Sandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin Company,

for the United States Department of Energy’s National Nuclear Security Administration

under contract DE-AC04-94AL85000.

NuMAD Cost Tool: Summer Internship Summary

Rachel Koh Student Intern

Mentor: Brian Naughton Manager: Dave Minster

Introduction

Ph.D. Student, Univ. of Massachusetts Amherst

Lab Affiliations: Wind Energy Center / Sustainable Building Materials Group

Academic Thrust Areas: Materials Science and Wind Energy

Dissertation Topic: Integration of Bio-based Materials into Megawatt-Scale Wind Turbine Blades

Project Goals

Review and summarize existing blade manufacturing cost models

Identify cost model requirements for integration with SNL design tools and adapt from existing design tools

Modify NuMAD to integrate new cost model

Do a blade cost study to demonstrate/validate tool

Presentation Outline

Summary of existing cost models

Motivation/Development of NuMAD cost tool

Tool Validation

Demonstration: Parametric Analyses

Future Work

Existing Cost Models

Tool/Model/Author Year public? fidelity scaling format strengths, limitations, notes

WindPACT (SNL/TPI) 2003 Y low-med limited Report/ TPI

quotes

manufacturing scaling and

trends analysis; somewhat

outdated

NREL Cost and

Scaling 2006 Y low yes excel trends analysis; looks at entire

turbine; very little detail

Fraunhofer IWES N med yes excel non-US reference; automation

analyses

SNL / Johanns-Griffith 2013 Y high- labor

med-materials yes excel high fidelity labor

NREL / James-

Goodrich 2013 N multi yes excel considers financing; labor

based on SNL (2013)

TPI / Nolet 2014 N med no excel industry experience; current

data; includes CAPEX

NREL / Berry IP N high IP excel

very thorough materials

analysis; other components

currently unfinished

Cost Tool Priorities

Integration with NuMAD

Highly automated for optimization

Medium-high fidelity

Format to integrate with other blade design tools

Low CPU time

Minimal changes to existing NuMAD codes and interfaces

Aside: Current State of NuMAD

preNuMAD: move to object-oriented programming

• motivations included incorporation of a cost tool

• improved ability to manage software complexity

• improved efficiency

blade object

• properties, e.g. blade.sparcapwidth, blade.materials, blade.materials(6).density

• methods, e.g. blade.generateCost, blade.generateCostReport

currently, blade object is defined manually or in excel input (xlsBlade.m) and gets converted back to NuMAD

Integrated Blade Cost Tool

Cost Tool Input added fields:

type

cost

cost unit

waste rate

resin infusion

Cost Tool Input

Integrated Blade Cost Tool

Cost Report Output SNL 5MW 61.5m Carbon Spar

78%

12%

2%

8%

Total Manufacturing Cost

materials

labor

molds

CAPEX

< 1%1%9%

2%

13%

41%

15%

11%

6%2%

Materials Cost

Gelcoat

E-LT-5500(UD)

SNL(Triax)

Saertex(DB)

FOAM

Carbon(UD)

Resin

waste

Misc.

Consumables

Cost Report Output SNL 5MW 61.5m Carbon Spar

Cost Report Output SNL 5MW 61.5m Carbon Spar

8%

6%

7%

9%

19%

10%

13%

11%

2%1%

4%

6%

4%

Labor Hours

Spar Caps

All Shear Webs

TE Prefabs

Root Prefabs and Small Parts

HP and LP Molds

Infusion

Prebond Assembly and Bond

Trim, Inspection, Wet Layup

T-Bolts

Cure

Edge Finishing

Prep Paint and Paint

Balance and Loading

Cost Report Output SNL 5MW 61.5m Carbon Spar

Additional Functions / Features

SNL materials library

Adaptable to custom manufacturing process steps

• labor40_xls2mat.m

• update or define custom steps in excel

Accepts many cost data input types

• cost in $/lb, $/m2, etc.

• resin infusion by vol. fraction, areal spread

< ¼ second CPU time

extensive error handling

Model Validation

many points of reference

shown here: GLWN Manufacturing Competitiveness Study

• 5MW

• 61.5m

• design from SNL/NREL

• data from 8 factories in different regions

• 3 from USA manufacturers

Model Validation

$25,982.00 $23,359.00 $17,708.00 $23,199.19

$46,698.00 $61,600.00

$44,942.00 $46,981.87

$32,860.00

$41,345.00

$104,494.00

$28,902.00

$31,560.00

$40,210.00

$49,395.00

$35,499.00

$-

$50,000.00

$100,000.00

$150,000.00

$200,000.00

$250,000.00

$300,000.00

USA Germany China SNL Cost Tool

Blade Materials Cost by Region

Auxiliary/Consumables

LPS

Hardware

Adhesive

Epoxy

Foams

Gelcoat

Saertex +/-45

Carbon-Uni

ELT-5500

CDB340

Model Validation

201.3

43.1

194.7

0

768.8

841.1

828.7

768.3

282

272.6

399.3

382

0

200

400

600

800

1000

1200

1400

1600

USA Germany China SNL

Blade Manufacturing Process Labor Hours

Finishing Steps

Fabrication Steps

Preparation Steps

Model Validation

$147,825.00

$184,084.00

$247,028.00

$157,050.00

$31,300.00

$39,912.00

$11,103.00

$37,660.00

$78,762.00

$117,430.00 $29,003.00

$29,560.00

$-

$50,000.00

$100,000.00

$150,000.00

$200,000.00

$250,000.00

$300,000.00

$350,000.00

$400,000.00

USA Germany China SNL Cost Tool

Total Blade Manufacturing Cost

Capex

Labor

Materials

Parametric Analysis

61.5m carbon spar blade

single-parameter variation: carbon cost

< 1%< 1%8%

2%

12%

47%

< 1%

13%

10%

5%1%Materials Cost

Gelcoat

E-LT-5500(UD)

SNL(Triax)

Saertex(DB)

FOAM

Carbon(UD)

E-LT-5500(ISO)

Resin

waste

Misc.

Consumables

Parametric Analysis

< 1%< 1%11%

3%

16%

31%

< 1%

18%

11%

7%2%

Materials Cost

Gelcoat

E-LT-5500(UD)

SNL(Triax)

Saertex(DB)

FOAM

Carbon(UD)

E-LT-5500(ISO)

Resin

waste

Misc.

Consumables

76%

13%

2%8%

Total Manufacturing Cost

materials

labor

molds

CAPEX

Total Cost:

199k

79%

12%

2%7%

Total Manufacturing Cost

materials

labor

molds

CAPEX

< 1%< 1%10%

3%

14%

40%

< 1%

15%

11%

6%2%Materials Cost

Gelcoat

E-LT-5500(UD)

SNL(Triax)

Saertex(DB)

FOAM

Carbon(UD)

E-LT-5500(ISO)

Resin

waste

Misc.

Consumables

Total Cost:

227k

81%

11%

2%7%

Total Manufacturing Cost

materials

labor

molds

CAPEXTotal Cost:

254k

20$/kg 30$/kg 40$/kg

Future Work

Optimization

• What do optimal blades look like when we optimize for cost?

• Tip Speed Study blades

• High-Modulus Carbon Fiber (properties-cost tradeoffs)

• Bio-based materials

CAPEX/Factory Model

Integration with AEP tool

Acknowledgements

Mentor: Brian Naughton

Design Codes: Jon Berg

NRT: Brian Resor

Supervisor: Dave Minster

Thank You