Wind Composite Services Group/WindCom 18/04/2018 Wind Composite Services Group/WindCom Introduction

Who We Are Established in 2006 Owned by Tecsis Headquarters in Houston, TX with offices in Spain & Brazil Over 75 Service Technicians in the USA Safety Culture Warehouse and training center (Houston) Drug free workplace Technically advanced

Preferred Access Method 360° Suspended Platform

Blade Fleet Failure Investigation Process 18/04/2018 Blade Fleet Failure Investigation Process

Problem Aging blade fleets require solutions to emerging issues

Objective To maximize the value of the rotor for the owner and minimize business risk

The Idea Compile and analyze original manufacturing data, operational experience, and damage reports to determine the root cause(s) of the blade failures Engineer and document standardized repairs and preventative measures to reliably extend the life of the blades WindCom will takes the role of the OEM to work with owners to find solutions. No owner group is required. WindCom retains data privacy for individual sites and owners, but aggregates knowledge across the fleet. Shares engineering results and critical findings to all owners without revealing any detailed data provided by individual owners.

The Process Manufacturing data is collected from manufacturer or owners if possible Owners are asked to provide data to the group Blade numbers and at which site they have been operating History of the blades- remediations, damage repairs, failures Damage reports for different failure types and their frequency of occurrence The team will analyze data to determine trends and root cause(s) of damages

Example of How Data can be Assimilated Blade populations vary from design values differently during manufacturing sequence Static Moment Mass Mass

Different Blade Failure Modes are Categorized Aft shell failure

Several Blade Failure Modes are Evident Aft shell failure

Different Blade Failure Modes are Evident Blade root cracking

Different Blade Failure Modes are Evident Trailing edge cracking

Different Blade Failure Modes are Evident Trailing edge cracking

Different Blade Failure Modes are Evident Surface Coating Failure

DMAIC Approach DEFINE Specify the goals of the blade remediation effort MEASURE Obtain manufacturing, failure, & repair data for the fleet ANALYZE Use forensic techniques to assess the root causes of failures IMPROVE Develop solutions to address the root causes of failures CONTROL Monitor remediation efforts to validate quality and longevity

Summary First document the failure types and frequency of occurrence for various failure types throughout the fleet Perform root cause analysis to understand why the blades are failing. Develop engineered repairs for each specific failure mode and perform tests to validate remediation methods Prepare standardized repair procedures that are repeatable, have documented engineering properties, and can be quoted using fixed cost Develop statistical models that assist with our ability to predict failure rates Develop preventative measures to lower risk and cost Develop tools to estimate blade maintenance costs accurately and optimize to control cost increases as the fleet ages over time

Maintenance Plan vs Reactive only Assumptions: • 200MW Wind Farm/ 100-2MW turbines in Midwest • 40% capacity factor PPA @ $25MW hour • Loss of revenue daily $60/summer and $420/winter • Average erosion which if left unattended would result in 5% loss of energy after 20 years (.25%/yr)• Lightening strikes (or other damage) effect 5 blades/year

For all your wind turbine composites servicing needs North America Houston – USA Sales 281-906-9572 T. +1 281 227 5130  F. +1 281 227 5192 Europe   Madrid -Spain T. +34 91 241 10 02 F. +34 91 293 51 96 South America Sao Paulo - Brasil T. +55 15 2105 4800 F. +55 15 2102 4875 info@windcomservices.com | www.windcomservices.com

Step 1: Define DEFINE Specify the goals of the blade remediation effort VALUE Maximize the value of the blades to the owner LIFETIME What is the goal for the design lifetime of repaired blades? 1 year, 5 years, 10 years, 20 years MODES What failure modes have occurred in the fleet? What is the observed risk for each mode of failure? How do modes affect WTG performance & safety?

Step 2: Measure MEASURE Obtain manufacturing, failure, & repair data for the fleet DESIGN Design manufacturing drawings and work instructions PRODUCTION Blade weight and balance values, dates of manufacturing HISTORY Operational and blade remediation history CONDITION Photography and non-destructive testing results

Step 3: Analyze ANALYZE Use forensic techniques to assess the root causes of failures IEC LOADS Perform calculations for IEC fatigue and extreme conditions DYNAMICS Assess the structural dynamic response across the fleet STRUCTURAL Evaluate the structural impacts for ultimate and fatigue cases

Step 4: Improve IMPROVE Implement solutions to address the root causes of failures DIAGNOSTICS Create procedures to identify blade issues before remediation REMEDIATION Document existing condition and perform remediation

Step 5: Control CONTROL Monitor remediation efforts to validate quality and longevity QUALITY Review the remediation process to assess field implementation LONGEVITY Implement processes quantify the remediated blade longevity

Blade Life Cycle Management A New Approach to a Critical Asset 18/04/2018 Blade Life Cycle Management A New Approach to a Critical Asset Sandia Blade Workshop August 2016

Management Plan Preventative Maintenance Predictive Maintenance Blades are inspected at regular intervals Data can be analysed using recognition software to quickly categorize blade condition and to determine corrective actions Data is entered into the data base to monitor blade condition Decisions can be made to prevent wear and tear, damage progression or lightning damage Repairs are made during the low wind season with leading edge protection at planned intervals Using database and newly collected data future issues with the blade can be predicted Using the predictions a plan can be made to minimize future problems. Known failure modes can be investigated in further detail to prevent occurrences before they happen. Maintenance is not random but calculated to minimize downtime and repair expenses customized site and turbine specific.