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DOE OSTI2025

A critical verification of beam and shell models of wind turbine blades

Ever-increasing wind turbine size has challenged predictive capabilities on several fronts. Here, to address part of the blade structural modeling uncertainty, a systematic model fidelity comparison study was conducted on commonly used finite elements. pyNuMAD was utilized to create beam, shell, and solid models of a 100 m long blade undergoing large static deflections. The solid model avoided the use of layered-solid elements by resolving core and facesheet layers. An unprecedented model with 73.7 million elements revealed insights that have never been possible from prior experimental and numerical studies. As compared to the solid element model, the tip deflection from the shell and beam model was found to be about 2% and 4.3% too low, respectively. The twist from the beam model was found to be about 5.6% too high, while the twist from shell model was 24% too low, though improvement was demonstrated with mesh refinement. The beam model adhesive stresses were more accurate than the shell model. Out-of-plane stresses were of great significance near geometric and material discontinuities, and neither the shell nor beam model captured these effects well. Failure predictions from beam, shell, or layered-solid models are unlikely to be reliable at trailing edges, adhesives, ply-drops, spar-cap boundaries.

17 WIND ENERGY↗

DOE OSTI2024

Definition of the IEA Wind 22-Megawatt Offshore Reference Wind Turbine

This technical report describes the design of a new 22 Megawatt reference wind turbine (RWT). The turbine model was designed collaboratively by two teams at the Denmark Technical University and at the National Renewable Energy Laboratory within the International Energy Agency (IEA) Wind Technology Commercialization Programme (TCP) Task 55 on Reference Wind Turbines and Farms. RWTs serve an important purpose in the wind energy community, since they provide openly available data for models representative of current wind turbine technology, which can be used by practitioners for a variety of modeling purposes, ranging from aerodynamic, structural, and aeroelastic turbine modeling to wind farm flow modeling, across a range of fidelities. The IEA 22 RWT aims to model machines with projected installation in the 2025-2030 time frame. The turbine has a rotor diameter of 284 meters and a hub height of 170 meters. It is a class 1-B machine with a rotor specific power nearing 350 W m -2 and it is mounted on either a fixed-bottom offshore foundation or a semi-submersible floating platform.

17 WIND ENERGY↗

DOE OSTI2020

Prognosis of Wind Turbine Gearbox Bearing Failures Using SCADA and Modeled Data

Predictive maintenance and condition monitoring systems for wind turbines have seen increased adoption to minimize downtime, reducing operation and maintenance costs. On today’s wind power plants, the integrated supervisory control and data acquisition (SCADA) system provides low- frequency operational data that can be leveraged to quantify a wind turbine’s health. The aim of this study is to utilize machine-learning techniques to predict axial cracking failures in wind turbine gearbox bearings up to 1 month ahead of time. The failures are assumed to have occurred when the investigated bearing was replaced. While current SCADA systems show the overall condition of a wind turbine, often they do not allow for the investigation of specific gearbox bearings’ health. To enrich bearing fault signatures, additional data are computed through physics-based models using gearbox design information. Based on SCADA data, modeled data, and bearing failure log data from an actual wind plant, the performances of different machine-learning models on unseen data are then evaluated using industry-standard metrics such as precision, recall, and F1 score. Results show the overall system performance enhancement in predicting bearing failure when modeled data are included with SCADA data. The reduction in terms of false alarms is about 50%, and improvement in terms of precision and F1 score is about 33% and 12% respectively, based on the best modeling case in this study.

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

DOE OSTI2020

An investigation into the potential for wind turbines to cause barotrauma in bats

The high rates of bat mortality caused by operating wind turbines is a concern for wind energy and wildlife stakeholders. One theory that explains the mortality is that bats are not only killed by impact trauma, but also by barotrauma that results from exposure to the pressure variations caused by rotating turbine blades. To date, no published research has calculated the pressure changes that bats may be exposed to when flying near wind turbines and then used these data to estimate the likelihood that turbines cause barotrauma in bats. To address this shortcoming, we performed computational fluid dynamics simulations of a wind turbine and analytical calculations of blade-tip vortices to estimate the characteristics of the sudden pressure changes bats may experience when flying near a utility-scale wind turbine. Because there are no data available that characterize the pressure changes that cause barotrauma in bats, we compared our results to changes in pressure levels that cause barotrauma and mortality in other mammals of similar size. This comparison shows that the magnitude of the low-pressures bats experience when flying near wind turbines is approximately 8 times smaller than the pressure that causes mortality in rats, the smallest mammal for which data are available. The magnitude of the high-pressures that bats may experience are approximately 80 times smaller than the exposure level that causes 50% mortality in mice, which have a body mass similar to several bat species that are killed by wind turbines. Further, our results show that for a bat to experience the largest possible magnitude of low- and high-pressures, they must take very specific and improbable flight paths that skim the surface of the blades. Even a small change in the flight path results in the bat being hit by the blade or experiencing a much smaller pressure change. Accordingly, if bats have a physiological response to rapid low- and high-pressure exposure that is similar to other mammals, we conclude that it is unlikely that barotrauma is responsible for a significant number of turbine-related bat fatalities, and that impact trauma is the likely cause of the majority of wind-turbine-related bat fatalities.

17 WIND ENERGY↗

DOE OSTI2024

Going beyond BEM with BEM: an insight into dynamic inflow effects on floating wind turbines

Blade element momentum (BEM) theory is the backbone of many industry-standard wind turbine aerodynamic models. To be applied to a broader set of engineering problems, BEM models have been extended since their inception and now include several empirical corrections. These models have benefitted from decades of development and refinement and have been extensively used and validated, proving their adequacy in predicting aerodynamic forces of horizontal-axis wind turbine rotors in most scenarios. However, the analysis of floating offshore wind turbines (FOWTs) introduces new sets of challenges, especially if new-generation large and flexible machines are considered. In fact, due to the combined action of wind and waves and their interaction with the turbine structure and control system, these machines are subject to unsteady motion and thus unsteady inflow on the wind turbine's blades, which could put BEM models to the test. Consensus has not been reached on the accuracy limits of BEM in these conditions. This study contributes to the ongoing research on the topic by systematically comparing four different aerodynamic models, ranging from BEM to computational fluid dynamics, in an attempt to shed light on the unsteady aerodynamic phenomena that are at stake in FOWTs and whether BEM is able to model them appropriately. Simulations are performed on the UNAFLOW 1:75 scale rotor during imposed harmonic surge and pitch motion. Experimental results are available for these conditions and are used for baseline validation. The rotor is analyzed in both rated operating conditions and low wind speeds, where unsteady aerodynamic effects are expected to be more pronounced. Results show that BEM, despite its simplicity, can adequately model the aerodynamics of FOWTs in most conditions if augmented with a dynamic inflow model.

17 WIND ENERGY↗

DOE OSTI2026

Grid and Wind Transient Ride Through Assessment of Type-5 Synchronous Wind Turbine

The integration of the inverter-based renewable energy resources is increasing and replacing conventional synchronous generators in the evolving bulk power system (BPS), impacting the system inertia along the way. Also, the limited over-current capability of power electronic converters continues to deteriorate the grid strength of the evolving power systems. Type-5 wind turbines have the potential to mitigate these problems because this configuration interfaces with the grid through a synchronous generator; hence, its operation and consequent grid impacts might mimic the conventional synchronous generator. The drivetrain of this type of turbines, however, is different from the more common Type-3 and Type-4 turbines. A hydraulic torque converter and gearbox with torque limiting feature are integral parts of a Type-5 wind turbine drivetrain, to isolate the wind speed variations at the wind turbine rotor from the grid connected generator side. This supports the synchronous operation of the generator. However, high fidelity models of Type-5 wind turbine drivetrain including these core components are not openly and widely available for grid integration and transient stability studies. Moreover, Type-5 turbines are not commonly deployed and hence its power generation and frequency stability characteristics are not widely publicized. This hinders appropriate assessment of Type-5 wind power plant's contribution to bulk grid resilience. This work provides transient stability assessment of a standalone Type-5 wind turbine. Normal operation and grid transient studies are performed to see the step load change and wind speed disturbance impacts on the Type-5 drivetrain and generation dispatch. Preliminary results show that Type-5 wind turbines can support load changes of between 0.6 p.u to 1.15 p.u. Beyond this point, the synchronization of the generator starts to deviate from its set point.

17 - WIND ENERGY↗

DOE OSTI2024

International Energy Agency 22 MW Offshore Reference Wind Turbine

The presentation will be used in a public webinar to introduce the newly developed 22 megawatt offshore reference wind turbine designed within the International Energy Agency Wind Technology Commercialization Programme Task 55 Reference Wind Turbines and Plants. The turbine was designed collaboratively by two teams at the Denmark Technical University and at the National Renewable Energy Laboratory. Reference turbines serve an important purpose in the wind energy community, since they provide openly available data for models representative of current wind turbine technology, which can be used by practitioners for a variety of modeling purposes, ranging from aerodynamic, structural, and aeroelastic turbine modeling to wind farm flow modeling, across a range of fidelities. The IEA 22 RWT aims to model machines with projected installation in the 2025-2030 time frame. The turbine has a rotor diameter of 284 meters and a hub height of 170 meters. It is a class 1-B machine with a rotor specific power nearing 350 W m-2 and it is mounted on either a fixed-bottom offshore foundation or a semi-submersible floating platform.

17 WIND ENERGY↗

DOE OSTI2022

Wind Turbine Gearbox Failure Detection Through Cumulative Sum of Multivariate Time Series Data

The wind energy industry is continuously improving their operational and maintenance practice for reducing the levelized costs of energy. Anticipating failures in wind turbines enables early warnings and timely intervention, so that the costly corrective maintenance can be prevented to the largest extent possible. It also avoids production loss owing to prolonged unavailability. One critical element allowing early warning is the ability to accumulate small-magnitude symptoms resulting from the gradual degradation of wind turbine systems. Inspired by the cumulative sum control chart method, this study reports the development of a wind turbine failure detection method with such early warning capability. Specifically, the following key questions are addressed: what fault signals to accumulate, how long to accumulate, what offset to use, and how to set the alarm-triggering control limit. We apply the proposed approach to 2 years’ worth of Supervisory Control and Data Acquisition data recorded from five wind turbines. We focus our analysis on gearbox failure detection, in which the proposed approach demonstrates its ability to anticipate failure events with a good lead time.

17 WIND ENERGY↗

DOE OSTI2020

Impedance Analysis and PHIL Demonstration of Reactive Power Oscillations in a Wind Power Plant Using a 4-MW Wind Turbine

This paper presents impedance-based analysis, mitigation, and power-hardware-in-the-loop (PHIL) demonstration of reactive power oscillations in a wind power plant using a 4-MW Type III wind turbine drivetrain. Because such low-frequency oscillations result from interactions among slower control loops of wind turbines regulating phasor quantities—active and reactive power output of the wind turbine and the magnitude of voltages at the point of interconnection (POI)—a new type of admittance is defined in terms of phasor quantities for their analysis. The so-called power-domain admittance of a wind turbine is defined as the transfer function from the frequency and magnitude of voltages at the POI to the active and reactive power output of the turbine. The power-domain admittance responses of the 4-MW wind turbine are measured using a 7-MVA grid simulator to identify the source of the reactive power oscillations. Power-domain impedance analysis and PHIL experiments are performed to explain how a resonant mode manifests as turbine-to-turbine and plant-to-grid reactive power oscillations. It is discovered that weaker grids exhibiting high inductive impedance mitigate oscillations in the reactive power output of wind power plants; however, a higher grid impedance does not help in damping turbine-to-turbine reactive power oscillations. This paper presents a simple droop-based solution to eliminate both turbine-to-turbine and plant-to-grid reactive power oscillations.

17 WIND ENERGY↗

DOE OSTI2022

Wind Turbine Drivetrain Reliability [Slides]

Pitch bearings, main bearings, and gearboxes in conventional wind turbine drivetrains often do not meet their 20-year minimum specified lifetime, resulting in turbine downtime as well as expensive, time-consuming repairs or replacements. The dominant failure modes of the drivetrain components and the conditions that lead to their failure are not fully accounted for during product design or routinely modeled for life management. Drivetrain reliability improvements and O&M cost reductions remain top priorities for both land-based and offshore wind turbines, especially as wind turbines continue to be deployed in increasingly remote and offshore locations, continue to increase in size, and are becoming expected to be in service beyond their original design life, all of which correspond to an increase in the impact of any reliability issues on O&M costs. This presentation summarizes the most recent activities by NREL and ANL on drivetrain reliability.

17 WIND ENERGY↗

DOE OSTI2025

Design of a Preliminary Family of Airfoils for High Reynolds Number Wind Turbine Applications

For the past 30 years, offshore wind turbines exhibited a continual pattern of growth that is expected to continue as the industry pushes for higher efficiency. Current designs for the next generation of wind turbines are so large that the chordwise Reynolds number of the blades is well beyond the design range of existing open-source airfoil families. This paper presents a preliminary family of new airfoils designed specifically for the needs of these next-generation offshore turbines, ranging from 21% thick to 30% thick with operating Reynolds numbers between 12 million and 18 million. These airfoils are intended to be alternative to the FFA airfoils that are commonly used on reference turbines such as the IEA 15MW and 22MW designs. In this work, airfoil performance metrics and design targets are developed, the design process is outlined, an optimization scheme is presented, and finally the airfoils and their simulated performance are compared to existing baselines. Lift to drag ratios in a clean condition were improved by up to 49.3% from the baseline FFA airfoil, and rough condition lift to drag ratio was improved by up to 9.3%. It is estimated that the cumulative improvements provided by this airfoil family would result in an approximately 1% increase of Annual Expected Power (AEP) for the 22 MW turbine compared to the current baseline.

airfoils↗

DOE OSTI2021

Estimation of the Ambient Wind Field From Wind Turbine Measurements Using Gaussian Process Regression

In the search for a lower levelized cost of wind energy, one approach is to increase the accuracy of wind turbine measurements such as wind speed and wind direction. The sensors available on wind turbines are susceptible to local turbulence and measurement bias, which can result in suboptimal turbine performance. As an alternative, recent research has considered using the sensor measurements in a coordinated manner. With such a cooperative approach, the local wind conditions can be estimated more accurately and reliably without the need for additional measurement equipment. In this paper, a novel wind field estimation approach is presented that estimates the local wind conditions based on turbine measurements using Gaussian processes. We show that the estimation framework is able to improve the accuracy of the wind direction estimate both in an offline and online manner, as well as identify possible biases in the sensors and reduce unnecessary wind turbine yaw activity.

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

DOE OSTI2020

Implementation of Substructure Flexibility and Member-Level Load Capabilities for Floating Offshore Wind Turbines in OpenFAST

OpenFAST is an open-source, physics-based engineering tool applicable to the load analysis of land-based and offshore wind turbines, including floating offshore wind turbines. The substructure for a floating wind turbine has historically been modeled in OpenFAST as a rigid body with hydrodynamic loads lumped at a point, which enabled the tool to predict the global response of the floating substructure but not the structural loads within its individual members. This limitation is an impediment to designing floating substructures - especially newer designs that are more streamlined, flexible, and cost-effective. This paper presents the development of new functionality in OpenFAST to model floating substructure flexibility and member-level loads, as well as the concepts and mathematical background needed to understand and apply it correctly.

17 WIND ENERGY↗

DOE OSTI2021

Wind Turbine Blade Finishing Automation: Robotic Toolpath Generation

Wind turbine blades are now over 100 meters long and can reach heights of several meters while in the finishing area of the factory. Because of this, automation should be used to lower the manufacturing cost and make the process safer for blade manufacturing technicians. This session will present a novel method that generates a six degree of freedom robotic toolpath with 3D cameras for the finishing of wind turbine blades to drive down the levelized cost and make wind energy even more competitive in the utility scale energy generation industry.

3d imaging↗

DOE OSTI2022

Wind turbine gearbox fault prognosis using high-frequency SCADA data

Condition-based maintenance using routinely collected Supervisory Control and Data Acquisition (SCADA) data is a promising strategy to reduce downtime and costs associated with wind farm operations and maintenance. New approaches are continuously being developed to improve the condition monitoring for wind turbines. Development of normal behaviour models is a popular approach in studies using SCADA data. This paper first presents a data-driven framework to apply normal behaviour models using an artificial neural network approach for wind turbine gearbox prognostics. A one-class support vector machine classifier, combining different error parameters, is used to analyse the normal behaviour model error to develop a robust threshold to distinguish anomalous wind turbine operation. A detailed sensitivity study is then conducted to evaluate the potential of using high-frequency SCADA data for wind turbine gearbox prognostics. The results based on operational data from one wind turbine show that, compared to the conventionally used 10-min averaged SCADA data, the use of high-frequency data is valuable as it leads to improved prognostic predictions. High-frequency data provides more insights into the dynamics of the condition of the wind turbine components and can aid in earlier detection of faults.

17 WIND ENERGY↗

DOE OSTI2020

The effect of dynamic near-wake modulation on utility-scale wind turbine wake development

High-resolution field-scale experiments using flow visualization with natural snowfall and high-fidelity large eddy simulations are combined to investigate the effect of dynamic turbine operation and atmospheric conditions on wind turbine wake mixing and recovery in the wake of a 2.5 MW wind turbine. Instantaneous near-wake expansion and deflection in response to changes in blade pitch and wind direction, termed dynamic wake modulation, is quantified using both techniques, demonstrating excellent agreement. The simulations are used to extend these results by calculating the energy flux into the wake 7 rotor diameters downstream, showing that dynamic turbine-atmospheric interactions enhance mixing in the far-wake. This finding is exhibited under both uniform and turbulent inflow conditions. Under turbulent flow, a synergistic relationship is also observed between dynamic wake modulation and wake meandering, as wake recovery can be further accelerated when the two phenomena occur together. The results of this study have implications for the development of more realistic far-wake models that include the significant impact of dynamic wake modulation on wake mixing and development. Additionally, the findings from the current study can be used to develop advanced control algorithms to speed up wake breakdown and recovery, further improving wind farm efficiency.

17 WIND ENERGY↗

DOE OSTI2024

High-Fidelity Modeling of a Type-5 Wind Turbine Gearbox (Intern Technical Presentation) (Poster)

Type-5 wind turbines are unique in their use of a permanent magnet synchronous generator, as well as their use of a hydraulic torque converter. This architecture presents an opportunity to provide steady and grid-ready energy without the need for a power converter. With infrastructure continuity and reliability being an important topic amongst renewable energies, researchers have been prompted to further investigate the benefits of type-5 turbines’ unique electromechanical configuration on stable electricity generation. Researchers involved in the WindSG project, SG standing for synchronous generator, are aiming to model a type-5 turbine using Real Time Digital Simulation (RTDS) to evaluate its efficacy in the grid. RSCAD, the software run on the RTDS, comes pre-loaded with electrical and electromechanical components to help simulate electrical generation and grid conditions. However, within this repertoire there is a lack of a component to represent a gearbox with high-fidelity. Within RSCAD’s case studies, the gearbox is often represented simply by a gear ratio value. This presented the task of developing a high-fidelity gearbox model in RSCAD for use in the larger RTDS type-5 wind turbine model. This presentation describes a method of developing a lumped parameter mathematical model to represent a planetary-parallel-parallel gearbox in RSCAD for use in RTDS.

17 WIND ENERGY↗

DOE OSTI2021

Wind turbine blade material in the United States: Quantities, costs, and end-of-life options

Wind energy has experienced enormous growth in the past few decades; as a result, there are thousands of wind turbines around the world that will reach the end of their design lifetimes in the coming years. Much of the material in those turbines can be recycled using conventional processes, but the composite material that is the main component of the blades is more challenging to recycle. In the United States, turbine blades may be disposed of in landfills, adding a new solid waste stream to the material already being landfilled. This paper presents a spatially resolved estimate of the mass and volume of wind turbine blade waste in each state by 2050 and compares these amounts to estimates of the remaining landfill capacity by state. In this work, we estimate costs for each stage of the disposal process to indicate cost levels for alternatives. Assuming a 20-year turbine lifetime, the cumulative blade waste in 2050 is approximately 2.2 million tons. This value represents approximately 1% of remaining landfill capacity by volume, or 0.2% by mass. We also find that the current cost of disposing of blades in large segments or through grinding is relatively low in comparison to the overall life-cycle cost of energy. Based on these findings, landfill space constraints and disposal costs appear unlikely to motivate a change in waste handling strategies under current policy conditions. Instead, more profound shifts in recycling technologies, blade materials, or policy may be needed to move towards a circular economy for wind turbine blades.

17 WIND ENERGY↗