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DOE OSTI2022

Ultraflexible Smart FLoating Offshore Wind Turbine (USFLOWT) (Final Report) [Slides]

In this final report, we summarize activities and results from the Ultraflexible Smart Floating Offshore Wind Turbine (USFLOWT) project. The project involved co-design of a 10-MW floating offshore wind system, especially the substructure. This substructure was based on the SpiderFLOAT, an ultra-compliant, ultralight, and modular system with actuators for smart platform control that was promising for control co-design. The project’s overall goal was to unlock the floating offshore wind market based on conditions on the North Atlantic coast of the United States. Tasks summarized in the report include Task 2.3 (including controller design for the turbine and the substructure and final design of the SpiderFLOAT), Task 2.4 (final design of the active can ballasting actuator), Task 2.5 (planning for a scale demonstrator), Task 3.1 (technology to market plan), and Task 3.3 (approval in principle). The report also summarizes project dissemination activities at a variety of venues including the lead author and/or presenter for each.

17 WIND ENERGY↗

DOE OSTI2022

Investigation of Multiple Data Streams for Gearbox Bearing Fault Prediction Through Machine-Learning Models

Operations and maintenance (O&M) cost of wind plant accounts up to 30% of total energy cost, which can be reduced through continuous monitoring and successfully detecting incipient wind turbine failures. To accomplish this, condition monitoring and predictive maintenance systems are being implemented in wind industry to support O&M decision making. A wide range of approaches for condition monitoring and fault prediction have been developed. These approaches generally use historical data of wind turbines collected by Supervisory Control and Data Acquisition (SCADA) system to identify patterns that lead to failure. These SCADA data show the overall condition of a wind turbine and can be leveraged to detect when the turbine's performance is degrading and to identify if a fault is developing. However, it becomes challenging to predict the failure of a specific wind turbine gearbox bearing, because the SCADA data are often not directly linked to the component. To bridge the gap, we have investigated features calculated from SCADA data using physics-based models and the gearbox design over the years. The damaged metric we used in the physics domain is frictional energy. Combining these physics domain variables with SCADA data as inputs to various machine learning models for gearbox bearing fault prediction, we have demonstrated the benefits of leveraging both physics and data domain models. It was an attempt to improve frictional-energy-based damage metric by adding data domain inputs, as we had learned that the frictional-energy-based damage metric alone is not sufficient to single out failed bearings from healthy. As condition monitoring data (either vibration or oil debris data) has become available at more and more wind plants, we would like to evaluate whether by adding the condition monitoring data can help further improve the performance of frictional-energy-based damage metric for gearbox bearing fault prediction. Both cases by modeling through various machine learning algorithms are discussed in this study along with some observations.

fault prediction↗

DOE OSTI2021

A Novel Multiagent Resource Sharing Algorithm for Control of Advanced Energy Systems

This paper implements a novel resource sharing control strategy on a fuel cell–gas turbine hybrid power system at the National Energy Technology Laboratory’s Hybrid Performance Facility (Hyper). In a fuel cell–gas turbine hybrid power system, the simultaneous interaction of the gas turbine and the fuel cell creates a tightly coupled environment characterized by conflicting dynamics. In this paper, a model-free control approach is applied to solve the tightly coupled control problem posed by this challenging environment. Specifically, this control problem is presented as a resource sharing problem that can be solved using a resource sharing algorithm that is defined based on the distribution construction concept. This algorithm creates computational agents and solves the problem through the distribution and redistribution of shared resources defined as blocks. Furthermore, two agents were created; the first agent (agent 1) controls the gas turbine speed by adjusting the electric load, and the second agent (agent 2) controls the cathode mass flow through the fuel cell using the cold-air bypass valve. A parametric study was performed over the course of 15 experimental tests for both agents 1 and 2 through an evaluation of the responses based on setpoint changes. The algorithm was shown to have behavior comparable to a previously implemented multi-input multioutput state-space controller, which was designed through a model-based control approach. The resource sharing algorithm was able to find stable performance during run-time operations without any prior system knowledge identification on the power plant and without creating models used in traditional control strategies.

25 ENERGY STORAGE↗

DOE OSTI2020

Field Validation of Wake Steering Control with Wind Direction Variability

Wake steering is a wind farm control strategy wherein upstream turbines are misaligned with the wind direction to redirect their wakes away from downstream turbines, increasing overall wind plant power. Wake steering is often analyzed assuming steady mean wind directions across the wind farm. However, in practice, the wind direction varies considerably over time because of large-scale weather phenomena. Wind direction variability causes the increase in power production from wake-steering to be less than predicted by steady-state models, but more robust wake-steering strategies can be designed that account for variable wind conditions. This paper compares the achieved yaw offsets and power gains from two different 2-turbine wake-steering experiments at a commercial wind farm with model predictions using the FLOw Redirection and Induction in Steady State (FLORIS) control-oriented model, assuming both fixed and variable wind directions. The impact of wind direction variability is modeled by including wind direction and yaw uncertainty in the FLORIS calculations. The field results match the trends predicted, assuming wind direction variability. Specifically, the yaw offsets achieved in the intended control regions are lower than desired, resulting in less power gain, while a slight loss in power occurs for wind directions outside of the intended control region because of unintentional yaw misalignment. The agreement between the model and field results suggests that the wind direction variability model can be used to design wake-steering controllers that are more robust to variable wind conditions present in the field.

17 WIND ENERGY↗

NASA NTRS1986

Squeeze-Film Damper Controls High Vibrations

Dual-clearance (two oil films) squeeze-film damper developed for controlling vibrations in aircraft turbine engines and other rotating machinery. New damper under normal conditions uses only one low-clearance film. Under high imbalance, both films active, controlling shaft vibration in nearoptimum manner and allowing continued operation until safe shutdown made.

Fleming, D. P.↗

DOE OSTI2020

Field Validation of Wake Steering Control with Wind Direction Variability: Preprint

Wake steering is a type of wind farm control strategy wherein upstream turbines are misaligned with the wind direction to redirect their wakes away from downstream turbines, increasing overall wind plant power. Wake steering is often analyzed assuming steady mean wind directions across the wind farm. However, in practice, the wind direction varies considerably over time because of large-scale weather phenomena. Wind direction variability causes wake steering controllers to increase power production less than predicted by steady state models, but more robust wake steering strategies can be designed that account for variable wind conditions. This paper compares the achieved yaw offsets and power gains from two 2-turbine wake steering experiments at a commercial wind farm with model predictions using the FLOw Redirection and Induction in Steady State (FLORIS) control-oriented model, assuming both fixed and variable wind directions. The impact of wind direction variability is modeled by including wind direction and yaw uncertainty in the FLORIS calculations. The field results match the trends predicted assuming wind direction variability. Specifically, the yaw offsets achieved in the intended control regions are lower than desired, resulting in less power gain, while a slight loss in power occurs for wind directions outside of the intended control region because of unintentional yaw misalignment. The agreement between the model and field results suggests that the wind direction variability model can be used to design wake steering controllers that are more robust to variable wind conditions present in the field.

17 WIND ENERGY↗

NASA NTRS2002

Effects of Endwall Geometry and Stacking on Two-Stage Supersonic Turbine Performance

Two methods are commonly used to control the secondary/separated flows (and associated losses) in supersonic turbines: endwall contouring and airfoil stacking. In the current investigation the flow path between the first-stage vanes and rotors, and the stacking of the first-stage vanes were varied in an effort to improve turbine performance. The geometric variations have been studied by performing a series of unsteady three-dimensional numerical simulations for the two-stage turbine.

Dorney, Daniel J.↗

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↗

NASA NTRS1951

Investigation of dynamic characteristics of a turbine-propeller engine

Time constants that characterize engine speed response of a turbine-propeller engine over the cruising speed range for various values of constant fuel flow and constant blade angle were obtained both from steady-state characteristics and from transient operation. Magnitude of speed response to changes in fuel flow and blade angle was investigated and is presented in the form of gain factors. Results indicate that at any given value of speed in the engine cruising speed range, time constants obtained both from steady-state characteristics and from transient operation agree satisfactorily for any given constant fuel flow, whereas time constants obtained from transient operation exceed time constants obtained from steady-state characteristics by approximately 14 percent for any given blade angle.

ENGINES, TURBO-PROPELLER↗

DOE OSTI2021

Loads Response That is Due to Wake Steering on a Pair of Utility-Scale Wind Turbines

The goal of this report is to present the resulting turbine loads of a full-scale wind turbine wake steering field campaign. In this experiment, wake steering controls were applied to an upwind turbine (T2) and the downwind turbine (T3) was instrumented to measure mechanical loads. The test subjects (T2 & T3) were GE 1.5SLE CWE turbines located on a wind farm with a prevailing wind direction coming from the northwest. The data collection strategy involved toggling the wake steering controls of T2 between on and off. This resulted in two databases (baseline and wake steered) with similar turbulence intensities. Valid data was extracted and processed. The analysis involved scaling data to engineering units, applying coordinate transformations where applicable, calculating 10-minutes statistics, and calculating damage equivalent loads (DELs) to assess fatigue. Figures are shown as statistics and DELs binned by wind speed with supplemental scatter plots provided in the appendices. Results between the baseline and wake steered databases were compared. Overall, the binned statistics showed minimal differences in loading between the two cases. However, the DELs of the wake steered case were observed to be consistently smaller than the baseline for most of the turbine components. A potential for future work was recognized based on the findings of this report. Some areas of further study include an analysis for more granular loads sensitivity to different yaw offset angles and rotor wake overlap, an in-depth comparison of loads between the upwind and downwind turbines, and further fatigue analysis to quantify differences observed in this experiment.

17 WIND ENERGY↗

DOE OSTI2022

Wind turbine drivetrains: state-of-the-art technologies and future development trends

Abstract. This paper presents the state-of-the-art technologies and development trends of wind turbine drivetrains – the system that converts kinetic energy of the wind to electrical energy – in different stages of their life cycle: design, manufacturing, installation, operation, lifetime extension, decommissioning and recycling. Offshore development and digitalization are also a focal point in this study. Drivetrain in this context includes the whole power conversion system: main bearing, shafts, gearbox, generator and power converter. The main aim of this article is to review the drivetrain technology development as well as to identify future challenges and research gaps. The main challenges in drivetrain research identified in this paper include drivetrain dynamic responses in large or floating turbines, aerodynamic and farm control effects, use of rare-earth material in generators, improving reliability through prognostics, and use of advances in digitalization. These challenges illustrate the multidisciplinary aspect of wind turbine drivetrains, which emphasizes the need for more interdisciplinary research and collaboration.

17 WIND ENERGY↗

NASA NTRS1972

High temperature compounds for turbine vanes

Fabrication and microstructure control studies were conducted on SiC, Si3N4, and composites based on these compounds. Charpy mode impact testing to 2400 F established that beta-spodumene, lithium aluminum silicate, coated Si3N4, Si3N4 derived from alpha-Si3N4 powder, and SiC containing 5-25 v/o chopped C fibers had the most promising strengths. Several other composite systems had excellent microstructures and could prove interesting materials in the future. Stress-rupture testing on Si3N4 established that increasing 2000 F - 100 hour strengths were obtained for increasing grain size to at least 5 micrometers, increasing density and possibly increasing phase purity. These parameters became less important at 2400 F where it is thought a grain boundary phase controls strength.

Rhodes, W. H.↗

NASA NTRS1974

High temperature compounds for turbine vanes

Fabrication and microstructure control studies were conducted on SiC, Si3N and composites based on Si3N. Charpy mode impact testing to 2400 F established that Si3N4/Mo composites have excellent potential. Attempts to fabricate composites of Si3N4 with superalloys, both by hot pressing and infiltration were largely unsuccessful in comparison to using Mo, Re, and Ta which are less reactive. Modest improvements in impact strength were realized for monolithic Si3N4; however, SiC strengths increased by a factor of six and now equal values achieved for Si3N4. Correlations of impact strength with material properties are discussed. Reduced MgO densification aid additions to Si3N4 were found to decrease densification kinetics, increase final porosity, decrease room temperature bend strength, increase high temperature bend strength, and decrease bend stress rupture properties. The decrease in bend strength at high temperature for fine grain size SiC suggested that a slightly larger grain size material with a nearly constant strength-temperature relation may prove desirable in the creep and stress rupture mode.

Rhodes, W. H.↗

NASA NTRS1976

The impact of emissions standards on the design of aircraft gas turbine engine combustors

Effective emission control techniques have been identified and a wide spectrum of potential applications for these techniques to existing and advanced engines are being considered. Results from advanced combustor concept evaluations and from fundamental experiments are presented and discussed and comparisons are made with existing EPA emission standards and recommended levels for high altitude cruise. The impact that the advanced low emission concepts may impose on future aircraft engine combustor designs and related engine components is discussed.

Rudey, R. A.↗

NASA NTRS2019

Control Technology Needs for Electrified Aircraft Propulsion Systems

Electrified aircraft propulsion (EAP) systems hold potential for the reduction of aircraft fuel burn, emissions, and noise. Currently, NASA and other organizations are actively working to identify and mature technologies necessary to bring EAP designs to reality. This paper specifically focuses on the envisioned control technology challenges associated with EAP designs that include gas turbine technology. Topics discussed include analytical tools for the dynamic modeling and analysis of EAP systems, and control design strategies at the propulsion and component levels. This includes integrated supervisory control facilitating the coordinated operation of turbine and electrical components, control strategies that seek to minimize fuel consumption and lessen the challenges associated with thermal management, and dynamic control to ensure engine operability during system transients. These dynamic control strategies include innovative control approaches that either extract or supply power to engine shafts dependent upon operating phase, which may improve performance and reduced gas turbine engine weight. Finally, a discussion of control architecture design considerations to help alleviate the propulsion/aircraft integration and certification challenges associated with EAP systems is provided.

Simon, Donald L.↗

NASA NTRS2019

Control Technology Needs for Electrified Aircraft Propulsion Systems

Engine Controls↗

DOE OSTI2021

wtDigiTwin (Wind Turbine Digital Twin) [SWR-21-15]

This wind turbine digital twin software (wtDigiTwin) provides a digital twin solution for wind turbine applications. The focus of wtDigiTwin is to estimate loads, motions and environmental conditions for an operating wind turbine. The program uses supervisory control and data acquisition (SCADA) measurements as inputs, together with a wind turbine model. The wind industry is currently challenged by the high cost of operation and maintenance. These costs could be mitigated if component failures are predicted, but such predictions are difficult unless the turbines are equipped with expensive measuring devices. The alternative is to use a digital twin such as wtDigiTwin to estimate the necessary signals. wtDigiTwin can perform online prediction of signals that are otherwise not measured, using a limited set of reliable measurements and a physics-based model. The predicted signals can be used in applications that have direct cost benefits: 1) real-time estimation of the fatigue consumption of key components of the wind turbine; 2) root cause analyses and failure detections ; 3) lifetime reassessments ; 4) improvements to follow-on designs. The current version provides examples to estimate wind speed, thrust, torque, tower-top position, and tower loads on an onshore wind turbine using the following measurements tower top acceleration, generator torque, pitch, and rotational speed. The model combines a linear state-space model, a wind speed estimator, and a Kalman filter algorithm that integrates measurements with the state model to perform state estimations. The state space model is obtained either using OpenFAST linearizations, or using the yams package provided with the software.

Branlard, Emmanuel↗

NASA NTRS1953

Analysis of turbine stator adjustment required for compressor design-point operation in high Mach number supersonic turbojet engines

For turbojet engines designed for flight Mach numbers of 2.5 and 3.0, use of turbine stator adjustment to maintain compressor design-point operation was evaluated analytically to determine the effect on the aerodynamics of the turbine. Since the effect of turbine stator adjustment is to make the turbine design sensitive to the particular engine design conditions selected, in some cases the turbine must be conservatively designed for the high-speed flight condition to assure satisfactory turbine performance at take-off. A new concept, the break-even point, is introduced to provide quick evaluation of the proximity of turbines to the blade-loading limit at any off-design operation.

ENGINES, CONTROL - TURBOJET↗