scope

of

Services

服务范围Training

for…

培训服务Rope

Access

绳索技术Rotor

Blade

Inspections

叶片检查Rotor

BladeRepairs

叶片维修Senior

Service

Engineers

高级服务工程师Services

On-Site风场服务Factory

Audits工厂审核StructuralFailures

结构失效Root

Cause

Analysis

根因分析Structural

Retrofits

结构性技改Performance

Improvement

性能提升Blade

Angle

Adjustment

叶片角度调整Minimization

of

Vibrations

减轻震动Vortex

Generators

增功VGBlade

Extensions

叶片加长Noise

ReductionDesignof

TES降噪锯齿设计Blade

TransportationSegmented

Blade叶片运输分段叶片Blade

Recycling叶片循环利用BladeExamination

forLife-TimeExtension叶片寿命延长检查LPS

Upgrades防雷升级CooperationModel合作模式“CooperativeWorkand

TechnologyTransfer”SampleProjectswithGermanEngineersorTechnicians

comingto

ChinaIntroductionofthe

Technologyusedtoourlocal

partnersTrainingandTechnology

Transfertoenableourlocalpartnersto

doallday-todayworksaccording

tointernational

standardsTechnicalSupportfrom

Germanyincaseof“non-standard”

issues“配合工作和技术转让”德国工程师或技术员到中国进行示例工程向当地合作伙伴进行技术介绍通过培训和技术转让，使合作伙伴可以根据国际标准开展日常工作从德国提供“非常规”

问题的技术支持Training

Services

培训服务Training

for…

培训服务Rope

Access

绳索技术RotorBlade

Inspections

叶片检查Rotor

Blade

Repairs

叶片维修SeniorService

Engineers高级服务工程师RepairHandbook维修手册Approx.90%ofallcommondamagescoveredApplicabletoSecondaryStructuresof

RotorBlades

only涵盖约90%的叶片损伤类型仅适用于叶片二级结构损伤Repair

Handbook

维修手册Repair

Handbook

维修手册RepairHandbook

维修手册Repair

Handbook

维修手册Repair

Handbook

维修手册Your

advantages

客户利益LongTermCostReduction

byEarlydetectionof

damagesQualifiedrepairsperformedaccordingtointernationalstandardsfollowingstandardized

proceduresBenefitfromRotorExperts‘long

timeexperienceBenefitfromsupportRotorExpertsinallnon-standard

issuesMiminumamountof

down-timemaximizesenergy

yieldKeepthevalueofyourwind

turbine长期降本:早期发现损伤根据国际化标准和标准化步骤进行保质维修借鉴RotorExperts的长期经验非常规化问题得到RotorExperts的支持最小停机时间最大限度地提高产能风机保值Performance

Improvement

性能提升Blade

Angle

Adjustment

叶片角度调整Minimizationof

VibrationsVortex

GeneratorsBlade

Extensions-

0,83°-

7,42°-

0,72°50%ofallwindturbinesmeasuredshowsignificantmisalignmentsoftherotor

blades经测试的50%的叶片表现出严重的角度不对准问题Performance

Improvement

性能提升Blade

Angle

Adjustment叶片角度调整Minimizationof

VibrationsVortex

GeneratorsBlade

ExtensionsUsingphotometricmeasurementandautomattedpictureprocessingthebladescanbesetwithinatoleranceof+/-0.1°accordingtothenominal

valuesspecifiedforoptimum

performance.使用光度测量和自动图像处理，可以根据为获得最佳性能而指定的标称值，将叶片设置在+/-0.1°的公差范围内。Aglobalmisaligmentof1°maycause

aperformanceshortfallofupto5%.Thecostfor

themeasurementswillbepaidbackwithinafew

daysof

operation.1°的整体偏差可能导致高达5%的性能损失。角度测量费用可在运行后几天内得到补偿。Performance

Improvement

性能提升BladeAngle

AdjustmentMinimization

of

Vibrations

减震Vortex

GeneratorsBlade

ExtensionsAerodynamic

imbalance气动失衡Mass

imbalance质量失衡Case1:AxialvibrationsduetoaerodynamicimbalanceCase2:Radialvibrationsduetomass

imbalanceCase3:Acombinationof

both案例1：气动失衡导致的轴向震动案例2：质量失衡引起的径向震动案例3：以上二者的结合Performance

Improvement

性能提升BladeAngle

AdjustmentMinimization

of

Vibrations

减震Vortex

GeneratorsBlade

ExtensionsCase1:Axialvibrationsduetoaerodynamicimbalancecanleadtoprematurefailureoffatiguecriticalcomponents(mainframe,gearbox,…)whichneedstobe

avoided.案例1：气动失衡导致的轴向震动会导致关键部件由于疲劳出现过早失效（主轴，齿轮箱等），这种情况需要避免。Step

1:

All

bladesset

to

nominal

所有叶片设定到额定值Step2:Usinghighprecisionsensors,theblades

areindividually

set

to

minimize

the

vibrations

使用高精度感应器分别设定每只叶片以减轻震动f=0.198Hz

(1P)â=1,49

mm/s2blade1:

0.00°blade2:

0.00°blade3:

0.00°f=0.198Hz

(1P)â=28,35

mm/s²Limit:15

mm/s²blade1:

0.02°blade2:

0.00°blade3:

0.22°Performance

Improvement

性能提升BladeAngle

AdjustmentMinimization

of

Vibrations

减震Vortex

GeneratorsBlade

ExtensionsCase2:Axialvibrationsduetomassimbalancecanleadtoprematurefailureoffatiguecriticalcomponents(mainframe,gearbox,…)whichneedstobeavoidedandperformencelossduetoincreasedcut-inwindspeed案例2：质量失衡导致的轴向震动可以导致关键部件由于疲劳出现过早失效（主轴，齿轮箱等），这种情况需要避免。切入风速增加也会导致性能损失。with

mass

imbalance

存在质量失衡without

mass

imbalance

没有质量失衡Rotor

speed

叶轮速度f=0,357Hz

(1P)Ampl.=13,1

mm/s2Rotor

speed

叶轮速度f=0,357Hz

(1P)Ampl.=162,4

mm/s2Performance

Improvement

性能提升BladeAngle

AdjustmentMinimization

of

Vibrations

减震Vortex

GeneratorsBlade

ExtensionsCase2:Axialvibrationsduetomass

imbalance案例2：质量失衡引起轴向震动Performingmeasurements,determinationofcorrectionmassesand

placement进行测量，确定校正质量和位置Version1:Leadweightsaroundthebladeroot(smallerturbines)叶根周围放置铅垂（适用于小风机）Version2:Waterfilled

inflatablebags

(larger

turbines)充水充气袋（适用于大风机）Placementofcorrectionmassesonspar

web

在腹板上放置正确配重块Performance

Improvement

性能提升BladeAngle

AdjustmentMinimizationof

VibrationsVortex

Generators

增功VGBlade

ExtensionsHighaltitudeswithlowairdensitywillleadtoreducedenergyyieldbelownominalperformance.Dependingontheaerodynamicdesignoftheblades,Vortexgeneratorscan

reduce

the

loss

inenergy

yield.高海拔和低空气密度会导致风机发电量下降到额定值一下。依据叶片空气动力设计原理，涡流发生器（VG）可以减少发电量损失。Performance

Improvement

性能提升BladeAngle

AdjustmentMinimizationof

VibrationsVortex

Generators

增功VGBlade

ExtensionsVGshavetobeindividuallycalculatedforthebladeANDthesite.GenericsolutionsorwronglyplacedVGscanleadtoasignificant

loss

in

performance

对于叶片和风场而言，每一个VG块都必须独立计算，块通用解方案或是错误放置VG决都会导致性能下降Mostreasonableapproach:Tuftexperiment(leftpicture)andCFD/empiricallayoutof

VG

pattern

and

size(right

picture)

最可行的方法：Tuft实验（如左图所示）及CFD/基于实验的VG模式和大小的布局Performance

Improvement

性能提升BladeAngle

AdjustmentMinimizationof

VibrationsVortex

GeneratorsBlade

Extensions

叶片加长Incaseofsitewithlowerthanexpectedwindspeeds,anincreaseinrotorareawillimprovetheenergyyield.Aslargerbladesaretypicallynotaneconomicallyfeasibleoptionduetothehighcost,anextendedbladetipcanbea

solution.如果风场风速低于预期风速，增加转子面积可以提高发电量。由于更大的叶片意味着更高的成本，所以从经济角度讲，更换更大叶片并非可行性选择，因而从叶尖处加长叶片长度可以为一种解决方案。Performance

Improvement

性能提升BladeAngle

AdjustmentMinimizationof

VibrationsVortex

GeneratorsBlade

Extensions

叶片加长BelowasampleLayoutfora34m1.5MW

bladeLimitedto3-5%ofblade

length.加长部分为叶片长度的3-5%Loadhavetobe

re-calculated需重新计算载荷Performance

Improvement

性能提升BladeAngle

AdjustmentMinimizationof

VibrationsVortex

GeneratorsBlade

Extensions

叶片加长Incaseofsitewithlowerthanexpectedwindspeeds,anincreaseinrotorareawillimprovetheenergyyield.Aslargerbladesaretypicallynotaneconomicallyfeasibleoptionduetothehighcost,anextendedbladetipcanbea

solution.如果风场风速低于预期风速，增加转子面积可以提高发电量。由于更大的叶片意味着更高的成本，所以从经济角度讲，更换更大叶片并非可行性选择，因而从叶尖处加长叶片长度可以为一种解决方案。Limitedto3-5%ofblade

length.加长部分为叶片长度的3-5%Noteasytodoaproperadjustmentoftheextension

piece.Onlyafew0.1°offwillresultinalossof

performance加长的部分很难调整到一个合适的角度，即使0.1°的偏差也能导致性能下降Loads

have

to

be

re-calculated

重新计算载荷Your

advantages

客户利益LongTermCostReduction

andincreasedincome

byAvoidingperformance

shortfallsOptimizethesitespecificenergy

yieldAvoidpre-maturefailureof

components长期降本，增加收益：避免性能不足优化风场特定产能避免部件的预成熟故障Structural

Failures

ofRotor

Blades

叶片结构性失效RootCause

AnalysisStructural

Retrofits根因分析结构性技改Incaseofstructuralfailures,RotorExpertsperformsindependentrootcauseanalysisrangingfrominspectionsonsiteorintheworkshoptoglobalordetailedre-calculationofthedesign.Picturesbelowshowdamaged

blades.对于结构性失效，RotorExperts根据风场或生产车间的检查结果，或对设计进行期或详细的重新计算进行根因分析下图为受损叶片示例。Structural

Failures

ofRotor

Blades

叶片结构性失效RootCause

AnalysisStructural

Retrofits根因分析结构性技改Bydetailedinvestigationandrelatedcalculationstherootcausecanbe

determined.通过详细的调查及相关计算，确定叶片受损根因。Structural

Failures

ofRotor

Blades

叶片结构性失效Basedonunderstandingtherootcauseofafailure,structuralretrofitscanbeworkedout.RotorExpertscansuperviseandtrainlocalteamorevenperformsuch

works.基于对失效根因的理解，编制结构性技改方案。RootCause

AnalysisStructural

Retrofits根因分析结构性技改Your

advantages

客户利益LongTermCostReduction

bySavingthebladesandenablingthemtowithstandthecalculated

lifetimeFeedbackforinspectionofbladesofsimilartypeinthe

fieldInformationforfactory

acceptance长期降本：挽救叶片并使其能够承受计算的寿命为风场同类叶片检查提供反馈为工厂验收提供信息Factory

Audits

叶片厂审核Factory

Audits叶片厂审核Factoryauditsareperfomredtoensurehighbladequalitybyreviewingandevaluating

the

manufacturing

processes

in

detail.

叶片厂审核通过详细审查及评估生产步骤，旨在保障叶片质量。RotorExpertsdevelopedanauditsystemforrotorblademanufacturewhichwas

certified

by

TÜV

Rheinland

in

January

2019.RotorExperts为叶片厂审核开发了一套审核体系，该体系已与2019年1月得到TÜV莱茵认证。Factory

Audits

叶片厂审核Factory

Audits叶片厂审核Theauditsystemhasbeenusedformorethan10rotorbladefactoriesuptonowandcertificateshavebeengranted.至今，叶片厂审核体系已用于10余家叶片厂并已为接受审核的生产厂家颁发证书。Your

advantages

客户利益Increasedamoreconsistent

rotorbladequality

byQualityharmonizationincaseofdifferentsuppliersBetterbladeshavealonger

lifetimeBetterbladesmakeless

troubleIntroducenecessaryinternationaldevicsand

technologies提高叶片质量一致性：不同供应商的叶片质量协调一致更好的叶片寿命更长更好的叶片问题更少引进国际先进生产设备和技术Noise

Reduction

降噪技术Designof

TES降噪技术Basedonsite-specificrequirements,rotorbladenoiseismoreandmoreanissuetobeaddressed.RotorExpertshastheknow-howtodesignTrailigEgdeSerrationsadptedtotheaerodynamicshapeoftherotorbladeandtheoperationalconditionsofthewindturbine.Theserrationpanelscanbefittedinthefactorypriortodeliveryorattachedon

site.基于风场的特定要求，解决叶片噪音问题越来越受关注。RotorExperts具有设计后缘锯齿的专有技术，可以适用于不同转子叶片气动形状和风机运行条件。锯齿板可在出厂前现场安装。Your

advantages

客户利益Increasedacceptanceofthe

windturbinesandincome

byLownoise

operationsLessneedforlowperformacne

operatingmodese.g.duringnight

time提供风机接受度，增加收益：低噪音运行对低性能运行模式（如夜间）的需求较少Blade

Transportation

叶片运输Segmented

Blade分段叶片Duetosize,bladetransporationgetsmoreandmoreanissue.

Tomanufacturebladesinpiecescanbeacosteffective

solution.由于叶片尺寸较大，叶片运输变得越来越困难。生产分段叶片可以是一种有效节约成本的方案。Blade

Transportation

叶片运输Segmented

Blade分段叶片Alreadyin2004theRotorExpertsengineersdevelopedandtesteda

boltedrotorbladeseparation

sucessfully.RotorExperts的工程师已于2004年成功研发并测试了一款上好螺栓的叶片。Blade

Transportation

叶片运输Segmented

Blade分段叶片RotorExperts‘closeconnectionbetweendesignand„reallife“makesustargetatdoablesolutionstoavoidsurprises(picture

left)…RotorExperts在设计与“生产及运维实践”的密切关联，使我们可以锁定可行的解决方案，以避免意外（左图）发生。Currentlyongoingworkstargetatfindingareliablebonded

conncetion(picture

right).目前正在进行的工作旨在寻找一个可靠的粘接点（右图）。Your

advantages

客户利益CostReductionand

increasedopportunities

byReductionoftransportation

costLessdamangesduring

transportationMoresitesget

accessible降低成本，增加机会：减少运输成本减少运输过程造成的损伤更容易运输到不同地形条件的风场LPS

Upgrades

防雷升级LPS

Upgrades防雷升级Lightningstrikesandresultingstructuraldamagesareoneofthemostcommonreasonforrotorblade

repair.雷击及其导致的结构性损伤是叶片维修的最常见原因之一LPS

Upgrades防雷升级Forsiteswithverystronglightningstrikes,conventionalLP-Systemsmightnotbesufficient.RotorExpertsdevelopedanupgradesolution.Thiscoppermadetipcapcanbeappliedon

site.由于所有风场在雷击强度和发生率方面都非常不同，RotorExperts开发了一种升级解决方案，用于使用铜制端盖在非常敏感的风场进行现场应用。LPS

Upgrades

防雷升级Your

advantages

客户利益LongTermCostReduction

andincreasedincome

byLesscostforblade

repairsLessdowntimeofthewind

turbine长期降本，增加收益：降低维修成本减少停机时间Recycling循环利用Capacitytobereplaced

peryear–

1000MW020000040000060000080000018000001600000140000012000001000000Morethan0.5Miotons/afrom2030onMorethan1Mio.tons/sfrom2040onSlowlythefirstgenerationofwindturbinesreachingtheendoftheirlife

timeandtheirbladeshavetobetakencareof.Theprojectionoftheamount

of„waste“wewillbefacingishardtoimagine...Currentlythereisnoenvironmentalfriendlyconcepttodealwiththerotorbladewaste

existing.慢慢地，第一代风机使用寿命到期，其叶片也必须进行维护。据预测，我们将面临的“浪费”数量难以想象…目前还没有环境友好的方法来处理转子叶片的废料。Recycling

of

Rotor

Blades

叶片的循环利用Recycling

of

Rotor

Blades

叶片的循环利用Recycling循环利用Butaretherotorbladesjustwaste?Thematerialmixmakesthemaninterestingcandidateforrawmaterialandenergeticrecyclingwhilesimpleburningisnotanoptionduetothespecificpropertiesofthe

materials.但是，这些叶片转只能做废物处理吗？混合材料使得其成为原材料和能量回收的一个有趣的候选者，而由于材料的特殊性质，简单燃烧并非首选。Recycling

of

Rotor

Blades

叶片的循环利用Recycling循环利用InternationalpartnersofRotorExpertshavedevelope