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At least 235 records · Page 13

Bearing Fault Detection on Wind Turbine Gearbox Vibrations Using Generalized Likelihood Ratio-Based Indicators

Studies in condition monitoring literature often aim to detect rolling element bearing faults because they have one of the biggest shares among defects in turbo machinery. Accordingly, several prognosis and diagnosis methods have been devised to identify fault signatures from vibration signals. A recently proposed method to capture the rolling element bearing degradation provides the groundwork for new indicator families utilizing the generalized likelihood ratio test. This novel approach exploits the cyclostationarity and the impulsiveness of vibration signals independently in order to estimate the most suitable indicators for a given fault. However, the method has yet to be tested on complex experimental vibration signals such as those of a wind turbine gearbox. In this study, the approach is applied to the National Renewable Energy Laboratory Wind Turbine Gearbox Condition Monitoring Round Robin Study data set for bearing fault detection purposes. The data set is measured on an experimental test rig of a wind turbine gearbox; hence the complexity of the vibration signals is similar to a real case. The outcome demonstrates that the proposed method is capable of distinguishing between healthy and damaged vibration signals measured on a complex wind turbine gearbox.

condition monitoring↗

Open Source High Fidelity Modeling Of A Type-5 Wind Turbine Drivetrain

The purpose of this code is to provide a high-fidelity model of Type-5 wind turbine drivetrain for grid integration and transient stability studies. The increasing integration of renewable energy resources in evolving bulk power system (BPS) is impacting the system’s inertia. Type-5 wind turbine generation has the potential to behave like a traditional synchronous generator and can help mitigate the aforementioned impact. A hydraulic torque converter (TC) and gearbox with torque limiting feature are integral parts of a Type-5 wind turbine unit. A generic and high-fidelity model of a Type-5 wind turbine drivetrain is not openly and widely available for grid integration and transient stability studies. This hinders appropriate assessment of Type-5 wind power plant's contribution to the BPS resilience. This work develops and validates a TC model based on those generally used in automobile's transmission system.

Hussain, Tanveer↗

via-wind (A Visual Impact Assessment Tool for Wind Turbines) [SWR-24-87]

Via-wind is an open-source tool for conducting visual impact assessments for wind turbines. It combines geographic information system (GIS) and 3D simulation methods to account for the key factors driving the visual impact of installed wind turbines, including distance, viewing angle, turbine orientation, visual exposure, and the cumulative effects of multiple turbines. This software is optimized for use in high-performance computing environments to enable large scale (e.g., country-wide) analysis, but can also be run on a single server or personal computer. For more information, please see the related journal article: https://www.sciencedirect.com/science/article/pii/S0306261924021846

Lopez, Anthony↗

An accumulation method for early fault warning and its application to wind turbine systems

Unexpected failures in engineering systems lead to expensive maintenance actions and should be avoided if at all possible. This is particularly true for wind turbine systems for which unexpected failures not only demand costly repairs but also cause long downtime. Motivated by this need, we present an accumulation method for fault early warning and failure anticipation. Here, our research shows that one critical element allowing the ability of early warning is to accumulate the small-magnitude symptoms resulting from gradual changes in an engineering system like wind turbines. Our idea is inspired by the classical cumulative sum method, or CUSUM, but we have to redesign the accumulation mechanism for tackling unique challenges in wind turbine data. The new accumulation method is applied to two real wind turbine datasets, one with gearbox failures and the other with generator failures, and demonstrates superior performance as compared with CUSUM.

17 WIND ENERGY↗

Wind Turbine Drivetrain Reliability [Slides]

Pitch bearings, main bearings, and gearboxes in conventional wind turbine drivetrains often do not meet their 20-year minimum specified lifetime, resulting in turbine downtime as well as expensive, time-consuming repairs or replacements. The dominant failure modes of the drivetrain components and the conditions that lead to their failure are not fully accounted for during product design or routinely modeled for life management. Drivetrain reliability improvements and O&M cost reductions remain top priorities for both land-based and offshore wind turbines, especially as wind turbines continue to be deployed in increasingly remote and offshore locations, continue to increase in size, and are becoming expected to be in service beyond their original design life, all of which correspond to an increase in the impact of any reliability issues on O&M costs. This presentation summarizes the most recent activities by NREL and ANL on drivetrain reliability.

17 WIND ENERGY↗

Advanced Airfoil Cooling Schemes to Increase Efficiency in Gas Turbines for Combined Heat and Power Applications

This report describes a three-year interdisciplinary effort funded by the U.S. Department of Energy’s (DOE) Energy Efficiency and Renewable Energy/Advanced Manufacturing Office (EERE/AMO) to promote market penetration of combined heat and power (CHP) technologies. Prior studies have shown the technical potential for CHP in the United States is much larger than the current deployment of CHP systems. A large portion of the technical potential CHP market aligns with small (<20 MWe) gas turbines. CHP systems are an attractive alternative to reduce greenhouse gas (GHG) emissions. For example, CHP systems can reduce GHG emissions by 30–40% relative to a conventional boiler and power configuration. These GHG emission reductions are “avoided emissions” which means no CO 2 separation or sequestration is required. This report describes an effort to use additive manufacturing (AM) technologies and advanced airfoil cooling designs to increase the turbine inlet temperature by 100 °C for small gas turbines typically used in CHP systems. At the beginning of this effort, baseline performance data for small gas turbines was not available, and the potential benefits of cooling system improvements were not quantified in the available literature.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Using Additive Manufacturing to Repair Gas Turbine Hot Section Components

Ni-based superalloys are used in the hot sections of gas turbine engines due to their excellent high temperature performance. During service the material degrades due to exposure at high temperature and mechanical loads. Hence, utility provides often inspect, service, and repair components in gas turbine engines to ensure safe operation. A major challenge, however, is that the most heat-resistant alloys are generally considered ‘non-weldable’ rendering them difficult to repair via welding operations. In these cases components are often scrapped and then replaced by parts which must be re-manufactured. This burdens utilities with additional cost and supply chain issues can result in long term outages or reduced operating limits. In this work EPRI and ORNL investigated a proposed repair strategy for gas turbine hot section components. Hot section superalloy GTD-111 was selected as a candidate repair material system and AM material ABD-900 the repair material. Sandwich structures were fabricated via electron beam melting additive manufacturing (EBM-AM) producing tensile bars with gage sections consisting of dissimilar ABD-900 / GTD-111 / ABD-900 material. Metallography revealed that the interface exhibited no deleterious phases or processing defeats. Creep rupture experiments on heat treated material demonstrates that the emulated repair coupons exhibit creep resistance between GTD-111 and ABD-900. This study demonstrates that the proposed EBM-AM repair strategy presents a viable opportunity towards enabling AM repair of gas turbine engine components.

36 MATERIALS SCIENCE↗

Uncertainty Quantification of Fatigue Behavior of Rough AM Surfaces and Microstructures to Enable Hydrogen Gas Turbine Combustion

Modification of fossil-fueled industrial gas turbines to accept no/low carbon fuels (Hydrogen, H2/natural gas blends) is a significant undertaking. Successful deployment of this technology sits at the intersection of three design criteria (1) new functional fuel injectors that can burn these fuels, (2) manufacturability to meet cost and time-to-market targets, and (3) durability in the harsh environment of an operating turbine. Additive manufacturing (AM) provides accelerated product development. However, uncertainty remains around the durability of parts with rough AM surfaces. A fully experimental approach towards quantifying fatigue performance of rough AM microstructures is costly and laborious. Instead, Solar Turbines Incorporated (Solar) proposes the use of a crystal plasticity finite element (CPFE) model to quantify the factors that drive AM surface fatigue behavior. Solar will use the CPFE results, along with targeted experimental data, to train a computationally efficient surrogate model that can be incorporated into existing turbine part lifing methods.

08 HYDROGEN↗

2026 Innovating the Gas Turbine Supply Chain Workshop

The 2026 Innovating the Gas Turbine Supply Chain Workshop was convened at the Oak Ridge National Laboratory’s Manufacturing Demonstration Facility (MDF) in Knoxville, Tennessee, on March 31–April 1, 2026. Organized by ORNL, NETL, and the Gas Turbine Association (GTA) including gas turbine original equipment manufacturers (OEMs) GE Vernova, MHI, Siemens Energy, and Solar Turbines. The workshop brought together approximately 70 participants representing OEMs, supply chain companies, national laboratories, universities, and federal government agencies. Edgar Lara-Curzio (ORNL) served as Workshop Chair.

42 ENGINEERING↗

Wind Turbine / Reviewed Data

The SUMR-D CART2 turbine data are recorded by the CART2 wind turbine's supervisory control and data acquisition (SCADA) system for the Advanced Research Projects Agency–Energy (ARPA-E) SUMR-D project located at the National Renewable Energy Laboratory (NREL) Flatirons Campus. For the project, the CART2 wind turbine was outfitted with a highly flexible rotor specifically designed and constructed for the project. More details about the project can be found here: https://sumrwind.com/. The data include power, loads, and meteorological information from the turbine during startup, operation, and shutdown, and when it was parked and idle.

17 WIND ENERGY↗

Wind Turbine Gearbox Failure Detection Through Cumulative Sum of Multivariate Time Series Data

The wind energy industry is continuously improving their operational and maintenance practice for reducing the levelized costs of energy. Anticipating failures in wind turbines enables early warnings and timely intervention, so that the costly corrective maintenance can be prevented to the largest extent possible. It also avoids production loss owing to prolonged unavailability. One critical element allowing early warning is the ability to accumulate small-magnitude symptoms resulting from the gradual degradation of wind turbine systems. Inspired by the cumulative sum control chart method, this study reports the development of a wind turbine failure detection method with such early warning capability. Specifically, the following key questions are addressed: what fault signals to accumulate, how long to accumulate, what offset to use, and how to set the alarm-triggering control limit. We apply the proposed approach to 2 years’ worth of Supervisory Control and Data Acquisition data recorded from five wind turbines. We focus our analysis on gearbox failure detection, in which the proposed approach demonstrates its ability to anticipate failure events with a good lead time.

17 WIND ENERGY↗

Local correlation-based transition models for high-Reynolds-number wind-turbine airfoils

Abstract. Modern wind-turbine airfoil design requires robust performance predictions for varying thicknesses, shapes, and appropriate Reynolds numbers. The airfoils of current large offshore wind turbines operate with chord-based Reynolds numbers in the range of 3–15 million. Turbulence transition in the airfoil boundary layer is known to play an important role in the aerodynamics of these airfoils near the design operating point. While the lack of prediction of lift stall through Reynolds-averaged Navier–Stokes (RANS) computational fluid dynamics (CFD) is well known, airfoil design using CFD requires the accurate prediction of the glide ratio (L/D) in the linear portion of the lift polar. The prediction of the drag bucket and the glide ratio is greatly affected by the choice of the transition model in RANS CFD of airfoils. We present the performance of two existing local correlation-based transition models – one-equation model (γ− SA) and two-equation model (γ-Reθt‾- SA) coupled with the Spalart–Allmaras (SA) RANS turbulence model – for offshore wind-turbine airfoils operating at a high Reynolds number. We compare the predictions of the two transition models with available experimental and CFD data in the literature in the Reynolds number range of 3–15 million including the AVATAR project measurements of the DU00-W-212 airfoil. Both transition models predict a larger L/D compared to fully turbulent results at all Reynolds numbers. The two models exhibit similar behavior at Reynolds numbers around 3 million. However, at higher Reynolds numbers, the one-equation model fails to predict the natural transition behavior due to early transition onset. The two-equation transition model predicts the aerodynamic coefficients for airfoils of various thickness at higher Reynolds numbers up to 15 million more accurately compared to the one-equation model. As a result, the two-equation model predictions are more comparable to the predictions from eN transition model. However, a limitation of this model is observed at very high Reynolds numbers of around 12–15 million where the predictions are very sensitive to the inflow turbulent intensity. The combination of the two-equation transition model coupled with the Spalart–Allmaras (SA) RANS turbulence model is a good method for performance prediction of modern wind-turbine airfoils using CFD.

17 WIND ENERGY↗

Validation of a Generalized Formulation for Load-Sharing Behavior in Epicyclic Gears for Wind Turbines: Preprint

In an ideal epicyclic gear set every parallel gear path transmits the same amount of torque. However, it is well known that certain manufacturing variations result in unequal load sharing between the parallel gear paths. Previous works have developed and validated a general closed-form analytical model of this phenomenon that describes the load sharing characteristics of epicyclic gear sets from three to six planets at any torque level. More recently, this analytical model has been reformulated to include the effects of gravity, carrier bearing clearance, and external applied moments, all of which are relevant to most gearboxes and their mounting configuration in horizontal-axis wind turbines. In this paper, the reformulated model is compared to load measurements collected from two similar wind turbine gearboxes with three-planet epicyclic gear sets. The resulting load sharing values are also compared to the mesh load factor requirements in the AGMA 6006 and IEC 61400-4 wind turbine gearbox design standards. Load sharing factors as high as 1.16 at extreme rotor moments and 1.08 with no moment were measured for the gearbox with cylindrical roller bearings, but the load sharing factor remained below 1.10 for the gearbox with tapered roller bearings The results show that in the wind turbine application, load sharing is not equal - even for three-planet systems with a floating central member because of the effects of gravity, rotor moments, and the resulting relative motions among the epicyclic gear components within the carrier bearing clearance.

closed-form analytical model↗

Validation of a Generalized Formulation for Load Sharing Behavior in Epicyclic Gears for Wind Turbines

In an ideal epicyclic gear set every parallel gear path transmits the same amount of torque. However, it is well known that certain manufacturing variations result in unequal load sharing between the parallel gear paths. Previous works have developed and validated a general closed-form analytical model of this phenomenon that describes the load sharing characteristics of epicyclic gear sets from three to six planets at any torque level. More recently, this analytical model has been reformulated to include the effects of gravity, carrier bearing clearance, and external applied moments, all of which are relevant to most gearboxes and their mounting configuration in horizontal-axis wind turbines. In this paper, the reformulated model is compared to load measurements collected from two similar wind turbine gearboxes with three-planet epicyclic gear sets. The resulting load sharing values are also compared to the mesh load factor requirements in the AGMA 6006 and IEC 61400-4 wind turbine gearbox design standards. Load sharing factors as high as 1.16 at extreme rotor moments and 1.08 with no moment were measured for the gearbox with cylindrical roller bearings, but the load sharing factor remained below 1.10 for the gearbox with tapered roller bearings The results show that in the wind turbine application, load sharing is not equal - even for three-planet systems with a floating central member because of the effects of gravity, rotor moments, and the resulting relative motions among the epicyclic gear components within the carrier bearing clearance.

closed-form analytical model↗

Apparatuses and methods for generating carbon particles and exhaust gas used by gas turbine systems

Apparatuses for generating carbon particles and exhaust gas used by gas turbine systems are disclosed. One apparatus may include a decarbonization component combusting or reacting a mixture of a fuel and a mixing gas to generate the carbon particles and the exhaust gas and an exhaust conduit to receive the exhaust gas generated by the decarbonization component. The apparatus may also include a mixing duct in fluid communication with the exhaust conduit and the gas turbine system. The mixing duct may receive the exhaust gas and provide the exhaust gas to the gas turbine system to be used to produce a working fluid within the gas turbine system. The apparatus may further include a carbon particle collection component for receiving and storing the generated carbon particles.

Berry, Jonathan Dwight↗

Integrated transient modeling of gas turbine and sCO2 power cycle for exhaust heat recovery application

For distributed generation installations, the transient response of the power generation system is critical to meet power quality (voltage and frequency) requirements. Transient models for gas turbine and supercritical carbon dioxide (sCO2) power cycle were integrated for an exhaust heat recovery bottoming cycle system for a distributed generation application. The transient model for the SGT-750 Siemens gas turbine was a ‘black-box’ functional mockup interface (FMI) model developed by Siemens Industrial Turbomachinery in $Finsp\mathring{a}ng$, Sweden. The SGT-750 is a twin-shaft gas turbine that produces 40 MW electricity with an efficiency of about 40% at ISO conditions. At 100% gas turbine throttle (load), the SGT-750 has average exhaust conditions of 114.6 kg/s and 469.8 °C.

20 FOSSIL-FUELED POWER PLANTS↗

Bearing Fault Detection on Wind Turbine Gearbox Vibrations Using Generalized Likelihood Ratio-Based Indicators: Preprint

Studies in condition monitoring literature often aim to detect rolling element bearing faults because they have one of the biggest shares among defects in turbo machinery. Accordingly, several prognosis and diagnosis methods have been devised to identify fault signatures from vibration signals. The underlying idea behind traditional indicators often revolves around tracking both cyclostationarity and abnormal impulses in the vibration signals without distinguishing the two. A recently proposed method to capture the rolling element bearing degradation lays out the groundwork for new indicator families utilizing generalized likelihood ratio test. This novel approach exploits the cyclostationarity and the impulsiveness of vibration signals independently in order to estimate the most suitable indicators for a given fault. However, the method has yet to be tested on complex experimental vibration signals such as those of a wind turbine gearbox. In this study, the approach is applied to the NREL Wind Turbine Gearbox Condition Monitoring Round Robin Study data set for bearing fault detection purposes. The data set is measured on an experimental test rig of a wind turbine gearbox, hence the complexity of the vibration signals is similar to a real case. Furthermore, the new indicators are also tested with signals that carry multiple fault signatures. The outcome demonstrates that the proposed method is capable of distinguishing between healthy and damaged vibration signals measured on a complex wind turbine gearbox.

condition monitoring↗

A Comparison of Generator Technologies for Offshore Wind Turbines

Leading wind turbine manufacturers are racing to build larger and more powerful offshore machines. Drivetrain configurations often use a permanent-magnet synchronous generator (PMSG), in either a direct-drive configuration or coupled to a gearbox. With increasing demand for critical rare-earth magnets, new generator technologies are emerging to ensure a stable and secure supply chain. We evaluate three different topologies of radial flux synchronous generators employing high field magnets with reduced or no rare-earth content: a direct-drive interior PMSG (DD-IPMSG), a geared drivetrain combining a medium speed gearbox with a PMSG (MS-PMSG), and a direct-drive low-temperature superconducting generator (DD-LTSG). We develop a conceptual design module for each of these technologies within a larger framework for full turbine design. This provides the fairest comparison between technologies at nominal power ratings from 15-25MW, which represent the next generation of offshore wind turbines. The analyses show that if operational expenditures (OpEx) are constant across the technologies, MS-PMSG results in the lowest LCOE with reductions of up to 7% relative to DD-IPMSG. DD-LTSG also yields lower LCOE values by 2-3% for fixed-bottom turbines and 3-5% with a floating platform. However, results are sensitive to OpEx assumptions, with a mere 10% increase causing the conclusions to shift.

direct drive↗