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include the costs of advertising for local employees, human resource functions of interviewing and hiring, and inevitable attrition of local employees during the training and production periods. Construction related costs that are incurred each time the on-site factory is deployed were estimated as follows: •

Metal factory building, concrete foundation, overhead structural cranes, laydown yard, and parking area $1.73M for 5,195 m2 facility ($332.80/m2)

Plumbing, wiring, interior walls, fixtures, finishing, utilities: $500k

Install, align, calibrate, major production equipment: $500k

Environmental, building, OSHA permitting/approvals: $200k

Total factory cost = $2.93M

DNV GL assumed the factory is required to produce one blade, as part of plant commissioning, worker training, and demonstration of quality control. It is assumed these first articles would not be installed on a wind turbine, thus their production costs are accounted for as a non-recurring cost. Due to ramp-up of related to processes and training, DNV GL approximated the cost of this article as 1.25 times the recurring cost of the blade, or $389.5k. In total, the combined non-recurring cost assumed for the Baseline blade is $9.82M. The primary contribution to estimated non-recurring costs is the training of a local workforce, followed by the planning and construction of the facility itself. Relative to these two cost elements, the costs for production of a firstarticle are modest.

6.3.3 75 m, 95 m, and 115 m on-site blade manufacturing DNV GL developed on-site blade manufacturing costs by applying the following scaling assumptions to parameters previously presented in the calculation of the Baseline 65 m blades. The scaling assumptions are based on DNV GL project team opinion and experience as well as guidance from a review of previous Sandia/TPI studies [5], [6], but are not grounded in detailed research. The following scaling assumptions were applied to account for factors related to producing larger blades. •

Labor workforce headcount: scales at ½ blade length (L) due to assumed labor efficiencies as blade size grows.

Factory area: -

scales at length over baseline length squared (L/Lb)2 for change from 65 m to 75m blades

-

factory area for 95 m blade is same size as for 75 m blade as 95 m production is reduced from

-

115 m blade factory also operates with only one line, so scales up from 95 m case using L/Lb2

two to one production lines

Overhead structural space: scales at L due to increasing building height requirements for overhead cranes to manipulate molds and blades

Plumbing, wiring, interior walls, fixtures, finishing, utilities: scales with factory area

Installation, alignment, and calibration of major production equipment: scales with factory area

Laydown yard, parking, other paved areas: 50% of factory area at cost of $5/sq ft

Environmental, AHJ approvals: no change with factory size

First article production cost: 1.25 * blade mass * recurring production costs

DNV GL – Document No.: 10080081-HOU-R-01, Issue: C, Status: FINAL www.dnvgl.com

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Supersized wind turbine blade study  

R&D pathways for supersized wind turbine bladesSupersized wind turbine blade studyLawrence Berkeley National LaboratoryDocument Number: 1008...

Supersized wind turbine blade study  

R&D pathways for supersized wind turbine bladesSupersized wind turbine blade studyLawrence Berkeley National LaboratoryDocument Number: 1008...

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