Accurate Modeling of Material Nonlinearities in a Wind Turbine Spar Cap.
Abstract not provided.
Clarke, Ryan↗
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IACMI Project 4.7: Pultruded Textile Carbon Fiber for Spar Caps (Final Report)
The primary objective of this project was to demonstrate the potential to significantly reduce the cost of wind turbine blades with carbon fiber reinforced polymer (CFRP) structure. Applicability of textile carbon fibers (TCF) were evaluated for use in pultruded spar cap (SC) elements as a path to cost reduction for utility scale wind turbine blades. In earlier work for the Department of Energy (DOE) Wind Energy Technologies Office (WETO), a collaboration of Sandia National Laboratory (SNL), Oak Ridge National Laboratory (ORNL), and Montana State University has demonstrated potential for pultruded TCF to compete with infused fiberglass and commercially available carbon fiber pultruded sections for spar cap construction. In the design cases evaluated, the TCF sections fared well when compared on cost per unit composite stiffness and cost per unit composite compressive strength for those designs [1]. Both stiffness and compressive strength tend to be key factors in the design of blade composite Spar Cap which carry the bulk of the blade structural loads in bending. Spar Cap design tends to distribute largely symmetric tensile and compressive stresses to opposite sides of the spar structure, but since carbon fiber composite compressive strength is typically 20-50% lower than tensile strength, the compressive loading reaches failure levels well before the tensile loading. Stiffness is critical in containing the large tip deflection in high wind loading situations. However, materials and process development were very limited in the earlier study and the work in this project was expanded to make the comparative information more representative of what will be required in order to make further inroads towards implementation. Similar to that study, this project team confirmed that the primary materials of interest for pultruded spar cap elements should be thermoset (TS) resins reinforced by carbon fibers, utilizing as high a percentage of TCF as practical to benchmark cost and performance against commercial carbon fibers. To make the closest comparison possible and eliminate specific test article size, resin selection, and equipment/operational nuance effects, the team planned to pultrude sections with 100% commercially available carbon fiber (Panex 35 carbon fiber from Zoltek) as well as samples utilizing high fractions of TCF. The resin system chosen was based on formulations recommended by large wind industry supplier Hexion and consisted of Hexion resin RSL-4597, curing agent CCA-138, and internal mold release additive 117, along with common kaolin filler ASP400P from BASF. As commonly deployed in spar cap configurations, the team had a mold built to pultrude a rectangular spar cap element of 100mm width and 3mm thickness. The extremely limited number of samples produced for the earlier study were produced with a “generic” epoxy utilized for a variety of applications by the pultruder contracted to produce test articles for demonstration purposes. More importantly, those samples were produced at a fiber fraction only slightly over 50%. Based on feedback from our industrial advisory team for that project and strongly recommended by this project team, the consensus is that it is highly desirable to obtain fiber fractions of 65-68% for significant penetration in wind blade spar cap. Although this requirement has yet to be exhaustively confirmed in readily available information, this was established as a project goal and informally decided we needed to exceed 60% fiber fraction to gain serious industry consideration. Previous TCF pultrusion trials have been challenged by the lack of robust TCF packages, resulting in non-uniform tension across and between tows, as well as excess labor and waste for removal of interleaved paper. The non-uniform tension and associated intermingling of tows in textile acrylic fiber tows and associated difficulties created from broken filaments in carbon fiber conversion inhibit the ordered packing necessary to enhance fiber fraction elevation. (These “cross-overs” are not considered undesirable for textile applications and there is some sense that they might be advantageous for those applications). In addition to work that is ongoing at the acrylic fiber manufacturers to improve their formats, The Institute of Advanced Composites Manufacturing Innovation (IACMI) Project 6.12 (report PA16-0349-6.12-01) [2] has developed and demonstrated a more robust packaging and creeling approach that at least partially addresses these issues, thus improving control of the TCF feed into the pultrusion unit. It was hoped that these and other improvements currently being implemented would allow us to achieve fiber fractions at least approaching these fiber fraction targets. During this project, sections utilizing 100% commercially available carbon fiber reinforcement were produced as a baseline, as well as sections reinforced with about 94% TCF and the balance being commercially available fiber for comparison. The most important finding was that similar to results reported in the earlier WETO-funded project and results from tests of TCF reported at IACMI meetings, this work demonstrated that sections pultruded with TCF in an epoxy resin frequently utilized in actual spar cap production had stiffness and compressive strengths largely comparable to similar sections pultruded with a commercially available carbon fiber also frequently utilized in the wind industry. Although the amount of that data is limited, some of the tensile strength results were actually closer than would have been expected based on fiber strength results provided by the TCF and commercial fiber producers. The actual test data are reported and discussed in detail in Section 5. The pultruded sections dominated by TCF reinforcement were approximately 8-10% lower in fiber fraction than for the sections produced using commercial fiber alone, making direct comparison difficult. The COVID-19 project has provided significant insight into the current state-of-the-art with various TCF product forms. The data obtained in this project will guide the planned improvements at the precursor level, especially in attaining uniform tensioning and payout to facilitate enhanced fiber fractions and overall processability of the TCF composites. The project team is providing guidance to stakeholders concerning the attributes, needs, and potential demand for TCF in wind blade spar caps. Results achieved in this project are consistent with findings in the related work cited [1] and support this guidance and the high potential for this product type. TCF precursor-producing partners continue to express interest in enhancing their product forms and the team looks forward to working with these improved materials as they become available.
42 ENGINEERING↗
Determination of a Generic Human Error Probability Distribution, Part 1: A Dynamic Formulation of SPAR-H
In almost all major nuclear power plants (NPP) events include a significant human error component. As an example, in Fukushima Daiichi (2011) nuclear meltdown, the human actions related to the high-pressure injection cooling strongly affected accident evolution. Furthermore, in the Three Mile Island accident (1979) (which was initiated by a stuck open valve and thus was triggered a loss of coolant accident) the unit operators made decisions based upon false assumptions that contributed negatively to the accident. Given these premises, the ability to accurately model human interactions with plant evolution and, in particular, dynamically calculate human error probability (HEP) plays a major role in a probabilistic risk analysis (PRA). Human reliability analysis (HRA) identifies and models the causes of human errors, and quantifies HEP by applying different methodologies. HRA methods identify errors and reflect on the understanding of error-prone people and systems. There are a number of HRA methods available that assist in identifying the vulnerabilities in the system and provide guidance in determining the HEP. HEP is the probability of a human failure event (HFE), and quantification of HEPs under various situations is utilized in PRA of large complex systems. One of the more prominent HRA methods is the Standardized Plant Analysis Risk-Human Reliability Analysis (SPAR-H) method that was developed to estimate HEPs for the use in the Standardized Plant Analysis Risk (SPAR) PRA models employed in U.S. NPPs. SPAR-H is implemented in U.S. NPPs by regulators at the U.S. Nuclear Regulatory Commission (NRC) to determine the HEP based on expert estimation through the use of calculation worksheets. In SPAR-H, the nominal HEPs (NHEPs) are multiplied by performance shaping factors (PSF) multiplier values to obtain the overall error probability. PSFs encompass the human components, individual characteristics, their environment, and aspects of the task. With PSFs, the goal is to capture all factors that can affect human performance. In SPAR-H there are eight PSFs used, each having respective levels corresponding to multipliers: Available Time, Stress/Stressors, Complexity, Experience/Training, Procedures, Ergonomics/Human Machine Interface, Fitness for Duty, and Work Processes. The PSF multipliers indicate enhanced, nominal, or degraded human performance. The SPAR-H method estimates the HEP through multiplying a NHEP with PSFs. Hence, SPAR-H is a traditional HRA method that assesses human performance at a fixed, or static, point in time. In a dynamic HRA framework, human performance is assessed on a continuous time basis. SPAR-H can be used within a dynamic PRA framework through the use of simulation and stochastic models. The goal of dynamic HRA is to build a more realistic model of the human-system interaction to enhance calculation of reliability, risk and safety analysis. The progression of events in dynamic SPAR-H considers that some PSFs may experience gradual change, while other change can be sudden due to individualistic differences or rapid plant status changes. The PSF changes are caused by contextual changes in the scenario. For example, as more time passes, the realization that a task should be completed sooner may cause the operator more stress. In another example, a sudden relay of information about sickness of a family member may alter the operator's general stress level and fitness for duty. Each PSF has a different dynamic nature; PSFs like stress and complexity change more quickly over the course of a task than experience and training. While the experience of an operator changes over the course of attaining the objective, the amount that this added experience changes the HEP is very minimal. In contrast, the stress, complexity, and procedures PSFs may change quite a bit over the course of task completion.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Determination of a Generic Human Error Probability Distribution, Part 2: A Dynamic SPAR-H Example Application
Humans are an integral part of a nuclear power plant (NPP) from its construction, to its everyday maintenance and operation. In the nuclear industry there are many approaches to quantifying component reliability, which is called probability risk assessment (PRA). In PRA there are two considerations given to the quantification, static and dynamic. Static is quantified before or after an operation; and dynamic is time dependent, in that the probability changes as real time data are provided. In PRA, the importance of the components is calculated, but what of the importance of the human component? There are several methods for human reliability analysis (HRA), which include but are not limited to: THERP, ATHEANA, CREAM, SPAR-H, ASEP, and SLIM. Each of these methods aims to provide a more accurate and objective human error probability (HEP) quantification. Of the methods listed above, ASEP, THERP, and SPAR-H are all inextricably linked. The Standardized Plant Analysis Risk-Human Reliability Analysis (SPAR-H) method was generated to better generalize the Technique for Human Error Rate Prediction (THERP) and Accident Sequence Precursor (ASEP). THERP is mapped to specific scenario templates, and ASEP is a simplified screening method, while SPAR-H employs generalizations to describe the spectrum of human behavior while maintaining the same theoretical underpinnings. SPAR-H is a well-known and accepted HRA method that uses performance shaping factors (PSFs) to classify inputs to the human component. PSFs capture a wide variety of input data, including plant status, crew dynamics, task description, and psychological aspects of the human operator. Current efforts have been focused to further generalize SPAR-H in to a dynamic framework. These methods can fit into dynamic NPP simulations such as RAVEN / RELAP-7. In order to do this, a dynamic methodology is applied to model the human as would be applied to the components. This method is applied in part one in the accompanying paper.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
WHEN MODEL MEETS REALITY – A REVIEW OF SPAR LEVEL 2 MODEL AGAINST FUKUSHIMA ACCIDENT
The Standardized Plant Analysis Risk (SPAR) models are a set of probabilistic risk assessment (PRA) models used by the Nuclear Regulatory Commission (NRC) to evaluate the risk of operations at U.S. nuclear power plants and provide inputs to risk informed regulatory process. A small number of SPAR Level 2 models have been developed mostly for feasibility study purpose. They extend the Level 1 models to include containment systems, group plant damage states, and model containment phenomenology and accident progression in containment event trees. A severe earthquake and tsunami hit the eastern coast of Japan in March 2011 and caused significant damages on the reactors in Fukushima Daiichi site. Station blackout (SBO), core damage, containment damage, hydrogen explosion, and intensive radioactivity release, which have been previous analyzed and assumed as postulated accident progression in PRA models, now occurred with various degrees in the multi-units Fukushima Daiichi site. This paper reviews and compares a typical BWR SPAR Level 2 model with the “real” accident progressions and sequences occurred in Fukushima Daiichi Units 1, 2, and 3. It shows that the SPAR Level 2 model is a robust PRA model that could very reasonably describe the accident progression for a real and complicated nuclear accident in the world. On the other hand, the comparison shows that the SPAR model could be enhanced by incorporating some accident characteristics for better representation of severe accident progression.
42 ENGINEERING↗
Calibration and validation of a spar-type floating offshore wind turbine model using the FAST dynamic simulation tool
In this study, high-quality computer simulations are required when designing floating wind turbines because of the complex dynamic responses that are inherent with a high number of degrees of freedom and variable metocean conditions. In 2007, the FAST wind turbine simulation tool, developed and maintained by the U.S. Department of Energy's (DOE's) National Renewable Energy Laboratory (NREL), was expanded to include capabilities that are suitable for modeling floating offshore wind turbines. In an effort to validate FAST and other offshore wind energy modeling tools, DOE funded the DeepCwind project that tested three prototype floating wind turbines at 1/50 th scale in a wave basin, including a semisubmersible, a tension-leg platform, and a spar buoy. This paper describes the use of the results of the spar wave basin tests to calibrate and validate the FAST offshore floating simulation tool, and presents some initial results of simulated dynamic responses of the spar to several combinations of wind and sea states. Wave basin tests with the spar attached to a scale model of the NREL 5-megawatt reference wind turbine were performed at the Maritime Research Institute Netherlands under the DeepCwind project. This project included free-decay tests, tests with steady or turbulent wind and still water (both periodic and irregular waves with no wind), and combined wind/wave tests. The resulting data from the 1/50th model was scaled using Froude scaling to full size and used to calibrate and validate a full-size simulated model in FAST. Results of the model calibration and validation include successes, subtleties, and limitations of both wave basin testing and FAST modeling capabilities.
17 WIND ENERGY↗
MODIFICATION OF THE SPAR-H METHOD TO SUPPORT HRA FOR LEVEL 2 PSA
Currently, available Human Reliability Analysis (HRA) methods were generally developed to support Level 1 Probabilistic Safety Analysis (PSA) models. There has been an increased emphasis placed on Level 2 PSA in recent years; however, the currently used HRA methods are not ideal for this application, including the SPAR-H method. Challenges that will likely be present during a severe accident such as degraded or hazardous operating conditions, shift in control from the main control room to the technical support center, unavailability of instrumentation, and others are not routinely considered for Level 1 HRA analysis. These factors combine to create a much more uncertain condition to be accounted for in the HRA analysis. While the SPAR-H shaping factors were established to support Level 1 HRA, previous studies have shown it may be used for Level 2 HRA analysis as well. The Canadian Nuclear Safety Commission (CNSC) and Idaho National Laboratory (INL) in a joint project are investigating modifications to the SPAR-H method to create more consistency in applying the performance shaping factors used in the method for Level 2 analysis.
99 GENERAL AND MISCELLANEOUS↗
Powering the Woods Hole X-Spar Buoy with Ocean Wave Energy—A Control Co-Design Feasibility Study
Despite its success in measuring air–sea exchange, the Woods Hole Oceanographic Institution’s (WHOI) X-Spar Buoy faces operational limitations due to energy constraints, motivating the integration of an energy harvesting apparatus to improve its deployment duration and capabilities. This work explores the feasibility of an augmented, self-powered system in two parts. Part 1 presents the collaborative design between X-Spar developers and wave energy researchers translating user needs into specific functional requirements. Based on requirements like desired power levels, deployability, survivability, and minimal interference with environmental data collection, unsuitable concepts are pre-eliminated from further feasibility study consideration. In part 2, we focus on one of the promising concepts: an internal rigid body wave energy converter. We apply control co-design methods to consider commercial of the shelf hardware components in the dynamic models and investigate the concept’s power conversion capabilities using linear 2-port wave-to-wire models with concurrently optimized control algorithms that are distinct for every considered hardware configuration. During this feasibility study we utilize two different control algorithms, the numerically optimal (but acausal) benchmark and the optimized damping feedback. We assess the sensitivity of average power to variations in drive-train friction, a parameter with high uncertainty, and analyze stroke limitations to ensure operational constraints are met. Our results indicate that a well-designed power take-off (PTO) system could significantly extend the WEC-Spar’s mission by providing additional electrical power without compromising data quality.
autonomous systems↗
Floating platform effects on power generation in spar and semisubmersible wind turbines
The design and financing of commercial-scale floating offshore wind projects require a better understanding of how power generation differs between newer floating turbines and well-established fixed-bottom turbines. In floating turbines, platform mobility causes additional rotor motion that can change the time-averaged power generation. In this work, OpenFAST simulations examine the power generated by the National Renewable Energy Laboratory's 5-MW reference turbine mounted on the OC3-UMaine spar and OC4-DeepCWind semisubmersible floating platforms, subjected to extreme irregular waves and below-rated turbulent inflow wind from large-eddy simulations of a neutral atmospheric boundary layer. For these below-rated conditions, average power generation in floating turbines is most affected by two types of turbine displacements: an average rotor pitch angle that reduces power, caused by platform pitch; and rotor motion upwind-downwind that increases power, caused by platform surge and pitch. The relative balance between these two effects determines whether a floating platform causes power gains or losses compared to a fixed-bottom turbine; for example, the spar creates modest (3.1%–4.5%) power gains, whereas the semisubmersible creates insignificant (0.1%–0.2%) power gains for the simulated conditions. Furthermore, platform surge and pitch motions must be analyzed concurrently to fully capture power generation in floating turbines, which is not yet universal practice. Finally, a simple analytical model for predicting average power in floating turbines under below-rated wind speeds is proposed, incorporating effects from both the time-averaged pitch displacement and the dynamic upwind-downwind displacements.
17 WIND ENERGY↗
Use of TCSR with Split Windings for Shortening the Spar Cycle Time in 500 kV Lines
The arc-fault recharge phenomenon in single-phase automatic reclosure (SPAR) of a line is examined. Abrief description is given of the design of a 500 kV thyristor controlled shunt reactor (TCSR) with split valve-side windings. This type of TCSR is shown to effectively quench a single-phase arc fault in a power transmission line and shortens the SPAR cycle time.
42 ENGINEERING↗
Thermal Instability in the Manufacturing of Wind Turbine Blade Spar Caps
As wind turbine blades continue to scale in length and total mass, the acceptability of traditional approaches for the engineering of processes to build these products has reached a limit. The continued need to reduce the levelized cost of energy (LCOE) drives manufacturing cycle times lower and the net mass of critical components challenges even the most experienced fabricators to meet the quality requirements for safe operating performance over the 25-year design life of the blade. In trying to reduce cycle time for key components of wind turbines, manufacturers discovered occasional buckling of fibers in wind turbine blade spar caps. The cause of the buckling was unknown. The goal of this project was to show that a comprehensive simulation, which considered all of the physics of the VARTM process, could identify the cause of the fiber buckling in spar caps that has been observed during the manufacturing process. Ultimately, the simulation determined the manufacturing process and parameters could lead to significant compressive stresses in the fibers eventually causing buckling. Simulation results suggest that the stress introduced from friction is the largest source of compressive stress in the fibers, the stress from the weight of gravity is significant but secondary, and the compressive stress from cure shrinkage does not play a significant role in the buckling of fibers. This report provides details of the testing and simulation methodology used to identify the cause of the fiber buckling.
17 WIND ENERGY↗
Thermal Instability in the Manufacturing of Wind Turbine Blade Spar Caps – Phase 2
As the wind turbine industry continues to develop, the technology surrounding the design, development, and manufacturing of blades requires advancement as well. Wind turbine blades continue to increase in size, increasing the cost and time associated with manufacturing. Simulation driven manufacturing cycle design is required for the industry to maintain manufacturing schedules and optimize the manufacturing process. A recent effort to reduce the cycle time of wind blade spar caps encountered a recurring manufacturing defect during the exotherm and curing of the resin system after filling in the vacuum-assisted resin transfer molding (VARTM) process. Thermal waves developed in sections of the spar cap resulting in unacceptable part tolerances, requiring the parts to be thrown out. The first phase of this IACMI project focused on characterizing the fabric and epoxy system used in manufacturing and simulating the manufacturing process to determine the root cause of the thermal waves. The second phase of this project refined and validated the manufacturing simulations. The simulation workflow was then used to analyze multiple cure cycle options to determine if the thermal waves would appear. The estimated filling time from the filling simulation was shown to match well to experiment, and the temperature history from the curing simulation lined up well with experiment. This indicates that these simulations could be used to evaluate future curing cycles to be used with manufacturing. It is recommended that the distortion simulation work be completed for this project, as it would allow for further manufacturing cycle evaluation through the prediction of stresses and strains in the part. This could provide indicators of defects like the thermal waves seen in manufacturing earlier.
17 WIND ENERGY↗
SPAR Model Structural Efficiencies
The Nuclear Regulatory Commission (NRC) and the Electric Power Research Institute (EPRI) are supporting initiatives aimed at improving the quality of probabilistic risk assessments (PRAs). Included in these initiatives are the resolution of key technical issues that are have been judged to have the most significant influence on the baseline core damage frequency of the NRC’s Standardized Plant Analysis Risk (SPAR) models and licensee PRA models. Previous work addressed issues associated with support system initiating event analysis and loss of off-site power/station blackout analysis.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Development of High Strength, High Fatigue Composites for Wind Blade Spars
Explore the source record for details and available documents.
17 WIND ENERGY↗
Nested control co-design of a spar buoy horizontal-axis floating offshore wind turbine
Not Available
Bayat, Saeid↗
Accurate Modeling of Material Nonlinearities in a Wind Turbine Spar Cap.
Abstract not provided.
Ennis, Brandon↗
Oak Ridge National Laboratory Thermoplastic Composite Joining of Pultruded Continuous Fiber Spars for Multi-Functional Battery Enclosure
Oak Ridge National Laboratory (ORNL) worked with DowAksa Industry to investigate the potential of using PA66 material to produce larger composite parts, transcending the limitations of traditional presses. The project aimed to develop a suitable material for printing battery boxes using Nylon 66 infused with 40 wt.% carbon fiber, compatible with the ORNL Additive Manufacturing and Compression Molding (AM-CM) system. However, even with extensive work, it was concluded that the material is not compatible with the AMCM process and suitable for joining using compression technique. Main reason for the incompatibility were found to be very high crystallinity of the PA66 grade chosen for this work. To improve printability, a modifier (proprietary) was added to decrease crystallinity, but this led to reduced thermal stability and adhesion issues.
36 MATERIALS SCIENCE↗