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DOE OSTI2023

Control Co-Design of Wind Turbines

Wind energy is recognized worldwide as cost-effective and environmentally friendly, and it is among the fastest-growing sources of electrical energy. To further decrease the cost of wind energy, wind turbines are being designed at ever-larger scales. To expand the deployment of wind energy, wind turbines are also being designed on floating platforms for placement in deep-water locations offshore. Both larger-scale and floating wind turbines pose challenges because of their greater structural loads and deflections. Complex, large-scale systems such as modern wind turbines increasingly require a control co-design approach, whereby the system design and control design are performed in a more integrated fashion. This article reviews recent developments in control co-design of wind turbines. We provide an overview of wind turbine design objectives and constraints, issues in the design of key wind turbine components, modeling of the wind turbine and environment, and controller coupling issues. Wind turbine control functions and the integration of control design in co-design are detailed with a focus on co-design compatible control approaches.

17 WIND ENERGY↗
DOE OSTI2023

On the Low Risk of SSR in Type III Wind Turbines Operating in Grid-Forming Control: Preprint

We have shown in a previous work that the risk of sub-synchronous resonance (SSR) between a wind power plant with Type III wind turbines and series-compensated transmission lines is low when the wind turbines in the plant are operated in grid-forming mode, instead of the standard grid-following mode. The fundamental mechanism behind the improved damping characteristics is explained in this paper by modeling the positive and negative sequence impedances of Type III wind turbines for GFM operation mode. It is discovered that the GFM control naturally acts against the negative resistance of Type III wind turbines that results from an interaction between the proportional gain of the rotor-side converter current controller and negative slip. The developed sequence impedance models and improved damping behavior are verified using PSCAD simulations of a 2.5-MW Type III GFM wind turbine. The modeling predictions are also supported by experimentally measuring the sequence impedance response of a 2.5-MW Type III wind turbine during operation in GFL and GFM modes.

grid-following turbine↗
DOE OSTI2022

A reference open-source controller for fixed and floating offshore wind turbines

Abstract. This paper describes the development of a new reference controller framework for fixed and floating offshore wind turbines that greatly facilitates controller tuning and represents standard industry practices. The reference wind turbine controllers that are most commonly cited in the literature have been developed to work with specific reference wind turbines. Although these controllers have provided standard control functionalities, they are often not easy to modify for use on other turbines, so it has been challenging for researchers to run representative, fully dynamic simulations of other wind turbine designs. The Reference Open-Source Controller (ROSCO) has been developed to provide a modular reference wind turbine controller that represents industry standards and performs comparably to or better than existing reference controllers. The formulation of the ROSCO controller logic and tuning processes is presented in this paper. Control capabilities such as tip speed ratio tracking generator torque control, minimum pitch saturation, wind speed estimation, and a smoothing algorithm at near-rated operation are included to provide modern controller features. A floating offshore wind turbine feedback module is also included to facilitate growing research in the floating offshore arena. All of the standard controller implementations and control modules are automatically tuned such that a non-controls engineer or automated optimization routine can easily improve the controller performance. This article provides the framework and theoretical basis for the ROSCO controller modules and generic tuning processes. Simulations of the National Renewable Energy Laboratory (NREL) 5 MW reference wind turbine and International Energy Agency 15 MW reference turbine on the University of Maine semisubmersible platform are analyzed to demonstrate the controller's performance in both fixed and floating configurations, respectively. The simulation results demonstrate ROSCO's peak shaving routine to reduce maximum rotor thrusts by over 10 % compared to the NREL 5 MW reference wind turbine controller on the land-based turbine and to reduce maximum platform pitch angles by nearly 30 % when using the platform feedback routine instead of a more traditional low-bandwidth controller.

17 WIND ENERGY↗
DOE OSTI2023

Robust multi‐loop control of a floating wind turbine

Abstract A principal challenge facing the control of floating offshore wind turbines (FOWTs) is the problem of instability, or “negative damping,” when using blade pitch feedback to control generator speed. This closed‐loop instability can be attributed to non‐minimum phase zeros in the transfer function from blade pitch to generator speed. Standard approaches to improving stability and performance include robust tuning of control gains and introducing multiple feedback loops to respond to platform motion. Combining these approaches is nontrivial because multiple control loops complicate the impact of coupling in the system dynamics. The single‐loop approach to analyzing stability robustness neglects inter‐loop coupling, while a simplistic multi‐loop approach is highly sensitive to dimensional scaling and overestimates the robustness of the single‐loop controller. This work proposes a sensitivity representation that separates some of the natural FOWT dynamic coupling into a parallel feedback loop in the sensitivity function loop to address both of these concerns. The modified robustness measure is used with a simplified linear FOWT model to optimize scheduled multi‐loop control parameters in an automated tuning procedure. This controller is implemented for the 10‐MW Ultraflexible Smart FLoating Offshore Wind Turbine (USFLOWT) and compared against conventional single‐ and multi‐loop controllers tuned using frequency‐domain analysis and high‐fidelity OpenFAST simulations. The multi‐loop robust controller shows the highest overall performance in generator speed regulation and tower load reduction, though consideration of power quality, actuator usage, and other structural loading leads to additional trade‐offs.

Stockhouse, David↗
DOE OSTI2022

Cyber-Physical Resiliency for Wind Power Generation

During the next three years, wind power generation is expected to add more generation capacity to the national electrical grid than any other energy sector. With new wind turbine designs rated power over 10 MW and wind farms reaching over 1 GW capacities, the consequences of cyber-attacks on wind power generation are becoming increasingly more critical. Moreover, the known vulnerabilities of wind turbine control systems and the potential damaging effects of intrusions, motivate an urgent protection improvement for the wind power generation sector. This program has developed a variety of new adaptive defense technologies that enable wind power generation systems to survive sophisticated cyberattacks by enhancing the control systems capabilities of detection, localization, and accommodation. The introduction of these technologies in the on-shore and the emerging off-shore market will result in a significantly more reliable and secure wind power infrastructure.

17 WIND ENERGY↗
DOE OSTI2023

Aero‐servo‐elastic co‐optimization of large wind turbine blades with distributed aerodynamic control devices

Abstract This work introduces automated wind turbine optimization techniques based on full aero‐servo‐elastic models and investigates the potential of trailing edge flaps to reduce the levelized cost of energy (LCOE) of wind turbines. The Wind Energy with Integrated Servo‐control (WEIS) framework is improved to conduct the presented research. Novel methods for the generic implementation and tuning of trailing edge flap devices and their controller are also introduced. Primary flap and controller parameters are optimized to demonstrate potential maximum blade tip deflection reductions of 21 % . Concurrent design optimization (i.e., co‐design) of a novel segmented wind turbine blade with trailing edge flaps and its controller is then conducted to demonstrate blade cost savings of 5 % . Additionally, rotor diameter co‐design optimization is demonstrated to reduce the LCOE by 1.3 % without significant load increases to the tower. These results demonstrate the efficacy of control co‐design optimization using trailing edge flaps, and the entirety of this work provides a foundation for numerous control co‐design‐oriented studies for distributed aerodynamic control devices.

17 WIND ENERGY↗
DOE OSTI2024

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

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

Lyu, Xue↗
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 OSTI2020

Developing More Efficient Wind Turbines: A Survey of Control Challenges and Opportunities

Wind energy has received considerable attention during the past two decades, owing to its vital role in battling both the energy crisis and global climate change. Wind energy has grown to become the most significant nonconventional renewable energy source. Today, modern wind turbines (WTs) are controlled to offer several functionalities that improve their flexibility at a level similar to conventional power sources. However, until now, there have been few reports in the literature summarizing and listing WT control concepts to encourage industry and academia to pursue improvements in developing more efficient WTs and bridge the gap between businesses and universities. Hence, this article focuses on a thoughtful investigation into developing better and more efficient WTs, detailing different issues involved in wind energy generation, such as WT components, control systems, operational modes, and, especially, new research and development trends.

17 WIND ENERGY↗
DOE OSTI2024

Characterization of Oscillatory Response of Light-Weight Wind Turbine Rotors under Controlled Gust Pulses

Given the industry-wide trend of continual increases in the size of utility-scale wind turbines, a point will come where reductions will need to be made in terms of the weight of the turbine’s blades to ensure they can be as long as needed without sacrificing structural stability. One such technique that may be considered is to decrease the material used for the shell and spar cap. While this will solve the weight issue, it creates a new one entirely—less material for the shell and spar cap will in turn create blades that are more flexible than what is currently used. This article aims to investigate how the oscillatory response of light-weight wind turbine rotors is affected by these flexibility changes. The object of our study is the Sandia National Lab National Rotor Testbed (SNL-NRT) wind turbine, which the authors investigated in the course of a research project supported by SNL. Using a reduced-order characterization (ROC) technique based on controlled gust pulses, introduced by the authors in a previous work, the aeroelastic dynamics of the NRT’s original baseline blade design and several of its flexible variations were studied via numerical simulations employing the CODEF multiphysics suite. Results for this characterization are presented and analyzed, including a generalization of the ROC of the SNL-NRT oscillatory dynamics to larger machines with geometrical similarity. The latter will prove to be valuable in terms of extrapolating results from the present investigation and other ongoing studies to the scale of current and future commercial machines.

Ponta, Fernando (ORCID:0000000321032864)↗
DOE OSTI2023

Wind/Wave Testing of a 1:70-Scale Performance-Matched Model of the IEA Wind 15 MW Reference Wind Turbine with Real-Time ROSCO Control and Floating Feedback

Experimental results from the Floating Offshore-wind and Controls Advanced Laboratory (FOCAL) experimental program, which tested a performance-matched model of the IEA Wind 15 MW Reference Turbine on a 1:70 scale floating semisubmersible platform, are compared with OpenFAST simulations. Four experimental campaigns were performed, and data from the fourth campaign, which focused on wind and wave testing of the scaled floating wind turbine system, are considered. Simulations of wave-only, wind-only, and wind/wave environments are performed in OpenFAST, and results for key metrics are compared with the experiment. Performance of the real-time Reference OpenSource COntroller (ROSCO) in above-rated wind conditions, including the effects of the floating feedback loop, are investigated. Results show good agreement in mean values for key metrics, and hydrodynamic effects are matched well. Differences in the surge resonant behavior of the platform are identified and discussed. The effect of the controller and floating feedback loop is evident in both the experiment and OpenFAST, showing significant reduction in platform pitch response and tower base bending load near the platform pitch natural frequency.

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 OSTI2024

Wind plant wake losses: Disconnect between turbine actuation and control of plant wakes with engineering wake models

Wake losses from neighboring plants may become a major factor in wind plant design and control as additional plants are constructed in areas with high wind resource availability. Because plant wakes span a large range of physical scales, from turbine rotor diameter to tens of kilometers, it is unclear whether conventional wake models or turbine control strategies are effective at the plant scale. Wake steering and axial induction control are evaluated in the current work as means of reducing the impact of neighboring wind plants on power and levelized cost of electricity. FLOw Redirection and Induction in Steady State (FLORIS) simulations were performed with the Gauss–Curl Hybrid and TurbOPark wake models as well as two operation and maintenance models to investigate control setpoint sensitivity to wake representation and economic factors. Both wake models estimate losses across a range of atmospheric conditions, although the wake loss magnitude is dependent on the wake model. Annual energy production and levelized cost of electricity are driven by wind direction frequency, with frequently aligned plants experiencing the greatest losses. However, both wake steering and axial induction are unable to mitigate the impact of upstream plants. Wake steering is constrained by plant geometry, since wake displacement is much less than the plant wake width, while axial induction requires curtailing the majority of turbines in upstream plants. Individual turbine strategies are limited by their effective scale and model representation. New wake models that include plant-scale physics are needed to facilitate the design of effective plant wake control strategies.

Scott, Ryan (ORCID:0000000328107574)↗
DOE OSTI2022

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

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

17 WIND ENERGY↗
DOE 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

Analysis of Power-Maximizing Region 2 Controllers for Wind and Marine Turbines

Wind and marine energy are rapidly growing and complementary technologies that share some techniques for simplified modeling and control, particularly in below-rated flow speeds. A turbine operator has several choices of controller for maximizing power in Region 2. The simple and ubiquitous KΩ 2 control law is often effective but limited in its flexibility. Alternative controllers use reference tracking to split the control objectives into a low-bandwidth optimal tip-speed ratio tracking loop to maximize steady-state power and a higher-bandwidth proportional-integral control loop to reject inflow turbulence. Several options exist for identifying the slowly varying optimal set point during operation, based on estimating the inflow velocity or filtering the power or torque signals. This study compares the trade-offs between performance and other design priorities for a few choices of reference-tracking controller in the literature for reference wind and marine turbines. Analysis is performed in the frequency domain using the linearization of each controller, and the impact of turbulent disturbances on the closed-loop system is described. The controllers are simulated in OpenFAST to analyze their performance with higher-order nonlinear turbine dynamics.

17 WIND ENERGY↗
DOE OSTI2022

Wind turbine blade design with airfoil shape control using invertible neural networks

Wind turbine blade design is a highly multidisciplinary process that involves aerodynamics, structures, controls, manufacturing, costs, and other considerations. More efficient blade designs can be found by controlling the airfoil cross-sectional shapes simultaneously with the bulk blade twist and chord distributions. Prior work has focused on incorporating panel-based aerodynamic solvers with a blade design framework to allow for airfoil shape control within the design loop in a tractable manner. Including higher fidelity aerodynamic solvers, such as computational fluid dynamics, makes the design problem computationally intractable. In this work, we couple an invertible neural network trained on high-fidelity airfoil aerodynamic data to a turbine design framework to enable the design of airfoil cross sections within a larger blade design problem. We detail the methodology of this coupled framework and showcase its efficacy by aerostructurally redesigning the IEA 15-MW reference wind turbine blade. The coupled approach reduces the cost of energy by 0.9% compared to a more conventional design approach. This work enables the inclusion of high-fidelity aerodynamic data earlier in the design process, reducing cycle time and increasing certainty in the performance of the optimal design.

17 WIND ENERGY↗
DOE OSTI2020

IEA Wind Task 32 and Task 37: Optimizing Wind Turbines with Lidar-Assisted Control Using Systems Engineering

Lidar-assisted control is a promising technology for reducing the levelized cost of energy from wind turbines, but quantifying its impact at the overall system level requires sophisticated systems engineering analysis and optimization frameworks. The joint workshop on Optimizing Wind Turbines with Lidar-Assisted Control Using Systems Engineering was held by the International Energy Agency Wind Task 32 (Lidar) and Task 37 (Systems Engineering) in October 2019 to address this challenge. This paper summarizes the outcome of the workshop and presents a road map for further research. The most promising applications of lidar-assisted control identified at the workshop and discussed here include 1) increasing annual energy production, 2) decreasing capital expenditure costs by reducing design loads, 3) extending turbine lifetime by reducing operating loads, and 4) enabling wind turbine class upgrades. For each application, we review the state of the art and highlight remaining research needs. Finally, we discuss strategies for addressing these research needs by conducting high-fidelity systems engineering optimizations.

17 WIND ENERGY↗