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DOE OSTI2023

Design of a Two-Body Wave Energy Converter Featuring Controllable Geometry: Preprint

While the field of wave energy has been the subject of numerical simulation, scale model testing, and precommercial project testing for decades, wave energy technologies remain in the early stages of development and must continuing proving themselves as a promising modern renewable energy field. A wave energy converter (WEC) concept, currently being explored, is hoping to add an extra control option to WEC design is the variable-geometry WEC (VGWEC). These VGWECs attempt to incorporate controllable geometric features to adjust the floating body hydrodynamics to favor either power absorption, load shedding, or other operational goals. These variable geometry components have been proposed to be controlled on a sea-state-to-sea-state or wave-to-wave time scale depending on the force (or toque) and bandwidth limitations of the actuators required to manipulate just the controllable geometric hull features. The opportunities of having control over both the WEC geometry components and the power-take-off (PTO) have the potential to improve overall system performance and reliability if a cost-effective solution can be found for a given WEC architecture. This paper will present the recent developments and results of a VGWEC concept that incorporates variable geometry modules into a two-body WEC. In the proposed VGWEC concept, the variable geometry modules consist of air inflatable bags in the surface float and a water inflatable ring in the subsurface body. The surface float is tethered directly to the subsurface body through tether lines each connected to a separate PTO. Adjusting the geometry of both the surface and subsurface bodies along with the PTO coefficients can be shown to maximize power in design sea states while reducing motion response and PTO forces when transitioning to sea states where rated power is reached and load shedding is prioritized in hopes of increasing the sea state operational map.

geometry control↗

DOE OSTI2023

Recent Hydrodynamic Modeling Enhancements in OpenFAST

To improve the hydrodynamic modeling capabilities of the offshore wind design and modeling tool OpenFAST, a restructuring of the HydroDyn hydrodynamics module was undertaken with several new features implemented. The generation of the wave field is now separated from HydroDyn into a new module called SeaState. Unlike previous versions of HydroDyn, which precomputed the wave kinematics at the undisplaced positions of the hydrodynamic nodes, the new SeaState module computes the complete time history of the wave field at the vertices of a user-defined wave grid. During the simulation, the wave kinematics at any point within the grid can be efficiently interpolated, allowing the strip-theory wave loads to be evaluated based on the wave kinematics at the displaced structure position. A phase correction was also implemented for the potential-flow wave-exciting loads to account for large structure displacements. Several wave-stretching methods were implemented for the strip-theory solution along with a wave-load redistribution method that ensures smooth variation of the nodal loads as the nodes of a discrete hydrodynamic mesh enter and exit the water. The load smoothing is included to avoid the excitation of unphysical high-frequency structural vibration during hydroelastic simulations. The MacCamy-Fuchs diffraction correction for the strip-theory solution and the capability to insert a constrained NewWave into extreme stochastic sea states with directional spreading were also added. The present article documents the formulations of the new improvements to HydroDyn with example applications and numerical results.

constrained wave↗

DOE OSTI2022

Recent Hydrodynamic Modeling Enhancements in OpenFAST: Preprint

constrained wave↗

DOE OSTI2022

Hydrodynamics of countercurrent flow in an additive-manufactured column with triply periodic minimal surfaces for carbon dioxide capture

Computational investigation of the countercurrent flows in an additively manufactured (AM) column packed with triply periodic minimal surface (TPMS) is challenging. Multiphase flow simulations using the volume of fluid (VOF) method can explain the column’s hydrodynamic characteristics, including interfacial area, liquid holdup, pressure drop, flow regime, etc. The interfacial area is a key factor dictating the mass transfer via the absorption process, and thereby the overall efficiency of the column. The impacts of a solvent's physical properties, liquid and gas loads, and contact angle on the hydrodynamics are extensively explored. The solvents include traditional solvent (monoethanolamine [MEA]) used in industry as well as a water-lean solvent (EEMPA) as prospective solvents for carbon capture. As expected, interfacial area and liquid holdup increase with increasing liquid loads (q L ). The EEMPA exhibits higher values for the interfacial area and liquid holdup compared to those for the MEA. The dry and wet pressure drops per unit length in the column at different gas loads (F G ) are calculated and further compared with the empirical correlations for traditional packings. At low gas loads, i.e., in the preloading regime, the predicted values of the wet and dry pressure drops match well with the corresponding values calculated from available correlations. The gas load has a marginal impact on the interfacial area at its lower value, but the higher value of F G (>2.18 $\sqrt{Pa}$) causes flooding in the column. The effect of varying contact angles on the interfacial area and liquid holdup in the preloading regime is also studied. Both interfacial area and liquid holdup decrease with the increase in the value of the contact angle. Altogether, the effect of the contact angle on interfacial area is more pronounced than other parameters influencing the interfacial area.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Design of a Two-Body Wave Energy Converter Featuring Controllable Geometry

While the field of wave energy has been the subject of numerical simulation, scale model testing, and precommercial project testing for decades, wave energy technologies remain in the early stages of development and must continue to prove themselves as a promising modern renewable energy field. A wave energy converter (WEC) concept currently being explored is the variable-geometry WEC (VGWEC), which aims to add an extra control option to WEC design. VGWECs attempt to incorporate controllable geometric features to adjust the floating body hydrodynamics to favor either power absorption, load shedding, or other operational goals. These variable geometry components have been proposed to be controlled on a sea-state-to-sea-state or wave-to-wave time scale depending on the force (or torque) and bandwidth limitations of the actuators required to manipulate just the controllable geometric hull features. Having control over both the WEC geometry components and the power takeoff (PTO) offers the potential to improve overall system performance and reliability if a cost-effective solution can be found for a given WEC architecture. This paper will present the recent developments and results of a VGWEC concept that incorporates variable-geometry modules into a two-body WEC. In the proposed VGWEC concept, the variable-geometry modules consist of air-inflatable bags in the surface float and a water inflatable ring in the subsurface body. The surface float is tethered directly to the subsurface body through tether lines, each connected to a separate PTO. Adjusting the geometry of both the surface and subsurface bodies along with the PTO coefficients can maximize power in design sea states while reducing motion response and PTO forces when transitioning to sea states where rated power is reached and load shedding is prioritized. The ability to transition between operating condition is expected to increase the sea state operational map and power capacity.

geometry control↗

DOE OSTI2026

A Physics-Based Digital Twin for Wave Elevation and Seabed Moment Estimation of Offshore Monopiles: Preprint

In this work, we present a proof of concept of a physics-based digital twin for a monopile structure (with overhead inertia) subjected to wave loading. The digital twin is formulated using reduced-order models derived from first principles and combined with a Kalman filter for state estimation. The proposed framework estimates the monopile top motion, the wave elevation, and the section forces and moments along the pile using primarily acceleration measurements at the monopile top. Key innovations include the use of a hydrodynamic shape function to represent distributed wave loading in a compact and computationally efficient manner, and the introduction of a shaping filter to augment the state-space with wave kinematics. Synthetic measurement data are generated using OpenFAST and used as a reference to assess the performance of the digital twin. Results demonstrate that the wave elevation can be accurately reconstructed without direct sea-state measurements as long as the wave regime is inertia-dominated. Under the ideal tested conditions, the total hydrodynamic force and sea-bed bending moment are estimated with relative errors on the order of 1% and correlation coefficients exceeding 96%. Future work will evaluate the estimator's performance under operational uncertainties and more complex loading conditions.

17 WIND ENERGY↗

DOE OSTI2024

Validation of Local Structural Loads Computed by OpenFAST Against Measurements From the FOCAL Experimental Campaign

This work presents the validation of the local structural load modeling capability in OpenFAST for floating substructures based on data from the FOCAL experimental campaign. Previously, OpenFAST could only represent the floating substructure as a rigid body, and though this approach can model the global response of the floater in most cases, it is not able to capture the structural loads within the floater's individual members. Consideration of local substructure loads is important for some floating designs, because the pursuit of cost reduction often results in lighter and more flexible structures. To address this limitation, the HydroDyn (hydrodynamics) and SubDyn (substructure dynamics) modules of OpenFAST have been recently extended to account for the flexibility of floating substructures. To validate this new capability, we compare the results obtained by OpenFAST with data measured during the FOCAL experimental campaign, which analyzed a 1:70 scale performance-matched model of the IEA 15-MW reference turbine atop a modified University of Maine VolturnUS-S semisubmersible in a wave basin under the action of both wind and waves. For the purposes of the present work, the most important feature of the experiment is the presence of load cells at the root of each pontoon, and our objective is to assess how well those loads are reproduced by OpenFAST. To model the distributed hydrodynamic and hydrostatic loads along the floating substructure, we adopt a strip-theory approach based on the Morison equation, and we discuss the impact of different hydrodynamic modeling options (wave stretching, MacCamy-Fuchs correction, and second-order wave kinematics) on both motions and loads. For simplicity, we focus on wave-only conditions, both regular and irregular. The results demonstrate good overall agreement for the loads at the root of the pontoons for the waves analyzed in this work, especially given the assumptions and simplifications inherent to a simple strip-theory model.

floating offshore wind turbine↗

DOE OSTI2024

Validation of Local Structural Loads Computed by OpenFAST Against Measurements From the Focal Experimental Campaign: Preprint

This work presents the validation of the local structural load modeling capability in OpenFAST for floating substructures based on data from the FOCAL experimental campaign. Previously, OpenFAST could only represent the floating substructure as a rigid body, and though this approach can model the global response of the floater in most cases, it is not able to capture the structural loads within its individual members. Consideration of local substructure loads is important for some floating designs, as the pursuit of cost reduction often results in lighter and more flexible structures. To address this limitation, the HydroDyn (hydrodynamics) and SubDyn (substructure dynamics) modules of OpenFAST have been recently extended to account for the flexibility of floating substructures. To validate this new capability, we compare the results obtained by OpenFAST with data measured during the FOCAL experimental campaign, which analyzed a 1:70 scale performance-matched model of the IEA 15-MW reference turbine atop a modified University of Maine VolturnUS-S semisubmersible in a wave basin under the action of both wind and waves. For the purposes of the present work, the most important feature of the experiment is the presence of load cells at the root of each pontoon, and our objective is to assess how well those loads are reproduced by OpenFAST. To model the distributed hydrodynamic and hydrostatic loads along the floating substructure, we adopt a strip-theory approach based on the Morison equation, and we discuss the impact of different hydrodynamic modeling options (wave stretching, MacCamy-Fuchs correction, and second-order wave kinematics) on both motions and loads. For simplicity, we focus on wave-only conditions, both regular and irregular. The results demonstrate good overall agreement for the loads at the root of the pontoons for the waves analyzed in this work, especially given the assumptions and simplifications inherent to a simple strip-theory model.

floating offshore wind turbine↗

NASA NTRS1984

Real Surface Effects in Elastohydrodynamic Lubrication

Following a general discussion of real effects in EHL, consideration is given in detail to the role played by stochastic roughness superimposed on the nominal solid boundaries. Particular attention is given to the full-film EHL regime where incipient asperity contact bears a negligible fraction of the load. Flow, from which an averaged Reynolds equation can be formed, is nonetheless modified by the amplitude and texture of the roughness patterns. In describing these effects by means of certain well-defined flow factors, it is found that only two extra parameters are needed - the rms surface height and the ratio of the correlation lengths in the two principal roughness directions. In a lowest order perturbation expansion of these flow factors in powers of the ratio of rms roughness to nominal film thickness, no other properties of the roughness appear. In most cases of practical interest, the factors describing Poiseuille flow are separable into the sum of two single-surface flow factors which means that a combination of a single equivalent rough surface versus an ideal smooth surface can always be found. For flow entrained by slip velocity the factors separate instead into a difference of single-surface factors and it becomes significant which of the two surfaces carries the equivalent roughness. Results are discussed of some applications of the averaged Reynolds equation based on the flow factor method to the EHL line contact problem. Finally, the partial EHL regime is considered where comparable load fractions are carried by the hydrodynamic film and by incipient mechanical contact. An extension of the method into this regime by combining it with asperity contact models appears most encouraging.

John H Tripp↗

DOE OSTI2021

Validation of simulated wave energy converter responses to focused waves

Focused waves are increasingly used as a design method to predict extreme loads for offshore structures, such as wave energy converters (WECs). However, the ability of computational methods to accurately simulate the prescribed focused waves and resulting wave structure interactions is not well validated. This study uses two computational fluid dynamic methods, WEC-Sim and STAR-CCM+, to evaluate the responses of two taut-moored WEC-like buoys to three different focused waves. WEC-Sim is a computationally efficient, mid-fidelity model, based on linearised potential flow theory. In contrast, STAR-CCM+ is a high-fidelity, three-dimensional, unsteady, Reynolds-averaged Navier–Stokes-based model. The two buoy geometries considered are a hemispherical-bottom cylinder and a truncated cylinder with a cylindrical moon pool. Three prescribed focused waves are generated in both codes, and the simulated displacements and mooring loads are obtained for each of the hydrodynamic bodies. The resulting STAR-CCM+ generated focused waves have approximately the same accuracy, in comparison with the analytic solution, as experimentally generated focused waves. The WEC-Sim simulated responses, when using viscous coefficients tuned to the measured displacements, are, on average, within 11.5% of experimentally measured values, whereas the STAR-CCM+ simulated responses are, on average, within 14.2% of the experimental values.

16 TIDAL AND WAVE POWER↗

DOE OSTI2021

Low friction bio-inspired polydopamine/polytetrafluoroethylene coating performance in hydrodynamic bearings

Purpose Low friction polymer coatings able to withstand high loadings and many years of continuous operation are difficult to formulate at low cost, but could find many applications in industry. This study aims to analyze and compare friction and wear performance of novel polydopamine/polytetrafluoroethylene (PDA/PTFE) and traditional tin Babbitt coatings applied to an industrial journal bearing. Design/methodology/approach This paper tested PTFE based coating, co-deposited with PDA, a biopolymer allowing sea mussels to adhere to ocean rocks. This coating was deposited on flat steel substrates and on a curved cast iron hydrodynamic journal bearing surface. The flat substrates were analyzed with a tribometer and an optical microscope, while the coated bearing liners were tested in an industrial laboratory setting at different speeds and different radial loads. Findings PDA/PTFE coating showed 2-3 times lower friction compared to traditional tin Babbitt for flat substrates, but higher friction in the bearing liners. PDA/PTFE also showed considerable wear through coating delamination and abrasion in the bearing liners. Research limitations/implications Five future modifications to mitigate coating flaws are provided, which include modifications to coating thickness and its surface finish. Originality/value While the novel coating showed excellent results on flat substrates, coating performance in a large scale bearing was found to be poor. This study shows that coating preparation needs to be improved to avoid frictional losses and unwanted damage to bearings. We provide several routes that could improve coating performance in industrial applications.

Engineering↗

DOE OSTI2021

Numerical Modelling of a Two-Body Point Absorber Featuring Variable Geometry

This work presents a novel wave energy converter (WEC) device concept that incorporates variable geometry modules into a two-body point absorber type WEC. The variable geometry modules consist of air inflatable bags in the surface float and a water inflatable ring in the reaction body. The variable geometry floats are able to provide greater control over the device hydrodynamics; they can be inflated or deflated to emphasize either power absorption or load shedding. The device geometry is controlled in a quasi-static fashion, while the power take-off (PTO) unit is controlled on a wave-to-wave timescale. The surface float is tethered directly to the submerged reaction body through PTO tether lines. A linear time-domain analysis, conducted using open-source Wave Energy Converter (WEC-Sim) software, was used to estimate the absorbed power of the WEC in sea states defined by the Wave Energy Prize. WEC power performance was weighted against the expected capital cost of building the load bearing structure of the device, providing an estimated ACE value. The inclusion of the variable geometry modules was shown to be effective in altering the device geometry to improve power capture with a near proportional increase in expected costs, providing a nearly constant power-to-cost ratio.

cost of energy↗

DOE OSTI2025

Countercurrent flow characteristics of next generation solvent in novel 3D printed columns for carbon capture

Solvent based absorption for carbon dioxide capture in a packed column is being considered as an efficient technology for the decarbonization process of point source. Significant efforts are underway to improve the design of packings with the cutting edge 3D printing technology for efficient carbon capture. Accordingly, multiphase flow studies were conducted to assess the performance of novel 3D printed columns with various triply periodic minimal surface (TPMS) designs. The effects of solvent properties, liquid and gas loads on the performance of TPMS columns are extensively explored. Hydrodynamics of the potential water-lean solvents (EEMPA) as well as aqueous monoethanolamine (MEA) solvent for carbon capture are evaluated and compared. The interfacial area and liquid holdup increase with increasing liquid loads (q L ) for TPMS columns. Schwarz column consistently shows the highest liquid holdup value. The EEMPA exhibits higher values for the interfacial area (10–15 %) and liquid holdup (~4 %) in comparison to the MEA. TPMS columns exhibit the intermediate value of dry pressure drop between the random and the structure packed columns. Among selected TPMS columns, the gyroid packing shows the lowest pressure drop. The gas load has marginal impact on the interfacial area at lower value while a higher gas load leads to column’s flooding. Prior to the flooding, the interfacial area in TMPS packings rises with increased gas load at a fixed liquid load except Schwarz packing where interfacial area is incentive to the gas load. Additionally, the liquid holdup and wet pressure drop rise as gas load increases in TPMS columns. Overall, Fisher Koch packing is more susceptible to flood as compared to other TPMS packings. Flow regimes: loading and flooding are also delineated in the TPMS packings.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1996

Scuffing Characteristics of High-Load Rolling/Sliding Contacts Operating in Liquid Oxygen: Effects of Materials and Surface Roughness

This research reports on an experimental study of the effects of materials and surface roughness on the scuffing characteristics of rolling/sliding contacts cooled and lubricated with liquid oxygen. Experiments were carried out under heavy loading with a Hertzian pressure in the range of 2.0 GPa to 3.0 GPa and with a high rolling velocity of up to 48 m/s. For contacts between AISI 440 C stainless-steel elements, the results showed that the scuffing behavior of the system was fairly consistent under a wide range of rolling velocity. Scuffing commenced at a small slide-to-roll ratio of around 0.02, and the scuffing behavior of the contact was not sensitive to surface roughness for the test-sample RMS roughness ranging from 0.02 microns to 0.10 microns. For contacts between 440 C and Si3N4 elements, on the other hand, the scuffing behavior of the system was not very consistent and somewhat unpredictable. The results were sensitive to surface roughness particularly that of the Si3N4 test sample. With well polished test samples, consistent results were obtained; the level of traction was lower than that with a 440 C toroid and scuffing did not take place up to a slide-to-roll ratio of near 0.03. The results strongly suggest that significant hydrodynamic effect can be generated by liquid oxygen under heavy loading and high velocity conditions. The results also suggest that the hydrodynamic action is likely generated by the conventional viscous mechanism as it can be largely destroyed by a narrow circumferential surface scratch running through the central region of the contact.

Chang, L.↗

DOE OSTI2023

Impact of Limited Degree of Freedom Drag Coefficients on a Floating Offshore Wind Turbine Simulation

The worldwide effort to design and commission floating offshore wind turbines (FOWT) is motivating the need for reliable numerical models that adequately represent their physical behavior under realistic sea states. However, properly representing the hydrodynamic quadratic damping for FOWT remains uncertain, because of its dependency on the choice of drag coefficients (dimensionless or not). It is hypothesized that the limited degree of freedom (DoF) drag coefficient formulation that uses only translational drag coefficients causes mischaracterization of the rotational DoF drag, leading to underestimation of FOWT global loads, such as tower base fore-aft shear. To address these hydrodynamic modeling uncertainties, different quadratic drag models implemented in the open-source mid-fidelity simulation tool, OpenFAST, were investigated and compared with the experimental data from the Offshore Code Comparison Collaboration, Continued, with Correlation (OC5) project. The tower base fore-aft shear and up-wave mooring line tension were compared under an irregular wave loading condition to demonstrate the effects of the different damping models. Two types of hydrodynamic quadratic drag formulations were considered: (1) member-based dimensionless drag coefficients applied only at the translational DoF (namely limited-DoF drag model) and (2) quadratic drag matrix model (in dimensional form). Based on the results, the former consistently underestimated the 95th percentile peak loads and spectral responses when compared to the OC5 experimental data. In contrast, the drag matrix models reduced errors in estimates of the tower base shear peak load by 7–10% compared to the limited-DoF drag model. The underestimation in the tower base fore-aft shear was thus inferred be related to mischaracterization of the rotational pitch drag and the heave motion/drag by the limited-DoF model.

17 WIND ENERGY↗

NASA NTRS1982

Theoretical results for fully flooded, elliptical hydrodynamic contacts

The influence of the ellipticity parameter and the dimensionless speed, load, and materials parameters on minimum film thickness was investigated. The ellipticity parameter was varied from 1 (a ball-on-plate configuration) to 8 (a configuration approaching a line contact). The dimensionless speed parameter was varied over a range of nearly two orders of magnitude. Conditions corresponding to the use of solid materials of bronze, steel, and silicon nitride and lubricants of praffinic and naphthemic mineral oils were considered in obtaining the exponent in the dimensionless materials parameter. Thirty-four different cases were used in obtaining the minimum film thickness formula H min = 3.63U to the 0.68 power G to the 0.49 power W to the -0.073 power 1-e to the 0.68K power). A simplified expression for the ellipticity parameter was found where k = 1.03 (r(y)/r(x)) to the 0.64 power. Contour plots were also shown which indicate in detail the pressure spike and two side lobes in which the minimum film thickness occurs. These theoretical solutions of film thickness have all the essential features of the previously reported experimental observations based upon optical interferometry.

Hamrock, B. J.↗

DOE OSTI2024

Power capture and power take-off load of a self-balanced dual-flap oscillating surge wave energy converter

Wave energy converters are an important part of future renewable energy infrastructure. Predicting their power matrix, capture width ratio, and power take-off loads at a targeted site is required for performance assessment before deployment. Because their testing is very expensive, numerical modeling and simulations play a significant role in those assessments. Linear potential flow theory has limited accuracy under large amplitude wave forcing. More accurate predictions can be obtained by using higher-fidelity models, which are computationally expensive. We present a framework for multi-fidelity numerical simulations to determine the hydrodynamic response, wave capture capability, and power take-off load of a full-scale dual-flap oscillating surge wave energy converter. This design exploits out-of-phase motion by setting the distance between the flaps to half the wavelength of the most occurring wave. The simulations are validated using a 1:10 model experiments in a wave tank. Based on these validations, it was determined that Euler simulations provide an acceptable prediction with 90% reduction in computational time with only 11% error. Utilizing Euler simulations at full-scale, the results demonstrate that the annual electrical energy output is 1.79 GWh under regular wave conditions. Here, one significant improvement over single-flap designs is the capture width ratio which exceeds unity.

16 TIDAL AND WAVE POWER↗

DOE OSTI2024

Theoretical modeling of a bottom-raised oscillating surge wave energy converter structural loadings and power performances

Here, this study presents theoretical formulations to evaluate the fundamental parameters and performance characteristics of a bottom-raised oscillating surge wave energy converter (OSWEC) device. Employing a flat plate assumption and potential flow formulation in elliptical coordinates, closed-form equations for the added mass, radiation damping, and excitation forces/torques in the relevant pitch-pitch and surge-pitch directions of motion are developed and used to calculate the system's response amplitude operator and the forces and moments acting on the foundation. The model is benchmarked against numerical simulations using WAMIT and WEC-Sim, showcasing excellent agreement. The sensitivity of plate thickness on the analytical hydrodynamic solutions is investigated over several thickness-to-width ratios ranging from 1:80 to 1:10. The results show that as the thickness of the benchmark OSWEC increases, the deviation of the analytical hydrodynamic coefficients from the numerical solutions grows from 3% to 25%. Differences in the excitation forces and torques, however, are contained within 12%. While the flat plate assumption is a limitation of the proposed analytical model, the error is within a reasonable margin for use in the design space exploration phase before a higher-fidelity (and thus more computationally expensive) model is employed. A parametric study demonstrates the ability of the analytical model to quickly sweep over a domain of OSWEC dimensions, illustrating the analytical model's utility in the early phases of design.

13 HYDRO ENERGY↗