Technical Blade Specification for LM 48.8 P rotor blade

Project : LM 48.8 P Document type :Technical Blade Specification Blade item number : 017545-02 Document no. / rev. : BS-00081/A2 Client : Fuhrlander Eng Change ID : 27486/A Number of pages : 10 Date : 11-05-2009 Title of the document: Technical Blade Specification for LM 48.8 P rotor blade Summary: In this document the technical specification for the LM 48.8 P rotor blade with bolt circle diameter 2300 mm is presented. Nominal power 2.5 MW for wind class GL III A and DIBt 2 A External Name Signature Date Drawn by Peter Hansen Checked by Thomas Rieck Approved by Thomas Rieck 3/9 2008 3/9 2008 3/9 2008 External Name Signature Date Approved by List of changes Revision Date Changed pages Description of changes A1 03-06-2008 All New document A2 03-09-2008 1,9 Blade geometry inaccuracy corrected R06 -> R07 Blade specification LM 48.8 P rotor blade Author: PHA Page: 1 of 10

1 INTRODUCTION... 3 2 TECHNICAL DATA... 3 2.1 MAIN BLADE DATA... 3 2.2 MATERIALS... 3 3 OPERATIONAL DATA... 4 3.1 MAIN TURBINE DATA... 4 3.2 CLIMATIC AND WIND DATA... 4 4 DOCUMENTATION... 5 4.1 CERTIFICATION... 5 4.2 LOADS... 5 4.3 TESTS AND MEASUREMENTS... 5 4.4 DOCUMENTATION... 5 4.5 INSPECTION CERTIFICATE... 5 4.6 QUALITY CONTROL SYSTEM... 6 4.7 BLADE TO PITCH BEARING BOLT CONNECTION... 6 5 OTHER SPECIFIC REQUIREMENTS... 7 5.1 LIGHTNING PROTECTION... 7 5.2 MARKING OF BLADE IDENTITY AND PITCH ANGLE SETTINGS... 7 5.3 BLADE STORAGE AND HANDLING... 7 5.4 BLADE ROOT BULKHEAD... 7 5.5 DRAINAGE SYSTEM... 7 REFERENCES... 8 APPENDIX A: BLADE GEOMETRY DATA LM 48.8 P R07... 9 APPENDIX B: STRUCTURAL DATA LM 48.8 P R07... 10 Blade specification LM 48.8 P rotor blade Author: PHA Page: 2 of 10

1 Introduction In this document the specification of the LM 48.8 P blade as to be used on the W100 turbine is given. 2 Technical data 2.1 Main blade data In the next table the main blade data of the LM 48.8 P are listed. The geometric data presented here are given for reference purposes. Geometric values are valid for 20 C. Blade length 48700 mm +/- 0.1 % Bolt hole circle 2300 ± 2.0 mm 1) Root flange out of plane deviation (max) directly after grinding of bushing 0.45 mm 2) Number of bolts x bolt size 92 x M36 Root flange outside diameter 2408 ± 1 mm Fibre glass root outside diameter 2406 +2/-3 mm Largest chord 3850 mm Blade area (projected) Vortex generators 119 m² None Start of aerodynamic part L= 10,0 m Aerodynamic profiles NACA / DU Reference cross section for 0 pitch mark L= 46.5 m -measure (position of 1 st bolt hole in root, measured clockwise from reference profile, seen from tip end of blade) 2.1 ± 0.5 0º-marking (relative from -measure) ± 0.2 Blade mass without blade root bolts 9950 ± 3 % Static moment to blade root 1400 ± 4.5 % knm Difference in static moment within a blade set 0.2 % (with respect to rotor centre) Eigenfrequency flapwise (standstill measured) 1. Flapwise 0.74 Hz Eigenfrequency edgewise (standstill measured) 1. Edgewise 1.45 Hz Clockwise, when looking downwind Direction of rotation towards the wind turbine. Blade tip flap wise Prebending 3060 mm Blade flapwise tracking Max. 490 mm deviation within rotor Blade edgewise tracking Max 240 mm deviation within rotor Design lifetime 20 years 1) When transported or stored for a longer period, the blade root may ovalize beyond 2.0 mm tolerance. The blade root can be restored to circular geometry where required. 2) Blade handling results in ovalisation and deformation of the blade interface. Due to this, the tolerance is only valid directly after the bushings have been grinded. 2.2 Materials Blade main structural materials: Glass fibre reinforced polyester. Blade root flange: Stainless steel. Blade surface: Gelcoat, polyester based. Local warning colours: Polyurethane paint. Surface colour reference: Matt grey colour code RAL 7035, other colours are optional. Surface gloss: Class 1 in accordance with Technical Criteria for the Danish Approval Scheme for Wind Turbines ver. 15. April 2000. Blade specification LM 48.8 P rotor blade Author: PHA Page: 3 of 10

3 Operational data 3.1 Main turbine data The blade is designed to fit the following turbine data: Electrical power rating P el 2.5 MW e Rotor diameter D 100.0 m Number of blades B 3 Concept variable speed with pitch to feather Tip speed at nominal power 75.0 m/s Min/nominal rotor speed range 7.94 / 14.3 rpm Hub radius (rotor centre to blade mounting face) 1.3 m Tilt angle 6 degrees Cone angle -2 degrees Design tip speed ratio 9.15 Cut-in wind speed approx 3 m/s Cut-out wind speed (10 min) 25 m/s Tower Height [m] 85, 100, 141 & 160 The turbine data are indicative. The design is valid for the loads as described in chapter 4.2. 3.2 Climatic and wind data The blade is designed to be approved for all the following wind classes. Parameter wind class GL III A and DIBt 2 A Annual avg. wind speed (fatigue calculations) 8.5 Air density (fatigue calculations) 1.225 Turbulence intensity 20 % Weibull shape factor (fatigue) 2 Outside ambient operation Temperatures -30 to +55 C Corrosion Class DS/ENV 1090-1 (LM standard) Ice No special demands The wind data are indicative. The design is valid for the loads as described in chapter 4.2. Blade specification LM 48.8 P rotor blade Author: PHA Page: 4 of 10

4 Documentation 4.1 Certification Certification by Germanischer Lloyds, according to Germanischer Lloyds 2004 rules and regulations. Tower clearance verified with a safety factor of 1/0.7. 4.2 Loads The design loads are supplied by Wind 2 Energy and listed in the reference [3]. The blade can be operated only within the load envelope of this document. Verification of the tip to tower clearance is the responsibility of the customer. 4.3 Tests and measurements One prototype blade will be tested by LM Glasfiber as follows: As large a part of the blade as possible is tested. This means that not only the parts, which are evaluated to have the largest stresses are tested. The static test (full scale) was carried out in such a way that the blade is tested for all extreme load cases in each main direction. This means that the blade was tested in 4 directions as follows: Flapwise direction from suction side to pressure side Flapwise direction from pressure side to suction side Edgewise direction from trailing edge towards leading edge Edgewise direction from leading edge towards trailing edge Edgewise and flapwise direction with reference to the directions in the 0º reference profile. Fatigue test (full scale) of complete blade in two main directions in separate test for each direction. Specifications for dynamic test will be based on Technical Criteria for the Danish Approval Scheme for Wind Turbines ver. 15. April 2000 (covers all requirements of IEC). Tests will be accelerated to 5.000.000 load cycles. The static and fatigue test will be used for the approval of the serial produced blades. In general load, power curve and noise measurements will be made by the customer and without delay distributed to LM Glasfiber. 4.4 Documentation LM will deliver the following documentation: Technical Manual (in English). Certification report of the blade 4.5 Inspection certificate Each rotor blade will be delivered with an inspection certificate showing: Blade serial no. + serial no. of matching blades. Blade mass Centre of gravity distance from root flange Static moment at blade root α-value (position of 1 st bolt hole in root, measured clockwise from reference profile, seen from tip end of blade) Flapwise tracking (deviation from reference blade in rotor) Blade specification LM 48.8 P rotor blade Author: PHA Page: 5 of 10

4.6 Quality control system The rotor blades will be manufactured according to the internal quality control system of LM Glasfiber, which is certified according to DS/EN ISO 9001-2000 4.7 Blade to pitch bearing bolt connection Staybolts for the blade to pitch bearing are not part of the blade delivery. LM can mount bolts, delivered by the customer. Verification and certification of the blade to pitch bearing bolt connection can be performed by LM and results can be sent to the customer. Blade specification LM 48.8 P rotor blade Author: PHA Page: 6 of 10

5 Other specific requirements 5.1 Lightning protection The lightning conductor will end inside the blade root and be connected electrically to the root flange. The blade is delivered with LM s standard lightning conducting system. This system is developed and designed to lightning protection level one according to IEC 61024-1. The lightning is captured by a receptor in the blade tip, and is diverted by a conduction system through a tinned copper cable (50 mm2, according to DIN 46 438) to a lightning bar connected at the root flange. The lightning receptors can be replaced if necessary. Two lightning receptors are placed close to the tip end at each side of the blade. A third one is located at the very tip end and is also equipped with a drainage function. A lightning registration card is placed inside the blade near the blade root end to register and log a possible lightning with an impact current up to 400 ka. 5.2 Marking of blade identity and pitch angle settings Marking of the blade is done embedded at the root and on some of the 0 -marking plates. In total four 0 -marking plates are located near the root, two in leading edge and two in trailing edge. 5.3 Blade storage and handling On each blade there is a sticker attached to the outside of the blade close to the root, describing how to store the blade and handle it during transport and installation. Blades can be delivered with a transportation rig (against a deposit), which allows stable temporary storage of the blades on the assembly site, also during strong winds. Loads due to handling and storage have been considered in the structural design. Further details on handling, storage and installation are to be discussed between the customer and LM. 5.4 Blade root bulkhead The blade root interior is closed with a bulkhead positioned at a radial position of 600+/-50 mm from the blade flange. The bulkhead is equipped with a covered manhole with an opening of 600x600 mm. At the moment the bulkhead will be capable of carrying a total static load of maximum 300 kg with a safety factor 2, and a point load of 150 kg within a surface of 200x200 mm (this is larger than 3000 N/m2). The bulkhead has a density class IP 44 EN 60529. The bulkhead serves the following purposes: To support one worker and tools to work on the hub internals. For safety reasons the worker must always be secured with a safety harness. To prevent larger particles or debris from the inside of the blade to enter the hub. 5.5 Drainage system The blade tip is equipped with a lightning receptor with a drainage function. Blade specification LM 48.8 P rotor blade Author: PHA Page: 7 of 10

References [1] Drawing no DR-03295/A1, Blade root section LM 48.8 P Fuhrlander [2] Drawing no DR-03292/A1, Outline drawing LM 48.8 P Fuhrlander [3] Design load document. W0402-B02-08-LOCO-308-W2E-001-1-E. W0402-B02-08-LOC O-308-W2E-001-1-E- [4] Document no BM-00024/A2 Blade manual LM 48.8 P [5] Drawing no DR-01696/A6 Transportation drawing LM 48.8 P. [6] Working Instruction WI-01178/A6 Pack & Stack mounting LM 48.8 P Blade specification LM 48.8 P rotor blade Author: PHA Page: 8 of 10

Appendix A: Blade geometry data LM 48.8 P R07 LMBfile: LM48_8P rev4, lay-up rev 4, web rev 3 Blade section Chord Twist Rel. thickness Centre line Predeflection TE thickness [m] [m] [deg] [%] [-] [m] [mm] 0 2.406 8.000 100.000 0.250 0.000 0.0 1 2.406 8.000 100.000 0.250 0.000 0.0 2 2.450 8.080 97.780 0.242 0.000 4.8 3 2.578 8.313 91.466 0.220-0.001 10.0 5 3.001 9.083 72.767 0.163-0.006 20.3 7 3.481 10.000 54.953 0.115-0.018 28.8 9 3.808 10.580 42.408 0.092-0.037 34.1 10 3.850 10.465 38.400 0.090-0.050 35.0 11 3.803 10.210 35.802 0.092-0.065 34.8 13 3.662 9.280 32.297 0.096-0.104 32.0 15 3.504 8.255 29.552 0.100-0.152 27.6 17 3.338 7.359 27.394 0.104-0.212 23.3 19 3.168 6.665 25.738 0.108-0.283 19.3 21 2.998 6.157 24.442 0.113-0.367 16.0 23 2.829 5.789 23.370 0.116-0.464 13.4 25 2.661 5.467 22.466 0.119-0.575 11.4 27 2.493 5.103 21.674 0.120-0.699 9.9 29 2.324 4.649 20.946 0.122-0.838 8.7 31 2.156 4.083 20.281 0.123-0.992 7.7 33 1.992 3.432 19.696 0.123-1.161 6.8 35 1.832 2.736 19.204 0.123-1.345 6.0 37 1.676 2.030 18.788 0.121-1.546 5.1 39 1.525 1.352 18.413 0.117-1.763 4.4 41 1.375 0.744 18.117 0.111-1.997 3.6 43 1.219 0.273 18.046 0.102-2.249 3.0 45 1.050 0.038 18.003 0.089-2.517 2.5 46.5 0.870-0.001 18.000 0.076-2.731 2.5 47.5 0.700 0.309 17.998 0.065-2.868 2.5 48 0.578 1.501 17.970 0.056-2.955 2.5 48.4 0.430 3.521 17.800 0.048-3.016 2.5 48.7 0.040 5.839 17.700 0.040-3.057 2.5 Blade specification LM 48.8 P rotor blade Author: PHA Page: 9 of 10

Appendix B: Structural data LM 48.8 P R07 LMBfile: LM48_8P rev4, lay-up rev 4, web rev 3 Blade Section Flapwise Edgewise Polar Torsional Shear center Mass center section mass stiffness stiffness mass Stiffness distance distance moment from lea- from leaof inertia ding edge ding edge [m] [kg/m] [Nm²] [Nm²] [kg m2/m] [Nm m/rad] [% chord] [% chord] 0 1877 5.93E+09 5.99E+09 6.51E+02 1.71E+09 0.5001 0.5003 1 773.8 6.03E+09 6.00E+09 6.85E+02 1.78E+09 0.4984 0.4928 2 447.9 5.31E+09 5.47E+09 5.69E+02 1.51E+09 0.4964 0.4889 3 424.3 4.30E+09 5.03E+09 5.45E+02 1.35E+09 0.4939 0.4931 5 344.6 2.96E+09 4.48E+09 4.54E+02 9.06E+08 0.4732 0.4695 7 306.8 1.99E+09 4.65E+09 4.30E+02 6.01E+08 0.4643 0.4663 9 292.8 1.37E+09 4.80E+09 4.17E+02 3.64E+08 0.4531 0.4612 10 276.2 1.15E+09 4.53E+09 3.83E+02 2.57E+08 0.4519 0.4619 11 262.5 9.90E+08 4.01E+09 3.38E+02 1.95E+08 0.4438 0.4594 13 236.3 7.28E+08 3.36E+09 2.70E+02 1.25E+08 0.4454 0.4688 15 217.1 5.55E+08 2.78E+09 2.11E+02 7.58E+07 0.4367 0.4593 17 208.1 4.26E+08 2.27E+09 1.72E+02 5.78E+07 0.4251 0.4525 19 193.6 3.27E+08 1.90E+09 1.39E+02 4.53E+07 0.4203 0.4453 21 180.9 2.53E+08 1.53E+09 1.10E+02 3.11E+07 0.4168 0.4423 23 174.5 1.98E+08 1.33E+09 9.31E+01 2.52E+07 0.4199 0.4448 25 160.6 1.51E+08 1.07E+09 7.35E+01 1.99E+07 0.4186 0.4385 27 151.1 1.15E+08 8.64E+08 5.90E+01 1.63E+07 0.4161 0.4373 29 134.6 8.48E+07 6.31E+08 4.33E+01 1.27E+07 0.4092 0.4274 31 123.0 6.13E+07 4.78E+08 3.30E+01 1.02E+07 0.4091 0.429 33 110.4 4.37E+07 3.26E+08 2.38E+01 7.99E+06 0.3997 0.4228 35 104.7 3.10E+07 2.55E+08 1.93E+01 6.75E+06 0.4045 0.4272 37 90.0 2.20E+07 1.72E+08 1.29E+01 4.88E+06 0.4011 0.4229 39 86.9 1.49E+07 1.18E+08 9.94E+00 3.99E+06 0.3992 0.4351 41 68.8 8.96E+06 7.64E+07 6.27E+00 2.80E+06 0.4058 0.4326 43 49.5 4.34E+06 4.36E+07 3.69E+00 1.75E+06 0.42 0.4377 45 39.9 2.04E+06 2.86E+07 2.31E+00 1.10E+06 0.4447 0.4582 46.5 37.7 1.21E+06 2.09E+07 1.54E+00 6.78E+05 0.4693 0.4715 47.5 29.9 4.93E+05 1.20E+07 9.03E-01 3.39E+05 0.4861 0.4829 48 21.7 2.19E+05 4.97E+06 3.81E-01 1.36E+05 0.5299 0.5101 48.4 26.4 1.19E+05 2.84E+06 2.16E-01 7.41E+04 0.5049 0.4855 48.7 15.5 5.64E+02 1.17E+04 1.86E-03 1.12E+03 0.4951 0.4987 Blade specification LM 48.8 P rotor blade Author: PHA Page: 10 of 10