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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 19 records
All sourcesNASA NTRSDOE OSTI
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 OSTI2022

FLASC (FLORIS-based Analysis for SCADA data)

FLASC provides a rich suite of analysis tools for SCADA data filtering & analysis, wind farm model validation, field experiment design, and field experiment monitoring. The repository is centrally built around NRELs in-house floris wind farm model, available at https://github.com/nrel/floris. FLASC also largely relies on the energy ratio to, among others, quantify wake losses in synthetic and historical data, to perform turbine northing calibrations, and for model parameter estimation.

Fleming, Paul↗
DOE OSTI2020

Validation of FAST.Farm Against Full-Scale Turbine SCADA Data for a Small Wind Farm

FAST.Farm is a new midfidelity engineering tool developed by the National Renewable Energy Laboratory targeted at accurately and efficiently predicting wind turbine power production and structural loading in wind farm settings, including wake interactions between turbines. FAST.Farm is based on some of the principles of the Dynamic Wake Meandering model—including passive tracer modeling of wake meandering—but addresses many of the limitations of previous Dynamic Wake Meandering (DWM) implementations. Previous FAST.Farm verification studies show the similarities and differences between FAST.Farm and large-eddy simulations for rigid and flexible turbines. In this validation study, FAST.Farm turbine responses are compared to multiturbine measurements from a subset of a full-scale wind farm. FAST.Farm predictions of turbine generator power, rotor speed, and blade pitch for five-turbine simulations are compared to supervisory control and data acquisition results. Results reveal that FAST.Farm generator power mean and standard deviation results reasonably match measured data for upstream and downstream turbines, as well as the mean rotor speed and blade pitch above rated wind speeds. However, FAST.Farm generally underpredicts the mean rotor speed and overpredicts the mean blade pitch below rated operation. These errors are likely related to inaccuracies in the generic controller simulated. Despite controller differences, FAST.Farm predicts the same overall relative rotor power trends for all waked turbines at all wind speeds.

17 WIND ENERGY↗
DOE OSTI2022

Investigation of Multiple Data Streams for Gearbox Bearing Fault Prediction Through Machine-Learning Models

Operations and maintenance (O&M) cost of wind plant accounts up to 30% of total energy cost, which can be reduced through continuous monitoring and successfully detecting incipient wind turbine failures. To accomplish this, condition monitoring and predictive maintenance systems are being implemented in wind industry to support O&M decision making. A wide range of approaches for condition monitoring and fault prediction have been developed. These approaches generally use historical data of wind turbines collected by Supervisory Control and Data Acquisition (SCADA) system to identify patterns that lead to failure. These SCADA data show the overall condition of a wind turbine and can be leveraged to detect when the turbine's performance is degrading and to identify if a fault is developing. However, it becomes challenging to predict the failure of a specific wind turbine gearbox bearing, because the SCADA data are often not directly linked to the component. To bridge the gap, we have investigated features calculated from SCADA data using physics-based models and the gearbox design over the years. The damaged metric we used in the physics domain is frictional energy. Combining these physics domain variables with SCADA data as inputs to various machine learning models for gearbox bearing fault prediction, we have demonstrated the benefits of leveraging both physics and data domain models. It was an attempt to improve frictional-energy-based damage metric by adding data domain inputs, as we had learned that the frictional-energy-based damage metric alone is not sufficient to single out failed bearings from healthy. As condition monitoring data (either vibration or oil debris data) has become available at more and more wind plants, we would like to evaluate whether by adding the condition monitoring data can help further improve the performance of frictional-energy-based damage metric for gearbox bearing fault prediction. Both cases by modeling through various machine learning algorithms are discussed in this study along with some observations.

fault prediction↗
DOE OSTI2021

Develop Wake Mitigation Strategy (CRADA CRD-17-00693 Final Report)

Wind turbines in a wind farm typically operate individually to maximize their own performance and do not take into account information from nearby turbines. In an autonomous wind farm, enabling cooperation to achieve farm-level objectives, turbines will need to use information from nearby turbines to optimize performance, ensure resiliency when other sensors fail, and adapt to changing local conditions. A key element of achieving an autonomous wind farm is to develop algorithms that provide necessary information to ensure reliable, robust, and efficient operation of wind turbines in a wind plant using local sensor information that is already being collected, such as supervisory control and data acquisition (SCADA) data, local meteorological stations, and nearby radars/sodars/lidars. In this work consensus control is applied in a hybrid analysis to data from an existing wind farm to demonstrate the benefit of consensus control.

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 OSTI2023

Virtual supervisory control and data acquisition (SCADA) automation controller

One or more virtual supervisory control and data acquisition (SCADA) controllers are provided. The virtual SCADA controller(s) may be deployed upon a detection of a failure of a physical SCADA controller. An on-site module may detect failure including a security breach which causes the physical SCADA controller to be disconnected from a network and the virtual SCADA controller(s) to take over control. The virtual SCADA controller(s) may be on-site or off-site.

Smith, Jared M.↗
DOE OSTI2024

An iterative bidirectional gradient boosting approach for CVR baseline estimation

Here this paper presents a novel Iterative Bidirectional Gradient Boosting Model (IBi-GBM) for estimating the baseline of Conservation Voltage Reduction (CVR) programs. In contrast to many existing methods, we treat CVR baseline estimation as a missing data retrieval problem. The approach involves dividing the load and its corresponding temperature profiles into three periods: pre-CVR, CVR, and post-CVR. To restore the missing load profile during the CVR period, the method employs a three-step process. First, a forward-pass GBM is executed using data from the pre-CVR period as inputs. Subsequently, a backward-pass GBM is applied using data from the post-CVR period. The two restored load profiles are reconciled, considering pre-calculated weights derived from forecasting accuracy, and only the leftmost and rightmost points are retained. The newly restored points are then included as inputs for the subsequent iteration. This iterative procedure continues until the original load data in the CVR period is fully restored. We develop IBi-GBM using actual smart meter and Supervisory Control and Data Acquisition (SCADA) data. Our results demonstrate that IBi-GBM exhibits robust performance across various data resolutions and in different seasons and outperforms existing methods by achieving a 1-2% reduction in normalized Root Mean Square Error (nRMSE).

42 ENGINEERING↗
DOE OSTI2020

Resilient Autonomous Wind Farms

With the advent of an increasing number of control strategies that seek to optimize wind turbine performance on a farm level, taking into account individual wind turbine information to achieve wind-farm-level objectives has become an increasingly important goal. Methods for controlling wind turbines on an individual and farm level have experienced significant development, and an abundance of new implementations for gathering and using data from turbines have created potential for novel control mechanisms that can further optimize the performance and delivery characteristics of a wind farm. A key element of making these wind farms more efficient is to develop reliable algorithms that use local sensor information that is already being collected, such as from local meteorological stations, nearby radars, sodars, and lidars, and supervisory control and data acquisition (SCADA) data. Making use of information from all wind turbines in a wind farm can enable such approaches as determining the atmospheric conditions across the farm, improving fault-finding, and ensuring more efficient overall control of farmwide optimizations through mechanisms such as wake steering. However, these approaches typically involve a centralized communications and control center. In order to ensure the resilient operation of the farm, it is necessary to develop an approach that distributes the calculation and communication amongst multiple nodes throughout the farm. In this fashion, a redundant, robust, and secure network can be created, which can tolerate faults in calculation, communication, and even external attacks that seek to disrupt the operation of the wind farm. This paper introduces the use of the Raft-Byzantine-Fault-Tolerant algorithm in the implementation of autonomous control of a wind farm. This implementation will allow for fault tolerance for malfunctioning nodes, sensors, transmitters, and connectors. This approach is equally extensible to account for malicious actors. It will...

fault tolerance↗
DOE OSTI2026

Condition monitoring of wind turbine drivetrains: state-of-the-art technologies, recent trends, and future outlook

As global wind capacity expands, reducing operations and maintenance costs is critical to lowering the levelized cost of energy. This paper explores the state of the art in condition monitoring and prognostic strategies for wind turbine drivetrains, which are among the most failure-prone and maintenance-intensive subsystems. Current diagnostic methodologies are evaluated, covering supervisory control and data acquisition (SCADA) data, high-frequency vibration and acoustic analysis, machine learning and digital twin frameworks. Finally, practical challenges are identified that limit wide-scale industrial adoption, in order to guide future research and industrial efforts.

17 WIND ENERGY↗
DOE OSTI2021

Design and analysis of a wake model for spatially heterogeneous flow

Abstract. Methods of turbine wake modeling are being developed to more accurately account for spatially variant atmospheric conditions within wind farms. Most current wake modeling utilities are designed to apply a uniform flow field to the entire domain of a wind farm. When this method is used, the accuracy of power prediction and wind farm controls can be compromised depending on the flow-field characteristics of a particular area. In an effort to improve strategies of wind farm wake modeling and power prediction, FLOw Redirection and Induction in Steady State (FLORIS) was developed to implement sophisticated methods of atmospheric characterization and power output calculation. In this paper, we describe an adapted FLORIS model that features spatial heterogeneity in flow-field characterization. This model approximates an observed flow field by interpolating from a set of atmospheric measurements that represent local weather conditions. The objective of this method is to capture heterogeneous atmospheric effects caused by site-specific terrain features, without explicitly modeling the geometry of the wind farm terrain. The implemented adaptations were validated by comparing the simulated power predictions generated from FLORIS to the actual recorded wind farm output from the supervisory control and data acquisition (SCADA) recordings and large eddy simulations (LESs). When comparing the performance of the proposed heterogeneous model to homogeneous FLORIS simulations, the results show a 14.6 % decrease for mean absolute error (MAE) in wind farm power output predictions for cases using wind farm SCADA data and a 18.9 % decrease in LES case studies. The results of these studies also indicate that the efficacy of the proposed modeling techniques may vary with differing site-specific operational conditions. This work quantifies the accuracy of wind plant power predictions under heterogeneous flow conditions and establishes best practices for atmospheric surveying for wake modeling.

17 WIND ENERGY↗
DOE OSTI2020

Resilient Autonomous Wind Farms: Preprint

With the advent of an increasing number of control strategies that seek to optimize wind turbine performance on a farm-level, taking account of individual wind turbine information to achieve wind farm-level objectives has become an increasingly important goal. Methods for controlling wind turbines on an individual and farm level have seen significant development, and an abundance of new implementations for gathering and using data from turbines have created potential for novel control mechanisms which can further optimize the performance and delivery characteristics of a wind farm. A key element of making these wind farms more efficient is to develop reliable algorithms that use local sensor information that is already being collected, such as supervisory control and data acquisition (SCADA) data, local meteorological stations, and nearby radars/sodars/lidars. Making use of information from all wind turbines in a wind farm can enable such approaches as determining the atmospheric conditions across the farm, improving fault-finding, and enabling more efficient overall control of farm-wide optimizations through mechanisms such as wake-steering. However, these approaches typically involve a centralized communications and control center. In order to ensure the resilient operation of the farm, it is necessary to develop an approach which distributes the calculation and communication amongst multiple nodes throughout the farm. In this fashion, a redundant, robust, and secure network can be created, which can tolerate faults in calculation, communication, and even external attacks which seek to disrupt the operation of the wind farm. This paper introduces the use of the Raft Byzantine Fault Tolerance algorithm in the implementation of autonomous control of a wind farm. This implementation will allow for fault tolerance for malfunctioning nodes, sensors, transmitters, and connectors. This approach is equally extensible to account for malicious actors. It will be shown to achieve overall consensus, provided the number of faults/malicious nodes is less than 3$n$+1, where $n$ is the number of turbine cluster faults which may occur, and to be robust in the face of multiple arbitrary faults.

autonomous↗
DOE OSTI2022

A Comparison of Preconstruction and Operational Wake Loss Estimates for Land-Based Wind Plants

Recent studies suggest that biases between wind plant pre-construction energy yield estimates and actual energy production are decreasing over time. However, variability in energy yield prediction accuracy across different projects and wind energy consultants remains high. Wake effects are one of the largest categories comprising the pre-construction energy yield assessment process. To assess the accuracy of wake loss predictions, we compare pre-construction wake loss estimates provided by 8 consultants to the estimated operational wake losses for 10 North American wind plants, as part of the Wind Plant Performance Prediction (WP3) Benchmark project. We estimate operational wake losses using supervisory control and data acquisition (SCADA) data by comparing total wind plant energy production to the potential energy production based on the power produced by freestream wind turbines. In the presentation, we will discuss the overall wake loss prediction bias as well as the project-to-project variability in the prediction accuracy. Further, we will highlight challenges encountered when estimating operational wake losses, including the impact of complex terrain and the presence of neighboring wind plants.

benchmark↗
DOE OSTI2026

Gearbox bearing crack growth prognostics and uncertainty quantification with physics-informed machine learning

This paper introduces the extreme theory of functional connections (X-TFC), a physics-informed machine learning algorithm, and tailors it to estimate the remaining useful life (RUL) of wind turbine gearbox bearings experiencing fatigue crack growth. Unlike purely data-driven methods, X-TFC embeds a physics model, based on Head's theory in this work, into its training objective. The core of X-TFC is a random-projection single-layer neural network trained via an extreme learning machine, which requires only limited damage progression data and solves for output weights with a least-squares optimization algorithm. A composite loss function balances the network's fit to observed degradation data against the residuals of the governing crack growth differential equation, ensuring the learned damage trajectory remains physically plausible. When applied to a vibration-based health-index (HI) dataset measured during the growth of a crack on the inner ring of a high-speed bearing in a wind turbine gearbox (Bechhoefer and Dubé, 2020), X-TFC achieves near-zero prediction bias. Even when trained on only the first 10 %–20 % of the damage progression data, with sufficient physics weighting its predictions remain monotonic and smooth, delivering high prognosability and trendability. To quantify the epistemic uncertainty, we employ a Monte Carlo ensemble of independently initialized X-TFC models trained on noise-perturbed data, which yields confidence intervals around each RUL estimate and captures both model-parameter and epistemic uncertainty. In addition to a vibration-based HI, we demonstrate that the proposed framework can be directly applied to a supervisory control and data acquisition (SCADA) data-based HI (Eftekhari Milani et al., 2026) measured during similar wind turbine gearbox bearing crack faults, preserving its accuracy and interpretability. This extension shows the versatility of our approach, which is applicable to bearings of multiple gearbox manufacturers, models, and ratings using only SCADA data. By integrating domain knowledge with machine learning, X-TFC offers a rapid, reliable tool for crack prognostics. Its adaptability to other bearing failure modes, such as pitch bearing ring cracks, positions X-TFC as a powerful enabler of data-driven, physics-informed asset management in the wind energy sector and beyond.

17 WIND ENERGY↗
DOE OSTI2023

A use-case-driven approach for demonstrating the added value of digitalisation in wind energy

Digitalisation is one of the key drivers for reducing the costs and risks of wind energy. When considering whether to embark on a digitalisation initiative, two key questions arise. The first is what business or operational opportunities might feasibly be addressed and the second is which of the many potential aspects of digitalisation are relevant to those opportunities. In this work, we show how these questions can be answered with a use-case-driven approach, based around a survey aiming to collect and collate the main "pain points" (or everyday challenges) of people in the wind energy sector. Although the relatively low number of participants of the survey (46) means that the results should only be used indicatively, it is still possible to make some general recommendations for priorities for digitalisation efforts in the wind energy sector. Firstly, digitalisation efforts should focus both on supporting people carrying out cross-lifecycle tasks, in particular sharing data, managing data, undertaking general data analyses and accessing data. Tools to do this should deal with varying data formats and naming conventions, make metadata more accessible, define data and metadata standards, make more data publicly available and improve the quality of data. Secondly, efforts should also focus on supporting people in the wind farm operational phase, in particular with failure detection, fault diagnosis, failure rate modelling and predictive maintenance. Solutions to do this should focus on accessible and validated tools for fault detection, cloud or other data pipeline solutions for SCADA data and tools for exhaustive data documentation. Finally, digitalisation efforts should focus on better communicating and helping people become aware of existing solutions and tools, as well as on helping people to exert a stronger influence on possible solutions.

17 WIND ENERGY↗
DOE OSTI2020

Analytical Functions for 200 West Pump-and-Treat SCADA Sensor Data

Historical operations at the U.S. Department of Energy’s Hanford Site included disposal of waste fluids to the subsurface in the 200 West Area on the Hanford Central Plateau. Subsequent infiltration of fluids has resulted in groundwater contamination with carbon tetrachloride, nitrate, uranium, technetium-99, and other contaminants. A pump-and-treat (P&T) system, with an extraction/injection well network and an aboveground treatment plant, was implemented as part of interim and final remedies in the 200 West area. The HYPATIA single-page web application (part of the SOCRATES suite) is being developed to provide access to and analysis of chemistry and treatment facility sensor data for this 200 West P&T system. For the web application, analytical algorithms were developed to perform summing, differencing, smoothing, outlier detection, change-point detection, mass flow rate, and injectivity calculations on the data. Candidate algorithms were identified and tested, with the best-performing algorithms then assembled for implementation in HYPATIA. Because HYPATIA is hosted on the Amazon Web Services (AWS) cloud computing platform, algorithms were implemented in a back-end AWS Lambda function that can be called by the HYPATIA front end. The Lambda function applies the requested data processing to specified data via functions written in R, Python, and JavaScript. Development, testing, and review of the data analysis algorithms was completed under an NQA-1 quality program. This new HYPATIA functionality will provide information to support site decisions regarding P&T system performance and optimization.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗