Method to retrofit a wind turbine rotor blade with a replacement blade tip segment

1. A method for retrofitting a wind turbine blade with a replacement blade tip segment, comprising:

providing a replacement blade tip segment with an internal beam receiver section;

cutting an existing blade tip segment from the wind turbine blade, wherein the cut defines a chord-wise joint line at a remaining blade root segment of the wind turbine blade;

providing a beam structure that is separate from the blade root segment;

inserting the beam structure into the blade root segment and fixing the beam structure into spar structure of the blade root segment;

aligning and connecting the replacement blade tip segment with the blade root segment a span-wise direction so that the beam structure moves into the beam receiver section; and

providing a finish surface to blade shell components of the blade root segment and the replacement tip segment at the joint line.

2. The method of claim 1 , wherein the wind turbine blade is operational on a wind turbine at a field site, comprising performing the retrofitting process with the wind turbine blade in an up-tower position on a rotor hub of the wind turbine.

3. The method of claim 1 , wherein the wind turbine blade is operational on a wind turbine at a field site, comprising removing and lowering the wind turbine bade from a rotor hub of the wind turbine and performing the retrofitting process with the wind turbine blade in a down-tower position relative to the rotor hub.

4. The method of claim 1 , wherein the internal beam receiver section is formed separately from the replacement blade tip segment and incorporated with spar structure in the replacement blade tip segment.

5. The method of claim 4 , wherein the replacement blade tip segment is pre-produced and transported to a field site for the retrofitting process.

6. The method of claim 5 , further comprising producing and maintaining an inventory of the replacement blade tip segments, wherein for the retrofitting process, one of the replacement blade tip segments is selected from the inventory and transported to the field site.

7. The method of claim 1 , further comprising modifying the spar structure in the blade root segment to accept the beam structure by removing a section of shear webs adjacent to the joint line, and moving a tapered end of the beam structure between the shear webs such that an opposite end of the beam structure extends span-wise from and becomes an extension of the spar structure.

8. The method of claim 7 , wherein the fixing of the beam structure into the spar structure of the blade root segment comprises drilling a span-wise pattern of holes through a blade shell component of the blade root segment to provide access to the beam structure and spar structure, and sequentially injecting an adhesive into the holes.

9. The method of claim 8 , wherein the pattern of holes allows injection of the adhesive between the tapered end of the beam structure and shear webs along a portion of the beam structure, and around the beam structure where the section of the shear webs is removed adjacent the joint line.

10. The method of claim 7 , further comprising tapering a section of shell components of the blade root segment from towards the joint line.

11. The method of claim 1 , wherein the providing a finish surface to the joint line comprises wrapping a seal around the wind turbine blade at the joint line.