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DOE OSTI2020

REopt Lite Overview & Training Exercise

This training exercise provides users with an introduction to and hands-on, interactive exploration of REopt Lite's capabilities. REopt Lite is a free, publicly available techno-economic optimization web tool for distributed energy systems, developed at the National Renewable Energy Laboratory (NREL). REopt Lite helps organizations evaluate the economic viability of grid-connected solar photovoltaics (PV), wind turbines, and battery storage; identify system sizes and battery dispatch strategies to minimize energy costs; and estimate how long a system can sustain critical load during a grid outage. The model is formulated as a mixed-integer linear program based in an underlying application programming interface (API) that is also free and publicly available. This training activity is structured as a group exercise. Participants split into eight groups and each group is assigned a different hypothetical site to model and assess the opportunity for solar PV + battery storage. Groups work together to develop results for their site and then re-convene to compare and discuss results, inputs/drivers of the analysis, and other factors impacting the decision-making process for behind-the-meter solar PV and battery storage.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Characterization and repair of core gap manufacturing defects for wind turbine blades

Various wind turbine blade components, such as shear webs and skins, commonly use fiber-reinforced composite sandwich structures with a core material like balsa or foam. During manufacturing, core gap defects may result from the misalignment of adjacent foam or balsa core sheets in the blade mold. It is important to understand the influence that core gaps have on the structural integrity of wind turbine blades and how to mitigate their influence. This research characterized the effects of core gap defects at the manufacturing and mechanical levels for both epoxy and next-generation thermoplastic composites. Common repair methods were assessed and compared. Multiple defect sizes were compared using temperature data gathered with thermocouples embedded during manufacturing to core gap defect characteristics obtained using image-mapping techniques, optical microscopy, and mechanical characterization by long beam flexure. Results showed that peak exothermic temperatures during curing were closely related to core gap size. The long beam flexure tests determined that transverse core gaps under pure bending loads can have a substantial effect on the ultimate facesheet strength of both epoxy and thermoplastic composite sandwich structures (up to 25% strength reduction), although the size of the defect itself had less of an influence on the magnitude of the strength reduction. The supporting image-mapping techniques indicated that the distortion of the composite facesheets by the core gaps contributed to the premature failures. The repair methods used in this study did very little to improve the ultimate strength of the sandwich panels that previously had core gap defects. The repair of the thermoplastic panel resulted in a further loss in ultimate facesheet strength. This research demonstrated that there is a vital need for the development of a compatible thermoplastic polymer repair resin system and appropriate resin specific repair procedures for the next generation of recyclable thermoplastic wind blades.

17 WIND ENERGY↗

DOE OSTI2023

A Revised International Standard for Gearboxes in Wind Turbine Systems

Gearbox and wind turbine design and application standards have contributed significantly to improvements in reliability over the past two decades. The International Electrotechnical Commission (IEC) 61400-4 standard of wind turbine gearbox design is currently being revised by a joint working group (JWG) of experts in IEC TC 88 (wind energy) and International Organization for Standardization (ISO) TC60 (gears) to further that effort. Experts from ISO TC4 (rolling bearings) and ISO TC28 (lubricants) have actively participated. This revision has implemented lessons learned from industry use of edition 1 since its publication in 2012. The main document, IEC 61400-4, was pared down to essential design requirements and application-specific recommendations along with a design verification framework. The JWG leveraged concurrent development of other standards, such as IEC 61400-8 on wind turbine structures, to replace edition 1 content. These are described along with how this works with the IEC Renewable Energy certification scheme for wind turbines (IECRE-WE). The JWG recognized the interest in maintaining informative parts of edition 1 including annexes on wind turbine architecture and loads, bearing and gear arrangements, bearing selection, lubrication system descriptions and lubricant performance recommendations. This information was retained in two technical reports: IEC/TR 61400-4-2 Lubrication and IEC/TR 61400-4-3 Explanatory Notes. Additionally, a technical specification, IEC/TS 61400-4-1, was drafted to provide a reliability calculation method for comparing different design options or conditions. Salient elements of these documents are described. All four documents were recently distributed for IEC/ISO review, ballot, and comment. Publication is expected in 2023.

gearbox↗

DOE OSTI2023

A Revised International Standard for Gearboxes in Wind Turbine Systems: Preprint

ENGINEERING,WIND ENERGY↗

DOE OSTI2025

Slender-body approach for computing second-order wave loads in the frequency domain

This work presents a slender-body approach to evaluate the second-order wave loads acting on a floating structure in the frequency domain. The approach is in the same spirit as the common use of Morison’s equation to approximate the wave loads without solving the radiation/diffraction problem. To do so, we employ Rainey’s equation, which can be seen as an extension of the inertial part of Morison’s equation to include nonlinear effects. We introduce modifications to Rainey’s formulation in order to evaluate wave kinematics at the mean body position instead of the original approach of considering instantaneous displacements. We also propose a simple approximation to partially account for wave scattering effects on the second-order loads based on the analytical solution of a surface-piercing bottom-mounted vertical circular cylinder. Though limited to structures composed of cylinders, this slender-body approach is orders of magnitude faster than computing second-order wave coefficients with a radiation/diffraction code. We implemented this approach for difference-frequency (slow drift) loads in an open-source frequency-domain floating wind turbine model. We present comparisons against results obtained with radiation/diffraction theory for three reference floating wind turbine designs: the OC3-Hywind spar, the OC4-DeepCwind semisubmersible, and the VolturnUS-S semisubmersible. In general, the results show that the proposed slender-body approach with the correction to approximate wave scattering effects provides useful estimations of the difference-frequency wave loads and the resulting motions of the floater.

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↗

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 OSTI2025

Investigation into the instantaneous centre of rotation for enhanced design of floating offshore wind turbines

The dynamic behaviour of floating offshore wind turbines (FOWTs) involves complex interactions of multivariate loads from wind, waves, and currents, which result in complex motion characteristics. Although methods for analysing global motion responses are well-established, the time- and location-dependent kinematics remain underexplored. This paper investigates the instantaneous centre of rotation (ICR), a point of zero velocity at a time instance of general plane motion. Understanding and strategically positioning the ICR can reduce the dynamic motion in critical structural locations, enhancing the performance and structural robustness of FOWTs. The paper presents a method for computing the ICR using time-domain simulation results and proposes a statistical analysis approach suitable for design studies. Building on prior research, it examines the sensitivity of the ICR to external loading and design features, providing insights into how these factors influence motion response and how the motion response influences the statistics of the ICR, structural loads, and other performance metrics of interest. The study explores two FOWT configurations, a spar and a semisubmersible, identifying design variables that most effectively control the ICR statistics and identifying the ICR statistics most correlated with the responses of interest. Finally, through two case studies, we demonstrate how to apply these new insights in a practical design scenario. By adjusting the design variables most correlated with the ICR (fairlead vertical position and centre of mass for the spar and mooring line length and offset column diameter for the semisubmersible), we successfully modified the designs of the floating support structures to reduce the loads in the mooring lines, tower base, and blade roots, improving the ultimate strength and fatigue characteristics compared to the original designs.

17 WIND ENERGY↗

DOE OSTI2024

Near wake evolution of a tidal stream turbine due to asymmetric sheared turbulent inflow with different integral length scales

Tidal stream turbines deployed at highly energetic open water sites are subjected to sheared inflow in the rotor plane. The inflow shear is expected to cause asymmetric loading on the rotor blades and affect the downstream wake. In the current study, two different turbulent inflow conditions, static-high shear and dynamic shear, were generated via an active-grid turbulence generator. A 1:20 scaled three-bladed horizontal axis tidal turbine model was tested in those conditions. The results were compared to a quasi-laminar case with no imposed turbulence or shear. The results show that the high shear reduces the average performance, with a drop of up to 16% in the optimal power coefficient. Besides, the shear profiles increase torque fluctuations and induce significant differences in wake hydrodynamics between the high-speed (upper) and low-speed (lower) regions. The large integral length scales further enhance the load fluctuations perceived by the rotor but have a negligible effect on the mean wake field quantities and the wake recovery. The lower half region featured a faster breakdown of tip vortex structure and a rapid drop of swirl number, a phenomenon conjectured to be a consequence of the strong turbulence intensities and Reynolds stresses in the lower half region. Furthermore, the sheared turbulent inflow also results in a very intensive energy redistribution process towards large-scale, low-frequency motions, which is important to the downstream turbines.

16 TIDAL AND WAVE POWER↗

DOE OSTI2021

OC6 Phase II: Integration and verification of a new soil–structure interaction model for offshore wind design

Abstract This paper provides a summary of the work done within the OC6 Phase II project, which was focused on the implementation and verification of an advanced soil–structure interaction model for offshore wind system design and analysis. The soil–structure interaction model comes from the REDWIN project and uses an elastoplastic, macroelement model with kinematic hardening, which captures the stiffness and damping characteristics of offshore wind foundations more accurately than more traditional and simplified soil–structure interaction modeling approaches. Participants in the OC6 project integrated this macroelement capability to coupled aero‐hydro‐servo‐elastic offshore wind turbine modeling tools and verified the implementation by comparing simulation results across the modeling tools for an example monopile design. The simulation results were also compared to more traditional soil–structure interaction modeling approaches like apparent fixity, coupled springs, and distributed springs models. The macroelement approach resulted in smaller overall loading in the system due to both shifts in the system frequencies and increased energy dissipation. No validation work was performed, but the macroelement approach has shown increased accuracy within the REDWIN project, resulting in decreased uncertainty in the design. For the monopile design investigated here, that implies a less conservative and thus more cost‐effective offshore wind design.

17 WIND ENERGY↗

DOE OSTI2023

Large-eddy simulations of turbulent flows in arrays of helical- and straight-bladed vertical-axis wind turbines

Effects of helical-shaped blades on the flow characteristics and power production of finite-length wind farms composed of vertical-axis wind turbines (VAWTs) are studied numerically using large-eddy simulation (LES). Two helical-bladed VAWTs (with opposite blade twist angles) are studied against one straight-bladed VAWT in different array configurations with coarse, intermediate, and tight spacings. Statistical analysis of the LES data shows that the helical-bladed VAWTs can improve the mean power production in the fully developed region of the array by about 4.94%–7.33% compared with the corresponding straight-bladed VAWT cases. The helical-bladed VAWTs also cover the azimuth angle more smoothly during the rotation, resulting in about 47.6%–60.1% reduction in the temporal fluctuation of the VAWT power output. Using the helical-bladed VAWTs also reduces the fatigue load on the structure by significantly reducing the spanwise bending moment (relative to the bottom base), which may improve the longevity of the VAWT system to reduce the long-term maintenance cost.

17 WIND ENERGY↗

DOE OSTI2024

Structural Characterization of Deployed Thermoplastic and Thermoset Composite Tidal Turbine Blades

The National Renewable Energy Laboratory worked with Verdant Power to manufacture, and characterize, novel thermoplastic composite blades on their Gen5d 5 m diameter turbines at the Roosevelt Island Tidal Energy (RITE) site in the East River in N.Y. to demonstrate a low-cost manufacturing process for marine energy structures. Verdant had designed, manufactured, and deployed epoxy thermoset composite blades on three Gen5d turbines in October 2020. At a maintenance cycle in May 2021, a Gen5d turbine equipped with the NREL thermoplastic blades was deployed and retrieved in October 2021. Modal, static and fatigue structural characterization was performed on both blade types before and after the deployment. The static and modal test results showed that the thermoplastic blades were slightly stiffer than the epoxy blades both dry and after the deployment. The epoxy blades had about 8% increase in strain at the applied load after the deployment, whereas the thermoplastic blade strains were not changed significantly. Ultimately the thermoplastic blade failed during fatigue testing due to a crack which is thought to have initiated between the internal foam and the laminate at the location of the internal instrumentation. The Verdant Power Gen5d epoxy blades did not have this internal instrumentation and did not have this failure, performing adequately through the operational period. A lack of design information and fatigue data for both the thermoplastic laminates and the adhesive used means that further work is needed to fully understand his failure and the root cause analysis is ongoing. This paper provides details on the thermoplastic blade manufacturing, materials, test methodology and results.

17 WIND ENERGY↗

DOE OSTI2024

Open-Source Tidal Energy Converter (OSTEC) Testbed: Design Basis Report

This report describes the design basis and design details for an instrumented marine turbine system intended to serve as the DOE’s marine tidal turbine test bed for foundational open-source R&D and data generation to advance our understanding and to identify knowledge gaps on the techno-economic performance of tidal energy converters (TEC) under real tidal flow conditions and at sufficiently large scale to enable upscaling of fluid-structure-interactions and component and material load responses

16 TIDAL AND WAVE POWER↗

DOE OSTI2025

High-Temperature Active Magnetic Bearing Development for Supercritical CO 2 Machinery Applications

Hermetic machinery utilizing gas bearings for MW-scale supercritical CO 2 (sCO 2 ) machinery applications can have significantly lower power loss and enable improved cycle efficiency compared to conventional machinery with oil-lubricated bearings. Active magnetic bearings (AMBs) are another option anticipated to have similar power loss and load capacity to gas bearings as well as offering larger mechanical tolerances, the ability to tune properties, and high reliability due to lack of mechanical wear. AMBs also have proven commercial experience at MW-scale, though environments for high-temperature sCO 2 power cycle machinery conditions are novel. Besides the potential impact of AMBs for sCO 2 turbomachinery, the technology also offers promising benefits for steam and gas turbines for power generation, compressors and expanders for industrial heat and power, and in other oil and gas and space applications. The goals of this project were to conceptual design an AMB and perform material testing. Conceptual designs for radial and thrust AMBs were produced based on a hermetically-sealed sCO 2 machinery waste-heat recovery (WHR) application for sizing and loads, and choosing a target design temperature of 540°C useful for high-temperature sCO 2 turbines for concentrating solar power (CSP) applications. Conceptual designs were initially developed for multiple radial and thrust AMBs with spreadsheet-based calculations before selecting one of each to develop further using higher-fidelity design methods for magnetic and structural performance. It was found that the radial AMB at 540°C was feasible, but the thrust AMB needed to be limited to 315°C for high-speed operation. The decision for a reduced-temperature thrust AMB was the result of several significant conclusions: 1) Hiperco 50A, originally chosen for good magnetic performance at high temperature, had insufficient strength for high-speed operation, so it was replaced with 17-4 PH. 2) The reduced magnetic performance from 17-4 PH yielded a larger bearing size, reducing the strength margin. 3) This ultimately led to a creative design implementing a more-compact E-core topology, compared to the original (conventional) C-core, and an integral shaft-disk with Hirth joint connection. These conceptual designs are unique for the size and temperature in CO 2 , relevant for MW-scale CSP applications. Long term, high temperature test data was generated for several materials, filling a void in the current body of literature. Corrosion and magnetic performance measurements were produced for PM materials (Alnico 5-7C, Alnico 9C, and SmCo) with and without nickel-coating for environments of high-temperature CO 2 up to 550°C at atmospheric pressure and 450°C at 103 bar for up to 6,000 hours. Corrosion measurements were also produced for Hiperco 50, a SM material relevant for AMB laminations, with and without C5 coating. Comparisons were also made for 450°C and 550°C, atmospheric pressure air exposures up to 5,000 hours. Results generally show that coatings can be effective at improving oxidation resistance of the bare materials, and Alnicos generally outperformed SmCo after high-temperature exposure. In addition to technical feasibility demonstrated by the design, economic feasibility was demonstrated by updating the TEA from the reference machine, re-evaluating it with CAPEX and OPEX to reflect estimated changes from process-lubricated bearings to AMBs. AMBs were shown to be comparable in performance to process-lubricated bearings, still showing a notable improvement over conventional machinery architecture with oil-lubricated bearings.

42 ENGINEERING↗

DOE OSTI2025

Frequency-domain modeling of floating wind arrays with shared mooring lines

A frequency-domain model for floating wind turbine dynamics has been extended to model floating wind farms with couplings from shared mooring systems. The model, called RAFT, could previously calculate the mean offsets and wave-induced response spectra for single floating wind turbines. Now, the model supports multiple floating wind turbines, each with their own properties and responses, along with mooring lines that run directly between floating wind turbines in the array, meaning that shared mooring lines or fully suspended dynamic power cables can be included. This capability is achieved by setting up an array-level solution of the system mean offsets and assembling the full system matrices for solving the dynamic response. The quasi-static mooring model MoorPy is used to linearize the mooring system properties. To compute the floating wind turbine relative motions, phase offsets are applied to each turbine's response as a function of wave frequency based on the wavelength and relative positions in the array. These differential motions are then applied to mooring system tension Jacobians to compute the tension loads in the shared mooring lines. Overall, the capability provides a frequency-domain analog to the modeling capabilities of the floating support structure in FAST.Farm. Mean offsets and power spectral density plots of responses are compared between RAFT and FAST.Farm to verify the implementation. The results indicate good agreement within the expectations of a frequency-domain modeling approach and suggest correct implementation of the shared mooring aspects. Additionally, a unique comb-like frequency response in the shared mooring line tensions has been observed. This phenomenon has a clear physical basis and may be an important design consideration for future shared mooring systems.

17 WIND ENERGY↗

DOE OSTI2020

Investigating Core Gaps and the Development of Subcomponent Validation Methods for Wind Turbine Blades: Preprint

Core gaps are a common manufacturing defect observed in wind blade composite sandwich constructions, which occur when sheets of core material are not properly butted up against each other in the mold. The aim of this study was to characterize core gaps in composite sandwich constructions at the coupon scale. This was to gain an initial understanding of the defect before developing appropriate methodologies for more complex subcomponents as part of a much broader wind blade structural validation and damage tolerance program. Long beam flexure in 4-point-bending was chosen as the most appropriate loading scenario. Beam specimens were characterized with and without 10 mm core gaps in fiberglass/balsa sandwich beams. The core gaps were characterized with two separate resin systems; a Hexion epoxy and Arkema's Elium resins system (a novel, infusible thermoplastic). Results showed that the Elium beams without the core gaps were had a 15% lower static strength than their epoxy counterparts. The introduction of the core gap to the epoxy beams reduced their static strength by 35%. The Elium beams, however, exhibited negligible strength reductions with the inclusion of the core gap. Overall, this characterization study provided pertinent information with regards to core gaps as a manufacturing defect to allow for continued development of damage tolerance and subcomponent validation methodologies with the inclusion of manufacturing defects.

17 WIND ENERGY↗

DOE OSTI2024

A Multiphysics Multiscale Simulation Platform for Damage, Environmental Degradation, and Life Prediction of CMCs in Extreme Environments

This project successfully developed a multiphysics, multiscale computational framework to enhance the design and development of CMCs, with a focus on modeling highly nonlinear, time-dependent damage mechanisms and material degradation under extreme conditions, such as those experienced in turbine service environments. The project made significant advances in improving our understanding of progressive damage, oxidative degradation, and time-dependent inelastic deformation in CMCs, with particular attention to the role of uncertainties in predictions. Key outcomes include the integration of advanced material characterization, uncertainty quantification, and multiphysics constitutive models to predict the behavior of CMCs over their service life. A novel multiscale methodology was employed, which integrated microscale constituent behaviors with structural-scale responses, enabling the manufacturing defects in the microstructure that are prone to damage nucleation. Through the development of DL algorithms, the project advanced the prediction of damage initiation and crack propagation, taking into account the defect morphology and statistical variations across multiple scales. The framework was rigorously validated using thermomechanical experiments, which tested CMCs under various mechanical loadings at elevated temperatures, further enhancing the model's predictive capability. Overall, the research outcomes have provided a more accurate, reliable method for predicting CMC component life, significantly advancing material design, and improving component reliability in extreme environments. This work has strong implications for the optimization of turbine components and other high-performance applications where CMCs are used.

03 NATURAL GAS↗