Materials selection and installation quality are key for lasting results Aerodynamic Upgrades are subject to the harsh conditions wind turbines experience out in the field. Using quality components and carrying out installations in line with Vestas’ specifications are critical in ensuring these upgrades are long-lasting and work most effectively. The materials we select for our Aerodynamic Upgrades are based on extensive industrial and field-support experience. The gurney flaps also have additional structural bonding at the trailing edge to ensure maximum hold, and a sealant is applied to prevent water ingress into the bond. Each component has been designed to withstand stronger winds and handle greater loads than those encountered in the field. The components are of the highest quality, and have passed a series of tests including accelerated life-time testing, UV tolerance, exposure to extreme hot and cold weather, as well as heavy rain, hail and ice build-up, as well as the impact of sand and dust. The installation process follows well-defined guidelines produced by highly-experienced engineers and field technicians. This guarantees instruction clarity and bonding quality. We have already installed Aerodynamic Upgrades on hundreds of turbines, both in the field and in factory conditions. Noise testing confirms upgrades have no impact on turbine sound power levels Acoustic emission is often considered the most significant environmental impact from wind turbines. As a result, many projects must meet strict noise requirements, set by local and national authorities. If noise levels exceed permitted limits, individual turbines may be banned from operating at certain noise modes. Aerodynamic Upgrades have undergone a series of noise tests in the field for a range of wind speeds in partial and full load. Our tests confirmed that sound power levels don’t exceed the guaranteed limits for the turbines. These tests were conducted for noise mode 0 and in accordance with the IEC 61400-11 ed.3 guidelines Validating the increased power performance of Aerodynamic Upgrades In designing products and upgrades, such as the vortex generators and gurney flaps, Vestas uses state-of-the-art simulation tools to model power curves and annual energy production. These simulations are then validated in field tests, using a relative power curve measurement campaign. We use a relative power curve measurement campaign instead of an absolute measurement because the latter’s uncertainty levels can be up to 5% – too high to validate gains of around 1%. To validate the improvement in annual energy production that Aerodynamic Upgrades deliver, we designed a detailed relative power curve measurement campaign, using a pair of turbines and a met mast. The power curve measurements were carried out in accordance with our internal guidelines and the IEC 6140012-1 norms. Together with the data analysis and the measurement sector choice, this reduced the measurement’s uncertainty. Figure 3 Illustration of verification test setup with a reference turbine (left), test turbine (right), and met mast
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