New Wind Turbine Blade Repair Technique Draws Attention 01/20/09
FOR IMMEDIATE RELEASE
Banning, California
January 20, 2009
Frontier Pro Services of Banning, California drew a crowd at the international ACE Competition at COMPOSITES+POLYCON 2009 held in Tampa Florida, January 15-16.
Frontier Pro presented a new blade root repair method (patent pending) that revitalizes thousands of older turbines for which blade replacement is simply not feasible.
After extensive field testing, the Frontier Pro root repair solution provides quick payback (< 1 year) for turbine owners, delivery significant cost advantage both in terms of savings over replacement, as well as in terms of operational gains over turbine retirement.
Problem Statement:
Older 7 1/2 and 9 meter wind turbine blades are starting to experience failures at the root. These failures are caused by a poor load path from the blade to the bolt flange. Unidirectional fiberglass was bent at a 90 degree angle, wound around metal tubes, and returned to the root end of the blade. This right angle area is where flexing and failure have occurred. Previous attempts to repair this area consisted of packing additional resin in the failing area. This was marginally successful because it did not address the underlying problem of a right angle load path.
Solution:
Add material outboard of the existing bolt flange to carry loads directly to the root end of the blade. The material can be placed directly on the blade, or the parts can be pre-molded so they can be quickly bonded to blades, even with the blades mounted on a turbine.
Testing Results:
The Frontier Pro root repair method yields an economic mix of materials that have been tested for adequate strength. After approximately 20 different tests, two types of repair methods were created, including embedded all-thread or hollow tube to take a through bolt. Some technical aspects of the repair are:
- Pre-fabrication of parts to allow repairs to be made in the air on turbine without a crane
- Epoxy bonding material is used to secure pre fabricated parts
- Parts are bolted into place before the bond sets, to ensure correct alignment thus changes to Blade pitch, clocking and coning angles are not a concern
- Minimum cost
- Minimum toxicity of materials
- Acceptable working time
- Brings dead blades back to life
About Frontier Pro Services
Frontier Pro Services is a full-service provider of operations, maintenance and asset management services for wind farm owners and operators. With a mobile force of technicians, Frontier Pro is committed to providing reliable, quality, on-demand service to wind developments throughout the United States and Canada. Our team of experts draws on over two decades of experience maintaining wind farms and a breadth of knowledge extending from gearbox servicing to blade repair to remote monitoring and predictive maintenance to optimize the financial performance of all your wind farm assets. Frontier Pro is a Frontier Energy Group Company.
About COMPOSITES+POLYCON 2009
COMPOSITES+POLYCON is the most comprehensive composites event in the world. Each year, the composites industry gathers together to see latest products and services, be educated, and find solutions. With a focus on growing your business, finding new markets and applications, and operating efficiently, the 2009 show can not be missed. www.acmashow.org
Contacts:
Jack Wallace Jr., Wind Turbine Technical Advisor, Frontier Pro Services.
951-849-3194
jwallace@frontierpro.com
Stacey Nelson, Marketing Manager, Frontier Pro Services.
831-427-1035
snelson@frontierpro.com
Survey Reveals Up to 60% of Turbines May Be Behind in Critical Maintenance 07/31/08
FOR IMMEDIATE RELEASE
Banning, California
July 31, 2008
Frontier Pro Services of Banning, California conducted an informal survey of approximately 75 wind farm operators in the United States. Designed to assess the specific operation and maintenance service needs of wind energy operators, the survey reveals potentially serious threats to wind farms owing largely to the industry-wide shortage of qualified turbine technicians.
Many wind farm operations and maintenance teams are so resource constrained that they are barely able to keep up with the unscheduled maintenance repairs their wind turbines require to generate electricity. Even regular, scheduled preventative-maintenance like oil changes and gearbox lubrication (services that are often still under warranty) are falling behind as manufacturers face similar resource struggles related to the shortage of qualified technicians.
Gearbox failures account for the largest amount of downtime, maintenance, and loss of power production. These costly failures can total 15-20% of the price of the turbine itself, making wind turbine and gearbox maintenance a high priority. "Most gearbox failures are preventable," explains Jack Wallace, an industry veteran who has been servicing wind turbines for more than 20 years, and lead technical advisor for Frontier Pro Services. "Most gearboxes fail as a direct result of improper lubrication and lack of routine maintenance. With so many turbines behind on inspections and regular service, there is real cause for concern here," Mr. Wallace continued.
If oil is not properly monitored and replaced as needed, bearing and gear wear will lead to more serious and costly damage to the drive train. When a $1,500 bearing fails unnoticed, it can lead to production loss and revenue loss including an unscheduled replacement of a $100,000 dollar gearbox and a unscheduled crane cost of up to $70,000 to access the failed components. "Damage caused by worn out or compromised gear oil can be irreparable. You can really see that it makes no sense to put off needed oil changes. The cost are too great," states Mr. Wallace.
Simple fluid analysis can save the typical wind farm operator hundreds of thousands of dollars in repair work; provided, of course, you have the technicians available to perform the work. And that is no small challenge for the wind industry today.
The Frontier Pro Services Operations & Maintenance survey was conducted through a combination of informal phone interviews and in-person meetings with operations and maintenance technicians, wind farm operators, and wind farm owners during the first six months of 2008.
Frontier Pro clients include both wind farm operators with operations and maintenance needs as well as manufacturers who are behind in warranty-work and need sub-contracting help. Specializing in fluids, Frontier Pro will perform individual services such as oil and hydraulic changes for wind farm operators. As a full-service provider, the company also offers asset management services, along with comprehensive outsourcing where wind farms can turn over their complete operations and maintenance programs to Frontier Pro to manage. For more information about Frontier Pro Services go to www.frontierpro.com.
About Frontier Pro Services
Frontier Pro Services is a full-service provider of operations, maintenance and asset
management services for wind farm owners and operators. With a mobile force of technicians,
Frontier Pro is committed to providing reliable, quality, on-demand service to wind developments
throughout the United States and Canada. Our team of experts draws on over two decades of
experience maintaining wind farms and a breadth of knowledge extending from gearbox servicing
to blade repair to remote monitoring and predictive maintenance to optimize the financial
performance of all your wind farm assets. Frontier Pro is a Frontier Energy Group Company.
Contacts:
Jack Wallace Jr., Wind Turbine Technical Advisor, Frontier Pro Services.
951-849-3194
jwallace@frontierpro.com
Stacey Nelson, Marketing Manager, Frontier Pro Services.
831-427-1035
snelson@frontierpro.com
Frontier Energy Group Launches Frontier Pro Services 03/19/09
FOR IMMEDIATE RELEASE
Banning, California
June 19, 2008
Banning, CA, June 19, 2008--FRONTIER ENERGY GROUP, a global leader in renewable energy, announced the launch of FRONTIER PRO SERVICES. The new company will provide a comprehensive suite of operations, maintenance and asset management services for wind farm owners and operators.
"Frontier Pro will service the operations and maintenance needs of wind farm operators, as well as manufacturers who are behind in warranty-work and need subcontracting assistance. The shortage is so widespread, we even receive calls from other O&M providers," reports Rob Giebel Jr., President of Frontier Energy Group. "Wind energy is finally poised to take off, and it is an exciting time to serve all industry segments through proactive management and maintenance of wind farm assets," continued Mr. Giebel.
At a time when the wind power industry is facing a sharpening shortage of qualified turbine technicians, Frontier Pro is poised for rapid growth. Spun out of Frontier Energy Group, the technicians of Frontier Pro have been operating wind farms for more than twenty years including most recently the Energy Unlimited, Inc. wind farm in Palm Springs, CA. Frontier Pro currently maintains over four hundred turbines nationwide.
The shortage of skilled wind turbine personnel is expected to intensify dramatically as the industry works toward the U.S. Department of Energy's goal of increasing wind energy's contribution to the US electric grid to 20% by 2030. Approximately 70,000 trained operations and maintenance personnel will be required, according to the 2008 U.S. Department of Energy report entitled 20 Percent Wind Energy by 2030. With roughly 2,500 qualified technicians today, the wind farm services business will remain in high demand for years to come.
Specializing in fluids, Frontier Pro will perform individual services such as oil and hydraulic changes for wind farm operators. As a full-service provider, the company also offers asset management services, along with comprehensive outsourcing where wind farms can turn over their complete operations and maintenance programs to Frontier Pro to manage.
Frontier Pro Services made its industry debut before record numbers of attendees at WINDPOWER 2008 Conference and Exhibition, North America's largest wind energy event organized by the American Wind Energy Association (AWEA). WINDPOWER 2008 was held in Houston, TX from June 1 to 4. Attendance at the conference nearly doubled from 2007, with 776 exhibitors and over 13,000 attendees.
About Frontier Pro Services
Frontier Pro Services is a full-service provider of operations, maintenance and asset
management services for wind farm owners and operators. With a mobile force of technicians,
Frontier Pro is committed to providing reliable, quality, on-demand service to wind developments
throughout the United States and Canada. Our team of experts draws on over two decades of
experience maintaining wind farms, and a breadth of knowledge extending from gearbox
servicing to blade repair to remote monitoring and predictive maintenance to optimize the
financial performance of all your wind farm assets. Frontier Pro is a Frontier Energy Group
Company.
Media Contact:
Stacey Nelson, Marketing Manager, Frontier Pro Services.
831-427-1035
snelson@frontierpro.com
FPS Lead Technical Advisor to Present at COMPOSITES 2010 12/22/09
FOR IMMEDIATE RELEASE
Banning,
December 22, 2009
Visit Frontier Pro Services of Banning,
After drawing a crowd at last year’s conference in
For more than twenty years, Mr. Wallace has helped design, test, and develop solutions that safely and effectively revitalize older turbines, extending the life of blades, gearboxes and other vital components when replacement is not a feasible option. This year, Mr. Wallace will speak on epoxy repair techniques specific to the unique challenges of wind turbines.
COMPOSITES 2010 will be held February 9-11, 2010 at
About Frontier Pro Services
Frontier Pro Services is a full-service provider of operations, maintenance and asset management services for wind farm owners and operators. With a mobile force of technicians, Frontier Pro is committed to providing reliable, quality, on-demand service to wind developments throughout the
Contact:
Jack Wallace Jr., Wind Turbine Technical Advisor, Frontier Pro Services.
951-849-3194
jwallace@frontierpro.com

