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At least 271 records · Page 15

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NASA NTRS2006

Brush Seals for Improved Steam Turbine Performance

GE Energy has retrofitted brush seals into more than 19 operating steam turbines. Brush seals offer superior leakage control compared to labyrinth seals, owing to their compliant nature and ability to maintain very tight clearances to the rotating shaft. Seal designs have been established for steam turbines ranging in size from 12 MW to over 1200 MW, including fossil, nuclear, combined-cycle and industrial applications. Steam turbines present unique design challenges that must be addressed to ensure that the potential performance benefits of brush seals are realized. Brush seals can have important effects on the overall turbine system that must be taken into account to assure reliable operation. Subscale rig tests are instrumental to understanding seal behavior under simulated steam-turbine operating conditions, prior to installing brush seals in the field. This presentation discusses the technical challenges of designing brush seals for steam turbines; subscale testing; performance benefits of brush seals; overall system effects; and field applications.

Turnquist, Norman↗

NASA NTRS2011

CFD Simulations of Supersonic Highly Swirling Flow Exiting a Turbine Vane Row Compared with Experimental Observations

Marshall Space Flight Center (MSFC) has been heavily involved in developing the J2-X engine. The Center has been testing a Work Horse Gas Generator (WHGG) to supply gas products to J2-X turbine components at realistic flight-like operating conditions. Three-dimensional time accurate CFD simulations and analytical fluid analysis have been performed to support WHGG tests at MSFC. The general purpose CFD program LOCI/Chem was utilized to simulate flow of products from the WHGG through a turbine manifold, a stationary row of turbine vanes, into a Can and orifice assembly used to control the back pressure at the turbine vane row and finally through an aspirator plate and flame bucket. Simulations showed that supersonic swirling flow downstream of the turbine imparted a much higher pressure on the Can wall than expected for a non-swirling flow. This result was verified by developing an analytical model that predicts wall pressure due to swirling flow. The CFD simulations predicted that the higher downstream pressure would cause the pressure drop across the nozzle row to be approximately half the value of the test objective. With CFD support, a redesign of the Can orifice and aspirator plate was performed. WHGG experimental results and observations compared well with pre-test and post-test CFD simulations. CFD simulations for both quasi-static and transient test conditions correctly predicted the pressure environment downstream of the turbine row and the behavior of the gas generator product plume as it exited the WHGG test article, impacted the flame bucket and interacted with the external environment.

West, Jeff S.↗

NASA NTRS2012

Durability Challenges for Next Generation of Gas Turbine Engine Materials

Aggressive fuel burn and carbon dioxide emission reduction goals for future gas turbine engines will require higher overall pressure ratio, and a significant increase in turbine inlet temperature. These goals can be achieved by increasing temperature capability of turbine engine hot section materials and decreasing weight of fan section of the engine. NASA is currently developing several advanced hot section materials for increasing temperature capability of future gas turbine engines. The materials of interest include ceramic matrix composites with 1482 - 1648 C temperature capability, advanced disk alloys with 815 C capability, and low conductivity thermal barrier coatings with erosion resistance. The presentation will provide an overview of durability challenges with emphasis on the environmental factors affecting durability for the next generation of gas turbine engine materials. The environmental factors include gaseous atmosphere in gas turbine engines, molten salt and glass deposits from airborne contaminants, impact from foreign object damage, and erosion from ingestion of small particles.

Misra, Ajay K.↗

NASA NTRS2014

A Fully Non-metallic Gas Turbine Engine Enabled by Additive Manufacturing

The Non-Metallic Gas Turbine Engine project, funded by NASA Aeronautics Research Institute (NARI), represents the first comprehensive evaluation of emerging materials and manufacturing technologies that will enable fully nonmetallic gas turbine engines. This will be achieved by assessing the feasibility of using additive manufacturing technologies for fabricating polymer matrix composite (PMC) and ceramic matrix composite (CMC) gas turbine engine components. The benefits of the proposed effort include: 50 weight reduction compared to metallic parts, reduced manufacturing costs due to less machining and no tooling requirements, reduced part count due to net shape single component fabrication, and rapid design change and production iterations. Two high payoff metallic components have been identified for replacement with PMCs and will be fabricated using fused deposition modeling (FDM) with high temperature capable polymer filaments. The first component is an acoustic panel treatment with a honeycomb structure with an integrated back sheet and perforated front sheet. The second component is a compressor inlet guide vane. The CMC effort, which is starting at a lower technology readiness level, will use a binder jet process to fabricate silicon carbide test coupons and demonstration articles. The polymer and ceramic additive manufacturing efforts will advance from monolithic materials toward silicon carbide and carbon fiber reinforced composites for improved properties. Microstructural analysis and mechanical testing will be conducted on the PMC and CMC materials. System studies will assess the benefits of fully nonmetallic gas turbine engine in terms of fuel burn, emissions, reduction of part count, and cost. The proposed effort will be focused on a small 7000 lbf gas turbine engine. However, the concepts are equally applicable to large gas turbine engines. The proposed effort includes a multidisciplinary, multiorganization NASA - industry team that includes experts in ceramic materials and CMCs, polymers and PMCs, structural engineering, additive manufacturing, engine design and analysis, and system analysis.

manufacturing↗

NASA NTRS2017

Method for Making Measurements of the Post-Combustion Residence Time in a Gas Turbine Engine

A method of measuring a residence time in a gas-turbine engine is disclosed that includes measuring a combustor pressure signal at a combustor entrance and a turbine exit pressure signal at a turbine exit. The method further includes computing a cross-spectrum function between the combustor pressure signal and the turbine exit pressure signal, calculating a slope of the cross-spectrum function, shifting the turbine exit pressure signal an amount corresponding to a time delay between the measurement of the combustor pressure signal and the turbine exit pressure signal, and recalculating the slope of the cross-spectrum function until the slope reaches zero.

Miles, Jeffrey H.↗

DOE OSTI2020

Detecting faults in wind turbines

A wind turbine generator fault detection method is described. The method includes obtaining a first signal from a generator of a wind turbine and a second signal from a vibration sensor coupled to the wind turbine, the first signal representing an output current of the generator, and the second signal being a time-sampled signal representing vibrations of a bearing in the wind turbine. Determining a shaft rotation frequency signal from the first signal, the shaft rotation frequency signal representing a time-varying rotational speed of a shaft of the wind turbine. Resampling an envelope of the second signal based on the shaft rotation frequency signal to provide a third signal, the third signal being an angular sampled signal. Detecting, by the at least one processor, a fault in the bearing of the wind turbine by identifying a characteristic signature of a bearing fault in the third signal.

Qiao, Wei↗

DOE OSTI2022

Implications of Shear and Thermal Stratification on Wind Turbine Tip-Vortex Stability

The interaction between wind turbines in a wind farm through their wakes is a phenomenon that has been studied for decades and is still relevant today. Turbines clustered together in arrays will often operate in the wake of other upstream turbines which may lead to significant power losses and fatigue loads. For modern large-scale wind turbines, the mean shear velocity profile and thermal stratification are major components of the atmospheric boundary layer so it is important to understand their impact on near-wake development. Additionally, veer is present due to the rotation of the Earth. The impact of shear, thermal stratification and veer on the stable wake length of turbines with a dynamic control strategy is studied numerically in this work using a suite of highly resolved large-eddy simulations. Instantaneous flow fields are extracted from the simulations and used to conduct proper orthogonal decomposition (POD) and compute the mean kinetic energy fluxes by different POD modes to better understand the tip-vortex instability mechanisms. Our findings show that the dynamic pitch control scheme is able to shorten the stable wake length to about 1.5R in uniform flow. Shear can significantly affect the break up of wind turbine tip-vortices as well as the shape and stable length of the wake, whereas thermal stratification seems to only have limited contribution to the spatial development of the near-wake field. Veer causes the wake boundary to skew but has a limited impact on the wake length.

length thermal stratification↗

DOE OSTI2022

Detecting faults in wind turbines

Qiao, Wei↗

DOE OSTI2021

Wake steering of multirotor wind turbines

Abstract In this paper, wake steering is applied to multirotor turbines to determine whether it has the potential to reduce wind plant wake losses. Through application of rotor yaw to multirotor turbines, a new degree of freedom is introduced to wind farm control such that wakes can be expanded, channelled or redirected to improve inflow conditions for downstream turbines. Five different yaw configurations are investigated (including a baseline case) by employing large‐eddy simulations (LES) to generate a detailed representation of the velocity field downwind of a multirotor wind turbine. Two lower‐fidelity models from single‐rotor yaw studies (curled‐wake model and analytical Gaussian wake model) are extended to the multirotor case, and their results are compared with the LES data. For each model, the wake is analysed primarily by examining wake cross‐sections at different downwind distances. Further quantitative analysis is carried out through characterisations of wake centroids and widths over a range of streamwise locations and through a brief analysis of power production. Most significantly, it is shown that rotor yaw can have a considerable impact on both the distribution and magnitude of the wake velocity deficit, leading to power gains for downstream turbines. The lower‐fidelity models show small deviation from the LES results for specific configurations; however, both are able to reasonably capture the wake trends over a large streamwise range.

17 WIND ENERGY↗

DOE OSTI2024

NREL 15-kW: An Advanced Horizontal-Axis Reference Turbine for Distributed Wind

Distributed wind energy can play a significant role in the renewable energy landscape. A recent study conducted by the National Renewable Energy Laboratory (NREL) identified the lack of availability and utilization of reference wind turbine models as a major hindrance in the development of the distributed wind energy technology sector, even though such models are widely used in offshore and land-based wind research. Therefore, NREL is developing three reference wind turbine architectures, also called archetypes, for distributed wind energy applications. This paper describes the detailed design and modeling of the first of the three reference turbine archetypes, called the NREL 15-kW turbine. It is a passive-yaw, upwind turbine with a rated power of 15 kW.

17 WIND ENERGY↗

DOE OSTI2024

Conceptual Design of a Tension Leg Platform With 22.3 MW Vertical Axis Turbine

Here, this paper presents the conceptual design of a tension leg platform (TLP) for the ARCUS “towerless” vertical-axis wind turbine (VAWT). VAWTs are ideal for floating offshore sites and have several advantages over horizontal-axis wind turbines (HAWT) including reduced top mass, lower center of gravity, increased energy capture, and in turn lower cost. The towerless ARCUS VAWT drives these advantages further through increased structural efficiency and by enabling more optimized TLP designs with simplified installation procedures. For hull sizing, we have studied three turbine sizes with corresponding power ratings of 5.1 MW, 10.4 MW and 22.3 MW. The largest turbine was identified as having the greatest potential to reduce the levelized cost of energy (LCOE) and is the reference size used for the further detailed design process. The conceptual design of the VAWT TLP has been awarded with an ABS Approval in Principle Certificate. This paper contains brief analysis results and design findings for a TLP designed to house a VAWT, including the following topics: • Applicable Design Codes • Metocean Conditions • ARCUS Turbine Loads • Design Load Cases and Requirements - Pre-service TLP Stability - In-place TLP Global Performance • Platform Configurations, Hull Structure Scantling Design, Weight and CG Estimation, and General Arrangement Drawings • Hull Ballast Plan for both Pre-service and In-place Conditions • Pre-service Quayside Integration, Transportation and Wet Tow Stability Analysis • Global Performance Analysis for Motions and Tendon tensions • Summary of cost components and system levelized cost of energy

17 WIND ENERGY↗

NASA NTRSDate not supplied

Exploration of the Versatile Electrically Augmented Turbine Engine Gearbox Concept

Integration of electric machines with the shafts of gas turbine engines is implied in various electrified aircraft propulsion concepts. This includes implementation of the Turbine Electrified Energy Management (TEEM) concept, a motivator for the Versatile Electrically Augmented Turbine Engine (VEATE) gearbox. The VEATE gearbox is a mechanical power transmission concept that seeks to interface electric machines with a gas turbine engine in a synergistic manner. It enables a hybrid electro-mechanical approach for managing power in a gas turbine engine. It is hypothesized that the mechanical design of the VEATE gearbox could be leveraged to enhance the versatility of the present electrical hardware. The VEATE gearbox concept is first introduced and applied to an electrified two-spool advanced geared turbofan meant for powering a single-aisle commercial aircraft. A modeling approach for the gearbox is presented and studies are conducted to investigate the potential application to TEEM and power extraction. There is evidence that the VEATE gearbox could help to reduce the size of the TEEM power system, provide flexibility in power extraction implementation, and exhibit fail-safe design attributes.

Versatile Electrically Augmented Turbine Engine Ge↗

DOE OSTI2024

Implementation and Validation of a Generalized Actuator Disk Parameterization for Wind Turbine Simulations Within the FastEddy Model

ABSTRACT Fast and accurate large‐eddy simulation (LES) of the atmospheric boundary layer plays a crucial role in advancing wind energy research. Long‐duration wind farm studies at turbine‐resolving scales have become increasingly important to understand the intricate interactions between large wind farms and the atmospheric boundary layer. However, the prohibitive computational cost of these turbulence‐ and turbine‐resolving simulations has precluded such modeling to be exercised on a regular basis. To that end, we implement and validate the generalized actuator disk (GAD) model in the computationally efficient, graphics processing unit (GPU)–resident, LES model FastEddy. We perform single‐turbine simulations under three atmospheric stabilities (neutral, unstable, and stable) and compare them against observations from the Scaled Wind Farm Technology (SWiFT) facility and other LES codes from the recent Wakebench turbine wake model benchmark. Our idealized LES results agree well with observed wake velocity deficit and downstream recovery across stability regimes. Turbine response in terms of rotational speed, generated power, torque, and thrust coefficient are well predicted across stability regimes and are consistent with the LES results from the benchmark. The FastEddy simulations are found to be at least two orders of magnitude more efficient than the traditional CPU‐based LES models, opening the door for realistic LES simulations of full wind plants as a viable standard practice.

17 WIND ENERGY↗

DOE OSTI2021

NREL’s Wind Turbine Drivetrain Condition Monitoring and Wind Plant Operation and Maintenance Research During the 2010s: A US Land-Based Perspective

The wind industry has seen tremendous growth during the past two decades, with the global cumulative installation capacity reaching more than 650 gigawatts by the end of 2019. Despite performance and reliability improvements of utility-scale wind turbines over the years, the industry still experiences premature component failures, leading to increased operation and maintenance (O&M) costs. Among various turbine components, gearboxes—and, more broadly, drivetrains—have shown to be costly to maintain throughout the design life of a wind turbine. The problem of premature component failure is industry wide. As early as 2007, the US Department of Energy (DOE) started to address this challenge through the National Renewable Energy Laboratory’s (NREL’s) reliability initiative that first focused on gearboxes and more recently expanded to entire drivetrains. The wind turbine drivetrain condition monitoring and wind plant O&M research that is the subject of this paper is part of the NREL initiative and includes a few research and development (R&D) activities conducted during the 2010s. These activities included technology evaluation during the first few years; novel monitoring technique investigation (specifically, compact filter analysis) during the middle years; and data and physics domain modeling for fault detection and prediction in recent years. A high-level summary of these activities is provided in this paper along with some key observations from each activity. Most of the work discussed has been published and can be referred to for more information. They reflect the expected evolution of wind turbine condition monitoring and O&M in the US market—primarily, a land-based perspective. In addition, we have identified several R&D opportunities that can be picked up by the research community to help industry advance in related areas, making wind power more cost competitive in the future.

17 WIND ENERGY↗

DOE OSTI2020

In situ characterization of the biological performance of a Francis turbine retrofitted with a modular guide vane

There are two strategies to lower overall project costs to an extent that will make many potential sustainable hydropower sites economically viable: (1) design standardized/modular components; (2) use advanced tools to reduce environmental evaluation costs. In this study an autonomous sensor device (Sensor Fish) was used to study a Francis turbine retrofitted with a modular guide vane. The median nadir pressures measured were 74.7, 66.6, and 56.6 kPaA for 90-, 190-, and 380-kW operating conditions respectively. These nadir pressures were compared to other Francis turbines studied using Sensor Fish and were found to be within the same range. The proportion of Sensor Fish releases with severe acceleration events (acceleration = 95G) was also investigated. The proportion ranged from 73 to 80% (runner region), 50 to 64% (guide vane region), and 9 to 28% (draft tube region), which was within the range of the other turbines used for comparison. The Sensor Fish testing that was conducted at Hurley Dam demonstrates that the modular guide vane that was retrofitted to the existing Francis turbine is potentially a suitable replacement that can provide biological performance similar to the guide vane used with other existing Francis turbines, but with the benefit of reduced fabrication costs.

13 HYDRO ENERGY↗

DOE OSTI2024

Mapping and Characterizing the Visual Impacts of the Existing US Wind Turbine Fleet

Visual impacts of wind turbines have been a persistent concern for wind energy development in the United States (US) for decades and remain a major source of project delays and cancellations. Assessments of visual impacts are frequently performed at a local scale for individual projects, but a comprehensive understanding of broader geographic patterns in visual impacts across the US is lacking. This paper presents a visual impact assessment of the existing land-based wind turbine fleet of the contiguous United States (CONUS). The assessment combines geographic information systems and 3D simulation methods to account for key factors driving the visual magnitude of impacts from the installed turbines. The results indicate that, despite the deployment of approximately 70,000 turbines and over 144 gigawatts of land-based wind in the CONUS, the visual impacts are very small when measured as a proportion of land area, population, and sensitive visual resources. Nonetheless, visual impacts are not evenly distributed: people experience a concentrated share in a small number of natural settings, primarily including plains, prairies, and deserts. Finally, we find that although increased density of wind development consistently leads to visual impacts across a greater proportion of land, it does not always lead to impacts to a greater share of the population. These findings suggest that visual impacts from wind energy are generally well-mitigated across the CONUS to date but also highlight the need for a deeper understanding of landscape sensitivity and individual perceptions of wind turbines in the most heavily impacted natural settings.

3D simulation↗

DOE OSTI2022

Turbine scale and siting considerations in wind plant layout optimization and implications for capacity density

Improvements in wind energy technology, reduced costs, and ambitious clean energy goals have led to projections of high wind contribution in coming years. Developing methodologies to design wind plants with a variety of siting constraints and turbine sizes helps enable high wind penetration, and gain a better understanding of how wind plants are sensitive to setback constraints and turbine design. In this paper, we present a two-step optimization method to simultaneously determine the optimal number of turbines and their locations in a wind plant domain divided into many small, discrete parcels. We present the optimized performance metrics of a wind plant optimized with different turbine sizes and ratings, and with different siting restrictions within the wind plant. Our results indicate that taller and larger turbines are more sensitive to increasing siting constraints. We also compare the optimal wind plant layouts and performance for wind plants optimized for minimum COE and maximum profit. Wind plants optimized for profit had 130%-190% of the capacity of plants optimized for COE, which demonstrates that the optimal results are greatly affected by the objective function, which should be carefully considered. Finally, in this paper we demonstrate the effect of increasing siting constraints on wind plant capacity density, and how the results change when different land areas are used to calculate capacity density. When using the entire wind plant boundary area to determine capacity density, increasing siting constraints decreases the capacity density. However, when we only use the available area (the area left after removing the siting constraints) to calculate the capacity density, increasing the siting constraints increases capacity density. This is a critical insight because of how capacity density is typically defined and used in research, and has important implications for assessment of technical potential and capacity expansion modeling, as well as future wind deployment potential.

17 WIND ENERGY↗

DOE OSTI2020

DICE-gas turbine compound reheat combined cycle

Coal-fired Direct Injection Carbon Engine – Gas Turbine (DICE-GT) Compound-Reheat Combined Cycle (CRCC), is a combined cycle power plant comprising a multiplicity of coal-fired reciprocating internal combustion engines (RICE), which is commonly referred to by the acronym DICE (Direct Injection Carbon Engine); a natural gas-fired gas turbine (turbine and combustor); a heat recovery steam generator (HRSG); a steam turbine generator; and an integrally geared and intercooled centrifugal air compressor. Finally, the concept uses coal-water slurry/fluid in the DICE and natural gas (or hydrogen) in the gas turbine for unmatched efficiency (well above 50% net LHV) and modularity (block sizes of 120, 240 and 360 MW) with easy adaptability to carbon capture and sequestration with minimal additional cost, complexity and performance hit.

42 ENGINEERING↗