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WORK INSTRUCTION

Wind O&M Wind Energy Maintenance

MTOE.INGS.IT.0002.01-EN

INSPECTION OF THE BLADES FROM THE GROUND USING CAMERA AND TELESCOPIC LENS

Dates and Signatures

This document has been approved by the same persons as the spanish one

FE08_PE0805 Rev01

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WORK INSTRUCTION
Wind O&M Wind Energy Maintenance INSPECTION OF THE BLADES FROM THE GROUND USING CAMERA AND TELESCOPIC LENS 1. 2. 3. 4.

MTOE.INGS.IT.0002.01-EN

OBJECTIVE 2 SCOPE 2 SAFETY AND THE ENVIRONMENT 2 DESCRIPTION 2 4.1. ASSIGNMENT OF CODES TO MOST USUAL DAMAGE TO BLADES. 2 4.2. OPERATING MODE FOR THE INSPECTION OF BLADES USING CAMERA AND TELESCOPIC LENS. 10 5. ATTACHMENTS 12 5.1. ATTACHMENT 1: ORGANIZATION OF THE BLADE INSPECTION FOLDERS. 12 5.2. ATTACHMENT 2: EXAMPLE OF COMPLETED CHECK LIST 13 5.3. ATTACHMENT 3: SUMMARY LIST OF DAMAGE CODES 14

1. OBJECTIVE
This document defines and assigns codes to the different types of damage which may generally be found on the blades. The objective in assigning codes to the different types of damage is to simplify the collection of data on the check list for the inspection of blades using a camera and telescopic lens. The steps to be followed during the inspection and the procedure for completing the check list are also explained in this document.

2. SCOPE
This document is applicable to all wind farms on which the blade maintenance is carried out by Acciona Energia except for NEG MICON wind turbines with TIP blades from LM.

3. SAFETY AND THE ENVIRONMENT


Safety: The measures indicated in the safety sheet, FS-01, must be taken. The environment: The regulations established in the document, Environmental Standards for wind farm maintenance (IE06_PG0804), shall be observed

4. DESCRIPTION 4.1. ASSIGNMENT OF CODES TO MOST USUAL DAMAGE TO BLADES. 4.1.1. DAMAGE ON LEADING EDGE
1.1-Crack on leading edge These are cracks which form just below the adhesive joint of the two shells on the leading edge

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Wind O&M Wind Energy Maintenance INSPECTION OF THE BLADES FROM THE GROUND USING CAMERA AND TELESCOPIC LENS 1.2-Leading edge broken

MTOE.INGS.IT.0002.01-EN

Knocks during assembly or as result of bird impact cause the fibers of the leading edge to break and may result in a hole.

1.3-Pitting on leading edge These are pits which form along the line of the overlap between the edging cloth and the shell cloth. Generally, any spots along the line of the cloth overlap may be considered as pitting.

1.4-Erosion on leading edge Erosion on the leading edge is observed as soon as the gel coat disappears and the yellow-brown coat of primer is visible on the surface.

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Wind O&M Wind Energy Maintenance INSPECTION OF THE BLADES FROM THE GROUND USING CAMERA AND TELESCOPIC LENS 1.5-Severe erosion on leading edge

MTOE.INGS.IT.0002.01-EN

The erosion can be considered serious when the leading edge cloth can be seen. This means that the erosion has removed the gel coat and the primer coat.

1.6-Spalling from pitting When pitting is observed on a blade, the coat often beings to flake from the overlap line between the edging cloth and the shell cloth.

4.1.2. DAMAGE ON TRAILING EDGE


2.1-Crack on trailing edge These include all the cracks affecting the trailing edge cloths. These are usually developed perpendicular to the trailing edge.

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Wind O&M Wind Energy Maintenance INSPECTION OF THE BLADES FROM THE GROUND USING CAMERA AND TELESCOPIC LENS 2.2-Trailing edge detached

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This is a fault in the adhesion of the two shells on the trailing edge. A gap is visible between the two shells on the trailing edge.

2.3-Trailing edge broken This damage usually occurs when the blade is being handled. The cloths may be broken or a piece of the trailing edge is missing.

2.4-Erosion on trailing edge This damage is found in the blade pressure shell and is caused by air friction. The yellow-brown coat of primer is usually visible on the surface.

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Wind O&M Wind Energy Maintenance INSPECTION OF THE BLADES FROM THE GROUND USING CAMERA AND TELESCOPIC LENS 2.5-Pitting on trailing edge

MTOE.INGS.IT.0002.01-EN

These are pits in the gel coat along the overlap lines of the cloths on the trailing edge.

4.1.3. DAMAGE IN SHELL


3.1-Spalling <200 x 200 mm These are poorly attached areas of gel coat <200 x 200 mm which have flaked to reveal the laminate. 3.2-Spalling >200 x 200 mm These are poorly attached areas of gel coat >200 x 200 mm which have flaked to reveal the laminate.

3.3-Crack with damaged cloths These are the cracks appearing on the cloths on the shells.

3.4-Cracks on the beam-shell joint

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WORK INSTRUCTION
Wind O&M Wind Energy Maintenance INSPECTION OF THE BLADES FROM THE GROUND USING CAMERA AND TELESCOPIC LENS

MTOE.INGS.IT.0002.01-EN

These are the cracks which appear along the beam or the struts on the cloths on the shell surface. These cracks are characterized by following the attachment line of the beam. These cracks are often perpendicular to the trailing edge and gradually spread over time (T- or Ycracks).

4.1.4. DAMAGE TO TIP


4.1-Cracks on baby joint These are cracks which appear on the tip just below the point where the beam joins the extension (the baby). These cracks may be a sign of weakness in the beam-baby joint or they may be the result of poor repairs to the tip.

4.2-Open tip These are tips with faults in the attachment of the two shells. Usually a gap is clearly visible between the two shells.

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WORK INSTRUCTION
Wind O&M Wind Energy Maintenance INSPECTION OF THE BLADES FROM THE GROUND USING CAMERA AND TELESCOPIC LENS

MTOE.INGS.IT.0002.01-EN

4.3-Lightning strike without damaging cloths Black marks can usually be seen next to the lightning rod as a result of the lightning strike.

4.4-Lightning strike with damaged cloths This refers to damage to the cloths at the tip as a result of lightning strikes. Black marks are usually visible around the broken cloths.

4.5-3M tape detached or damaged Generally, when a 3M tape is detached or damaged, black dirt marks are visible as a result of the irregularity caused by the defect. Air bubbles, detached or torn pieces, knocks from the cutter during unpacking may be encountered.

4.1.5. DAMAGE TO ROOT


5.1-Crack on root on leading edge Cracks that start at the root of the blade on the leading edge side.

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WORK INSTRUCTION
Wind O&M Wind Energy Maintenance INSPECTION OF THE BLADES FROM THE GROUND USING CAMERA AND TELESCOPIC LENS

MTOE.INGS.IT.0002.01-EN

5.2-Crack on root on trailing edge Cracks that start between the root and the apex of the blade on the leading edge side.

5.3-Rust or cracks on extender These are defects which can be found in the extender zone. These include rust, pits, poor seals at the joint and cracks.

4.1.6. DAMAGE TO THE GEL COAT


6.1-Grease stains These are stains caused by traces of grease from the pitch system or from the blade bearing.

6.2-Other types of dirt


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WORK INSTRUCTION
Wind O&M Wind Energy Maintenance INSPECTION OF THE BLADES FROM THE GROUND USING CAMERA AND TELESCOPIC LENS Stains caused due to air, dust, insect or particle contamination.

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6.3-Coat damaged or worn These are areas in which the gel coat is observed to be incorrectly attached, with blisters or large stains due to poor gel coat mixture.

6.4-Cracks on coat or cuts from cutter These are surface cracks resulting from knocks by the cutter or due to the application of the coat too thickly. These cracks do not damage the fiber as they only superficial.

4.2. OPERATING MODE FOR THE INSPECTION OF BLADES USING CAMERA AND TELESCOPIC LENS. 4.2.1. POSITION OF BLADE
The blade is placed vertically to permit the inspection of the two shells, moving the tripod and camera from one side of the blade to the other. The three blades of the wind turbine should be feathered. The wind turbine should be in PAUSE mode and the emergency button pressed to lock the rotor in the required position. Before stopping the turbine, notify Remote Control of the expected times for stopping and starting the turbine. The orientation of the turbine is defined by the position of the sun in order to ensure good light when taking photos.

4.2.2. DATA COLLECTION (SEE ATTACHMENT 2)


Step 1: Complete the table on page 1 with the following data: Work order number Subcontractor number Name of operators performing the inspection

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WORK INSTRUCTION
Wind O&M Wind Energy Maintenance INSPECTION OF THE BLADES FROM THE GROUND USING CAMERA AND TELESCOPIC LENS Name of wind farm Date of inspection Model of blade (Manufacturer and length) Serial number of blade 1 Serial number of blade 2 Serial number of blade 3 Step 1: Position the first blade in accordance with 4.2.1 Step 2: Set up the camera and tripod

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Step 3: For each damage found, complete the table in the check list with the following information: Distance of damage to the leading edge in centimeters. Approximate radius point of damage. In the event of cracks and large spalling, note the radius at the start and the end of the damage. Size in centimeters of the damage. Damage code according to 4.1 Assignment of codes to most usual types of damage on blades. Step 4: Move the numbered circles corresponding to each damage type across the diagram of the blade to establish the approximate position. If the damage is repeated in several areas of the blade, copy the corresponding numbered circle and place it on the blade diagram. Step 5: In the last column of the table, set up a link to the photos corresponding to each damage. The photos and the check list are placed in the same folder in accordance with the organization defined in Attachment 1. Step 6: Inspect the next blade

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WORK INSTRUCTION
Wind O&M Wind Energy Maintenance INSPECTION OF THE BLADES FROM THE GROUND USING CAMERA AND TELESCOPIC LENS

MTOE.INGS.IT.0002.01-EN

5. ATTACHMENTS 5.1. ATTACHMENT 1: ORGANIZATION OF THE BLADE INSPECTION FOLDERS.


Alaitz Wind Farm A.E A3.7 Photos Blade 1

Photos Blade 2 Photos Blade 3

Check List A.E A3.7

A.E A3.8

A.E A3.9

Etc. Moncayuelo Wind Farm

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WORK INSTRUCTION
Wind O&M Wind Energy Maintenance INSPECTION OF THE BLADES FROM THE GROUND USING CAMERA AND TELESCOPIC LENS

MTOE.INGS.IT.0002.01-EN

5.2. ATTACHMENT 2: EXAMPLE OF COMPLETED CHECK LIST


I-BLADE I

Data capture
NO=DAMAGE DISTANCE FROM LE (CM) RADIUS SIZE OF DAMAGE (CM) DAMAGE CODE COMMENTS LINKS TO PHOTOS

30

19000

15

3.3

Cracks with damaged cloths Open tip on trailing edge

1.2.3.

23000

30

4.2

1.2.3.

4000 From 14000 to 23000

40

5.1

Crack on leading edge, root area

1.2.3.

4 5 6 7 8

900

1.4

Mild erosion on leading edge

1.2.3.

Position of damage

Pressure Valve

Suction Valve

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WORK INSTRUCTION
Wind O&M Wind Energy Maintenance INSPECTION OF THE BLADES FROM THE GROUND USING CAMERA AND TELESCOPIC LENS

MTOE.INGS.IT.0002.01-EN

5.3. ATTACHMENT 3: SUMMARY LIST OF DAMAGE CODES

Damage codes

Description of damage Leading edge

1.1 1.2 1.3 1.4 1.5 1.6

Crack on leading edge Leading edge broken Pitting on leading edge Leading edge erosion Severe erosion on leading edge Spalling from pitting Trailing edge

2.1 2.2 2.3 2.4 2.5

Crack on trailing edge Trailing edge detached Trailing edge broken Erosion on trailing edge Pitting on trailing edge Shells

3.1 3.2 3.3 3.4

Spalling <200 x 200 mm (gel coat detached) Spalling >200 x 200 mm (gel coat detached) Cracks with damaged cloths Cracks on the beam-shell joint Tip

4.1 4.2 4.3 4.4 4.5

Cracks on baby joint Open tip Lightning strike without damaging cloths Lightning strike with damage to cloths 3M tape detached or damaged Root

5.1 5.2 5.3

Crack on root on leading edge Crack on root on trailing edge Rust or cracks on extender Gel coat

6.1 6.2 6.3 6.4

Grease stains Other types of dirt Coat damaged or worn Cracks on coat or cuts from cutter

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WORK INSTRUCTION
Wind O&M Wind Energy Maintenance INSPECTION OF THE BLADES FROM THE GROUND USING CAMERA AND TELESCOPIC LENS Record of changes
Rev. 01 02 03 Date 2007/01/03 ----/--/-----/--/-Description Drafting of Work Instruction

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