Category:
Structural Failure
Gamesa Inc. on Friday identified a defect in an applicator used to apply a thin Fiberglas layer to wind-turbine blades as the cause of blade splintering and breakage.
The blades are manufactured at Gamesa's Ebensburg-area factory.
It all came down to glue. And how it was misapplied by workers.
Spanish wind-energy company Gamesa said "insufficient and irregular distribution of glue" caused large pieces to break off seven turbine blades at the Allegheny Ridge Wind Farm near Lilly, Cambria County. No one was injured during the mishap in mid-March, but pieces of the blades flew more than 500 feet, according to residents.
Whatever is causing turbine blades made at Gamesa Energy USA near Ebensburg to splinter should be known within weeks, a company representative said Wednesday.
Meanwhile, the startup of the Allegheny Ridge Wind Farm - which will become Pennsylvania's largest wind farm - will be on hold until the blade investigation is completed, Ellen Lutz, director of development for Gamesa's Atlantic Region, said Wednesday.
DARTMOUTH - One of the many casualties of this weekend's storm was a windmill installed by former state Rep. Mark A. Howland.
Arthur Larrivee paid Mr. Howland $16,000 for a windmill and solar panel system for his home at 620 Tucker Road and received everything he asked for: two windmills atop 35-foot-high poles, four solar panels and electrical equipment to convert the power generated into electricity.
But on Monday morning, he woke to find that the steel poles of one windmill had snapped clean off about 4 feet above the ground, leaving the windmill lying on the ground. "I honestly couldn't believe it," said Mr. Larrivee, a real estate broker and Republican activist. "It had to be a flaw in the piping."
An Australian company that wants to buy a Cambria County wind farm might walk away if it's not determined what caused seven turbine blades to crack and large pieces of two blades to fly off.
The problems at the Allegheny Ridge wind farm are a serious concern, said Neal Emmerton, regional asset manager for Sydney-based Babcock & Brown. Gamesa, the Spanish firm that developed the facility, has been paid, but the deal won't be final until the blade issues are resolved, he said.
Wind-energy experts say incidents such as the splintering of two blades and cracks in five others produced at Gamesa's Cambria Township factory are rare.
The American Wind Energy Association views the problem as a fluke, an anomaly that turned up in a time-proven industry involving a highly respected company.
"We haven't heard of anything like this before. There have been thousands of blades installed, and this is a first," said Christine Real-de-Azua, spokeswoman for the wind energy national trade association, based in Washington, D.C.
"Offhand, this doesn't seem like a big issue. We haven't heard of any other problems."
The Allegheny Ridge Wind Farm's phase one startup has been put on hold because some of Gamesa's locally made blades are chipping apart.
Gamesa officials, who met with Portage and Washington township officials Wednesday for the go-ahead on a second phase, said they found issues with seven blades after realizing two of them splintered on the towers.
They had hoped to have the first phase online by the end of the month.
"The structure of the blade was intact in most places ... it somehow split open and fell," said Alberto Gros Isla, the plant's manager.
It wasn't the blades that fell; rather, it was a "thin fiberglass skin" that coated them, he said.
One piece stretched the length of the 147-foot-blade, and another was at least 20 feet long, Gros Isla said.
Repair work is due to begin this week on a wind farm off the coast of Kent which has seen a third of its turbines grind to a halt since early December.
Of the 36 turbines erected off Herne Bay - on the Kentish Flats - 12 have experienced gearbox problems.
Four have been repaired but the others have been running at reduced efficiency pending a break in the weather.
The Danish firm Vestas, which owns and maintains them, said the high failure rate was unusual.
HIGASHIDORI, Aomori Prefecture–The industry ministry Wednesday said it is trying to determine what caused a 68-meter-high wind turbine to collapse earlier this week since strong winds apparently were not blowing at the time.
The incident at the Iwaya Wind Farm in the Iwaya district of Higashidori in this northern prefecture is thought to have occurred late Monday, according to officials of Eurus Energy Holdings Corp., which manages the wind farm.
While no one was injured, the incident resulted in temporary power outages to homes in the area because power lines were severed.
The fire was caused by burning debris from a wind turbine that caught fire due to a malfunction.
To continue its rapid growth, wind energy must overcome some major hurdles in the next few years. Market development in the United States is strongly dependent on the federal PTCs, which for now must be periodically renewed by Congress.
"Most windfarms are near roads, railways, or walking paths, and the dangers are obvious."
IDAHO FALLS, Idaho Blades on two turbines at the Wolverine Creek wind farm have snapped, forcing crews to shut them down for repairs.
LINDSBORG -- Rose Bacon, member of the Governor's Energy Task Force and a rancher who owns property in the Flint Hills, spoke about the vulnerability of communities facing proposals from international companies that want to build commercial wind farms in rural areas. She pointed to the lack of “teeth” in regulations, and the attractive tax write-offs granted to wind energy companies, and the inexperience of local officials in dealing with such monstrous deals, depicting a state-wide scenario akin to the “wildcatter days in the oil business.”
Following the catastrophic failure of two Vestas wind turbines on Feb 22 and 23, 2008, the Danish energy agency requested an investigation into the events. A report was produced by engineers at Risø DTU. Below is the report translated into English. The original report, in Danish, can be accessed by clicking on the link below. A video of one of the failures can be seen here:
http://www.windaction.org/videos/14294 . It is important to note that the debris from the first turbine failure which occurred on February 22 spread as far as 700 meters away. Risø DTU is formerly a government research institution under the Danish Ministry of Science, Technology and Innovation.
This short GE Energy document explains the risk in the event of extreme wind conditions including hurricane or tornado and any mitigation. Note, the document acknowledges the risk of blade throws and tower collapse.
"Today, the task before the Joint Committee (regarding Bill S40) is to hear from the public on what would appear simple
- the giving and taking of “driveway” easements between the Commonwealth’s Wachusett Reservation
(Stagecoach Trail) and the Town of Princeton’s legal “right of way” for its wind power site. As well, the town is offering
the to transfer to the Commonwealth, ownership of, five acres of their 16-acre wind site.
I urge the Joint Committee for Bill S40 to carefully consider the following with regard to your recommendations an for
easement exchange and accession of land from Princeton:
1. The Wachusett Wind Site is a 16 acre parcel wholly surrounded by the Wachusett Reservation and flanked within
few feet, on three sides, by the well traveled Midstate, Harrington and Stagecoach trails. This portion of the state
park is accessible and popular.
2. The present eight windmills are 120-feet high and are proposed to be replaced with two windmills as high as a 35-
story building and with blades that stretch as wide as a football field - windmills whose elevation will come with 150-
feet of the mountain’s elevation.
3. In the wintertime Wachusett experiences unusual ice storms in number and severity
4. In the wintertime, the windmills accumulate ice - then release it when it melts and falls, when it is blown off by wind
or is thrown it off by the rotating blades
5. This ice has put holes in the roofs of utilty buildings on the wind farm and scattters itself across the fully accesssible
wind site, the state reservation and hiking trails, threatening state park viisitors The risk associated with being
struck windmill ice can be quantified and is relative to one’s distance from the windmills and will increase geometrically
with the proposed windmills.
6. Windmills and wind data collection towers at Wachusett have structurally failed five times in twenty years on the
Town of Princeton (PMLD) site. This also threatens the state park visitors as well with collapsing metal structures and
flying blades. Proposed windmills and data towers will not be installed in compliance withthe manufacuturer’s recommendations
and safety warnings."......
BBC Research & Consulting's 2005 report for the National Wind Coordinating Committee that studies 9 wind plant sitings in an effort to identify circumstances that distinguish welcomed projects from projects that were not accepted by communities.
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