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DOE OSTI2025

Floating Offshore Wind US Manufacturing and Commercialization: Cooperative Research and Development (Final Report)

NREL assessed the supply chain and workforce considerations for the OCG-Wind floater technology, a floating semi-submersible offshore wind substructure, as well sharing vessel needs to inform their installation strategy. This technical assistance was in support of the FLoating Offshore Wind ReadINess (FLOWIN) Prize Phase 2 submission. NREL provided an assessment of domestic supplier capabilities for the main components of their floating offshore wind platform design and analyzed US regional and national supply chain constraints and gaps. Thirteen interviews with companies including steel distributors, forges, foundries, ports, large component fabricators, subcomponent fabricators, and secondary suppliers provided key insights such as 1) assembly ports are the key infrastructure barrier standing in the way of unlocking the domestic assembly and component fabrication for steel-based FOW platforms, 2) domestic steel producers can supply the types and quantities of steel necessary for FOW platforms, and 3) coordination between stakeholders will be a vital part of successfully developing the supply chain and infrastructure needed to domestically produce FOW platforms. In the workforce assessment, NREL documented a step-by-step approach to conduct a place-based assessment of the foundational workforce consideration for recruiting, upskilling, and retaining a workforce, such as supportive local and state policy, nearby education and training programs, and existing relevant industry. This approach was applied to Tacoma, Washington. Tacoma was indicated to have the potential be a successful location for fabrication and assembly of floating offshore wind energy in terms of workforce development. To share data on vessel requirements to install the OCG-Wind floater, NREL compiled resources that help answer the questions related to anchor handling tug vessels, shared a database of cable laying vessels, and answered questions on complying with the Jones Act.

17 WIND ENERGY↗
DOE OSTI2024

A digital twin solution for floating offshore wind turbines validated using a full-scale prototype

Abstract. In this work, we implement, verify, and validate a physics-based digital twin solution applied to a floating offshore wind turbine. The digital twin is validated using measurement data from the full-scale TetraSpar prototype. We focus on the estimation of the aerodynamic loads, wind speed, and section loads along the tower, with the aim of estimating the fatigue lifetime of the tower. Our digital twin solution integrates (1) a Kalman filter to estimate the structural states based on a linear model of the structure and measurements from the turbine, (2) an aerodynamic estimator, and (3) a physics-based virtual sensing procedure to obtain the loads along the tower. The digital twin relies on a set of measurements that are expected to be available on any existing wind turbine (power, pitch, rotor speed, and tower acceleration) and motion sensors that are likely to be standard measurements for a floating platform (inclinometers and GPS sensors). We explore two different pathways to obtain physics-based models: a suite of dedicated Python tools implemented as part of this work and the OpenFAST linearization feature. In our final version of the digital twin, we use components from both approaches. We perform different numerical experiments to verify the individual models of the digital twin. In this simulation realm, we obtain estimated damage equivalent loads of the tower fore–aft bending moment with an accuracy of approximately 5 % to 10 %. When comparing the digital twin estimations with the measurements from the TetraSpar prototype, the errors increased to 10 %–15 % on average. Overall, the accuracy of the results is promising and demonstrates the possibility of using digital twin solutions to estimate fatigue loads on floating offshore wind turbines. A natural continuation of this work would be to implement the monitoring and diagnostics aspect of the digital twin to inform operation and maintenance decisions. The digital twin solution is provided with examples as part of an open-source repository.

17 WIND ENERGY↗
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 OSTI2026

Computational capacity in hydrodynamic real-time hybrid simulation applied to simulate the dynamic response of floating offshore wind turbines

Real-time hybrid simulation (RTHS) mitigates similitude distortions in model-scale tests of floating offshore wind turbines (FOWTs) by coupling physical experiments with numerical models in real time. The coupling requires faster-than-real-time numerical computations to satisfy temporal similitude with the physical experiment, presenting a bottleneck for using more complex numerical models in RTHS. This paper presents a hydrodynamic-RTHS (hydro-RTHS) framework for FOWTs that simulates the hydrodynamics physically and the aerodynamics numerically with sensor feedback from the physical testing. The framework adapts the three-loop hardware architecture to leverage greater computational resources and mitigate strict temporal requirements, enabling more computationally demanding numerical analyses in hydro-RTHS. The three-loop hardware architecture integrates multiple machines, each dedicated to either numerical analysis or RTHS controls, with a rate-transition algorithm to synchronize the tasks executed across the different machine processors. Virtual and physical tests verified and validated the hydro-RTHS framework, respectively. The ”virtual” tests, which approximates the physical domain numerically, verified the RTHS framework with respect to a numerical full-scale complete FOWT model simulated in the open-source software, OpenFAST. The virtual tests were able to maintain comparable control signals while enabling greater computational resources for the numerical calculations. Real-world physical tests demonstrated that the hydro-RTHS framework computes aerodynamic forces similar to the complete OpenFAST model, validating the hydro-RTHS framework using the three-loop hardware architecture. Findings show that the hydro-RTHS framework with the three-loop hardware architecture is computationally efficient, with reserve capacity to simulate more complex problems due to the customized software, hardware, and rate-transition algorithm.

17 WIND ENERGY↗
DOE OSTI2024

Preliminary Workforce Development and Environmental and Co-use Management Plans for a Floating Offshore Wind Platform - CRADA 609 (Final Report)

Pacific Northwest National Laboratory (PNNL) provided technical assistance to Glosten, Inc. and its affiliate, PelaStar, LLC to advance the development of their floating offshore wind (FOSW) platform. PNNL provided guidance and assessment in two areas that are important to address in the development of FOSW platforms: (1) workforce development and (2) environmental impacts and ocean co-use considerations. This work was funded by the U.S. Department of Energy’s (DOE) Wind Energy Technologies Office (WETO) through Phase 2 of the FLoating Offshore Wind ReadINess (FLOWIN) Prize. It should be noted that the Plans presented in this report are specific to the PelaStar tension-leg platform (TLP) and may not be applicable to all FOSW platforms. Workforce development and environmental/co-use impacts are highly dependent on the geographical region in which activities take place. At the request of PelaStar, PNNL focused on two regions where development may take place: the Gulf of Maine and Northern California. PNNL generated a preliminary Workforce Development Plan for PelaStar, which includes estimated job numbers and skillsets required to establish a workforce to manufacture, install, and operate their platform as part of FOSW projects. The Plan offers methods to increase diversity, equity, and inclusion practices when developing a new workforce and includes colleges and training centers for potential recruitment. Both positive and negative impacts to communities are evaluated, with potential mitigation strategies for reducing negative impacts. The structure of Community Benefit Agreements and Project Labor Agreements are discussed, noting the limitations of the role of a platform manufacturer versus the offshore wind developer. PNNL also drafted a preliminary Environmental and Co-Use Management Plan that serves as a guide to preparing an environmental assessment related to the installation and operation of PelaStar’s unique TLP design, including its potential ecological, socioeconomic, and emissions impacts. The Plan summarizes information on relevant regulatory requirements, potential impact producing factors, monitoring and mitigation measures, and physical and biological resources in the Gulf of Maine and Northern California. One of the primary perceived benefits of the PelaStar TLP is its reduced footprint due to its tensioned tendons versus catenary or taut moorings, but more research must be done as there are no studies on PelaStar’s TLP system to-date. The section also highlights ocean co-use considerations for PelaStar’s TLP system, specifically for fisheries, including existing perspectives, methods, examples, and limitations. The PNNL team established through this preliminary work and review of available literature and resources that there is not yet much research or planning around FOSW. With FOSW being a new industry, many of the findings and planning are adapted from fixed bottom offshore wind, which itself is only just taking off in the United States. More research is needed to establish best practices for workforce development and to assess environmental and ocean co-use impacts and mitigation approaches.

17 WIND ENERGY↗
DOE OSTI2022

Demonstration of NREL Modeling Capability to Design the Next Generation of Floating Offshore Wind Turbines with Stiesdal and Magellan Wind (Cooperative Research and Development Final Report)

This Technology Commercialization Fund (TCF) CRADA involved demonstration of NREL modeling capability using OpenFAST (formerly known as FAST) to design the next generation of floating offshore wind turbines (FOTW) with Stiesdal’s TetraSpar design. The objective of the project was to enable the design and optimization of next generation FOWT that show promise to make FOWT cost-competitive with other energy technologies by upgrading, verifying, and validating improvements to OpenFAST. This objective was achieved by (1) upgrading OpenFAST to compute floating substructure flexibility and member-level loads, which is critical to enable the design of floating substructures—especially newer designs that are streamlined, flexible, and cost-effective; (2) verifying the new OpenFAST capabilities through model-to-model comparisons and validating the capabilities through comparisons to empirical data generated with wave-tank testing, using TetraSpar data provided by Stiesdal; and (3) making available the upgraded OpenFAST tool to the wind energy community to enable next-generation floating wind designs.

17 WIND ENERGY↗
DOE OSTI2020

The Cost of Floating Offshore Wind Energy in California Between 2019 and 2032

California’s energy planning is centered around meeting the emissions reduction and renewable energy requirements of Senate Bill 350 by 2030. However, state power system planning is expected to eventually address California’s requirement to achieve 100% of total retail electricity sales from renewable energy and zero-carbon resources by 2045, as mandated by Senate Bill 100. To comply with these directives, California needs to investigate the further development of energy efficiency, storage, and a diverse range of renewable energy, zero-carbon emission, and transmission resources, including offshore wind. Wind resources off the coast of California have the potential to generate a significant portion of the state’s electric energy as it moves toward a zero-carbon economy and can help diversify its energy mix. Floating offshore wind technology, which is suitable for the deep waters along the California coast, is currently in a precommercial phase, with approximately 84 megawatts (MW) installed worldwide at the end of 2019. Globally there are over 7,000 MW in planning and permitting phases of development, with the first commercial-scale projects expected to be operational in 2024. This study provides site-specific cost and performance data for floating offshore wind to inform California’s long-term energy planning. The identification of new resources to meet California’s policy goals at least cost is part of the Integrated Resource Planning (IRP) process, which is coordinated by the California Public Utilities Commission (CPUC). In 2019–2020 IRP modeling, offshore wind was included for the first time as a candidate resource in some sensitivity cases (CPUC 2019). The data and information presented in this report can be used to update offshore wind inputs in future IRP cycles. The authors conducted a geospatial cost analysis over portions of the offshore wind resource area of California. The analyzed spatial domain includes sites with a mean wind speed of at least 7 meters per second and water depths between 40 meters (m) and 1,300 m. Costs and energy production vary across this analysis domain. We calculated these parameters on a grid layout with over 750 sites, with each site representing a 1,000-MW commercial offshore wind power plant. Levelized cost of energy (LCOE) was calculated at each site over the analysis domain. The resulting variation in LCOE across the analysis domain is illustrated through heat maps in this report. Five study areas were selected within the analysis domain where more detailed cost analysis was conducted and cost parameters, such as annual energy production, capital cost expenditures (CapEx), operational cost expenditures (OpEx), and net capacity factors are reported. These five study areas include Morro Bay, Diablo Canyon, Humboldt, Cape Mendocino and Del Norte.

17 WIND ENERGY↗
DOE OSTI2023

Open-Loop Control Co-Design of Semisubmersible Floating Offshore Wind Turbines Using Linear Parameter-Varying Models

Here, this paper discusses a framework to design elements of the plant and control systems for floating offshore wind turbines in an integrated manner using linear parameter-varying models. Multiple linearized models derived from aero-elastic simulation software in different operating regions characterized by the incoming wind speed are combined to construct an approximate low-fidelity model of the system. The combined model is then used to generate open-loop, optimal control trajectories as part of a nested control co-design strategy that explores the system’s power production and stability using the platform pitch tilt as a proxy in the context of crucial plant and control design decisions. The radial distance between the central and outer columns and the diameter of the outer columns of the semisubmersible platform are the plant design variables. The platform stability and power production are studied for different plant design decisions. The effect of plant decisions on subsequent power production and stability response of the floating wind turbine is quantified in terms of the levelized cost of energy. The results show that the inner-loop constraints and the plant design decisions affect the turbine’s power and, subsequently, the cost of the system.

17 WIND ENERGY↗
DOE OSTI2026

An adaptive model-free robotic force control strategy for hydrodynamic real-time hybrid simulation of floating offshore wind turbines

Real-time hybrid simulation (RTHS) - a cyber-physical testing approach - promises to enhance the simulation fidelity of the model-scale experiments used to prototype floating offshore wind turbines (FOWTs). In hydrodynamic RTHS (hydro-RTHS), actuators emulate aerodynamic forces on model-scale FOWT specimens subjected to physical waves in a hydrodynamic laboratory. Robotic arms are promising candidates for actuation in hydro-RTHS due to their compact multi-degree-of-freedom (DOF) capabilities. Unlike classical RTHS for seismic applications, which typically relies on displacement control, hydro-RTHS requires 6-DOF force control on newly designed floating prototypes in a model-scale setting, which presents significant challenges, including modeling uncertainties, directional asymmetry, configuration drift, bandwidth limitations, and time-varying delays. To mitigate these constraints without extensive pre-test calibration, this study proposes an adaptive model-free robotic force control strategy that combines task-space explicit force control with a secondary joint-space pose-keeping task. The Adaptive Feedforward Compensator (AFC) is integrated into the force control loop to compensate for time-varying delay. Experimental testing was conducted using a Franka Emika Panda robotic arm with a 1:50 scale FOWT specimen under operational wind and wave conditions. Results demonstrate stable and consistent 6-DOF force tracking. Effective delay compensation was observed, with low-frequency delay reductions ranging from 71.4% to 91.8% and improvements in low-frequency surge force tracking of 25.0% to 52.1%. This study enhances robotic actuation performance in hydro-RTHS and introduces a force control strategy that supports reliable robotic operation in uncertain floating environments. Future work will explore disturbance-observer mechanisms to further enhance wave rejection capabilities under extreme wind and wave conditions.

17 WIND ENERGY↗
DOE OSTI2022

American-Made Challenges: FLoating Offshore Wind ReadINess (FLOWIN) Prize

The goal of this prize is to establish a pathway to cost-effective domestic manufacture and deployment of gigawatt-scale floating wind farms in U.S. waters. Toward realization of that goal, the prize will: (1) incentivize and support further development of technically and economically viable floating wind platform structures that can support 12-MW-rated or larger wind turbines in water depths over 40 meters. (2) incentivize the creation of a supply chain that will enable domestic on-site manufacturing of floating offshore wind farm components utilizing a skilled and trained workforce. (3) promote awareness of the importance and principles of inclusion and environmental justice.

American-Made Challenges↗
DOE OSTI2023

Rigid-flexible coupling multi-body dynamics modeling of a semi-submersible floating offshore wind turbine

A 14-degree-of-freedom (14-DOF) flexible multibody dynamics model is developed and verified for a semi-submersible floating offshore wind turbine (FOWT). The model considers the coupled dynamics of the platform, tower, nacelle, blades, and mooring subjected to external wind and wave loads. The platform is simplified as a rigid body connected to the seabed by the mooring system. The tower and blade are modeled as flexible cantilever beams. The energy method is used to derive the governing equations of motion, where the kinetic energy, potential energy, and work done by external wind-wave forces are all deduced in a global coordinate system. The 5-MW baseline semi-submersible FOWT is used to verify the derived model against the results simulated from FAST developed by the US National Renewable Energy Laboratory (NREL) at two scenarios: free decay state and different wind-wave load cases. Results show that the established FOWT model can well reflect the vibration characteristics of FAST model. The application of the model to the control of platform pitch with a tuned mass damper is studied. Furthermore, the simplified model could provide a low-order method for the structural dynamics analysis and advanced vibration control design for the multi-body components of the semi-submersible FOWT in the future.

17 WIND ENERGY↗
DOE OSTI2024

OC6 project Phase IV: validation of numerical models for novel floating offshore wind support structures

Abstract. This paper provides a summary of the work done within Phase IV of the Offshore Code Comparison Collaboration, Continued with Correlation and unCertainty (OC6) project, under International Energy Agency Wind Technology Collaboration Programme Task 30. This phase focused on validating the loading on and motion of a novel floating offshore wind system. Numerical models of a 3.6 MW horizontal-axis wind turbine atop the TetraSpar floating support structure were compared using measurement data from a 1:43-Froude-scale test performed in the University of Maine's Alfond Wind–Wave (W2) Ocean Engineering Laboratory. Participants in the project ran a series of simulations, including system equilibrium, surge offsets, free-decay tests, wind-only conditions, wave-only conditions, and a combination of wind and wave conditions. Validation of the models was performed by comparing the aerodynamic loading, floating support structure motion, tower base loading, mooring line tensions, and keel line tensions. The results show a relatively good estimation of the aerodynamic loading and a reasonable estimation of the platform motion and tower base fore–aft bending moment. However, there is a significant dispersion in the dynamic loading for the upwind mooring line. Very good agreement was observed between most of the numerical models and the experiment for the keel line tensions.

17 WIND ENERGY↗
DOE OSTI2023

Experimental investigation of advanced turbine control strategies and load-mitigation measures with a model-scale floating offshore wind turbine system

To advance the control co-design of offshore wind energy systems, the authors perform basin-scale experiments with a fully instrumented and actuated floating offshore wind turbine model. The model consists of a 1:70 scale performance-matched model of the International Energy Agency Wind Technology Collaboration Programme 15-MW reference turbine atop the VolturnUS-S semisubmersible platform. The Reference OpenSource Controller provides real-time blade pitch and generator torque control. Here we aim to develop an open data set for the validation of numerical models in predicting the influence of turbine control and load-mitigation measures. For this purpose, we measure the effects of advanced turbine control features, including peak shaving and floating feedback as well as hull-based control using tuned mass dampers on the system. Overall, the results demonstrate measurable and consistent influences from the control and load-mitigation measures, thus confirming the usefulness as a validation data set. Peak shaving attenuates the response to wind turbulence at near-rated wind speed. Floating feedback reduces the load and platform pitch motion associated with the negative damping induced by blade pitch control. The tuned mass dampers also attenuate the system response near the targeted frequencies under suitable conditions. We also identify detrimental side effects of each load-mitigation measure.

17 WIND ENERGY↗
DOE OSTI2024

Review of Feasibility and Cost Drivers for Floating Offshore Wind Energy in Washington State

The state of Washington must double its clean electricity supply by 2050 to meet its clean energy goals and comply with the Clean Energy Transformation Act. With more than 6.6 GW of technical resource potential in federal waters where Bureau of Ocean Energy Management has leasing authority, offshore wind energy could play an important role in diversifying Washington State's clean energy mix, reducing dependence on out-of-state energy sources, and helping meet state decarbonization goals. Decision makers need technology-specific information to assist with long-term energy system planning, so the Bureau of Ocean Energy Management requested that the National Renewable Energy Laboratory provide an overview of several drivers of offshore wind energy feasibility and cost in Washington. This study summarizes some of the existing engagement efforts and perspectives on offshore wind energy in the region and quantifies the offshore wind resources in Washington as well as technology costs and performance of potential projects. Furthermore, this report reviews existing grid and port infrastructure and discusses infrastructure needs along with information gaps. This study also explores opportunities and barriers to Washington entities supporting the broader floating offshore wind energy supply chain along the U.S. West Coast. Note that this study is not part of a formal project planning process or official engagement effort, nor does it assess environmental or economic impacts from potential offshore wind energy development.

17 WIND ENERGY↗
DOE OSTI2021

Functional Requirements for the WEIS Toolset to Enable Controls Co-Design of Floating Offshore Wind Turbines

The goal of the new Wind Energy with Integrated Servo-control (WEIS) toolset under development is to provide the offshore wind industry and research communities with an open-source, user-friendly, flexible tool to enable true controls co-design (CCD) of the physical design of a floating offshore wind turbine together with the controller. WEIS will use a multifidelity library of models built on the foundations of WISDEM® and OpenFAST formerly known as FAST). This paper presents the WEIS development plan, including the functional requirements of WEIS (including improvements to WISDEM and OpenFAST) together with associated rationale for their establishment and a qualitative description of the modeling approaches that will be implemented to address these functional requirements. The development of WEIS is a project under the Aerodynamic Turbines Lighter and Afloat with Nautical Technologies and Integrated Servo-control program funded by the U.S. Department of Energy Advanced Research Projects Agency – Energy.

27 ARPA - Advanced Research Projects Agency-Energy↗
DOE OSTI2020

Functional Requirements for the WEIS Toolset to Enable Controls Co-Design of Floating Offshore Wind Turbines: Preprint

The goal of the new Wind Energy with Integrated Servo-control (WEIS) toolset under development is to provide the offshore wind industry and research communities with an open-source, user-friendly, and flexible tool to enable true Controls Co-Design (CCD) of the physical design of a floating offshore wind turbine (FOWT) together with the controller. WEIS will utilize a multifidelity library of models built upon the foundations of WISDEM and OpenFAST (formerly known as FAST). This paper presents the WEIS development plan, including the functional requirements of WEIS (including improvements to WISDEM and OpenFAST) together with associated rationale for their establishment, and a qualitative description of the modeling approaches that will be implemented to address these functional requirements. The development of WEIS is a project under the Aerodynamic Turbines, Lighter and Afloat, with Nautical Technologies and Integrated Servo-control (ATLANTIS) program funded by the U.S. Department of Energy (DOE) Advanced Research Projects Agency - Energy (ARPA-E).

27 ARPA - Advanced Research Projects Agency-Energy↗