Jan Hornbech

Project Closure Coordinator:

• Manage SATs of 8 different lifting tools.
• Completion of physical deliveries
• Update missing or incomplete documentation.
• Customer point of contact.
• Project group coordinator.
• Resulting in increased customer satisfaction.

Cooling Specialist:

Air Cooling System for Generator Test Bench:

• Technical Requirements Analysis.
• Assessment of required uptime vs. requested inlet air temperature vs. Danish Reference Year (DRY).
• Assessment of combinations of cooling systems, - chillers and liquid nitrogen (LN2) capacity cost vs. operational cost in reference to inlet temperature requirements and DRY.
• Specification of pressure levels in the compartments.
• Specification of required sensors.
• Product Requirements Specification (PRS) for quote inquiry.

Water cooling (5 systems) for generator test bench auxiliaries:

• Cooling system design - heat loss/cooling capacity.
• Design of pipe sizes, pressure schedules, pump capacities, control valves, modelling of existing dry coolers to be reused, instrumentation.
• Technical specifications of system components for BOM.
• PRS for piping quote inquiry.

Offshore wind turbine monopile welding table - engineering quoting:

• Specification of concept for welding table.
• In coordination with CAD design/FEM assessment of engineering manhours
• Successful delivery to Technical Sales dept. estimate of manhour for quote calculation.

Rotor blades leading edge protection application - support equipment:

• Teamworking with Project Manager to clarify customer requirements.
• Cooperating with and Industrial designer to develop concept for blade handling equipment working in a tight space setup.
• Successful delivery to Project Manager a blade support concept which fulfils the identified functional requirements.

Rotor blade test responsible:

• Teamworking with Blade Design department to clarify and requirements to a rotor blade certification test to be performed at external blade test center.
• Prepare a Scope of Work document for the external test center.
• Prepare a preliminary time schedule for the full certification test for agreement with external test center and Blade Certification dept.
• Feed the external test center with answers to inquiries.
• Monitor fatigue test damage accumulation and report to Design- and Blade Certification department.
• Monitor static tests and verify resulting test loads.
• In coordination with Blade Design dept. prepare blade test verification reports to the Blade Certification department.

Investigation of feasible designs of rotor blade clamps suited for off-axis load directions.

• Assessment of quantities and sizes of clamps required for future blade tests.
• Assessments of internal forces in a test clamp performing at off-axis load directions.
• Preparation of Technical Requirements Specification for initial quote inquiring.

Rotor blade test responsible and test support:

• Planning modal analysis/natural frequencies tests and torsion stiffness tests in coorporation with Blade Design dept.
• Check instrumentation and load introduction together with the technical staff.
• Perform the blade tests and troubleshooting if required.
• Test reporting delivery to Blade Certification dept..
• Technical support of fatigue test exciter machine and general fatigue test setup.

Modal analysis - new rotor blade test method:

• Preparation of work Instructions, forms, report templates.
• GR&R and uncertainty calculations of test results integrated in a test data post-processing tool.
• Documentation package including test data post-processing tool ith reference to IEC 17025 Testing and calibration laboratoies and IEC 61400-23 Full-scale structural testing of rotor blades was delivered to the customer.
• DANAK audited the test method documentation which successfully was approved.

Fatigue test exciter machine:

• Development and implementation of exciter rotor speed control principle for motion synchronization of the test blade and blade exciter.
• In cooporation with a controller programmer implementation in the exciter's servo drive.
• Development of a calculation tool which for test setup geometry generates a specific rotation compensation table for import into the servo drive controller.
• Resulting in the fatigue test exciter became capable of exciting the blades as originally intended.

Equipment for fatigue test of rotor blades

• Customer requirements clarification
• Development of concept
• Documentation management: RS, FMEA, SAT protocol

• Verification of the applied test bending moment distribution based on data files and records delivered by the company's blade test engineer fulfils the rotor blade test plan provided by the customer of the blade test.
• Calculation of uncertainty of results by software utilizing the Monte Carlo method.
• Preparation of rotor blade test reports in accordance with the report templates standard.

CFRP helicopter blade development

Responsible for auxiliary systems in blade

• tip lights
• lightning protection
• leading edge protection
• anti-icing system
• Coordination with Legal dept. NDAs for sub-suppliers

Rotor blade repair instructions implementation:

• Identification of the level of the repair instructions for correct Implementation in the company’s DMS systems in accordance with the company's documentation standard.
• Conclusion of the rotor blade inspection- and maintenance strategy.
• Assessment of rotor blade damages from inspection photos.
• Assessment and reporting of the severity of a specific damage observed in multiple blades.

Engineering department - typical tasks:

• Rotor blade damage assessment and categorization based inspection photos.
• Develop work instructions for new blade repair methods and new repair materials.
• Root cause analysis of rotor blade damages.
• Rotor balancing support after replacements of rotor blades.
• Supporting wind turbine sites’ service management in rotor blade matters.
• Multiple full wind turbine site blade damage assessments and reporting in connection with End-Of-Warranty negotiations.

Supplier quality development department - typical tasks:

Sub-supplier of rotor blade top coating:

• Ensuring the supplier delivers the required top coat quality an fulfil the QMS requirements in cooperation with the end customer of the wind turbine generators.
• Auditing the supplier’s level of QMS implementation.
• Support the sub-supplier where QMS audit reveals improvements are needed.
• First Article Inspection: Planning, execution, reporting.

Rotor blade tests:

• Test plan clarification in cooperation with the customer.
• Natural frequencies test and reporting.
• Static test and reporting.
• Fatigue test and reporting.

Blade test equipment development - SQL database introduction:

• In cooperation with programmer lead the transition from temporary storing test data internally in the DAQ software during the execution of the static blade tests to continously storing test data in SQL database.
• Resulting in a more rugged and less fragile test data handling with reduced risk of loss of test data.

Blade test equipment development - method to upgrade pulling capacity of older pulling stations with insufficient pulling capacity:

• Introduction of multiple pulleys on a mounting plate for gearing up the resulting pulling forces of low yielding pulling stations.
• Resulting in a static blade test was able to be performed on a test rig originally having insufficient pulling capacity to fulfil the required bending moment to be introduced in the test blade.

• Wind turbine blades - accredited structural tests; static test, fatigue test natural frequencies test.
• DANAK approved test engineer and underwriter for all blade tests offered by the blade test center.
• Developed and verified the power reducing effects of attaching EPS (flamingo) wind breakers on blades in fatigue test.
• Developed a fully integrated data acquisition system and data post-processing tools to replace strip prints and visual reading and make manual dialling in results from from measuring instruments obsolete.
• Temporary constituted test center manager.

Re-building the factory after a total factory burnout:

• Listing of all damaged equipment for insurance negotiations.
• Participation in team for rebuilding new and improved rubber granulate factory.
• Running-in and optimizing the start-up of the factory.
• Educating the staff in operating the plant.
• Resulting in a fully operational rubber granulate plant with educated staff for operating.

Factory restored and running at full production capacity:

• Quality control, - granulate grain size distribution tests.
• Daily maintenance planning.

Establishing a rubber powder milling section in the factory:

• Participation in the planning of and running-in a rubber powder production section.
• Milling down granulate to powder in two powder production lines lines running at cryo- (LN2) and ambient temperatures, respectively. Instruction sets for both production lines.
• Resulting in a fully operational powder production section with educated staff for operating.

Relocation of noisy vacuum pumps to a designated housing.

• Design of new routing of vacuum pipes.
• Planning of stepwise transition to new vacuum system layout to be executed in 8 hours time slots available at maintenance shutdowns every second week.
• Specification of water seperators and pumps operating in vacuum.
• Specification of additional vacuum pump.
• Layout of external building for vacuum pumps in cooperation with architect.
• Layout of electrical cables routing in cooperation with electrician.
• Supervision at rebuild time slots.
• Resulting in fully functional highly efficient vacuum system and considerably reduction of noise level at factory floor.

Piping rearrangement to cancel out the operation of one of two large energy consuming water filters.

• Re-routing piping for the two filters to facilitate operation of only one filter.
• In cooperation with electrician cancel out the operation of the filter to be shut down, - feed pump and filter rotation motor.
• Resulting in energy savings as one filter had sufficient capacity for the total flow directed to the filters.

Introdution of dew point control of dryer section:

• Mounting and electrical installation of multiple temperature transmitters in the dryer section.
• Re-programming the PLC controlling the blowers for the dryer section to maintain a defined operating condition in the dryer section.
• Resulting in more efficient drying of the paper in the dryer section.

Project work of introducing an additional natural gas heated dryer section in the dryer section to increase the production rate substatially. Not realised due to job change.