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At least 37 records · Page 2
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DOE OSTI2024

Active Aerodynamic Load Control for Wind Turbines

The goal of this project was to develop and demonstrate an advanced dielectric barrier discharge (DBD) plasma actuator technology. We set out to demonstrate the efficacy and impact of the new actuator technology as a key component of an active load control system for wind turbines. A DBD plasma actuator consists of a thin layer of dielectric material separating a pair of offset electrodes. One of those electrodes is embedded between the dielectric layer and a non-conductive substrate, while the other is exposed to air. When driven by an appropriate high voltage waveform, the device ionizes the air near the surface of the dielectric and adjacent to the exposed electrode. Collisions between the ions in the plasma and neutral air molecules result in a wall-jet – a region of induced air velocity that can be used to modify the flow around a lifting body. Use of the device near the trailing edge of a wind turbine blade, designed in such a way as to amplify the effects of the flow-modifying device, can result in large changes to the global forces experienced by the blade. Because of the fast response time of the device, it can allow the turbine to react in real time to changes in the wind associated with turbulence, wind shear, gusts, and the like, when paired with appropriate sensors and control algorithms. The goal of this project was to increase the capacity of the device to induce velocity on its surface at the levels required by large, utility-scale wind turbines. The first technical goal was to increase the induced velocity from the current industry-best of about 4 m/s to 10 m/s by modifying the electrical waveform used to drive the device and by introducing a semi-conductive surface coating to control electrostatic charge build-up on the surface. The second goal was to use the device to modify the lift on a representative airfoil in a wind tunnel, demonstrating a reduction in lift coefficient of 0.2 or better. The third goal was to produce an actuator-induced velocity of 20 m/s. Alongside our partners at the University of Texas at Dallas, we also applied modern, advanced design methods to optimize the impact of the technology on the design of wind turbines. We also had planned to install a segmented, active load control system on a test turbine to demonstrate the ability to reduce unsteady aerodynamic forces on the turbine associated with changes in the wind. The highest induced velocity achieved during this research was 11 m/s. However, practical design constraints limited the change in lift coefficient to about 0.12 for a representative airfoil in the wind tunnel at a Reynolds number of 400,000. The primary conclusion is that the plasma actuator control authority remains insufficient for practical purposes when extrapolated to Reynolds numbers over 1 million. The potential impact of the active lift control concept was evaluated through detailed simulations for three wind turbine sizes: a 3.4MW onshore turbine, a 10MW offshore turbine, and a 15MW offshore turbine. A feedback control system was designed for each turbine within two scenarios: one where the active lift control is used as a retrofit capability on the baseline design, and the other where the designers were permitted to “upscale” the turbines in order increase annual energy production. The levelized cost of energy was then evaluated for the range of turbine sizes and design configuration. It was found that the LCOE reduction associated with active lift control fell in the range of 0.7% to 7.2%, with the highest reduction associated with upscaling the 3.4MW turbine.

17 WIND ENERGY↗
DOE OSTI2022

Lifetime fatigue response due to wake steering on a pair of utility-scale wind turbines

Quantifying the impacts on turbine loads during wind farm control is an important consideration in assessing power production benefits. Wake steering controls aim to improve total wind farm performance by coordinating the control actions of individual turbines, wherein an upstream turbine is intentionally yawed at an offset angle from the measured wind direction. Consequently, this redirects its wake for improved power production and potentially reduces fatigue loads of the downstream turbines. This paper studies the lifetime fatigue loads associated with wake steering by using utility-scale wind turbine experimental data to conduct an analysis on a pair of wind turbines. This study was part of a large field experiment in which a group of five GE 1.5-MW SLE CWE turbines were selected as targets for conducting wake steering research. A standard loads instrumentation package and data acquisition system were installed on two turbines within the cluster to measure turbine fundamental loads. The time-series databases were used to calculate loads statistics as well as short-term and lifetime damage equivalent loads. Fatigue calculations followed the guidance in Annex H of the International Electrotechnical Commission standard 61400-1, Edition 4. Lifetime fatigue calculation results are presented in this analysis; three methods of assessing lifetime fatigue were used to determine percent difference for blade root moments, main shaft moments, main shaft torque, and tower top torque. For all three fatigue treatments, some components’ lifetime fatigue increases for the controlled turbine; however, the downwind turbine experienced a reduction in lifetime fatigue and combined effect for the turbine pair results in a reduction of fatigue when wake steering controls are applied.

17 WIND ENERGY↗
DOE OSTI2023

Effects of finite sampling on fatigue damage estimation of wind turbine components: A statistical study

The variability of the wind turbine loads complicates fatigue assessment in the design phase, as performing simulations covering the entire lifetime is computationally expensive. The current work provides important information for assessing the uncertainty in fatigue damage estimation due to finite data. Here we study the sample size effect on mean, variance, and skewness of damage in each wind bin, identify the important wind bins, and study the uncertainty propagation from each wind bin to the lifetime damage using 3600 aeroelastic simulations and bootstrapping. To achieve less than 1% error in the damage estimation across all load channels in the current case study, at least 100 turbulence seeds are needed. Damage in different wind bins follows a lognormal distribution when using the conventional approach of six seeds. The provided insights and information allow the designer to achieve a specific level of accuracy for a given computational cost using strategic bin sampling.

17 WIND ENERGY↗
DOE OSTI2024

Investigation of an Intermittent Binary Control Strategy for Distributed Aerodynamic Control Devices for Load Alleviation in Wind Turbine Blades

A study was conducted of an intermittent binary control strategy for trailing edge flaps and leading edge spoilers installed on wind turbine blades for the purpose of load alleviation. Cost estimation models were developed for the systems to predict overall impact on levelized cost of energy over the lifecycle of the turbine system. Aeroelastic simulations of turbines with the control strategy implemented showed improved levelized cost for some, but not all cases.

17 WIND ENERGY↗
DOE OSTI2024

Impact of wake steering on loads of downstream wind turbines at an above-rated condition

Wake steering strategies often seek to gain power at the expense of increased fatigue loads. Here, we investigate the feasibility of applying wake steering at an above-rated condition. In such a condition, the farm is operating at rated power, and thus, increased power output is not the goal. Instead, wake steering is considered in the context of load reduction. We perform a sweep of wind directions and yaw misalignment angles, ranging from negative to positive values. This approach allows us to obtain trends and identify asymmetries in turbine response for symmetric scenarios. We use a wind farm consisting of five aligned IEA Wind 15-MW reference wind turbines, and analyze trends related to the blade-root, low-speed shaft, and tower-base moments, both in terms of standard deviation and damage equivalent loads. We show that for any given fixed wind direction, the turbines can be yawed such that the fatigue loads are reduced. Reductions of up to 5% (depending on the component) in terms of standard deviation and damage equivalent loads can be achieved by negatively yawing the turbine. A negative yaw misalignment has shown to be the direction of larger improvements. Such results contrast those found for below-rated conditions, where a positive yaw misalignment is typically preferred. However, since load reduction is not uniform across all component loads, more study and consideration is required before operational recommendations can be made.

17 WIND ENERGY↗
DOE OSTI2025

Field Validation of Dynamic Mechanical Torque Measurements for Geared Wind Turbines

Accurate knowledge of the mechanical loads of wind turbine gearboxes has become essential in modern, highly loaded gearbox designs, as maintaining or even improving gearbox reliability with increasing torque density demands is proving to be challenging. Unfortunately, the traditional method of measuring dynamic mechanical torque using strain gauges placed on the outer surface of a rotating shaft and transmitting the resulting signal is unsuitable for serial deployment due to technical and economic constraints. An alternative method based on fiber-optic strain sensors placed on the stationary outer surface of the gearbox ring gear has been proposed. Like shaft torsion, the radial deformation of the ring gear is proportionate to the rotor torque. Placing the sensors on a stationary component is a cost-effective alternative for serial implementation because the need for complex and expensive data transfer via wireless transmission or a slip ring is eliminated. In this paper, we present the results of an extensive field experiment conducted to evaluate the torque measurement accuracy of this novel sensing solution installed on the gearbox of a Gamesa G97 2-MW wind turbine at the National Renewable Energy Laboratory's Flatirons Campus. Torque measurements derived from fiber-optic strain sensors placed on the ring gear of the planetary stage are compared to conventional torque measurements from strain gauges placed on the main shaft. Two different torque estimation data processing methods were evaluated, with the method based on operational deflection shapes providing the most accurate results with an average normalized root mean square error below 0.7% for a load revolution distribution analysis. The effect of operating conditions on the torque estimate was also investigated, and the third planet-passing operational deflection shape was found to be the least sensitive to nontorque load-related effects. The fiber-optic strain sensors' successful operation during the complete test campaign has demonstrated a robust and accurate solution for fleet-wide enhanced gearbox remaining useful life estimation.

17 WIND ENERGY↗
DOE OSTI2021

A proposed criteria to identify wind turbine drivetrain bearing loads that induce roller slip based white-etching cracks

In this article, the type of roller slip behavior that may result in the formation of white-etching cracks (WECs) in wind turbine gearbox bearings is identified. A new hypothesis based on the inner raceway normal contact load magnitude at the time of roller slip is proposed as the probable cause of WECs. For this purpose, the maximum normal contact loads are identified when roller slip occurs in high-speed shaft bearings at different mean wind speeds. Subsequently, the annual probability of occurrence of the maximum normal loads are obtained. The probability of maximum load under slip exceeding a limit probability is hypothesized as a probable cause for WEC. In order to apply the proposed hypothesis, two different wind turbines high-speed shaft bearings are used: the cylindrical roller bearing of the General Electric 1.5 SLE turbine and the tapered roller bearing of Vestas V52 turbine. Both the chosen bearings are on the generator side of the high-speed shaft. For both turbines, measurement data together with analytical models are used for identifying the slip and the maximum normal contact loads. We propose forecasting the probability of exceedance of a threshold maximum normal contact load level during slip to identify the possibility for inducing WECs.

17 WIND ENERGY↗
DOE OSTI2023

OC6 project Phase III: validation of the aerodynamic loading on a wind turbine rotor undergoing large motion caused by a floating support structure

Abstract. This paper provides a summary of the work done within Phase III of the Offshore Code Comparison Collaboration, Continued, with Correlation and unCertainty (OC6) project, under the International Energy Agency Wind Technology Collaboration Programme Task 30. This phase focused on validating the aerodynamic loading on a wind turbine rotor undergoing large motion caused by a floating support structure. Numerical models of the Technical University of Denmark 10 MW reference wind turbine were validated using measurement data from a 1:75 scale test performed during the UNsteady Aerodynamics for FLOating Wind (UNAFLOW) project and a follow-on experimental campaign, both performed at the Politecnico di Milano wind tunnel. Validation of the models was performed by comparing the loads for steady (fixed platform) and unsteady (harmonic motion of the platform) wind conditions. For the unsteady wind conditions, the platform was forced to oscillate in the surge and pitch directions under several frequencies and amplitudes. These oscillations result in a wind variation that impacts the rotor loads (e.g., thrust and torque). For the conditions studied in these tests, the system aerodynamic response was almost steady. Only a small hysteresis in airfoil performance undergoing angle of attack variations in attached flow was observed. During the experiments, the rotor speed and blade pitch angle were held constant. However, in real wind turbine operating conditions, the surge and pitch variations would result in rotor speed variations and/or blade pitch actuations, depending on the wind turbine controller region that the system is operating. Additional simulations with these control parameters were conducted to verify the fidelity of different models. Participant results showed, in general, a good agreement with the experimental measurements and the need to account for dynamic inflow when there are changes in the flow conditions due to the rotor speed variations or blade pitch actuations in response to surge and pitch motion. Numerical models not accounting for dynamic inflow effects predicted rotor loads that were 9 % lower in amplitude during rotor speed variations and 18 % higher in amplitude during blade pitch actuations.

17 WIND ENERGY↗
DOE OSTI2025

Field validation of dynamic mechanical torque measurements using fiber-optic strain sensors for geared wind turbines

Abstract Accurate knowledge of the mechanical loads of wind turbine gearboxes has become essential in modern, highly loaded gearbox designs, as maintaining or even improving gearbox reliability with increasing torque density demands is proving to be challenging. Unfortunately, the traditional method of measuring dynamic mechanical torque using strain gauges placed on the outer surface of a rotating shaft and transmitting the resulting signal is unsuitable for serial deployment due to technical and economic constraints. An alternative method based on fiber-optic strain sensors placed on the stationary outer surface of the gearbox ring gear has been proposed. Like shaft torsion, the radial deformation of the ring gear is proportionate to the rotor torque. Placing the sensors on a stationary component is a cost-effective alternative for serial implementation because the need for complex and expensive data transfer via wireless transmission or a slip ring is eliminated. In this paper, we present the results of an extensive field experiment conducted to evaluate the torque measurement accuracy of this novel sensing solution installed on the gearbox of a Gamesa G97 2-MW wind turbine at the National Renewable Energy Laboratory’s Flatirons Campus. Torque measurements derived from fiber-optic strain sensors placed on the ring gear of the planetary stage are compared to conventional torque measurements from strain gauges placed on the main shaft. Two different torque estimation data processing methods were evaluated, with the method based on operational deflection shapes providing the most accurate results with an average normalized root mean square error below 0.7% for a load revolution distribution analysis. The effect of operating conditions on the torque estimate was also investigated, and the third planet-passing operational deflection shape was found to be the least sensitive to nontorque load-related effects. The fiber-optic strain sensors’ successful operation during the complete test campaign has demonstrated a robust and accurate solution for fleet-wide enhanced gearbox remaining useful life estimation.

17 WIND ENERGY↗
DOE OSTI2021

A Methodology for Robust Load Reduction in Wind Turbine Blades Using Flow Control Devices

Decades of wind turbine research, development and installation have demonstrated reductions in levelized cost of energy (LCOE) resulting from turbines with larger rotor diameters and increased hub heights. Further reductions in LCOE by up-scaling turbine size can be challenged by practical limitations such as the square-cube law: where the power scales with the square of the blade length and the added mass scales with the volume (the cube). Active blade load control can disrupt this trend, allowing longer blades with less mass. This paper presents the details of the development of a robust load control system to reduce blade fatigue loads. The control system, which we coined sectional lift control or SLC, uses a lift actuator model to emulate an active flow control device. The main contributions of this paper are: (1) Methodology for SLC design to reduce dynamic blade root moments in a neighborhood of the rotor angular frequency (1P). (2) Analysis and numerical evidence supporting the use of a single robust SLC for all wind speeds, without the need for scheduling on wind speed or readily available measurements such as collective pitch or generator angular speed. (3) Intuition and numerical evidence to demonstrate that the SLC and the turbine controller do not interact. (4) Evaluation of the SLC using a full suite of fatigue and turbine performance metrics.

17 WIND ENERGY↗
DOE OSTI2022

Leading Edge Microspoilers for Load Dumping in Wind Turbine Rotors

As rotor designs have grown in size and flexibility, new design challenges have arisen that could benefit from novel control strategies. Leading edge microspoilers (LEMS) have been shown to effectively reduce forces on airfoils by inducing stall at lower angles of attack. This paper investigates how LEMS can be used to reduce blade loading on large, flexible, downwind rotors during design-limiting design load cases. During shutdown in turbulent flows near cutout speed, LEMS could reduce the tip deflection spikes toward the tower by over 50% and keep flapwise root bending moments below normal operating conditions, thus eliminating these as design-driving load cases. In power producing load cases, deploying LEMS for a short period of time during a load spike can be effective to reduce toward-tower tip deflections without significantly impacting power produced, assuming these load spikes can be identified by a controller. Leveraging this technology could allow for lower specific power machines to be designed.

17 WIND ENERGY↗
DOE OSTI2020

FAST.Farm Development and Validation of Structural Load Prediction Against Large Eddy Simulations

FAST.Farm is a mid-fidelity engineering tool developed by the National Renewable Energy Laboratory targeted at accurately and efficiently predicting wind turbine power production and structural loading in wind farm settings, including wake interactions between turbines. FAST.Farm is based on several principles of the dynamic wake meandering (DWM) model, but also addresses limitations of previous DWM implementations. Previous FAST.Farm studies have shown the similarities and differences between FAST.Farm and large eddy simulations for rigid turbine cases. The objective of this work is to quantify the ability of FAST.Farm to accurately predict turbine structural response in a small wind farm. This is done by comparing FAST.Farm structural response to SOWFA-OpenFAST results for three laterally-aligned turbines. The purpose of this study is to characterize the similarities and differences between FAST.Farm and a higher fidelity model for predicting turbine structural response in a wind farm for differing atmospheric inflows. Strong statistical agreement was found between FAST.Farm and SOWFA-OpenFAST structural response for the non-waked upstream turbine, and good agreement was found for the downstream turbines for most structural quantities. Higher differences were seen for downstream turbines with low ambient turbulence intensity or yawed turbines, suggesting areas for FAST.Farm wake dynamics modeling improvements. For all cases and turbines, small statistical differences were seen between blade deflections and bending moments, with larger differences for tower-top and tower-base bending moments. Overall, the results establish confidence for applying FAST.Farm to wind farm power and loads analyses and identify areas where further model validations and model improvements should be targeted.

49 EE - Wind and Water Power Program - Wind (EE-4W↗
DOE OSTI2025

The influence of wind veer and drivetrain flexibility on fatigue loading for large floating wind turbines

To reduce costs, offshore wind turbines are expected to be designed with significantly increased rotor diameters. Larger turbines become more flexible and span a larger portion of the atmospheric boundary layer. With these changes, the validity of traditional modeling assumptions should be investigated. This work challenges two common assumptions: (1) that the drivetrain can be considered rigid (except in torsion) and does not couple with the rotor and tower and 2) that wind directional change with height (veer) does not greatly influence the fatigue damage in the tower, blades and drivetrain. Two large semi-submersible floating wind turbines are considered: a 15 and a 22 MW reference turbine. Both use direct-drive generators. Aero-hydro-servo-elastic simulations are performed using OpenFAST, with drivetrain bending flexibility and main bearing response implemented in the coupled analysis. The turbines are subjected to a set of load cases at below-, near- and above-rated mean wind speeds, assembled based on the 3 km Norwegian reanalysis (NORA3) hourly wind and wave hindcast data for Utsira Nord, off the coast of Norway. In each load case, conditions with and without veer are simulated to evaluate the influence of veer on damage equivalent loads (DELs) of the turbine tower, blades and main bearings. Further, these load cases are applied to evaluate the influence of drivetrain flexibility on aero-elastic turbine response. The results indicate that, depending on the veer gradient, mean wind speed, operating regime and turbine size, veer can be very important for tower-top DELs and the fluctuations of main bearing radial loads, while main bearing and blade-root flapwise DELs are less affected. Considering these specific load cases and turbine models, drivetrain flexibility is found to significantly influence tower-top DELs of the largest turbine: the tower-top fore-aft and torsional damage equivalent moments of the 22 MW turbine are reduced by more than 20 % at near-rated wind speeds when the drivetrain is modeled as flexible.

17 WIND ENERGY↗
DOE OSTI2025

An airfoil-based synthetic actuator disk model for wind turbine aerodynamic and structural analysis

Here, this study introduces an airfoil-based refinement technique to enhance the Actuator Disk Model (ADM) for improved wind turbine aerodynamic load prediction and structural simulation in conjunction with Large Eddy Simulations of the wind flow. While ADM offers higher computational efficiency than the more detailed but resource-intensive Actuator Line Model (ALM), it traditionally lacks the resolution needed to capture the localized blade forces accurately. To address this limitation, we introduce a refinement technique that uses airfoil-specific data and employs interpolation-based grid point refinement, achieving ALM-comparable accuracy while preserving ADM's efficiency. Unlike conventional ADM that provides only rotor-disk averaged forces, our synthetic method tracks transient aerodynamic load variations over multiple blade revolutions, allowing us to calculate the distributions of maximum and minimum loads during typical cycles. Applied to the NREL 5 MW reference turbine, our enhanced ADM accurately predicts key aerodynamic parameters (angle of attack, axial velocity, lift, drag, axial and tangential forces along the blades) as well as structural responses (blade tip deflection, maximum stress, and stress concentration). Our results show that the tip deflection ranges from 2.33m (3.69 % of blade length) to 4.28m (6.79 %), with maximum stress concentration occurring near the blade root. This research demonstrates that a refined synthetic ADM approach can serve as a computationally efficient alternative for both aerodynamic analysis and structural simulation of wind turbine blades subjected to realistic wind fields.

17 WIND ENERGY↗
DOE OSTI2022

Impacts of wind field characteristics and non-steady deterministic wind events on time-varying main-bearing loads

Abstract. This work considers the characteristics and drivers of the loads experienced by wind turbine main bearings. Simplified load response models of two different hub and main-bearing configurations are presented, representative of both inverting direct-drive and four-point-mounted geared drivetrains. The influences of deterministic wind field characteristics, such as wind speed, shear, yaw offset, and veer, on the bearing load patterns are then investigated for similarity scaled 5, 7.5, and 10 MW reference wind turbine models. Main-bearing load response in cases of deterministic gusts and extreme changes in wind direction are also considered for the 5 MW model. Perhaps surprisingly, veer is identified as an important driver of main-bearing load fluctuations. Upscaling results indicate that similar behaviour holds as turbines become larger, but with mean loads and load fluctuation levels increasing at least cubically with the turbine rotor radius. Strong links between turbine control and main-bearing load response are also observed.

17 WIND ENERGY↗
DOE OSTI2022

Wind turbine response in waked inflow: A modelling benchmark against full-scale measurements

Predicting the power and loads of wind turbines in waked inflow conditions still presents a major modelling challenge. It requires the accurate modelling of the atmospheric flow conditions, wakes of upstream turbines and the response of the turbine of interest. Rigorous validations of model frameworks against measurements of utility-scale wind turbines in such scenarios remain limited to date. In this study, six models of different fidelity are compared against measurements from the DanAero experiment. The two benchmark cases feature a full-wake and partial-wake scenario, respectively. The simulations are compared against local pressure forces and inflow velocities measured on several blade sections of the downstream turbine, as well as met mast measurements and standard SCADA data. Regardless of the model fidelity, reasonable agreements are found in terms of the wake characteristics and turbine response. For instance, the azimuth variation of the mean aerodynamic forces acting on the blade was captured with a mean relative error of 15-20%. Additionally, while various model-specific deficiencies could be identified, the study highlights the need for further full-scale measurement campaigns with even more extensive instrumentation. Furthermore, it is concluded that validations should not be limited to integrated and/or time-averaged quantities that conceal characteristic spatial or temporal variations.

17 WIND ENERGY↗
DOE OSTI2024

Coupled Aero-Hydro-Mechanical Hybrid Simulation Testing of Offshore Wind Turbines Subjected to Operational and Extreme Loading Conditions

Understanding the response of the Offshore Wind Turbine (OWT) subjected to realistic applied loads requires modeling the whole structure including its soil-foundation system. This requires unique and innovative testing facilities. OWT systems experience cyclic and dynamic loading due to wind, wave, current, rotor vibrations (i.e., 1P load) and vibrations caused by the blade shadowing effects (2P/3P loads). These loads are complicated in nature and have varying amplitudes, frequencies, and directions. Investigating the response of the entire OWT system including the soil-foundation system under these complex loading conditions, requires: (1) full understanding of the loading characteristics including: the power take-off mechanical load (1P and 3P), and areo- and hydrodynamic loads that the OWT system is subjected to; (2) testing facility with unique multidirectional loading capabilities that allows for simultaneous application of realistic wind, wave and machine loads, axial gravity loads, and induced overturning moments; and (3) unique and cost-effective testing techniques that allow for accurate analysis of the overall response of the OWT system under realistic conditions such as: Real-Time Hybrid Simulation (RTHS).

17 WIND ENERGY↗