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Engineering drawings and the detailed mechanical and electrical design of a horizontal-axis wind turbine designed for DOE at the NASA Lewis Research Center and installed in Clayton, New Mexico are discussed. The drawings show the hub, pitch change mechanism, drive train, nacelle equipment, yaw drive system, tower, foundation, electrical power systems, and the control and safety systems.
A major phase of the Federal Wind Energy Program, the Mod-2 wind turbine, a second-generation machine developed by the Boeing Engineering and Construction Co. for the U.S. Department of Energy and the Lewis Research Center of the National Aeronautics and Space Administration, is described. The Mod-2 is a large (2.5-MW power rating) horizontal-axis wind turbine designed for the generation of electrical power on utility networks. Three machines were built and are located in a cluster at Goodnoe Hills, Washington. All technical aspects of the project are described: design approach, significant innovation features, the mechanical system, the electrical power system, the control system, and the safety system.
The technological development of large, horizontal-axis wind turbines (100 kW-2500 kW) is surveyed with attention to prototype projects managed by NASA. Technical feasibility has been demonstrated in utility service for systems with a rated power of up to 200 kW and a rotor diameter of 125 ft (Mod-OA). Current designs of large wind turbines such as the 2500 kW Mod-2 are projected to be cost competitive for utility applications when produced in quantity, with capital costs of 600 to 700 dollars per kW (in 1977 dollars).
The design and fabrication of composite blades for the WTS-4, a four-megawatt horizontal-axis wind turbine, is discussed. The blade consists of a two-cell, monolithic structure of filament-wound, fiberglass/epoxy composite. Filament winding is a low-cost process which can produce a blade with an aerodynamically efficient airfoil and planform with nonlinear twist to achieve high performance in terms of energy capture. Its retention provides a redundant attachment for long, durable life and safety. Advanced tooling concepts and as sophisticated computer control is used to achieve the unique filament-wound shape.
Experimental data, together with supporting analysis, are presented on the power conversion performance and blade loading of large, horizontal-axis wind turbines tested at electric utility sites in the U.S. Four turbine rotor configurations, from 28 to 61 meters in diameter, and data from five test sites are included. Performance data are presented in the form of graphs of power and system efficiency versus free-stream wind speed. Deviations from theoretical performance are analyzed statistically. Power conversion efficiency averaged 0.34 for all tests combined, compared with 0.31 predicted. Round blade tips appeared to improve performance significantly. Cyclic blade loads were normalized to develop load factors which can be used in the design of rotors with rigid hubs.
The WTS-4 is a four-megawatt, horizontal-axis wind turbine presently being fabricated for the U.S. Department of Interior, Bureau of Reclamation, by United Technologies' Hamilton Standard division. This unit, called the System Verification Unit (SVU) will be installed at Medicine Bow, Wyoming, early next spring. The specifications, characteristics and features of the WTS-4 are discussed. The major components-such as rotor, nacelle and tower-are described and their status in the fabrication phase is presented.
Horizontal-axis wind turbines utilize partial or full variable blade pitch to regulate rotor speed. The weight and costs of these systems indicated a need for alternate methods of rotor control. Aileron control is an alternative which has potential to meet this need. The NASA Lewis Research Center has been experimentally testing aileron control rotors on the Mod-U wind turbine to determine their power regulation and shutdown characteristics. Experimental and analytical shutdown test results are presented for a 38 percent chord aileron-control rotor. These results indicated that the 38 percent chord ailerons provided overspeed protection over the entire Mod-O operational windspeed range, and had a no-load equilibrium tip speed ratio of 1.9. Thus, the 38 percent chord ailerons had much improved aerodynamic braking capability when compared with the first aileron-control rotor having 20 percent chord ailerons.
The concept of a one-bladed horizontal-axis wind turbine has been of interest to wind turbine designers for many years. Many designs and economic analyses of one-bladed wind turbines have been undertaken by both United States and European wind energy groups. The analyses indicate significant economic advantages but at the same time, significant dynamic response concerns. In an effort to develop a broad data base on wind turbine design and operations, the NASA Wind Energy Project Office has tested a one-bladed rotor at the NASA/DOE Mod-O Wind Turbine Facility. This is the only known test on an intermediate-sized one-bladed rotor in the United States. The 15.2-meter-radius rotor consists of a tip-controlled blade and a counterweight assembly. A rigorous test series was conducted in the Fall of 1985 to collect data on rotor performance, drive train/generator dynamics, structural dynamics, and structural loads. This report includes background information on one-bladed rotor concepts, and Mod-O one-bladed rotor test configuration, supporting design analysis, the Mod-O one-blade rotor test plan, and preliminary test results.
Tests were conducted on the DOE/NASA Mod-O 200-kW horizontal-axis wind turbine in a one-bladed rotor configuration. The objectives of the test were to evaluate the performance, loads, and dynamic characteristics of a one-bladed rotor, and then to compare these parameters with those of an aerodynamically similar two-bladed rotor configuration. Test operations showed that this intermediate-size (15.2-m radius) one-bladed rotor configuration can be operated successfully. Test results show that the one-bladed rotor had cyclic blade loads comparable to those of a two-bladed rotor. A moderate power penalty equivalent to a reduction in windspeed of 1 m/sec occurred with the one-bladed rotor when operated at a rotor speed 50 percent higher than that of the two-bladed rotor.
The purpose of this presentation is to show how structural technology was applied in the design of modern wind turbines, which were recently brought to an advanced stage of development as sources of renewable power. Wind turbine structures present many difficult problems because they are relatively slender and flexible; subject to vibration and aeroelastic instabilities; acted upon by loads which are often nondeterministic; operated continuously with little maintenance in all weather; and dominated by life-cycle cost considerations. Progress in horizontal-axis wind turbines (HAWT) development was paced by progress in the understanding of structural loads, modeling of structural dynamic response, and designing of innovative structural response. During the past 15 years a series of large HAWTs was developed. This has culminated in the recent completion of the world's largest operating wind turbine, the 3.2 MW Mod-5B power plane installed on the island of Oahu, Hawaii. Some of the applications of structures technology to wind turbine will be illustrated by referring to the Mod-5B design. First, a video overview will be presented to provide familiarization with the Mod-5B project and the important components of the wind turbine system. Next, the structural requirements for large-scale wind turbines will be discussed, emphasizing the difficult fatigue-life requirements. Finally, the procedures used to design the structure will be presented, including the use of the fracture mechanics approach for determining allowable fatigue stresses.
Computer program WINDY predicts broadband noise spectra of horizontal-axis wind-turbine generators. Enables adequate assessment of impact of broadband wind-turbine noise. Effects of turbulence, trailing-edge wakes, and bluntness taken into account. Program has practical application in design and siting of wind-turbine machines acceptable to community. Written in GW-Basic.
This publication contains a compilation of static and fatigue strength data for laminated-wood material made from Douglas fir and epoxy. Results of tests conducted by several organizations are correlated to provide insight into the effects of variables such as moisture, size, lamina-to-lamina joint design, wood veneer grade, and the ratio of cyclic stress to steady stress during fatigue testing. These test data were originally obtained during development of wood rotor blades for large-scale wind turbines of the horizontal-axis (propeller) configuration. Most of the strength property data in this compilation are not found in the published literature. Test sections ranged from round cylinders 2.25 in. in diameter to rectangular slabs 6 by 24 in. in cross section and approximately 30 ft. long. All specimens were made from Douglas fir veneers 0.10 in. thick, bonded together with the WEST epoxy system developed for fabrication and repair of wood boats. Loading was usually parallel to the grain. Size effects (reduction in strength with increase in test volume) are observed in some of the test data, and a simple mathematical model is presented that includes the probability of failure. General characteristics of the wood/epoxy laminate are discussed, including features that make it useful for a wide variety of applications.
During the late 1970's and early 1980's, concerns about the potential interference of wind turbine generators with electromagnetic communication signals led to a series of research studies, both in the laboratory and in the field, conducted by the staff of the University of Michigan Radiation Laboratory. These studies were sponsored by organizations such as the U.S. Department of Energy, the Solar Energy Research Institute, and private developers of wind power stations. Research objectives were to identify the mechanisms by which wind turbines might adversely affect communication signals, estimate the severity of these effects for different types of signals (e.g. television, radio, microwave, and navigation), and formulate mathematical models with which to predict the sizes of potential interference zones around wind turbines and wind power plants. This work formed the basis for preliminary standards on assessing electromagnetic interference (EMI) by wind turbines. With the current renewal of interest in wind energy projects, it is appropriate that the many experimental and analytical aspects of this pioneering work be reviewed and correlated. The purpose of this study is to combine test data and theory from previously published and unpublished research reports into a unified and consistent set of equations which are useful for estimating potential levels of television interference from wind turbines. To be comprehensive, these equations will include both horizontal-axis and vertical-axis wind turbines (HAWT's and VAWT's), blade configuration parameters (e.g. number, size, material, twist, and coning), signal frequency and power, and directional characteristics of the receiving antenna. The approach that is followed in this report is as follows. First, some basic equations that describe electromagnetic signals with interference are presented without detailed derivations, since the latter are available in the references. Minor changes in terminology are made for purposes of consistency. Next, the concept of a signal scatter ratio is introduced, which defines the fraction of the signal impinging on a wind turbine that is scattered by its blades onto a nearby receiver. Equations from references are modified for the calculation of experimental scatter ratios (from measured signals containing interference) and idealized scatter ratios (from rotor characteristics and relative locations of the transmitter, the turbine, and the receiver). Experimental and idealized scatter ratios are then calculated and compared for 75 cases from the literature, in which TVI measurements were made around a variety of wind turbines. An empirical equation is then defined for estimating the probability that an actual scatter ratio will differ from an idealized ratio by a given amount. Finally a sample calculation of the size of a potential TV interference zone around a hypothetical wind power station is presented.
A major program of research and development projects on wind turbines for generating electricity was conducted at the NASA Lewis Research Center from 1973 to 1988. Most of these projects were sponsored by the U.S. Department of Energy (DOE), as a major element of its Federal Wind Energy Program. One other large-scale wind turbine project was sponsored by the Bureau of Reclamation of the Department of Interior (DOI). The peak years for wind energy work at Lewis were 1979-80, when almost 100 engineers, technicians, and administrative personnel were involved. From 1988 their conclusion in 1995, NASA wind energy activities have been directed toward the transfer of technology to commercial and academic organizations. Wind energy activities at NASA can be divided into two broad categories which are closely related and often overlapping: (1) Designing, building, and testing a series of 12 large-scale, experimental, horizontal-axis wind turbines (HAWT's); and (2) conducting supporting research and technology (SR&T) projects. The purpose of this bibliography is to assist those active in the field of wind energy in locating the technical information they need on wind power planning, wind loads, turbine design and analysis, fabrication and installation, laboratory and field testing, and operations and maintenance. This bibliography contains approximately 620 citations of publications by over 520 authors and co-authors. Sources are: (1) NASA reports authored by government grantee, and contractor personnel, (2) papers presented by attendees at NASA-sponsored workshops and conferences, (3) papers presented by NASA personnel at outside workshops and conferences, and (4) outside publications related to research performed at NASA/ DOE wind turbine sites.
Empirical equations are presented with which to model rotationally-sampled (R-S) turbulence for input to structural-dynamic computer codes and the calculation of wind turbine fatigue loads. These equations are derived from R-S turbulence data which were measured at the vertical-plane array in Clayton, New Mexico. For validation, the equations are applied to the calculation of cyclic flapwise blade loads for the NASA/DOE Mod-2 2.5-MW experimental HAWT's (horizontal-axis wind turbines), and the results compared to measured cyclic loads. Good correlation is achieved, indicating that the R-S turbulence model developed in this study contains the characteristics of the wind which produce many of the fatigue loads sustained by wind turbines. Empirical factors are included which permit the prediction of load levels at specified percentiles of occurrence, which is required for the generation of fatigue load spectra and the prediction of the fatigue lifetime of structures.
Analytical investigation of dynamic stall on HAWT (horizontal-axis wind turbines) rotor loads was conducted. Dynamic stall was modeled using the Gormont approach on the MOD-2 rotor, treating the blade as a rigid body teetering about a fixed axis. Blade flapwise bending moments at station 370 were determined with and without dynamic stall for spatial variations in local wind speed due to wind shear and yaw. The predicted mean flapwise bending moments were found to be in good agreement with test results. Results obtained with and without dynamic stall showed no significant difference for the mean flapwise bending moment. The cyclic bending moments calculated with and without dynamic stall effects were substantially the same. None of the calculated cyclic loads reached the level of the cyclic loads measured on the MOD-2 using the Boeing five-minute-average technique.
Design comparisons have been performed for a number of different tidal energy systems, including a fully submerged, horizontal-axis electro-turbine system, similar to Verdant Tidal Turbines in New York's East River, a platform-based Marine Current Turbine, now operating in Northern Ireland's Strangford Narrows, and the Rotech Lunar Energy system, to be installed off the South Korean Coast. A fourth type of tidal energy system studied is a novel JPL/Caltech hydraulic energy transfer system that uses submerged turbine blades which are mechanically attached to adjacent high-pressure pumps, instead of to adjacent electrical turbines. The generated highpressure water streams are combined and transferred to an onshore hydroelectric plant by means of a closed-cycle pipeline. The hydraulic energy transfer system was found to be cost competitive, and it allows all electronics to be placed onshore, thus greatly reducing maintenance costs and corrosion problems. It also eliminates the expenses of conditioning and transferring multiple offshore power lines and of building offshore platforms embedded in the sea floor.
Distributed wind energy systems supply electricity for nearby homes and businesses, often in remote and rural regions. Systems capable of capturing energy in areas with low wind speeds make it possible to deploy these clean energy systems in many geographic locations. Pecos Wind Power's 85-kilowatt (kW) horizontal-axis PW85 wind turbine shows potential to reduce the levelized cost of energy by approximately 55% when compared to typical small wind systems while achieving utility-scale capacity factors of more than 40% in areas with lower wind speeds. To maximize cost competitiveness, the Pecos Wind Power turbine needs a blade optimized for low wind speeds. Through its 2022 Competitiveness Improvement Project (CIP) award, Pecos Wind Power and partner Wetzel Wind Energy Services will model, optimize, fabricate, and validate a 14.5-meter wind turbine blade made specifically for these applications. Three prior CIP awards supported Pecos Wind Power's initial development of the PW85 turbine.