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DOE OSTI2024

Instantaneous mesh load factor ( K γ ) measurements in a wind turbine gearbox using fiber-optic strain sensors

The mesh load factor, K γ , describes how loads are shared between planet gears and has become one of the key design challenges in modern wind turbine gearboxes. Planet load sharing directly impacts tooth root stresses, a critical driver of torque density and gearbox reliability. Experimental evaluation of K γ is typically performed from sun gear tooth root strain gauge measurements, which are complex. Furthermore, such measurements can only provide an average value of load sharing. The present study describes an alternative method to evaluate the mesh load factor in wind turbine gearboxes based on fiber-optic strain sensors installed on the outer surface of the fixed ring gear. We present the results of an extensive measurement campaign to evaluate this novel sensing solution installed on the input planetary stage of a 2-MW wind turbine gearbox at the National Renewable Energy Laboratory's Flatirons Campus (Colorado, USA). The number of strain sensors on the ring gear was selected as an integer multiple of the number of planets, which has enabled an instantaneous evaluation of the mesh load factor. The effect of operating conditions on the planet load-sharing behavior of the gearbox has been investigated. The mesh load factor measured for operating conditions close to rated was below 1.05, well below IEC 61400-4 standard requirements.

17 WIND ENERGY↗

DOE OSTI2020

Augmented Kalman filter with a reduced mechanical model to estimate tower loads on a land-based wind turbine: a step towards digital-twin simulations

This article presents an application of the Kalman filtering technique to estimate loads on a wind turbine. The approach combines a mechanical model and a set of measurements to estimate signals that are not available in the measurements, such as wind speed, thrust, tower position, and tower loads. The model is severalfold faster than real time and is intended to be run online, for instance, to evaluate real-time fatigue life consumption of a field turbine using a digital twin, perform condition monitoring, or assess loads for dedicated control strategies. The mechanical model is built using a Rayleigh–Ritz approach and a set of joint coordinates. We present a general method and illustrate it using a 2-degrees-of-freedom (DOF) model of a wind turbine and using rotor speed, generator torque, pitch, and tower-top acceleration as measurement signals. The different components of the model are tested individually. The overall method is evaluated by computing the errors in estimated tower-bottom-equivalent moment from a set of simulations. From this preliminary study, it appears that the tower-bottom-equivalent moment is obtained with about 10 % accuracy. The limitation of the model and the required steps forward are discussed.

17 WIND ENERGY↗

DOE OSTI2020

Wind Turbine Rotor Design Optimization Using Importance Sampling: Preprint

Probabilistic methods are commonly adopted to estimate both ultimate and fatigue loads in wind turbines, and multiple papers have presented a variety of approaches. In contrast, system-level, integrated design optimization methods for wind turbines have so far relied on deterministic methods to estimate loads and deflections. This work aims at addressing this gap by adopting importance sampling to estimate ultimate blade deflection for use within a rotor design optimization. A comparison between the results of this approach against traditional approaches using deterministic load evaluations show that the probabilistic approach is more conservative and that the solutions found with deterministic approaches violate the probabilistic constraint on tip deflection between 13% and 17%. This highlights the importance of accurate load and deflection estimates and demonstrates that probabilistic approaches can be successfully integrated within a wind turbine design process despite the higher computational costs.

17 WIND ENERGY↗

DOE OSTI2021

Loads Response That is Due to Wake Steering on a Pair of Utility-Scale Wind Turbines

The goal of this report is to present the resulting turbine loads of a full-scale wind turbine wake steering field campaign. In this experiment, wake steering controls were applied to an upwind turbine (T2) and the downwind turbine (T3) was instrumented to measure mechanical loads. The test subjects (T2 & T3) were GE 1.5SLE CWE turbines located on a wind farm with a prevailing wind direction coming from the northwest. The data collection strategy involved toggling the wake steering controls of T2 between on and off. This resulted in two databases (baseline and wake steered) with similar turbulence intensities. Valid data was extracted and processed. The analysis involved scaling data to engineering units, applying coordinate transformations where applicable, calculating 10-minutes statistics, and calculating damage equivalent loads (DELs) to assess fatigue. Figures are shown as statistics and DELs binned by wind speed with supplemental scatter plots provided in the appendices. Results between the baseline and wake steered databases were compared. Overall, the binned statistics showed minimal differences in loading between the two cases. However, the DELs of the wake steered case were observed to be consistently smaller than the baseline for most of the turbine components. A potential for future work was recognized based on the findings of this report. Some areas of further study include an analysis for more granular loads sensitivity to different yaw offset angles and rotor wake overlap, an in-depth comparison of loads between the upwind and downwind turbines, and further fatigue analysis to quantify differences observed in this experiment.

17 WIND ENERGY↗

DOE OSTI2021

Design of a 3.4-MW wind turbine with integrated plasma actuator-based load control

Historically, cost reduction in wind energy has been accomplished by increasing hub heights and rotor diameters to capture more energy per turbine. The growth in rotor and turbine costs with increasing turbine sizes is also driven by the additional structure that must be added to withstand unsteady aerodynamic loads caused by turbulence, gusts, wind shear, misaligned yaw, upwind wakes, and the tower shadow. In this paper, we present a holistic design solution to integrate active load control using a controllable Gurney flap based on plasma actuators. We illustrate the design solution for a land-based 3.4-MW wind turbine rotor. Comparisons to a baseline reference 3.4-MW wind turbine show significant load reduction (15–18% DEL reduction for flap-wise blade root moments), rotor mass reduction (5–8%), and LCOE reduction (1.16–3.11%). To achieve these results, a comprehensive sequential-iterative design procedure is introduced to integrate the controllable Gurney flap into the turbine design and to drive the design solution toward the best LCOE reduction solution. Results are presented for mapping fatigue load reductions into cost reductions. In addition, an evaluation of active load control extended from Region-III to also include Region-II showed a further 34% reduction in DEL.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Wind turbine performance enhancement with minimal structural load penalty: A design philosophy

The performance benefits of using tip devices on wind turbines has been well-documented. However, previous studies show that adding blade tip devices such as winglets leads to a significant increase in blade root bending moment, potentially requiring structural reinforcement with cost and weight drawbacks. A new and unique design philosophy for retrofit blade tip devices for wind turbines is presented. By balancing generated aerodynamic and centrifugal loads, these devices offer an increase in power production without the need for structural reinforcement. Predicted performance and cost benefits of using retrofit blade tip devices on the National Renewable Energy Laboratory 5 MW reference wind turbine are shown. Finally, the addition of blade tip devices resulted in significant improvements in the coefficient of power (C p ) and annual energy production (AEP).

17 WIND ENERGY↗

DOE OSTI2024

Wind Farm Wakes and Farm-to-Farm Interactions: Lidar and Wind Tunnel Tests

Recent experimental and numerical evidence has shown that the cumulative wake generated from the overlapping of multiple wakes within a wind farm could reduce power performance and enhance fatigue loads of wind turbines installed in neighboring downstream wind farms and may also extend up to distances one order of magnitude larger than those typically considered for intra-farm wake interactions. Similar to individual wind turbine wakes, wind farm wakes have a velocity deficit and added turbulence intensity, both affected by the turbine rotor thrust forces and the incoming turbulence intensity. Therefore, the evolution of wind farm wakes will vary for different operational and atmospheric conditions. In this paper, lidar measurements collected during the American WAKE experimeNt (AWAKEN) and wind tunnel tests of wind farms reproduced by porous disks are leveraged to investigate wind farm wakes.

17 WIND ENERGY↗

NASA NTRS1980

Performance of a steel spar wind turbine blade on the Mod-0 100 kW experimental wind turbine

The performance and loading of a large wind rotor, 38.4 m in diameter and composed of two low-cost steel spar blades were examined. Two blades were fabricated at Lewis Research Center and successfully operated on the Mod-0 wind turbine at Plum Brook. The blades were operated on a tower on which the natural bending frequency were altered by placing the tower on a leaf-spring apparatus. It was found that neither blade performance nor loading were affected significantly by this tower softening technique. Rotor performance exceeded prediction while blade loads were found to be in reasonable agreement with those predicted. Seventy-five hours of operation over a five month period resulted in no deterioration in the blade.

Keith, T. G., Jr.↗

DOE OSTI2024

Wind farm structural response and wake dynamics for an evolving stable boundary layer: computational and experimental comparisons

Abstract. The wind turbine design process requires performing thousands of simulations for a wide range of inflow and control conditions, which necessitates computationally efficient yet time-accurate models, especially when considering wind farm settings. To this end, FAST.Farm is a dynamic-wake-meandering-based mid-fidelity engineering tool developed by the National Renewable Energy Laboratory targeted at accurately and efficiently predicting wind turbine power production and structural loading in wind farm settings, including wake interactions between turbines. This work is an extension of a study that addressed constructing a diurnal cycle evolution based on experimental data (Quon, 2024). Here, this inflow is used to validate the turbine structural and wake-meandering response between experimental data, FAST.Farm simulation results, and high-fidelity large-eddy simulation results from the coupled Simulator fOr Wind Farm Applications (SOWFA)–OpenFAST tool. The validation occurs within the nocturnal stable boundary layer when corresponding meteorological and turbine data are available. To this end, we compared the load results from FAST.Farm and SOWFA–OpenFAST to multi-turbine measurements from a subset of a full-scale wind farm. Computational predictions of blade-root and tower-base bending loads are compared to 10 min statistics of strain gauge measurements during 3.5 h of the evolving stable boundary layer, generally with good agreement. This time period coincided with an active wake-steering campaign of an upstream turbine, resulting in time-varying yaw positions of all turbines. Wake meandering was also compared between the computational solutions, generally with excellent agreement. Simulations were based on a high-fidelity precursor constructed from inflow measurements and using state-of-the-art mesoscale-to-microscale coupling.

17 WIND ENERGY↗

DOE OSTI2024

Streamlined Loads Analysis of Floating Wind Turbines With Fiber Rope Mooring Lines

This paper presents an approach for more accurate yet relatively streamlined accounting for the nonlinear characteristics of synthetic fiber rope mooring lines for floating wind turbines. First, we select a minimal set of parameters that can efficiently approximate a mooring line material's quasi-static and dynamic stiffness characteristics. We also develop a set of baseline coefficients for different rope materials based on published product information and research papers. We then expand a quasi-static mooring model to include dynamic mooring line stiffness terms in a way that allows the nonlinear stiffness behavior of fiber ropes to be considered even in quasi-static analyses. For dynamic analysis, we have updated the model MoorDyn, coupled with OpenFAST, to work with the new dynamic mooring line stiffness terms. This includes the implementation of a new viscoelastic approach that allows the tension-strain relation of each mooring line segment to vary between two stiffness values, depending on the strain rate. After presenting the formulation of the approaches for modeling synthetic ropes, they are demonstrated on a floating wind turbine mooring system with taut polyester rope mooring lines. The results are compared with those of other approaches of similar fidelity, including the static-dynamic method and separate simulations with static and dynamic stiffness values. Comparing the results shows the ability of the new method to match the results of the previous methods in a more streamlined manner.

elasticity↗

DOE OSTI2024

Streamlined Loads Analysis of Floating Wind Turbines With Fiber Rope Mooring Lines: Preprint

This paper presents an approach for more accurate yet relatively streamlined accounting for the nonlinear characteristics of synthetic fiber rope mooring lines for floating wind turbines. First, we select a minimal set of parameters that can efficiently approximate a mooring line material's quasi-static and dynamic stiffness characteristics. We also develop a set of baseline coefficients for different rope materials based on published product information and research papers. We then expand a quasi-static mooring model to include dynamic mooring line stiffness terms in a way that allows the nonlinear stiffness behavior of fiber ropes to be considered even in quasi-static analyses. For dynamic analysis, we have updated the model MoorDyn, coupled with OpenFAST, to work with the new dynamic mooring line stiffness terms. This includes the implementation of a new viscoelastic approach that allows the tension-strain relation of each mooring line segment to vary between two stiffness values depending on the strain rate. After presenting the formulation of the approaches for modeling synthetic ropes, they are demonstrated on a floating wind turbine mooring system with taut polyester rope mooring lines. The results are compared with those of other approaches of similar fidelity including the static-dynamic method and separate simulations with static and dynamic stiffness values. Comparing the results shows the ability of the new method to match the results of the previous methods in a more streamlined manner.

elasticity↗

DOE OSTI2023

Grid Forming Fast Frequency Response for PMSG-Based Wind Turbines

Electric power systems are undergoing a rapid transition from fuel-based generation using synchronous generators to renewable generation interfaced by power electronics. In this context, a key challenge is using renewable generation with limited controllability to contribute to power system stability. In this work, we investigate grid-forming control of permanent magnet synchronous generator (PMSG) wind turbines. The proposed control and curtailment strategy supports the entire spectrum of standard functions of grid-following (e.g. maximum power point tracking (MPPT) and grid-forming control (e.g., primary frequency control) without explicit mode switching. A detailed case study is used to compare the performance of the proposed control at operating points corresponding to MPPT and frequency control with standard grid-forming and grid-following controls. Further, the results demonstrate that (i) the proposed energy balancing grid forming control is self-synchronizing in MPPT mode, (ii) the (limited) energy storage and controllability of wind turbines can be adequately utilized to provide grid support, and (ii) the proposed control exhibits good performance under variable wind speeds and does not result in a significant increase of wind turbine fatigue loads.

17 WIND ENERGY↗

DOE OSTI2024

Design Load Basis Guidance for Distributed Wind Turbines

Aeroelastic modeling (AM) is the primary methodology for structural and performance assessment of any wind turbine. Nonetheless, the use of AM in the distributed wind (DW) industry sector is limited due to several challenges (Damiani, Davis, & Summerville, 2022). One of these challenges lies in the perceived complexity of generating a proper set of numerical simulations to extract and process the key outputs for component design and verification, and, ultimately, achieve certification. This makes it difficult to reliably predict the structural and performance response of small wind turbines. From the investigation carried out in (Damiani & Davis, 2022), it is apparent that many stakeholders in this sector believe that a comprehensive guide for developing a design load basis (DLB) for distributed wind turbines (DWTs) is necessary.

17 WIND ENERGY↗

DOE OSTI2020

Validation of a Generalized Formulation for Load Sharing Behavior in Epicyclic Gears for Wind Turbines

In an ideal epicyclic gear set every parallel gear path transmits the same amount of torque. However, it is well known that certain manufacturing variations result in unequal load sharing between the parallel gear paths. Previous works have developed and validated a general closed-form analytical model of this phenomenon that describes the load sharing characteristics of epicyclic gear sets from three to six planets at any torque level. More recently, this analytical model has been reformulated to include the effects of gravity, carrier bearing clearance, and external applied moments, all of which are relevant to most gearboxes and their mounting configuration in horizontal-axis wind turbines. In this paper, the reformulated model is compared to load measurements collected from two similar wind turbine gearboxes with three-planet epicyclic gear sets. The resulting load sharing values are also compared to the mesh load factor requirements in the AGMA 6006 and IEC 61400-4 wind turbine gearbox design standards. Load sharing factors as high as 1.16 at extreme rotor moments and 1.08 with no moment were measured for the gearbox with cylindrical roller bearings, but the load sharing factor remained below 1.10 for the gearbox with tapered roller bearings The results show that in the wind turbine application, load sharing is not equal - even for three-planet systems with a floating central member because of the effects of gravity, rotor moments, and the resulting relative motions among the epicyclic gear components within the carrier bearing clearance.

closed-form analytical model↗

DOE OSTI2020

Validation of a Generalized Formulation for Load-Sharing Behavior in Epicyclic Gears for Wind Turbines: Preprint

closed-form analytical model↗

DOE OSTI2021

Loads on a Jacket-Supported Wind Turbine During Hurricane Sandy Simulation

Abstract The dynamic response of a jacket-supported offshore wind turbine under coupled wind, wave, and current fields during Hurricane Sandy is the subject of this study. To illustrate the detailed procedure related to the response evaluation of a 5-MW offshore wind turbine with a jacket support structure, we consider a single site where the water depth is 50 m. Loads are computed using two simulation tools, fast and abaqus, with partial coupling. Aerodynamic loads on the turbine rotor are first evaluated using a wind turbine model in fast with a fixed base; then, these rotor aerodynamic loads are applied as point loads at the top of a model of a tower that is supported by a jacket structure in abaqus. On the basis of stochastic simulations, we discuss the applicability of the abaqus jacket modeling and describe the characteristics and comparisons of the aerodynamic and hydrodynamic effects on loads on the jacket members. Details related to the structural model and soil–pile interaction model employed in the analyses are also discussed.

Engineering↗

DOE OSTI2022

A time‐varying formulation of the curled wake model within the FAST.Farm framework

Abstract In this article, we present a time‐varying formulation of the curled wake model that we implemented in FAST.Farm. The curled wake model, originally developed for steady‐state conditions, is used to produce realistic wake profiles behind a wind turbine in yawed (or skewed) conditions. We begin by introducing the key elements of the FAST.Farm framework. Then, after briefly summarizing the original wake dynamics formulation of FAST.Farm based on a polar wake profile, we present the new time‐varying formulation of the curled wake model, compare the two, and highlight the differences with the original curled wake model. After discussing some implementation details, we present different applications with increasing levels of complexity: single turbine with uniform and turbulent inflow, fixed and transient yaw, and multiple turbines. We verify our results using the original FAST.Farm implementation and large‐eddy simulations. The results with the new curled wake model are improved compared to the original implementation, as they include cross‐flow velocities and wake asymmetry. Yet, large‐eddy simulation results show a more pronounced lateral convection of the wake and a stronger concentration of vorticity at the top vortex. The new curled wake implementation in FAST.Farm should enable the calculation of not only generator power but also wind turbine structural loads for applications involving intentional or unintentional skewed flow and wind‐farm control involving wake steering.

17 WIND ENERGY↗

DOE OSTI2023

Wind Fields in Category 1–3 Tropical Cyclones Are Not Fully Represented in Wind Turbine Design Standards

Abstract Offshore wind energy deployment in the U.S. is expected to increase in the years to come, with proposed wind farm sites located in regions with high risk for tropical cyclones. Yet, the wind turbine design criteria outlined by the International Electrotechnical Commission for extreme events may not account for wind field characteristics unique to tropical cyclones. To evaluate if current design standards capture the extreme conditions of these storms, we perform idealized large‐eddy simulations of three tropical cyclones (one Category 1, one Category 2, and one Category 3 storms) using the Weather Research and Forecasting model. Wind conditions near the eyewall of Cat‐1, Cat‐2, and Cat‐3 storms can exceed current design standards for offshore wind turbines. Winds at 90 m can be faster than outlined in the design criteria for Class I and Class T turbines for 50‐year recurrence periods. Wind speed shear across the turbine rotor layer is also larger than assumed in design specifications. Moreover, vertical variations in wind direction across the turbine rotor layer are large for tropical cyclones of all intensity levels, suggesting design standards should include veer, which can amplify loads in wind turbines. The existence of hurricane wind field characteristics that are not represented in design standards does not imply that damage or failure will certainly occur. Engineering safety factors incorporated in the design of the turbine's blades and structural components may prevent damage from occurring.

17 WIND ENERGY↗