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This presentation covers wind turbine life and reliability. It provides information on fatigue analysis and the probability of failure of wind turbines with constant-amplitude tests and provides a plant-wide cost estimate.
Failures in gearbox bearings have been a primary source of reliability issues for wind turbine drivetrains, leading to costly downtime and unplanned maintenance. The most common failure mode is attributed to so-called white-etching cracks (WECs). This mode of failure can occur at 5%-20% of the predicted design life and has been observed in many other industries, bearing locations, bearing types, bearing parts, and steel types. The main drivers for the creation of WECs in steel specimens have been identified and verified by material testing. In a full-scale wind turbine gearbox, however, the conditions leading to WECs, the process by which this failure culminates, and the reasons for their apparent prevalence are all still highly debated. In a collaborative project, Flender Corporation, SKF and the National Renewable Energy Laboratory have instrumented a commercial drivetrain, installed it in a wind turbine, and operated the turbine for over a year. In this report, these measurements are used to validate two different modelling approaches for bearing sliding, one analytical dynamic model and one multi-body model. Once validated, these models can then be used to evaluate the roller slip losses or cumulative frictional energy that are each considered as potential driving factors for wind turbine gearbox bearing failures by WEC.
Wind-tunnel tests are reported of five 3-blade 10-foot propellers operating in front of a radial and a liquid-cooled engine nacelle. The range of blade angles investigated extended from 15 degrees to 45 degrees. Two spinners were tested in conjunction with the liquid-cooled engine nacelle. Comparisons are made between propellers having different blade-shank shapes, blades of different thickness, and different airfoil sections. The results show that propellers operating in front of the liquid-cooled engine nacelle had higher take-off efficiencies than when operating in front of the radial engine nacelle; the peak efficiency was higher only when spinners were employed. One spinner increased the propulsive efficiency of the liquid-cooled unit 6 percent for the highest blade-angle setting investigated and less for lower blade angles. The propeller having airfoil sections extending into the hub was superior to one having round blade shanks. The thick propeller having a Clark y section had a higher take-off efficiency than the thinner one, but its maximum efficiency was possibly lower. Of the three blade sections tested, Clark y, R.A.F. 6, and NACA 2400-34, the Clark y was superior for the high-speed condition, but the R.A.F. 6 excelled for the take-off condition.
Design of the thermal protection system for any hypersonic flight vehicle requires determination of both the peak temperatures over the surface and the heating-rate history along the flight profile. In this paper, the process used to generate the aerothermal environments required for the X-34 Testbed Technology Demonstrator thermal protection system design is described as it has evolved from a relatively simplistic approach based on engineering methods applied to critical areas to one of detailed analyses over the entire vehicle. A brief description of the trajectory development leading to the selection of the thermal protection system design trajectory is included. Comparisons of engineering heating predictions with wind-tunnel test data and with results obtained using a Navier- Stokes flowfield code and an inviscid/boundary layer method are shown. Good agreement is demonstrated among all these methods for both the ground-test condition and the peak heating flight condition. Finally, the detailed analysis using engineering methods to interpolate the surface-heating-rate results from the inviscid/boundary layer method to predict the required thermal environments is described and results presented.
Design of the thermal protection system for any hypersonic flight vehicle requires determination of both the peak temperatures over the surface and the heating-rate history along the flight profile. In this paper, the process used to generate the aerothermal environments required for the X-34 Testbed Technology Demonstrator thermal protection system design is described as it has evolved from a relatively simplistic approach based on engineering methods applied to critical areas to one of detailed analyses over the entire vehicle. A brief description of the trajectory development leading to the selection of the thermal protection system design trajectory is included. Comparisons of engineering heating predictions with wind-tunnel test data and with results obtained using a Navier-Stokes flowfield code and an inviscid/boundary layer method are shown. Good agreement is demonstrated among all these methods for both the ground-test condition and the peak heating flight condition. Finally, the detailed analysis using engineering methods to interpolate the surface-heating-rate results from the inviscid/boundary layer method to predict the required thermal environments is described and results presented.
Abstract This paper evaluates the technical and economic feasibility of repurposing decommissioned offshore oil and gas platforms as electrical substations for offshore wind projects in the U.S. Gulf of America, a region characterized by relatively low and highly variable wind speeds, extensive legacy offshore infrastructure, and exposure to merchant electricity markets. A unified techno-economic framework is developed using the Repurposing Offshore Infrastructure for Continued Energy (ROICE) Economic Model (REM) to integrate Gulfspecific wind resource assessment, commercial wind turbine performance, offshore infrastructure cost modeling, and wholesale electricity market exposure. Gulf wind speed data are vertically extrapolated to turbine hub height and combined with manufacturer power curves to compute annual energy production and capacity factors across a broad portfolio of commercial turbines, enabling identification of turbine designs best suited for low-wind offshore environments. Hourly electricity price data from the Midcontinent Independent System Operator (MISO) day-ahead market are incorporated to characterize revenue potential, price volatility, and the temporal alignment between wind generation and market conditions. In addition, a conceptual framework for offshore battery energy storage system (BESS) integration is developed to support future investigation of market-responsive energy shifting at repurposed platforms. Results from the turbine evaluation demonstrate that machines with lower cut-in wind speeds and earlier ‘rated-power’ characteristics significantly outperform larger, industry-standard offshore turbines for the same net power under Gulf wind conditions, underscoring the need for region-specific technology selection. Market analysis further reveals substantial price variability and limited intrinsic alignment between wind production and high-price periods, motivating consideration of operational flexibility mechanisms. While storage optimization is not implemented in this study, the REM framework establishes a transparent and replicable foundation for co-evaluating turbine selection, infrastructure constraints, and market exposure, providing a practical pathway for assessing the potential role of repurposed offshore platforms in enabling economically viable offshore wind development in the Gulf of America.
This report presents a discussion on modeling a wind power plant for short-circuit studies at the transmission level. Due to the longer history of use and experience with synchronous machines in the electric power grid, the short-circuit behavior of power plants using these types of machines is well understood compared to a wind power plant. It is the goal of this guideline to educate utility engineers on short-circuit modeling of wind power plants in order to increase the level of understanding of wind power plant behavior. The methods presented in this paper will assist in determining the maximum short-circuit contribution from a wind power plant for system impact studies (verifying current is within interrupting ability of protection devices), relay coordination, and arc flash hazard studies.
The Block Island Power Company (BIPCO), on Block Island, Rhode Island, operates an isolated electric power system consisting of diesel generation and an experimental wind turbine. The 150-kW wind turbine, designated MOD-OA by the U.S. Department of Energy is typically operated in parallel with two diesel generators to serve an average winter load of 350 kW. Wind generation serves up to 60 percent of the system demand depending on wind speed and total system load. Results of diesel fuel consumption measurements are given for the diesel units operated in parallel with the wind turbine and again without the wind turbine. The fuel consumption data are used to calculate the amount of fuel displaced by wind energy. Results indicate that the wind turbine displaced 25,700 lbs. of the diesel fuel during the test period, representing a calculated reduction in fuel consumption of 6.7 percent while generating 11 percent of the total electric energy. The amount of displaced fuel depends on operating conditions and system load. It is also shown that diesel engine throttle activity resulting from wind gusts which rapidly change the wind turbine output do not significantly influence fuel consumption.
An investigation was conducted on a turbine-propeller engine in the NACA Lewis altitude wind tunnel at altitudes from 5000 to 35,000 feet. The applicability of generalized parameters to turbine-propeller engine data, analyses of the compressor, the combustion chambers, and the turbine, and a study of the over-all engine performance are reported. Engine performance data obtained at sea-level static conditions could be used to predict static performance at altitudes up to 35,000 feet by use of the standard generalized parameters.
A reduced-order model for a wind turbine wake is sought from large eddy simulation data. Fluctuating velocity fields are combined in the correlation tensor to form the kernel of the proper orthogonal decomposition (POD). Proper orthogonal decomposition modes resulting from the decomposition represent the spatially coherent turbulence structures in the wind turbine wake; eigenvalues delineate the relative amount of turbulent kinetic energy associated with each mode. Back-projecting the POD modes onto the velocity snapshots produces dynamic coefficients that express the amplitude of each mode in time. A reduced-order model of the wind turbine wake (wakeROM) is defined through a series of polynomial parameters that quantify mode interaction and the evolution of each POD mode coefficients. The resulting system of ordinary differential equations models the wind turbine wake composed only of the large-scale turbulent dynamics identified by the POD. Tikhonov regularization is used to recalibrate the dynamical system by adding additional constraints to the minimization seeking polynomial parameters, reducing error in the modeled mode coefficients. The wakeROM is periodically reinitialized with new initial conditions found by relating the incoming turbulent velocity to the POD mode coefficients through a series of open-loop transfer functions. The wakeROM reproduces mode coefficients to within 25.2%, quantified through the normalized root-mean-square error. Furthermore, a high-level view of the modeling approach is provided as a platform to discuss promising research directions, alternate processes that could benefit stability and efficiency, and desired extensions of the wakeROM.
The goal of this paper is to investigate the behaviour of the high-speed stage of a wind turbine gearbox during transient grid-loss events triggered at different power levels in a full-scale nacelle dynamometer test. The gear mesh behaviour and the bearing roller slip during these events are characterized by strain measurements placed in the gear teeth roots and embedded in the outer rings of the tapered roller bearing locating pair. From our experiments, we conclude that the high-speed stage experiences a multidimensional loading consisting of bending and torsional deformation during the transient event. This loading propagates throughout the gearbox and results in unfavourable loading conditions at the bearing that have the potential to go beyond the preload during the torque reversals that occur during the grid-loss event. During the torque reversal, roller slip can occur in the bearings. It is observed that the slip behaviour is directly linked to the initial power level of the generator. Electrically induced excitation that typically leads to dynamic torque events can therefore cause mechanical gearbox degradation.
This Small Business Voucher CRADA will focus on wind turbine blade fatigue analysis for development of predictive life models. The parties will cooperate to conduct structural validation fatigue testing that produces high quality data enabling validation of blade damage models with sensing technologies developed by Sentient.
The final webinar in NREL's Offshore Wind Technology Basics series focuses on offshore wind technology below the water, including foundations and cables. Specific aspects of offshore wind that are covered by the webinar include fixed bottom turbines, floating turbines, mooring lines for floating turbines, cabling options and installation, and decommissioning. The webinar also addresses the technology options and development considerations for diverse seafloor and oceanographic characteristics.
Extreme wind load cases are one of the most important external conditions in the design of offshore wind turbines in hurricane prone regions. Furthermore, in these areas, the increase in load with storm return-period is higher than in extra-tropical regions. However, current standards have limited information on the appropriate models to simulate wind loads from hurricanes. This study investigates turbulent wind models for load analysis of offshore wind turbines subjected to hurricane conditions. Suggested extreme wind models in IEC 61400-3 and API/ABS (a widely-used standard in oil and gas industry) are investigated. The present study further examines the wind turbine response subjected to Hurricane wind loads. Three-dimensional wind simulator, TurbSim, is modified to include the API wind model. Wind fields simulated using IEC and API wind models are used for an offshore wind turbine model established in FAST to calculate turbine loads and response.
Turbine-mounted lidars provide preview measurements of the incoming wind field. By reducing loads on critical components and increasing the potential power extracted from the wind, the performance of wind turbine controllers can be improved [2]. As a result, integrating a light detection and ranging (lidar) system has the potential to lower the cost of wind energy. This paper presents an evaluation of turbine-mounted lidar availability. Availability is a metric which measures the proportion of time the lidar is producing controller-usable data, and is essential when a wind turbine controller relies on a lidar. To accomplish this, researchers from Avent Lidar Technology and the National Renewable Energy Laboratory first assessed and modeled the effect of extreme atmospheric events. This shows how a multirange lidar delivers measurements for a wide variety of conditions. Second, by using a theoretical approach and conducting an analysis of field feedback, we investigated the effects of the lidar setup on the wind turbine. This helps determine the optimal lidar mounting position at the back of the nacelle, and establishes a relationship between availability, turbine rpm, and lidar sampling time. Lastly, we considered the role of the wind field reconstruction strategies and the turbine controller on the definition and performance of a lidar's measurement availability.
Several methods have been proposed in the literature to find a state-space model for the wave-radiation forces. In this paper, four methods were compared, two in the frequency domain and two in the time domain. The frequency-response function and the impulse response of the resulting state-space models were compared against the ones derived by the numerical code WAMIT. The implementation of the state-space module within the FAST offshore wind turbine computer-aided engineering (CAE) tool was verified, comparing the results against the previously implemented numerical convolution method. The results agreed between the two methods, with a significant reduction in required computational time when using the state-space module.
Fire safety, aviation, wind energy, and structural-engineering operations are impacted by thunderstorm outflow boundaries or gust fronts (GFs) particularly when they occur in mountainous terrain. For example, during the 2013 Arizona Yarnell Hill Fire, 19 firefighters were killed as a result of sudden changes in fire behavior triggered by a passing GF. Knowledge of GF behavior in complex terrain also determines departure and landing operations at nearby airports, and GFs can induce exceptional structural loads on wind turbines. Furthermore, while most examinations of GF characteristics focus on well-organized convection in areas such as the Great Plains, here the investigation is broadened to explore GF characteristics that evolve near the complex terrain of the Colorado Rocky Mountains. Using in situ observations from meteorological towers, as well as data from wind-profiling lidars and a microwave radiometer, 24 GF events are assessed to quantify changes in wind, temperature, humidity, and turbulence in the lowest 300 m AGL as these GFs passed over the instruments. The changes in magnitude for all variables are on average weaker in the Colorado Front Range than those typically observed from organized, severe storms in flatter regions. Most events from this study experience an increase in wind speed from 1 to 8 m s -1 , relative humidity from 1% to 8%, and weak vertical motion from 0.3 to 3.6 m s -1 during GF passage while temperature drops by 0.2°–3°C and turbulent kinetic energy peaks at >4 m2 s -2 . Vertical profiles reveal that these changes vary little with height in the lowest 300 m.
Another concern for the vehicle during its design trajectory was the separation of the first stage solid rocket booster from the upper stage component after it had depleted its solid fuel propellant. There has been some concern about the interstage of the first stage from clearing the nozzle of the J2-X engine. A detailed separation aerodynamic wind tunnel investigation was conducted in the AEDC VKF Tunnel A to help to investigate the interaction aerodynamic effects5. A comparison of the separation plane details between the Ares I architecture and the Ares I-X demonstration flight architecture is shown in figure 12. The Ares I design requires a more complex separation sequence and requires better control in order to avoid contact with the nozzle of the upper stage engine. The interstage, which houses the J2-X engine for the Ares I vehicle, must be able to separate cleanly to avoid contact of the J2-X engine. There is only about approximately 18 inches of buffer inside the interstage on each size of the nozzle so this is a challenging controlled separation event. This complex experimental investigation required two separate Ares I models (upper stage and first stage with interstage attached) with independent strain gauge balances installed in each model. It also required the Captive Trajectory System (CTS) that was needed to precisely locate the components in space relative to each other to fill out the planned test matrix. The model setup in the AEDC VKF Tunnel A is shown in figure 13. The CTS remotely positioned the first stage at the required x, y, and z positions and was able to provide interactions within 0.2" of the upper stage. A sample of the axial force on the first stage booster is shown in figure 14. These results, as a function of separation distance between the two stages, are compared to pre-test CFD results. Since this is a very challenging, highly unsteady flow field for CFD to correctly model, the experimental results have been utilized by GN&C discipline to more accurately represent the interaction aerodynamics. In addition to the integrated forces and moments obtained from the test, flow visualization data was obtained from this test in the form of Schlieren photographs, as shown in figure 15, which show the shock structure and interaction effects after the two stages separate during flight. This separation test was crucial in the successful flight test of the Ares I-X vehicle and provided the GN&C discipline with the unpowered proximity aerodynamic effect for a separation of the Ares I vehicle.