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The activities leading to the completion of detail design of the MOD-1 wind turbine generator are described. Emphasis is placed on the description of the design as it finally evolved. However, the steps through which the design progressed are also traced in order to understand the major design decisions.
The design, development and analysis of the 7.3 MW MOD-5A wind turbine generator covering work performed between July 1980 and June 1984 is discussed. The report is divided into four volumes: Volume 1 summarizes the entire MOD-5A program, Volume 2 discusses the conceptual and preliminary design phases, Volume 3 describes the final design of the MOD-5A, and Volume 4 contains the drawings and specifications developed for the final design. Volume 1, the Executive Summary, summarizes all phases of the MOD-5A program. The performance and cost of energy generated by the MOD-5A are presented. Each subsystem - the rotor, drivetrain, nacelle, tower and foundation, power generation, and control and instrumentation subsystems - is described briefly. The early phases of the MOD-5A program, during which the design was analyzed and optimized, and new technologies and materials were developed, are discussed. Manufacturing, quality assurance, and safety plans are presented. The volume concludes with an index of volumes 2 and 3.
To demonstrate the concept of utility scale electricity production from a high wind energy resource, a program was initiated to construct and test a 3 megawatt (3,000 kW) Schachle wind turbine generator near Palm Springs, California. The background and current status of this program are presented along with a summary of future planned program activities.
The Energy Research and Development Administration and the NASA Lewis Research Center engaged jointly in a Wind Energy Program which included the design and erection of a 100 kW wind turbine generator. This test machine consists of a rotor turbine, transmission, shaft, alternator, and tower. The rotor, measuring 125 feet in diameter and consisting of two variable pitch blades, operates at 40 rpm and generates 100 kW of electrical power at a wind velocity of 18 mph. The entire assembly is placed on top of a tower 100 feet above ground level. The machine was scheduled to be ready for operation in August, 1975.
This paper provides descriptions of the requirements analysis, hardware development and software development phases of the Control System design for the MOD-5A 7.3 mW Wind Turbine Generator. The system, designed by General Electric Company, Advanced Energy Programs Department, under contract DEN 3-153 with NASA Lewis Research Center and DOE, provides real time regulation of rotor speed by control of both generator torque and rotor torque. A variable speed generator system is used to provide both airgap torque control and reactive power control. The wind rotor is designed with segmented ailerons which are positioned to control blade torque. The central component of the control system, selected early in the design process, is a programmable controller used for sequencing, alarm monitoring, communication, and real time control. Development of requirements for use of aileron controlled blades and a variable speed generator required an analytical simulation that combined drivetrain, tower and blade elastic modes with wind disturbances and control behavior. An orderly two phase plan was used for controller software development. A microcomputer based turbine simulator was used to facilitate hardware and software integration and test.
The design, development and analysis of the 7.3 MW MOD-5A wind turbine generator is documented. This volume contains the drawings and specifications developed for the final design. This volume is divided into 5 books of which this is the third, containing drawings 47A380074 through 47A380126. A full breakdown parts listing is provided as well as a where used list.
Window and wall acceleration measurements and interior noise measurements ere made for two different building structures during excitation by noise from the WTS-4 horizontal axis wind turbine generator operating in a normal power generation mode. With turbine noise input pulses resulted in acceleration pulses for the wall and window elements of the two tests buildings. Response spectra suggest that natural vibration modes of the structures are excited. Responses of a house trailer were substantially greater than those for a building of sturdier construction. Peak acceleration values correlate well with similar data for houses excited by flyover noise from commercial and military airplanes and helicopters, and sonic booms from supersonic aircraft. Interior noise spectra have peaks at frequencies corresponding to structural vibration modes and room standing waves; and the levels for particular frequencies and locations can be higher than the outside levels.
The design, development and analysis of the 7.3 MW MOD-5A wind tunnel generator is documented. There are four volumes. In Volume 2, book 2 the requirements and criteria for the design are presented. The development tests, which determined or characterized many of the materials and components of the wind turbine generator, are described.
Comparison noise measurements were made for a standard MOD-2 machine and for one modified to include an array of vortex generators on the suction sides of the blades near maximum thickness. Data were obtained for comparable azimuth angles and distances for a range of wind velocities of 7.6 to 10.3 m/s and for power outputs of 1.4 MW. Since the observed differences are small it is concluded that the inclusion of vortex generators on this machine will result in no significant increase in environmental impact due to noise.
The project requirements, approach, system description, design requirements, design, analysis, system tests, installation safety considerations, failure modes and effects analysis, data acquisition, and initial performance for the MOD-OA 200 kw wind turbine generator are discussed. The components, the rotor, driven train, nacelle equipment, yaw drive mechanism and brake, tower, foundation, electrical system, and control systems are presented. The rotor includes the blades, hub and pitch change mechanism. The drive train includes the low speed shaft, speed increaser, high speed shaft, and rotor brake. The electrical system includes the generator, switchgear, transformer, and utility connection. The control systems are the blade pitch, yaw, and generator control, and the safety system. Manual, automatic, and remote control and Dynamic loads and fatigue are analyzed.
The thresholds of detection of low frequency, impulsive wind turbine sounds in the presence of background noise were examined. Seven wind turbine sounds, six of which were synthesized, were used in conjunction with three background noise conditions; quiet, 35, and 45 dB(A). The results indicate that thresholds of detection are predictable based on assumed characteristics of the auditory system. The synthesized wind turbine sounds were found to adequately represent a real recording.
The MOD-1 detail design is appended. The supporting analyses presented include a parametric system trade study, a verification of the computer codes used for rotor loads analysis, a metal blade study, and a definition of the design loads at each principal wind turbine generator interface for critical loading conditions. Shipping and assembly requirements, composite blade development, and electrical stability are also discussed.
Progress in explaining variations of power experienced in the on-line operation of a 100 kW experimental wind turbine-generator is reported. Data are presented that show the oscillations tend to be characteristic of a wind-driven synchronous generator because of low torsional damping in the power train, resonances of its large structure, and excitation by unsteady and nonuniform wind flow. The report includes dynamic analysis of the drive-train torsion, the generator, passive driveline damping, and active pitch control as well as correlation with experimental recordings. The analysis assumes one machine on an infinite bus with constant generator-field excitation.
The results of a dynamic interaction investigation to characterize any disturbances caused by interfacing the Mod 0A wind turbine (150 kW configuration) with the Block Island utility diesel generator grid are reported. The tests were run when only two diesel generators were on line, and attention was given to power, frequency, and voltage time profiles. The interconnected system was examined in the start-up and synchronization phase, normal shutdown and cut-out of the wind turbine, during fixed pitch generation, and during variable pitch operation. Governors were installed on the diesel generators to accommodate the presence of wind-derived electricity. The blade pitch control was set to maintain power at 150 kW or below. Power and voltage transients were insignificant during start-up and shutdown, and frequency aberrations were within the range caused by load fluctuations. It is concluded that wind turbine generation can be successfully implemented by an isolated utility, even with a significant penetration to the total grid output.
Synchronous and induction generators are considered. A comparison is made between wind turbines, steam, and hydro units. The unusual phenomena associated with wind turbines are emphasized. The general control requirements are discussed, as well as various schemes for torsional damping such as speed sensitive stabilizer and blade pitch control. Integration between adjacent wind turbines in a wind farm is also considered.
The Mod 1 program objectives are defined. The Mod 1 wind turbine is described. In addition to the steel blade operated on the wind turbine, a composite blade was designed and manufactured. During the early phase of the manufacturing cycle of Mod 1A configuration was designed that identified concepts such as partial span control, a soft tower, and upwind teetered rotors that were incorporated in second and third generation industry designs. The Mod 1 electrical system performed as designed, with voltage flicker characteristics within acceptable utility limits. Power output versus wind speed equaled or exceeded design predictions. The wind turbine control system was operated successfully at the site and remotely from the utility dispatcher's office. During wind turbine operations, television interference was experienced by the local residents. As a consequence, operations were restricted. Although not implemented, two potential solutions were identified. In addition to television interference, a few local residents complained bout objectionable sound, particularly the 'thump' as the blade passed behind the tower. To eliminate objections, the sound generation level was reduced by 10 dB by reducing the rotor speed from 35 rpm to 23 rpm. Bolts in the drive train fractured. A solution was identified but not implemented. The public reaction toward the Mod 1 wind turbine program was overwhelmingly favorable.
Sound measurements are reported for a wind velocity of about 5 m/s and a power output of about 70 kW. Both broadband and narrowband data were obtained for a range of distances and azimuth angles from the machine. Both discrete frequency and broadband components were identified. Loading harmonics at multiples of the blade passage frequency and electrical generator harmonics at multiples of the shaft speed dominated the spectrum below 100 Hz. The 10,000 Hz peak is believed to be of mechanical origin in the nacelle and the other arises from blade aerodynamic sources. Aural detection distances of about 525 m upwind and 850 downwind were observed.
The General Electric Company, Advanced Energy Programs Department, is designing under DOE/NASA sponsorship the MOD-5A wind turbine system which must generate electricity for 3.75 cent/KWH (1980) or less. During the Conceptual Design Phase, completed in March, 1981, the MOD-5A WTG system size and features were established as a result of tradeoff and optimization studies driven by minimizing the system cost of energy (COE). This led to a 400' rotor diameter size. The MOD-5A system which resulted is defined in this paper along with the operational and environmental factors that drive various portions of the design. Development of weight and cost estimating relationships (WCER's) and their use in optimizing the MOD-5A are discussed. The results of major tradeoff studies are also presented. Subsystem COE contributions for the 100th unit are shown along with the method of computation. Detailed descriptions of the major subsystems are given, in order that the results of the various trade and optimization studies can be more readily visualized.