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Windworks 8-kW wind-turbine generator: failure analysis and corrective-design modification

On March 8, 1980, approximately two weeks after being installed at the Rocky Flats Wind Systems Test Site, the Windworks 8 kW prototype wind system dropped one of its three blades. Although this failure occurred during a moderate wind period during a weekend, strong winds ensued the next day, preventing the tower from being lowered. These winds caused the two remaining blades to periodically turn the rotor, resulting in additional damage to the blades, tower, instrument wiring, nacelle, and alternator. One of these two blades finally broke at the root attachment and fell at the base of the tower, nearly in the same position as the first blade. The analysis which proceeded from this failure determined that a combination of material defects, design deficiency, and inadequate quality control combined to produce the failure. The failed part is being redesigned to increase the strength. In the future, radiographic inspection of the critical parts will be increased by the manufacturer.