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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 163 records · Page 9

Lidar-Based Evaluation of HRRR Performance in California’s Diablo Range

The performance of the NOAA High-Resolution Rapid Refresh (HRRR) model for capturing low-level winds near a wind energy production site during summer 2019 is evaluated. This study catalogs the ability of HRRR to predict boundary layer dynamics relevant to wind energy interests over complex terrain, which has presented challenges for weather and energy forecasting. Performance is evaluated by comparing HRRR output to wind-profiling Doppler lidars at Lawrence Livermore National Laboratory Site 300. HRRR captured the diurnal profile of horizontal winds in the observed 150-m layer, despite strong underpredictions (∼4 m s −1 ) during evening and nighttime hours. These underpredictions may be a result of local speedup flows observed by the lidars, which were unresolved in HRRR due to their small spatial extent. HRRR bias magnitude relative to observations was found to be minimal during days with synoptic-scale troughs and strong 850-hPa geopotential gradients, while bias magnitude was maximal during days with synoptic ridging and weak 850-hPa geopotential gradients. To translate wind speed predictions to energy forecasting, generic turbine models were used to estimate power generation for turbines characteristic of the nearby Altamont Pass Wind Resource Area. Results show that HRRR-based energy estimates predicted daytime power generation adequately relative to lidar-based estimates with an 18-h lead time (bias magnitude < 0.4 MW from 0900 to 1400 LT) but overpredicted power during the rest of the diurnal cycle (bias > 1 MW). These results demonstrate conditions under which HRRR performs well for wind energy applications in complex terrain, while highlighting biases that require further investigation to support usage of a high-resolution model for wind energy forecasts.

Boundary layer↗

The effects of blade mounted vortex generators on the noise from a MOD-2 wind turbine generator

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.

Hubbard, H. H.↗

There’s plenty of room at the top

Richard Feynman’s famous words, “there’s plenty of room at the bottom,” referred to the opportunities for revolutionizing the electronics industry by developing the science and technology of how to manufacture very small components (sub-micron to nanometer sized features). In additive manufacturing (AM), the opposite may be true: There’s plenty of room at the top. AM’s strength is in the low volume production of complex components, which is demanded in big industries such as oil and gas, construction, tooling, wind and water turbines, and infrastructure. Is AM’s ‘big’ future in the manufacture of large structures? Here, this special issue surveys the technical challenges and enormous opportunities associated with large scale additive manufacturing while discussing the materials, processes and applications that are enabled by scaling to much larger structures, much faster speeds and lower manufacturing costs. The authors believe that, if Professor Feynman was alive, he’d say “There’s plenty of room at the top.”

36 MATERIALS SCIENCE↗

Effect of Heat Treatment on Microstructure and Mechanical Property of 316L Stainless Steel Produced by Laser Powder Bed Fusion

The advanced non-light water reactor designs (Gen IV reactors), including molten salt/ very high temperature/ sodium-cooled and lead-cooled fast reactors, typically operate at higher temperatures and more extreme radiation conditions than light water reactors. An intrinsic part of the deployment and progress of Gen IV reactor designs is selecting the most suitable structural material for a specific application. Additive manufacturing (AM), a fairly new process of making physical, three-dimensional objects from a computer design file, is going to completely change the way of design, build and certify nuclear systems. It offers a range of opportunities to produce complex geometries from existing materials, offers new routes for processing of previously difficult to process materials, allows for design of new high-performance materials, and finally facilitates hybridization of dissimilar materials. This emerging technology has successfully produced cars, wind turbine blade molds and even live cells. It could also open up big opportunities for the nuclear industry to quickly deploy technologies at a fraction of the cost. So far, AM techniques have been preliminarily applied in the field of nuclear reactors, including the classical parts such as the pressure vessel of a small reactor with 508-III steel, the bottom nozzle of a fuel assembly with 304L steel, the fuel cladding with zirconium alloy and the integrated impeller of a pump and the multi-channel valve body with 316L steel [6,7]. The AM applications for operating nuclear reactors started in auxiliary plant components and have slowly migrated to metallic reactors and core components, but many of these are not safety critical components. Although many parts used for nuclear reactors have been fabricated by AM techniques, practical applications in engineering are still a long way off due to the uncertainty factors focused on the processing, material properties, analysis methods and application standards, which feeds the safety and life-cycle of the nuclear reactor. Due to rapid, repeated heating and cooling during production, a high dislocation density was present in the AM material. This microstructure feature is unstable at elevated temperature while high temperature is one of the typical operation environments for nuclear reactors. Thus, it is important to understand the thermal effect on the microstructure of AM material. The objectives of this study are to investigate the effect of heat treatment on the microstructure and mechanical properties of 316L stainless steel produced by laser powder bed fusion additive manufacturing, and to determine an appropriate heat treatment practice that will be applied to the lightweight AM lattice-structured material with the same chemistry. The heat treatment study consisted of annealing the samples at a temperature range of 800 to 1200 oC with a 50 oC increment for different times (1-24 hours), followed by vacuum or air cooling. Microstructural characterization was carried out by Scanning Electron Microscope (SEM). Grain size and crystallographic orientation were investigated by Electron Backscatter Diffraction (EBSD). Vickers hardness tests with a 0.5 kg load were employed to determine the hardness of samples after different heat treatments. After heat treatment, the random crystallographic orientation was preserved, and the volume fraction of high-angle grain boundaries (grain boundary misorientation =15 oC) remained the same. The dislocation density decreased with annealing temperature due to recovery. The fine subgrain structures in the as-printed specimen were quite stable up to 1200 oC. Minimal recrystallization was observed up to 1200 oC. Recrystallization initiated only after 8.5 hours at 1200 oC. The SEM images did not show obvious dependence of microstructure on cooling rate. The hardness of the specimens decreased with increasing annealing temperature as a result of the decrease in dislocation density. It is interesting to note that the AM material showed very similar hardness to the wrought material when annealing at similar temperature, although the microstructures are very different. Annealing at 1050 oC for 1 hour followed by air cooling was selected as the heat treatment procedure for the lattice designed lightweight AM 316L material.

36 MATERIALS SCIENCE↗

2022 Prototype Manufacture and Installation Awardee: Sonsight Wind

The Sonsight Wind 3.5-kilowatt (kW) prototype turbine is designed to compete with solar power, meeting energy needs for a wide range of smaller-scale applications, such as powering individual homes and irrigation systems on farms and ranches in remote areas. The technology's innovative high-torque, low-rotations-per-minute generator permits the use of longer blades that, at moderate wind speed sites, generate the energy of a 5-kW turbine with lower thrust forces than similarly rated turbines. The 3.5-kW turbine is projected to ofer greater durability at a signifcantly lower levelized cost of energy. Sonsight Wind advanced the development of the prototype with a previous Competitiveness Improvement Project (CIP) funding award.

competitiveness improvement project↗

Mountain waves can impact wind power generation

Abstract. Mountains can modify the weather downstream of the terrain. In particular, when stably stratified air ascends a mountain barrier, buoyancy perturbations develop. These perturbations can trigger mountain waves downstream of the mountains that can reach deep into the atmospheric boundary layer where wind turbines operate. Several such cases of mountain waves occurred during the Second Wind Forecast Improvement Project (WFIP2) in the Columbia River basin in the lee of the Cascade Range bounding the states of Washington and Oregon in the Pacific Northwest of the United States. Signals from the mountain waves appear in boundary layer sodar and lidar observations as well as in nacelle wind speeds and power observations from wind plants. Weather Research and Forecasting (WRF) model simulations also produce mountain waves and are compared to satellite, lidar, and sodar observations. Simulated mountain wave wavelengths and wave propagation speeds (group velocities) are analyzed using the fast Fourier transform. We found that not all mountain waves exhibit the same speed and conclude that the speed of propagation, magnitudes of wind speeds, or wavelengths are important parameters for forecasters to recognize the risk for mountain waves and associated large drops or surges in power. When analyzing wind farm power output and nacelle wind speeds, we found that even small oscillations in wind speed caused by mountain waves can induce oscillations between full-rated power of a wind farm and half of the power output, depending on the position of the mountain wave's crests and troughs. For the wind plant analyzed in this paper, mountain-wave-induced fluctuations translate to approximately 11 % of the total wind farm output being influenced by mountain waves. Oscillations in measured wind speeds agree well with WRF simulations in timing and magnitude. We conclude that mountain waves can impact wind turbine and wind farm power output and, therefore, should be considered in complex terrain when designing, building, and forecasting for wind farms.

17 WIND ENERGY↗

SAM™ (System Advisor Model™) [SWR-16-02, SWR-10-13]

See the SAM™ website to build a desktop version of the National Laboratory of the Rockies' (NLR's) System Advisor Model™ (SAM). https://sam.nlr.gov/ The System Advisor Model™ (SAM™) is a free techno-economic software model that facilitates decision-making for people in the renewable energy industry: -Project managers and engineers -Policy analysts -Technology developers -Researchers SAM can model many types of renewable energy systems: -Photovoltaic systems, from small residential rooftop to large utility-scale systems -Battery storage with Lithium ion, lead acid, or flow batteries for front-of-meter or behind-the-meter applications -Concentrating Solar Power systems for electric power generation, including parabolic trough, power tower, and linear Fresnel -Industrial process heat from parabolic trough and linear Fresnel systems -Wind power, from individual turbines to large wind farms -Marine energy wave and tidal systems -Solar water heating -Fuel cells -Geothermal power generation -Biomass combustion for power generation -High concentration photovoltaic systems SAM's financial models are for the following types of projects: -Residential and commercial projects where the renewable energy system is on the customer side of the electric utility meter (behind the meter), and power from the system is used to reduce the customer's electricity bill. -Power purchase agreement (PPA) projects where the system is connected to the grid at an interconnection point, and the project earns revenue through power sales. The project may be owned and operated by a single owner or by a partnership involving a flip or leaseback arrangement. -Third party ownership where the system is installed on the customer's (host) property and owned by a separate entity (developer), and the host is compensated for power generated by the system through either a PPA or lease agreement. For a more detailed description of SAM, see Blair et al. (2018), System Advisor Model (SAM) General Description (Version 2017.9.5), NREL/TP-6A20-70414. https://www.nrel.gov/docs/fy18osti/70414.pdf

Ryberg, David↗

TBCC Inlet Experiments and Analysis

A research plan is being implemented at NASA to investigate inlet mode transition for turbine-based combined-cycle (TBCC) propulsion for the hypersonic community. Unresolved issues have remained on how to design an inlet system to supply both a turbine engine and a ram/scramjet flowpath that operate with both high performance and stability. The current plan is aimed at characterizing the design, performance and operability of TBCC inlets through a series of experiments and analyses. A TBCC inlet has been designed that is capable of high performance (near MIL-E-5008B recovery) with smooth transitioning characteristics. Traditional design techniques were used in an innovative approach to balance the aerodynamic and mechanical constraints to create a new TBCC inlet concept. The inlet was designed for top-end Mach 7 scramjet speeds with an over/under turbine that becomes cocooned beyond its Mach 4 peak design point. Conceptually, this propulsion system was picked to meet the needs of the first stage of a two-stage to orbit vehicle. A series of increasing fidelity CFD-based tools are being used throughout this effort. A small-scale inlet experiment is on-going in the GRC 1'x1' Supersonic Wind Tunnel (SWT). Initial results from both the CFD analyses and test are discussed showing that high performance and smooth mode transitions are possible. The effort validates the design and is contributing to a large-scale inlet/propulsion test being planned for the GRC 10' x10' SWT. This large-scale effort provide the basis for a Combined Cycle Engine Testbed, (CCET), that will be able to address integrated propulsion system and controls objectives.

Saunders, Dave↗

Combined Cycle Integrated Thermal Energy Storage “CiTES” (Final Scientific/Technical Report)

The Phase I of this project confirmed the technical feasibility of a Combined Cycle integrated Thermal Energy Storage “CiTES” system, calculated the key performance parameters like power efficiency and costs, and proved its commercial value with full-year simulations for several US electricity markets with high degree of variable renewable generation and volatile hourly electricity prices. The core element of this project is the Electro Thermal Energy Storage (ETES) technology from Siemens Gamesa Renewable Energy GmbH, using thermally stable and inexpensive volcanic rocks as storage material and air as heat transfer medium. This technology is backed by more than 10 years of experience and a 440MMBTU (130MWh-th) pilot plant in Hamburg, Germany, which is in operation since 2019. The integration of this thermal storage in an existing combined cycle power plant (CCPP) is typical power plant technology without any major technology risks. It allows the storage of inexpensive renewable energy during times of surplus renewable generation and the discharge of this energy in times of high energy demand when the fossil plant is in operation. This supplements the fossil power generation with CO2-emission-free energy. The secondary effect of the CiTES system is that a small part of the stored thermal energy is used to keep the heat recovery steam generator (HRSG) and steam turbine (ST) of the combined cycle power plant in hot and ready-to-start condition. This enables the plant to start rapidly when fossil generation is required to satisfy demand as soon variable generation drops off in the evenings or during cloud cover and calm wind periods. Without pre-warming of the HRSG and ST, the CCPP would need several hours for a cold or warm start, burn a lot of gas and release high NOx emissions during start and wouldn’t be able to use the short times of high energy prices in an efficient or economical manner. The economic parameters of CiTES were determined by a full year “8760” simulation using a data set calculation for each of the hours of the year, and historical electricity and gas prices. For consistency, the simulations were focused on the pre-COVID year 2019. The financially most attractive markets were in the Energy Reliability Council of Texas (ERCOT) region, which allowed substantial value generation with arbitrage (charge with cheap energy during renewable surplus times and discharge when energy is needed and expensive). The improvement of flexibility with the CiTES system by pre-heating and warm-keeping of the CCPP allowed for additional power generation during short time periods when demand is high but renewable generation is down; when the hourly energy prices are highest in these markets. The simulations are based on 2019 data, when ERCOT had 27GW of installed photovoltaic (PV) and wind generation. They showed that the created revenue with the prototypically sized CiTES system of 1,000MMBTU (300MWh-th) falls a little bit short of what is expected from a commercially viable investment. The system has optimization opportunities for cost reduction and increased effectiveness which will be realized during a potential Phase II Pre-FEED study following this project. Furthermore, it is safe to assume that a lot of renewable generation capacity will be added all over the US in the coming years. As an example, ERCOT is predicting to more than double its renewable generation from 27GW in 2019 to a forecasted 63GW in 2023. This will increase the amount of renewable overproduction exponentially. This rapid increase of local overproduction and the need to curtail renewable generation is well documented by the California ISO (www.CAISO.com / managing oversupply). However, the simulations also revealed a weakness in the structure of the electricity markets in the US. More specifically, when electricity prices are very low and approaching negative levels, the owners of Variable Renewable Energy (VRE) will curtail a part of their facility to stabilize the price by reducing supply. This results in a situation in which storage facilities, which are integrated in existing fossil assets and don’t have the behind-the-meter benefit of a VRE, won’t be able to purchase low cost – otherwise curtailed – renewable energy off the grid. A special tariff, which motivates VRE owners to sell otherwise curtailed renewable energy to storage facilities (Hydrogen, thermal, pumped hydro, etc.) can solve this issue. The implementation of such a regulating tariff by Independent System Operators, thus avoiding renewable curtailment, is a pre condition for successful commercialization for renewable energy storage technologies. With this advancement of design and technology and improvements in the market environment, it can be expected that the Combined Cycle integrated Thermal Energy Storage proves itself as an important innovation to keep highly efficient, natural gas-based power generation economically successful and relevant for the power industry in the United States of America.

Wolf, Thorsten↗

Effect of vortex generators on the power conversion performance and structural dynamic loads of the Mod-2 wind turbine

Applying vortex generators from 20 to 100 percent span of the Mod-2 rotor resulted in a projected increase in annual energy capture of 20 percent and reduced the wind speed at which rated power is reached by nearly 3 m/sec. Application of vortex generators from 20 to 70 percent span, the fixed portion of the Mod-2 rotor, resulted in a projected increase in annual energy capture of about half this. This improved performance came at the cost of a small increase in cyclic blade loads in below rated power conditions. Cyclic blade loads were found to correlate well with the change in wind speed during one rotor revolution.

Sullivan, T. L.↗

Aeroelastic equations of motion of a Darrieus vertical-axis wind-turbine blade

The second-degree nonlinear aeroelastic equations of motion for a slender, flexible, nonuniform, Darrieus vertical-axis wind turbine blade which is undergoing combined flatwise bending, edgewise bending, torsion, and extension are developed using Hamilton's principle. The blade aerodynamic loading is obtained from strip theory based on a quasi-steady approximation of two-dimensional incompressible unsteady airfoil theory. The derivation of the equations has its basis in the geometric nonlinear theory of elasticity and the resulting equations are consistent with the small deformation approximation in which the elongations and shears are negligible compared to unity. These equations are suitable for studying vibrations, static and dynamic aeroelastic instabilities, and dynamic response. Several possible methods of solution of the equations, which have periodic coefficients, are discussed.

Kaza, K. R. V.↗

Investigation of main bearing operating conditions in a three-Point mount wind turbine drivetrain

Wear-related failures of spherical roller bearings in the main bearing position of three-point mount wind turbines have been higher than expected and can contribute to higher than anticipated operation-and-maintenance costs. In this paper, the operational conditions of such a main bearing—including measured axial displacement and velocity subject to the estimated axial loads—are described for an instrumented, commercial wind turbine. The field measurements suggest a maximum axial speed between the bearing rings that is less than 2 millimeters per second. It is estimated that the axial speed between the ring and rollers is approximately 25% of this value. When compared to a speed of rolling from approximately 200–352 millimeters per second, the measured axial sliding is therefore significantly less than 1% of the speed of rolling. Previous numerical studies of lubricant film formation in rolling contacts have shown that the effect of axial sliding starts to be noticeable only when this ratio exceeds 10%; therefore, the axial velocity represents only a small disturbance to the nominal pure rolling case, and the influence on oil film building can be neglected. A simple analytic model of the main bearing motion was also developed and demonstrated similar displacement and velocity characteristics.

17 WIND ENERGY↗

Wind energy developments in the 20th century

Wind turbine systems for generating electrical power have been tested in many countries. Representative examples of turbines which have produced from 100 to 1250 kW are described. The advantages of wind energy consist of its being a nondepleting, nonpolluting, and free fuel source. Its disadvantages relate to the variability of wind and the high installation cost per kilowatt of capacity of wind turbines when compared to other methods of electric-power generation. High fuel costs and potential resource scarcity have led to a five-year joint NASA-NSF program to study wind energy. The program will study wind energy conversion and storage systems with respect to cost effectiveness, and will attempt to estimate national wind-energy potential and develop techniques for generator site selection. The studies concern a small-systems (50-250 kW) project, a megawatt-systems (500-3000 kW) project, supporting research and technology, and energy storage. Preliminary economic analyses indicate that wind-energy conversion can be competitive in high-average-wind areas.

Vargo, D. J.↗

Investigation of Main Bearing Operating Conditions in a Three-Point Mount Wind Turbine Drivetrain

Wear related failures of spherical roller bearings in the main bearing position of three-point mount wind turbines have been higher than expected and can contribute to higher than anticipated operation-and-maintenance costs. In this paper, the operational conditions of such a main bearing, including measured axial displacement and velocity subject to the estimated axial loads are described for an instrumented, commercial wind turbine. The field measurements suggest a maximum axial speed between the bearing rings that is less than 2 millimeters per second. It is estimated that the axial speed between the ring and rollers is approximately 25% of this value. When compared to a speed of rolling from approximately 200-352 millimeters per second, the measured axial sliding is therefore significantly less than 1% of the speed of rolling. Previous numerical studies of lubricant film formation in rolling contacts have shown that the effect of axial sliding starts to be noticeable only when this ratio exceeds 10%; therefore, the axial velocity represents only a small disturbance to the nominal pure rolling case, and the influence on oil film building can be neglected. A simple analytic model of the main bearing motion was also developed and demonstrated similar displacement and velocity characteristics.

49 EE - Wind and Water Power Program - Wind (EE-4W↗

Parametric Inlet Tested in Glenn's 10- by 10-Foot Supersonic Wind Tunnel

The Parametric Inlet is an innovative concept for the inlet of a gas-turbine propulsion system for supersonic aircraft. The concept approaches the performance of past inlet concepts, but with less mechanical complexity, lower weight, and greater aerodynamic stability and safety. Potential applications include supersonic cruise aircraft and missiles. The Parametric Inlet uses tailored surfaces to turn the incoming supersonic flow inward toward an axis of symmetry. The terminal shock spans the opening of the subsonic diffuser leading to the engine. The external cowl area is smaller, which reduces cowl drag. The use of only external supersonic compression avoids inlet unstart--an unsafe shock instability present in previous inlet designs that use internal supersonic compression. This eliminates the need for complex mechanical systems to control unstart, which reduces weight. The conceptual design was conceived by TechLand Research, Inc. (North Olmsted, OH), which received funding through NASA s Small-Business Innovation Research program. The Boeing Company (Seattle, WA) also participated in the conceptual design. The NASA Glenn Research Center became involved starting with the preliminary design of a model for testing in Glenn s 10- by 10-Foot Supersonic Wind Tunnel (10 10 SWT). The inlet was sized for a speed of Mach 2.35 while matching requirements of an existing cold pipe used in previous inlet tests. The parametric aspects of the model included interchangeable components for different cowl lip, throat slot, and sidewall leading-edge shapes and different vortex generator configurations. Glenn researchers used computational fluid dynamics (CFD) tools for three-dimensional, turbulent flow analysis to further refine the aerodynamic design.

Slater, John W.↗

Modeling Languages Refine Vehicle Design

Cincinnati, Ohio s TechnoSoft Inc. is a leading provider of object-oriented modeling and simulation technology used for commercial and defense applications. With funding from Small Business Innovation Research (SBIR) contracts issued by Langley Research Center, the company continued development on its adaptive modeling language, or AML, originally created for the U.S. Air Force. TechnoSoft then created what is now known as its Integrated Design and Engineering Analysis Environment, or IDEA, which can be used to design a variety of vehicles and machinery. IDEA's customers include clients in green industries, such as designers for power plant exhaust filtration systems and wind turbines.

Source record↗

Aerodynamic Rotor Design for a 25 MW Offshore Downwind Turbine

Continuously increasing offshore wind turbine scales require rotor designs that maximize power and performance. Downwind rotors offer advantages in lower mass due to reduced potential for tower strike, and is especially true at large scales, e.g., for a 25 MW turbine. In this study, three 25 MW downwind rotors, each with different prescribed lift coefficient distributions were designed (chord, geometry, and twist) and compared to maximize power production at unprecedented scales and Reynolds numbers, including a new approach to optimize rotor tilt and coning based on aeroelastic effects. To achieve this objective the design process was focused on achieving high power coefficients, while maximizing swept area and minimizing blade mass. Maximizing swept area was achieved by prescribing pre-cone and shaft tilt angles to ensure the aeroelastic orientation when the blades point upwards was nearly vertical at nearly rated conditions. Maximizing the power coefficient was achieved by prescribing axial induction factor and lift coefficient distributions which were then used as inputs for an inverse rotor design tool. The resulting rotors were then simulated to compare performance and subsequently optimized for minimum rotor mass. To achieve these goals, a high Reynolds number design space was developed using computational predictions as well as new empirical correlations for flatback airfoil drag and maximum lift. Within this design space, three rotors of small, medium and large chords were considered for clean airfoil conditions (effects of premature transition were also considered but did not significantly modify the design space). The results indicated that the medium chord design provided the best performance, producing the highest power in Region 2 from simulations while resulting in the lowest rotor mass, both of which support minimum LCOE. The methodology developed herein can be used for the design of other extreme-scale (upwind and downwind) turbines.

downwind rotors↗

Sandia NRT Blade-0 Laboratory Modal Survey

Modal testing was performed on the Sandia NRT Blade-0 in building A-60 at NREL/NWTC. Modal testing was intended to identify the fundamental frequencies of the blade. The blade was cantilevered to the A-60 test stand. Fundamental frequencies were identified using impact modal testing. Additional tests included free-decay testing to quantify damping at small displacements. Small-displacement modal testing aims to minimize the influence of aerodynamic damping; roaming accelerometer impact testing with the development of a dynamic frame model enabled visualization of mode shapes.

17 WIND ENERGY↗