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DOE OSTI2020

Opportunities for and challenges to further reductions in the “specific power” rating of wind turbines installed in the United States

A wind turbine’s “specific power” rating relates its capacity to the swept area of its rotor in terms of Watt per square meter. For a given generator capacity, specific power declines as rotor size increases. In land-rich but capacity-constrained wind power markets, such as the United States, developers have an economic incentive to maximize megawatt-hours per constrained megawatt, and so have favored turbines with ever-lower specific power. To date, this trend toward lower specific power has pushed capacity factors higher while reducing the levelized cost of energy. We employ geospatial levelized cost of energy analysis across the United States to explore whether this trend is likely to continue. We find that under reasonable cost scenarios (i.e. presuming that logistical challenges from very large blades are surmountable), low-specific-power turbines could continue to be in demand going forward. Beyond levelized cost of energy, the boost in market value that low-specific-power turbines provide could become increasingly important as wind penetration grows.

geospatial modeling↗

DOE OSTI2026

Modeling, Validation, and Control of the IEA‐15 MW Reference Wind Turbine and VolturnUS‐S Platform

This paper presents the acausal modeling, validation, and control of floating offshore wind turbines (FOWTs). The model simulates the IEA‐15 MW reference turbine and the semi‐submersible VolturnUS‐S platform utilizing a Control‐oriented, Reconfigurable, and Acausal Floating Turbine Simulator (CRAFTS), which integrates the key coupled aero‐hydro‐elasto‐servo dynamics and is being developed by authors at the University of Central Florida. Verification and validation are conducted using numerical data from the industry‐standard simulation platform OpenFAST and experimental data from the Floating Offshore‐wind and Controls Advanced Laboratory (FOCAL) project, in which the authors were involved. Numerical results demonstrate the model's ability to qualitatively capture loads and responses across various load cases, highlighting the impact of the control system under different wind and wave conditions and opening new opportunities for optimizing FOWT designs. This paper provides wind turbine researchers with valuable insights into system characteristics, system frequencies, damping effects, and internal reaction forces, serving as a reference for future studies in FOWT modeling and control.

17 WIND ENERGY↗

DOE OSTI2023

Grid Forming Fast Frequency Response for PMSG-Based Wind Turbines

Electric power systems are undergoing a rapid transition from fuel-based generation using synchronous generators to renewable generation interfaced by power electronics. In this context, a key challenge is using renewable generation with limited controllability to contribute to power system stability. In this work, we investigate grid-forming control of permanent magnet synchronous generator (PMSG) wind turbines. The proposed control and curtailment strategy supports the entire spectrum of standard functions of grid-following (e.g. maximum power point tracking (MPPT) and grid-forming control (e.g., primary frequency control) without explicit mode switching. A detailed case study is used to compare the performance of the proposed control at operating points corresponding to MPPT and frequency control with standard grid-forming and grid-following controls. Further, the results demonstrate that (i) the proposed energy balancing grid forming control is self-synchronizing in MPPT mode, (ii) the (limited) energy storage and controllability of wind turbines can be adequately utilized to provide grid support, and (ii) the proposed control exhibits good performance under variable wind speeds and does not result in a significant increase of wind turbine fatigue loads.

17 WIND ENERGY↗

DOE OSTI2023

Wind Turbine Design Optimization for Hydrogen Production

To help meet the need for inexpensive green fuels, we are working on wind turbine design optimization specifically for hydrogen production. We have thus far achieved a 1.53% decrease in LCOH as compared to a turbine optimized for LCOE using the same code, design variables, and models . We accomplished this by optimizing some components of the wind turbine tower, rotor, and drivetrain design with hydrogen production and costs in the design loop.

design↗

DOE OSTI2026

OC6 Phase III: Validation of Wind Turbine Aerodynamic Loading During Surge/Pitch Motion

The objective of Phase III of the Offshore Code Comparison Collaboration, Continued, with Correlation and unCertainty (OC6) project was to validate the accuracy of aerodynamic load predictions by offshore wind modeling tools for a floating offshore wind turbine as it experiences large surge-translational and pitch-rotational motion, as would occur during normal operation. The test data considered were generated at Politecnico di Milano – a wind tunnel with a robotic excitation system to emulate wave loading on the wind turbine. Testing was performed using a scaled version of the DTU 10-MW reference model, and motion was prescribed as harmonic oscillations in the surge and pitch directions, independently. A variety of models were examined in the project, performing a three-way validation between engineering-level tools, higher-fidelity tools, and measurement data from two wind tunnel experimental campaigns. The Load Cases (LC) considered in this testing are as follows: LC 1.X - Steady Wind LC 2.X - Unsteady Wind - Surge Motion LC 3.X - Unsteady Wind - Pitch Motion Details on the results of the OC6 Phase III campaign can be found in the following reference: Bergua R., et al. OC6 project Phase III: validation of the aerodynamic loading on a wind turbine rotor undergoing large motion caused by a floating support structure, Wind Energ. Sci., 8, 465–485, https://doi.org/10.5194/wes-8-465-2023, 2023.

17 WIND ENERGY↗

DOE OSTI2023

New insights on wind turbine wakes from large‐eddy simulation: Wake contraction, dual nature, and temperature effects

Abstract Large‐eddy simulation (LES) has been adopted to study wind turbine wakes because it can capture fine‐scale details of turbulent wind flows and interactions with wind turbines. Here, we use the LES version of the Weather Research and Forecasting (WRF) model with an actuator disk model to gain insights on several wake effects that have been traditionally difficult to measure. The first finding is that the wake has a “dual nature,” meaning that the wind speed deficit behaves differently from the added turbulent kinetic energy (TKE) and the two are not co‐located in space. For example, the wind speed deficit peaks at hub height and reaches the ground within 8D (D is the rotor diameter), but added TKE peaks near the rotor tip and generally remains aloft. Second, temperature changes near the ground are driven by the added TKE in the rotor area and by atmospheric stability. The combination of these two factors determines the sign and intensity of the vertical heat flux divergence below the rotor, with convergence and warming associated with stable conditions and weak divergence and modest cooling with unstable conditions. Third, wakes do not expand indefinitely, as suggested by similarity theory applied to the wind speed deficit, but eventually stop expanding and actually contract, at different rates depending on atmospheric stability. The implication of these findings is that, in order to study wakes, it is not sufficient to focus on wind speed deficit alone, because TKE is also important and yet behaves differently from the wind speed deficit.

17 WIND ENERGY↗

DOE OSTI2022

Toward control co-design of utility-scale wind turbines: Collective vs. individual blade pitch control

A large-eddy simulation framework has been coupled with controller modules to systematically investigate the impacts of collective (CPC) and individual (IPC) pitch control strategies on utility-scale wind turbine energy production and fatigue loads. Wind turbine components were parameterized using an actuator surface model to simulate the rotor blades and the turbine nacelle. The baseline CPC and IPC algorithms, consisting of single-input single-output proportional–integral controllers and two integral controllers, respectively, were incorporated into the numerical framework. A series of simulations were carried out to investigate the relative performance of the two controllers under various turbulent inflow conditions, spanning hub-height velocities of 7 to 14 m/s. The numerical simulation results of this study showed that, in comparison to the CPC, the IPC controller could successfully reduce the damage equivalent loads of utility-scale turbines at regions 2 and 3 of turbine operation by about 3% and 40%, respectively, without any penalty on the power production of the turbine. It was also shown that, despite its minor impact on the turbulence kinetic energy of the wake, the IPC controller did not influence the recovery of the turbine wake.

17 WIND ENERGY↗

DOE OSTI2022

Offshore reanalysis wind speed assessment across the wind turbine rotor layer off the United States Pacific coast

Abstract. The California Pacific coast is characterized by considerable wind resource and areas of dense population, propelling interest in offshore wind energy as the United States moves toward a sustainable and decarbonized energy future. Reanalysis models continue to serve the wind energy community in a multitude of ways, and the need for validation in locations where observations have been historically limited, such as offshore environments, is strong. The U.S. Department of Energy (DOE) owns two lidar buoys that collect wind speed observations across the wind turbine rotor layer along with meteorological and oceanographic data near the surface to characterize the wind resource. Lidar buoy data collected from recent deployments off the northern California coast near Humboldt County and the central California coast near Morro Bay allow for validation of commonly used reanalysis products. In this article, wind speeds from the Modern-Era Retrospective analysis for Research and Applications version 2 (MERRA-2), the Climate Forecast System version 2 (CFSv2), the North American Regional Reanalysis (NARR), the European Centre for Medium-Range Weather Forecasts Reanalysis version 5 (ERA5), and the analysis system of the Rapid Refresh (RAP) are validated at heights within the wind turbine rotor layer ranging from 50 to 100 m. The validation results offer guidance on the performance and uncertainty associated with utilizing reanalyses for offshore wind resource characterization, providing the offshore wind energy community with information on the conditions that lead to reanalysis error. At both California coast locations, the reanalyses tend to underestimate the observed rotor-level wind resource. Occasions of large reanalysis error occur in conjunction with stable atmospheric conditions, wind speeds associated with peak turbine power production (> 10 m s−1), and mischaracterization of the diurnal wind speed cycle in summer months.

17 WIND ENERGY↗

DOE OSTI2021

A Biomimetic Ultrasonic Whistle for Use as a Bat Deterrent on Wind Turbines

Our project goal was to design a novel mechanical ultrasonic deterrent for use on wind turbines in order to reduce bat fatalities around these structures. Our proposed deterrent design would be composed of a series of ultrasonic pulse generators, or whistles, affixed to a wind turbine blade, which produce ultrasound through mechanical means. The whistles would produce sounds mimicking the spectrotemporal patterns of bat echolocation pulses, thereby enhancing the bats’ ability to detect, localize and avoid the moving blades. These whistles are intended to be operated passively, blown by the wind, and to be positioned at intervals along a turbine blade. Because the source of sound generation will be mechanical in nature, these devices will require no external power source, should require little maintenance, and will be small and cost-effective.

17 WIND ENERGY↗

DOE OSTI2023

Infusible Thermoplastic Composites for Wind Turbine Blade Manufacturing: Fatigue Life of Thermoplastic Laminates under Ambient and Low-Temperature Conditions

Traditionally, thermoset resins such as polyesters (PE) and epoxies are used as the polymer matrix for construction of wind turbine blades. However, concern about their end-of-life treatment garners interest to use thermoplastics for increased recyclability. However, the high viscosity of molten thermoplastics inhibits their use in manufacturing wind turbine blades with injection or compression molding. A recently developed, infusible, reactive thermoplastic resin overcomes this technological barrier. Toward verifying that this recyclable resin is suitable for use in wind turbine blades, a dataset of R?=?0.1 and R?=?10 fatigue data for glass fiber-reinforced acrylic composites is provided and equal fatigue life to industry standard epoxy and unsaturated PE resin systems is demonstrated. Specifically, R?=?0.1 fatigue data for acrylic composites at room temperature and -30?degrees C for verification of low-temperature performance are tabulated. To elucidate failure mechanisms, in situ mechanical testing with X-ray computed tomography demonstrates that damage accumulation occurs by crack propagation along the fiber-matrix interface under cyclic loading. Infrared (IR) thermography predicts failure points in composites specimens with porosity defects introduced from nonideal manufacturing processes. Furthermore, these manufacturing defects are shown to compromise the fatigue life of the acrylic laminates by an order of magnitude.

effect of defects↗

DOE OSTI2025

Unsteady aerodynamics of large-scale floating offshore wind turbines in surge motion

Unsteady aerodynamic loads significantly influence the design and wake flow field of floating offshore wind turbines, especially due to wave- or vibration-induced tower top motions triggering various unsteady phenomena. Recent studies show that increasing turbine sizes amplify unsteady aerodynamic effects, as their impact typically grows with rotor diameter. This work combines recent findings from experiments and simulations on model-scale FOWT aerodynamics with new numerical analyses of large-scale rotors, providing a comprehensive understanding of unsteady phenomena occurrence and impact. Numerical analyses of the IEA 15-MW and 22-MW rotors undergoing surge motions characterise the combined influence of motion-induced unsteady phenomena on rotor thrust. Results indicate that unsteady effects can reduce thrust force variations by up to 40% at realistic surge periods. These findings contrast with prior model-scale rotor investigations, attributed to the specialised design of the model rotors. Comparisons between numerical methods - the dynamic blade element momentum method in OpenFAST and free vortex wake modules in panMARE and OpenFAST - reveal persistent differences in thrust predictions under both idealised and realistic conditions. This highlights that classical blade element momentum approaches require enhancement to accurately capture unsteady loads on large-scale floating offshore wind turbines at low wind speeds.

16 TIDAL AND WAVE POWER↗

DOE OSTI2025

OpenFAST simulation of floating wind turbines with large heading change

Previous versions of OpenFAST, the physics-based wind turbine engineering and design tool developed by the National Renewable Energy Laboratory, were limited to small rotations of the floating platform. This prevented OpenFAST from being used to simulate important events, such as the loss of a mooring line, or specific floater concepts that might experience large platform yaw motion. To overcome this limitation, we modify the structural dynamics and hydrodynamics modules of OpenFAST to allow unrestricted platform yaw motion. We apply the improved version of OpenFAST to simulate the drifting of a floating wind turbine system after the loss of a mooring line. The results, including both global motion and the internal structural loads at selected locations, appear credible and consistent with expectations.

17 WIND ENERGY↗

DOE OSTI2024

Toolpath generation for automated wind turbine blade finishing operations

Incorporating automation into wind turbine blade manufacturing is important for reducing costs to meet current offshore wind energy production goals in the United States. This work proposes a process for automating three operations in wind blade manufacturing: trimming to remove flashing left over after bonding two blade skins together, grinding to produce a desired leading-edge shape, and sanding to prepare the blade for bonding overlamination or adding paint to the surface. The majority of this work focuses on the toolpath generation. The algorithms were tested on a 5-m blade section, and the results were analyzed in terms of operation speed and accuracy. Finally, future work is discussed to improve the performance of the system.

17 WIND ENERGY↗

DOE OSTI2025

Modal dynamics of wind turbine wake meandering from lidar observations

Horizontal scans from nacelle-mounted lidars provide time series measurements of wind turbine wakes across diverse atmospheric conditions, enabling analysis of coherent turbulent structures that influence wake meandering through proper orthogonal decomposition (POD). While low-order modes capture the most energetic turbulent structures, our analysis reveals that they do not necessarily dominate wake meandering dynamics. We evaluate more than 16,000 combinatorial reconstructions of the flow field for each inflow case, demonstrating that mode relevance depends on mode symmetry, turbulent kinetic energy content, and inflow characteristics. Cases with low turbulence intensity and large integral timescales show stronger correlations between POD modes and wake meandering, whereas higher turbulence conditions (turbulence intensity > 7%) are less effectively described by reduced-order models. However, the qualitative similarity of POD modes across varied atmospheric conditions suggests the potential existence of a semi-universal basis for representing wind turbine wakes, with implications for improving engineering wake models.

17 WIND ENERGY↗

DOE OSTI2020

Structural validation of a thermoplastic composite wind turbine blade with comparison to a thermoset composite blade

Reactive infusible thermoplastics have the potential to be advantageous for wind turbine blade composites because they are recyclable at end of life, can have reduced manufacturing costs, enable thermal joining and have similar, and in some cases better, structural properties than traditional thermoset epoxy composites. However, these materials are new to the wind industry and there is risk to investing in a material that has not been validated at a blade scale. Industry cannot adopt a new material such as this without large-scale validation and demonstration of system-level advantages in cost and/or performance. This paper presents structural characterization of a 13-m thermoplastic composite wind turbine blade compared to an identical geometry thermoset epoxy blade. In this work, the results of this comparison showed that the flatwise structural static performance and the fatigue performance of the two blades were similar, but the thermoplastic composite blade had increased damping compared to the epoxy blade, which may result in reduced operational loads.

17 WIND ENERGY↗

DOE OSTI2021

Sequence Impedance Measurement of Utility-Scale Wind Turbines and Inverters – Reference Frame, Frequency Coupling, and MIMO/SISO Forms

Sequence impedance responses with or without considering frequency coupling in both MIMO and SISO forms are increasingly used for the stability analysis of three-phase power electronic systems; however, many aspects of sequence impedance measurement are not fully explored. It is not clear if the sequence impedance has a reference frame similar to the dq impedance. If so, the role of the grid voltage angle estimation in aligning the sequence impedance reference frame has not been discussed. Additionally, existing methods for measuring the sequence impedance with frequency coupling are complicated, are not feasible for large wind turbines and inverters, and provide the sequence impedance responses in only either MIMO or SISO form. This paper presents a sequence impedance measurement method that considers the frequency coupling, performs reference frame alignment, demonstrates the impact of the grid voltage angle estimation, and obtains the sequence impedance response in both MIMO and SISO forms. This paper demonstrates the proposed method and practical problems associated with the sequence impedance measurement of utility-scale wind turbines and inverters on a 1.9-MW Type III wind turbine and a 2.2-MVA inverter using an impedance measurement system built around a 7-MW/13.8-kV grid simulator and a 5-MW dynamometer.

17 WIND ENERGY↗

DOE OSTI2024

Instantaneous mesh load factor ( K γ ) measurements in a wind turbine gearbox using fiber-optic strain sensors

The mesh load factor, K γ , describes how loads are shared between planet gears and has become one of the key design challenges in modern wind turbine gearboxes. Planet load sharing directly impacts tooth root stresses, a critical driver of torque density and gearbox reliability. Experimental evaluation of K γ is typically performed from sun gear tooth root strain gauge measurements, which are complex. Furthermore, such measurements can only provide an average value of load sharing. The present study describes an alternative method to evaluate the mesh load factor in wind turbine gearboxes based on fiber-optic strain sensors installed on the outer surface of the fixed ring gear. We present the results of an extensive measurement campaign to evaluate this novel sensing solution installed on the input planetary stage of a 2-MW wind turbine gearbox at the National Renewable Energy Laboratory's Flatirons Campus (Colorado, USA). The number of strain sensors on the ring gear was selected as an integer multiple of the number of planets, which has enabled an instantaneous evaluation of the mesh load factor. The effect of operating conditions on the planet load-sharing behavior of the gearbox has been investigated. The mesh load factor measured for operating conditions close to rated was below 1.05, well below IEC 61400-4 standard requirements.

17 WIND ENERGY↗

DOE OSTI2024

Grid Forming Control of PMSG-based Wind Turbines under Fault Conditions

Grid-forming control is widely envisioned as core technology ensuring stable operation of future power systems with increasing deployment of converter-interfaced renewable generation. However, research on grid forming control of wind turbines, especially under faults, is still in its early stages. In this context, this paper augments dual-port grid-forming control for type IV wind turbines with auxiliary controls to enable reliable fault ride through capabilities. In particular, the proposed control does not require a dc chopper or mode switching to grid-following control. Instead, energy-balancing dual-port GFM control is augmented with active rotor speed damping control and threshold virtual impedance for current limiting during faults. Different operating conditions of wind turbines are considered in a detailed electromagnetic transient simulation study to validate the effectiveness of the proposed control.

Lyu, Xue↗