Attachment_No._1_-_Appendix_A_Statement_of_Work.pdf

Attachment No. 1 – Appendix A, Statement of Work Page 1 of 7

Attachment No. 1

APPENDIX A

STATEMENT OF WORK

“Segmented Ultralight Morphing Rotor Demonstration Field Test Blade Set”

August 16, 2017

1.0 BACKGROUND

The Segmented Ultralight Morphing Rotor (SUMR) Project (https://sumrwind.com/arpa-e/) is pursuing a revolutionary horizontal axis wind turbine design concept under Advanced Research Projects Agency– Energy (ARPA-E) sponsorship. The SUMR concept takes advantage of highly flexible blades that deflect significantly under load, and thus enable shedding of destructive forces to survive extreme wind events.

Whereas SUMR includes design and analysis of very large rotor blades, the focus of this Statement of Work is on the SUMR-D rotor, where ‘D’ stands for demonstrator. The SUMR-D rotor blades are gravo-aero-elastically scaled-down versions (approximately 21 m in length) of much larger blades (106.8 m long), which were designed for a 13 MW, IEC Class IIA (IEC 61400-1) wind turbine (SUMR-13). The SUMR-D blade design was created to validate, through a field measurement campaign, the predicted load response, control system characteristics, and performance of the larger SUMR-13. At about 1:4 scale of the SUMR-13, the SUMR-D rotor blade is ~21 m long and weighs ~575 kg, and was designed to mount on the CART2, a 600 kW research wind turbine installed at the NREL National Wind Technology Center (NWTC) near Boulder, CO. The SUMR-D rotor will operate only in very light winds (5-12 m/s) with a rated rotor power of about 85 kW.

2.0 OBJECTIVE

The purpose of this effort is to award a subcontract for the SUMR-D blade fabrication and delivery to the National Wind Technology Center (NWTC) to an appropriately qualified fabricator. The Subcontractor shall provide at a minimum a set of 2 blades with adapters to be mounted and tested on the CART2, an existing 600 kW wind turbine installed at the NWTC, near Boulder, Colorado. The blades shall have all the necessary hardware and adapters to mount on the existing hub configuration shown in Attachment B:

‘Adapters and Hardware’.

In addition to these 2 test blades, additional blades (up to 2) could be used for structural and modal testing on a test-stand mounted on the ground, and as spares. Because of the limited production run, it is expected that the Subcontractor(s) will employ economical and efficient tooling fabrication techniques and devices to minimize mold manufacturing costs.

The blade aerodynamic design and structural laminate schedule are given in Attachment A: ‘Blade Specifications’. The blades are 20.87 m long with a maximum chord of ~1.56m. The blade root is shown in the Appendix ‘Blade Specifications’ as an oval to match the hub spindle, with a maximum chord length of 0.9 m. However, depending on the adapter configuration chosen, the blade root can be made circular with a diameter of ~1.03 m. The proposed layup includes the use of glass fiber plies (double bias, triax, and unidirectional plies), balsa (or foam) cores, and gelcoat for the outer layer. The connection to the adapter will require T-bolts (studs, nuts on the adapter side, and barrel nuts within the root buildup) or inserts (also known as carrots) in the blade root plus studs and nuts (on the adapter side). No lightning protection is requested, but sensor installation and signal cabling are required. Also the manufacturer will need to make provisions for weight ballasting in each blade.

Attachment No. 1 – Appendix A, Statement of Work Page 2 of 7

Because the CART2 is an existing upwind turbine (designed to rotate clockwise when viewed from upwind) that will be turned downwind, the SUMR-D blades shall be mounted on a left-handed rotor, which will rotate counterclockwise as viewed from upwind of the turbine.

The fabricated blade set shall be delivered to the NWTC no later than May 29, 2018, to enable field testing to begin by June 15, 2018. In addition to the blades, molds and tooling developed to produce the blades shall also be delivered to the NWTC.

3.0 SCOPE OF WORK

The SUMR-D specifications include blade external geometry (chord, twist, pitch axis, airfoil section, all

vs. blade span radial station), internal geometry (shear webs, spar caps), materials (fabrics, core materials, resins), and laminate schedule. These specifications are given in Attachment A: ‘Blade Specifications’.

The Subcontractor shall review the specifications and agree or recommend alternatives to any of the design choices in order to facilitate the manufacturing of the tooling and blades. Additionally, the fabrication shall include the following activities:

• Source and acquire materials and supplies;

• Fabricate blade molds and tooling for blades molding (e.g., Vacuum Resin Transfer Molding, or other infusion processes selected by the Subcontractor);

• Carry out layup, infusion, and curing operations;

• Complete assembly and joining;

• Incorporate bolts/inserts in blade root;

• Balance blade set;

• Finish and coat the blade surface;

• Proof-load test two blades (optional);

• Design/manufacture two adapters and procure necessary studs and hardware;

• Provide quality control reports verifying that specifications were met;

• Arrange to ship the finished blades, adapters, and molds to NREL, with appropriate shipment frames and insurance;

• Ensure blade set arrives at NREL ready for mounting on the turbine and field testing.

4.0 TASKS

4.1 Review of Design Specification and Drawings and Acceptance of Design Documentation:

The Subcontractor shall review the design provided by NREL and offer recommendations for any potential engineering changes to facilitate and expedite the manufacturing process. Any proposed change shall not significantly modify the expected weight distribution, stiffness distribution, or aerodynamics (outer geometry) of the blade. Examples of changes are the bonding line geometry, fastener location and sizing, adapter geometry, sensor location and routing, coating, tolerance choices, etc.

The changes shall be reviewed and agreed upon with NREL via Engineering Change Notices (ECN) issued by the Subcontractor and approved by NREL. As built drawings and related documentation are expected to be received as a deliverable of this phase. This deliverable constitutes Milestone 1.

4.2 Revised Manufacturing Process Plan:

The Subcontractor shall submit to NREL a detailed manufacturing process plan and a schedule for the deliverables and milestones described in this Statement of Work, which is compatible with the final delivery to the NWTC of the blade set, two adapters, and (if applicable) tooling set by 5/29/2018. A tentative schedule is shown in Table 1.

Attachment No. 1 – Appendix A, Statement of Work Page 3 of 7

The manufacturing process plan should include at a minimum a listing and a description of the following elements with the expected dates of completion:

• Receive Material and Acceptance QA

• Tooling Fabrication Steps o Male plug/ blade pattern fabrication if applicable (steps & materials used) o Fabrication of the molds (steps & materials used) o Assembly tooling fabrications (steps & materials used)

• Blade Fabrication Steps o Low and high pressure shell (steps & QA/QC methods used, e.g. ply install, bag install, vacuum check, vacuum infusion, curing, bag removal, demolding) o Shear webs lamination (steps & QA/QC methods used) o Bonding of shear webs to low pressure shell (steps & QA/QC methods used) o Bonding of high and low pressure shell (steps & QA/QC methods used) o Reinforcement cloth (steps & QA/QC methods used) o Root fastener hole preparation (as needed) (steps & QA/QC methods used) o Fastener installation (steps & QA/QC methods used) o Surface preparation, finishing, and coating (steps & QA/QC methods used) o Balancing (steps & QA/QC methods used) o Final QA/QC o Proof load test (if applicable) o Transportation (packaging, shipment frames, and protection steps taken for the blades transport, transportation strategy)

• Adapter Fabrication Steps and QA/QC o Design evaluation o Casting/machining/etc.

o QA/QC o Coating o Hardware/fastener selection and procurement o Tensioning/torqueing specifications

The manufacturing process plan reduces the project risk and indicates the safest and most efficient strategy to fabricate and ship the blades to the NWTC. The plan shall also prove to NREL that the Subcontractor has devised sound manufacturing and QA/QC procedures to meet the project goals. This deliverable constitutes Milestone 2.

4.3 Tooling Fabrication:

The Subcontractor is expected to produce:

1. Male plug(s), or templates, as needed for the SUMR-D blade;

2. One low-pressure skin mold and one high-pressure skin mold;

3. Two shear web molds (the blade is a two-shear-web design).

The molds shall render smooth blade surfaces, free of wrinkles.

The Subcontractor shall send NREL as-built drawings, documents, and photographs of the tooling set.

This deliverable constitutes Milestone 3.

4.4 Material Sourcing

The Subcontractor shall source all the materials including the composite plies and resins, bonding epoxy, and fasteners for joining to the adapters and to the hub spindles (details of the spindle bolt-hole pattern are shown in Appendix B: ‘Adapters and Hardware’). The Subcontractor shall either make use of materials as specified in the Attachments to this document or source materials of equivalent mechanical properties after NREL’s review and approval.

Attachment No. 1 – Appendix A, Statement of Work Page 4 of 7

4.5 Adapters:

The Subcontractor shall source or fabricate two adapters to allow fastening of the blade root to the hub spindle per specifications in Attachment D: ‘Adapters and Hardware’. The adapter allows for a downwind precone angle of 12.5°. The Subcontractor shall either fabricate the adapters based on NREL’s design or design and fabricate them based on the Subcontractor’s own design to be approved by NREL.

The Subcontractor shall also source the necessary fasteners to allow the connection of the adapter to the spindle and the connection of the adapter to the blade. The Subcontractor shall provide tensioning and torqueing specifications for all the fasteners. The Subcontractor shall send NREL as-built drawings, documents, and photographs of the adapter/fastener set. This deliverable constitutes Milestone 4. In Attachment D ‘Adapters and Hardware’, a few possible solutions to the adapter design are provided.

4.6 Blade Lamination, Sensor Embedment, Assembly, Finishing, and Balancing:

For each blade, the Subcontractor shall carry out ply and core layup, positioning of the inserts (unless T-bolts [preferred] are utilized) in the root layup, infusion of the laminates for each of the two skins, spar caps, and shear webs. The Subcontractor shall coordinate with NREL to provide time for strain-gauge installation after skin and spar-cap laminate curing. NREL staff or delegates will travel to the Subcontractor’s facility to perform the sensor installation and to either route the signal cable or give instructions for its routing along one or both of the shear webs. The two skins and webs shall then be bonded and cured to form the blade assembly. In this process, provisions shall be made for balancing.

The Subcontractor shall also finish the blade with necessary deburring, sanding, and coating.

Additionally, the Subcontractor shall balance the blades, guaranteeing a mass and mass moment imbalance less than 0.5%. The Subcontractor shall send NREL drawings, photographs of the process employed for the blade manufacturing and balancing. This deliverable constitutes Milestone 5.

4.7 Blade Proof Loading (Optional):

If applicable, the Subcontractor shall proof-load two of the manufactured blades. Static loading should be performed in the flatwise direction according to Attachment D: ‘Proof Load Testing’. If the Subcontractor cannot perform the static test, it should be clearly specified in the proposal; NREL shall then be in charge of proof loading the blade prior to installation on the CART2 turbine. Photographs and documents reporting the execution and results of the static load test shall be sent to NREL. This deliverable constitutes Milestone 6. If the blades do not pass the proof loading test because of a manufacturing defect, the manufacturer shall produce replacement blades at no additional cost to NREL.

4.8 Delivery of Blades, Adapters, and Tooling Shipment:

The Subcontractor shall arrange for insured shipment of the blades, adapter plates, hardware, shipment frames, and possibly tooling to the NWTC. Shipment frames provide protection to the blades while on the ground and general safe handling procedures. The successful receipt of the products will make up Milestone 7.

5.0 REVIEW MEETINGS AND TRAVEL REQUIREMENTS

After the execution of the subcontract, the project shall commence with a kick-off meeting at the Subcontractor’s facility to go over the scope of work in detail. The Subcontractor shall give updates on the project execution during biweekly, 1-hr web-meetings. The Subcontractor may request one additional conference call/web-meeting per week as needed to discuss questions and request/approve Engineering Changes. NREL staff is expected to travel to the Subcontractor’s facilities to install necessary instrumentation before laminate curing or to witness the proof-load test.

Attachment No. 1 – Appendix A, Statement of Work Page 5 of 7

6.0 DELIVERABLES

The deliverables are as follows, for due dates refer to Table 1:

6.1. Drawings and documentations including any photograph related to the design and manufacturing of the tooling set, adapters, and blades after approval of specifications and ECNs as described in Task 4.1.

6.2. Revised Manufacturing Process Plan and Schedule for Deliverables, compatible with firm delivery date of 5/11/2018 (5/29/2018 if Task 4.7 applies), as described in Task 4.2

6.3. As-built drawings, documents, photographs related to the manufacturing of the tooling set, as described in Task 4.3

6.4. As-built drawings, documents, photographs related to the manufacturing of the adapters, as described in Task 4.5

6.5. Notification of blade laminate ready for sensor installation

6.6. Drawings, photographs of the process employed for the blade manufacturing and balancing, as described in Task 4.6

6.7. Photographs and documents reporting the execution and results of the static load test (if applicable), as described in Task 4.7

6.8. Shipment documentation and proof of insurance for blades, adapter plate, and tooling set, as described in Task 4. 8

The proposed schedule is shown in Table 1

Table 1. Deliverable Schedule

Activity or Milestone Deliverable1 Date Due ECN approvals – Milestone 1 6.1: Acceptance Memo 11/24/2017

Revised Manufacturing Process Plan – Milestone 2 6.2: Memo describing plan 12/8/2016

Tooling set completed – Milestone 3 6.3: Memo 3/1/2018 Adapters completed - Milestone 4 6.4: Memo 2/1/2018

Ready for Lamination, Curing of Blade Set 6.5: Memo 3/8/2018

All Blades balanced – Milestone 5 6.6: Memo 4/19/2018 All Blades proof tested - Milestone 6 6.7: Memo2 4/30/2018

Shipment Shipping Invoice3 4/27/2018 (5/9/2018)

Delivery to NWTC – Milestone 7 6.83 5/11/2018 (5/29/2018)

(1) Memo includes 1-2 page text, plus drawings, and photographs as applicable

(2) This Milestone applies if Task 4.7 is performed by the Subcontractor

(3) If Task 4.7 is elected and performed by the Subcontractor, the due date for blade shipment and delivery is given in parentheses

Attachment No. 1 – Appendix A, Statement of Work Page 6 of 7

7.0 ELECTRONIC REPORTING REQUIREMENTS FOR SUBCONTRACT REPORT

DELIVERABLES

It is NREL’s intention to publish subcontract report deliverables containing publicly available information (e.g. non-confidential, non-protected, non-proprietary information) for distribution on the internet.

The Subcontractor shall provide the final approved version of report deliverables in accordance with the electronic reporting requirements described below.

The technical monitor may specifically direct the Subcontractor to provide reports in one or more of the file format standards provided below.

a. The Subcontractor shall submit all report deliverables (including status, annual, or final reports) as electronic files in Adobe .pdf format, preferably with all graphics and images embedded within the document.

b. All final approved version submissions shall be delivered to NREL via e-mail to the 1) NREL Technical Monitor, 2) the NREL Subcontract Administrator or Associate (as specified in the Deliverable Addresses below).

c. If it is not possible to include all of the graphics and images (figures, illustrations, and photographs) in the same file as the text, NREL will accept the text in Adobe .pdf formats and the graphics and images as separate electronic graphic or image files*. The accepted standard for page layout and graphics is the Adobe Creative Suite of programs.

*The acceptable graphic or image file formats are: .eps, .tif, .gif, .jpg, .wmf, .emf, .pct, .png, .bmp, .psd, .ai, .fh, .qif, .fpx, cdr. The preferred resolution for graphics or images is 300 dpi. Include all fonts used in creating the file.

d. For animation, video, or multi-media elements, CD-ROM, DVR and thumb drive are acceptable technical deliverable media.

e. For all calculations in support of subcontract reports that are conducted in ASPEN+, an electronic copy of INPUT, REPORT and BACKUP (if Model Manager is used) must be submitted with all reports. Additionally, if costing or sizing calculations are conducted in a spreadsheet [no process calculations (heat and material balances) in spreadsheet format are permitted], a copy of the fully documented MS Excel file shall be supplied.

f. A fully executed model release shall be supplied to NREL with all photographs and images, regardless of whether such photographs or images are delivered to NREL electronically or in hard copy. Such model release shall certify that the Alliance for Sustainable Energy, LLC, Management and Operating Contractor for the National Renewable Energy Laboratory for the U.S. Department of Energy is granted a non-exclusive, paid-up, irrevocable, worldwide license to publish such photographs in any medium or reproduce such photographs or allow others to do so for United States Government purposes. Model releases are required in all situations in which a reasonable person would respond in the affirmative to the question – could someone, other than the model himself/herself, recognize the person in this photograph or image? All model releases shall be provided to the subcontract associate as a condition of final payment, in accordance with the subcontract. To obtain a Subcontractor Model Release form, please contact images@nrel.gov.

8.0 ACKNOWLEDGEMENTS IN SUBCONTRACTOR PUBLICATIONS

In any scientific or technical report or article, conference paper, journal article, etc. based on or containing data first produced in the performance of this subcontract and published in academic, technical or professional journals, symposia proceedings or similar works, the Subcontractor shall use this acknowledgement stating, “This [article, conference paper, journal article, etc.] was developed based upon funding from the Alliance for Sustainable Energy, LLC, Managing and Operating Contractor for the National Renewable Energy Laboratory for the U.S. Department of Energy.”

mailto:images@nrel.gov

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9.0 COPYRIGHT PERMISSION/AUTHORIZATIONS

The Subcontractor is responsible for obtaining copyright permissions and/or authorizations for all information and/or data, as applicable that is incorporated into all final technical reports. Electronic copies of these copyright permissions and/or authorizations shall be provided to the subcontract associate at the email address provided below. The Subcontractor shall also provide a written certification to the subcontract associate as to such permissions and/or authorizations as a condition of final payment. The Subcontractor’s (including all lower tier Subcontractors, as applicable) certification shall specify that “I have obtained all necessary and legally required copyright permissions and/or authorizations for any and all information, data, graphs, images, etc., as applicable, that is incorporated into the final Technical Report titled __________________________, delivered under this Subcontract No.__________. Copies of these permissions and/or authorizations are attached.”

Deliverable Addresses:

The Subcontractor shall clearly label all deliverables to include:

• The Subcontractor’s name

• NREL’s subcontract number

• NREL Technical Monitor’s name

• Deliverable date, and

• Deliverable description.

Deliverables shall be sent via email to each of the following addresses:

1) Rick Damiani, Technical Monitor National Renewable Energy Laboratory 15013 Denver West Parkway Golden, CO 80401 e-mail: rick.damiani@nrel.gov

• One (1) master electronic version, including graphics

2) **, Subcontract Associate National Renewable Energy Laboratory 15013 Denver West Parkway Contracts and Business Services Golden, CO 80401 e-mail: **

• One (1) master electronic version, including graphics mailto:rick.damiani@nrel.gov