Thermal fatigue testing of simulated turbine blades
Simulated turbine blade thermal fatigue testing under transient and steady state heating and spanwise loading, obtaining crack initiation and propagation data
Bizon, P. T.↗
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A new coupling of a GPU-resident large-eddy simulation code with a multiphysics wind turbine simulation tool
The development of new wind farm control strategies can benefit from combined analysis of flow dynamics in the farm and the behavior of individual turbines within one simulation environment. In this work, we present such an environment by developing a new coupling between the large-eddy simulation (LES) code GRASP and the multiphysics wind turbine simulation tool OpenFAST via an actuator line model (ALM). In addition, the implementation of the recently proposed filtered actuator line model (FALM) within the coupling is described. The new ALM implementation is cross-verified with results from four other commonly used research LES codes. The results for the blade loads and the near wake obtained with the new coupling are consistent with the other codes. Deviations are observed in the far wake. The results further indicate that the FALM is able to reduce the lift and power overprediction from which the traditional ALM suffers on coarse LES grids. This new simulation environment paves the way for future wind farm simulations under realistic weather conditions by leveraging GRASP's ability to impose data from large-scale meteorological models as boundary conditions.
17 WIND ENERGY↗
WEST-3 wind turbine simulator development
The software developed for WEST-3, a new, all digital, and fully programmable wind turbine simulator is given. The process of wind turbine simulation on WEST-3 is described in detail. The major steps are, the processing of the mathematical models, the preparation of the constant data, and the use of system software generated executable code for running on WEST-3. The mechanics of reformulation, normalization, and scaling of the mathematical models is discussed in detail, in particulr, the significance of reformulation which leads to accurate simulations. Descriptions for the preprocessor computer programs which are used to prepare the constant data needed in the simulation are given. These programs, in addition to scaling and normalizing all the constants, relieve the user from having to generate a large number of constants used in the simulation. Also given are brief descriptions of the components of the WEST-3 system software: Translator, Assembler, Linker, and Loader. Also included are: details of the aeroelastic rotor analysis, which is the center of a wind turbine simulation model, analysis of the gimbal subsystem; and listings of the variables, constants, and equations used in the simulation.
Hoffman, J. A.↗
ExaWind: Open‐source CFD for hybrid‐RANS/LES geometry‐resolved wind turbine simulations in atmospheric flows
Abstract Predictive high‐fidelity modeling of wind turbines with computational fluid dynamics, wherein turbine geometry is resolved in an atmospheric boundary layer, is important to understanding complex flow accounting for design strategies and operational phenomena such as blade erosion, pitch‐control, stall/vortex‐induced vibrations, and aftermarket add‐ons. The biggest challenge with high‐fidelity modeling is the realization of numerical algorithms that can capture the relevant physics in detail through effective use of high‐performance computing. For modern supercomputers, that means relying on GPUs for acceleration. In this paper, we present ExaWind, a GPU‐enabled open‐source incompressible‐flow hybrid‐computational fluid dynamics framework, comprising the near‐body unstructured grid solver Nalu‐Wind, and the off‐body block‐structured‐grid solver AMR‐Wind, which are coupled using the Topology Independent Overset Grid Assembler. Turbine simulations employ either a pure Reynolds‐averaged Navier–Stokes turbulence model or hybrid turbulence modeling wherein Reynolds‐averaged Navier–Stokes is used for near‐body flow and large eddy simulation is used for off‐body flow. Being two‐way coupled through overset grids, the two solvers enable simulation of flows across a huge range of length scales, for example, 10 orders of magnitude going from O(μm) boundary layers along the blades to O(10 km) across a wind farm. In this paper, we describe the numerical algorithms for geometry‐resolved turbine simulations in atmospheric boundary layers using ExaWind. We present verification studies using canonical flow problems. Validation studies are presented using megawatt‐scale turbines established in literature. Additionally presented are demonstration simulations of a small wind farm under atmospheric inflow with different stability states.
17 WIND ENERGY↗
Thermal fatigue testing of simulated turbine blades
Burner rig tests on simulated turbine blades, with and without internal cooling, to predict thermal fatigue performance
Bizon, P. T.↗
WEST-3 wind turbine simulator development. Volume 1: Summary
This report is a summary description of WEST-3, a new real-time wind turbine simulator developed by Paragon Pacific Inc. WEST-3 is an all digital, fully programmable, high performance parallel processing computer. Contained in the report are descriptions of the WEST-3 hardware and software. WEST-3 consists of a network of Computational Units (CUs) working in parallel. Each CU is a custom designed high speed digital processor operating independently of other CUs. The CU, which is the main building block of the system, is described in some detail. A major contributor to the high performance of the system is the use a unique method for transferring data among the CUs. The software aspects of WEST-3 covered in the report include the preparation of the simulation model (reformulation, scaling and normalization), and the use of the system software (Translator, Linker, Assembler and Loader). Also given is a description of the wind turbine simulation model used in WEST-3, and some sample results from a study conducted to validate the system. Finally, efforts currently underway to enhance the user friendliness of the system are outlined; these include the 32-bit floating point capability, and major improvements in system software.
Sridhar, S.↗
WEST-3 wind turbine simulator development. Volume 2: Verification
The details of a study to validate WEST-3, a new time wind turbine simulator developed by Paragib Pacific Inc., are presented in this report. For the validation, the MOD-0 wind turbine was simulated on WEST-3. The simulation results were compared with those obtained from previous MOD-0 simulations, and with test data measured during MOD-0 operations. The study was successful in achieving the major objective of proving that WEST-3 yields results which can be used to support a wind turbine development process. The blade bending moments, peak and cyclic, from the WEST-3 simulation correlated reasonably well with the available MOD-0 data. The simulation was also able to predict the resonance phenomena observed during MOD-0 operations. Also presented in the report is a description and solution of a serious numerical instability problem encountered during the study. The problem was caused by the coupling of the rotor and the power train models. The results of the study indicate that some parts of the existing WEST-3 simulation model may have to be refined for future work; specifically, the aerodynamics and procedure used to couple the rotor model with the tower and the power train models.
Sridhar, S.↗
Design of a real-time wind turbine simulator using a custom parallel architecture
The design of a new parallel-processing digital simulator is described. The new simulator has been developed specifically for analysis of wind energy systems in real time. The new processor has been named: the Wind Energy System Time-domain simulator, version 3 (WEST-3). Like previous WEST versions, WEST-3 performs many computations in parallel. The modules in WEST-3 are pure digital processors, however. These digital processors can be programmed individually and operated in concert to achieve real-time simulation of wind turbine systems. Because of this programmability, WEST-3 is very much more flexible and general than its two predecessors. The design features of WEST-3 are described to show how the system produces high-speed solutions of nonlinear time-domain equations. WEST-3 has two very fast Computational Units (CU's) that use minicomputer technology plus special architectural features that make them many times faster than a microcomputer. These CU's are needed to perform the complex computations associated with the wind turbine rotor system in real time. The parallel architecture of the CU causes several tasks to be done in each cycle, including an IO operation and the combination of a multiply, add, and store. The WEST-3 simulator can be expanded at any time for additional computational power. This is possible because the CU's interfaced to each other and to other portions of the simulation using special serial buses. These buses can be 'patched' together in essentially any configuration (in a manner very similar to the programming methods used in analog computation) to balance the input/ output requirements. CU's can be added in any number to share a given computational load. This flexible bus feature is very different from many other parallel processors which usually have a throughput limit because of rigid bus architecture.
Hoffman, John A.↗
Measurement of transient strain and surface temperature on simulated turbine blades using noncontacting techniques
Noncontacting techniques were used to measure strain and temperature in thermally cycled simulated turbine blades. An electro-optical extensometer was used to measure the displacement between parallel targets mounted on the leading edge of the blades throughout a complete heating and cooling cycle. An infrared photographic pyrometry method was used to measure blade steady state surface temperature. The blade was cyclically heated and cooled by moving it into and out of a Mach 1 hot-gas stream. Transient leading edge strain and steady state surface temperature distributions are presented for blades of three different configurations.
Calfo, F. D.↗
Implementation and Validation of a Generalized Actuator Disk Parameterization for Wind Turbine Simulations Within the FastEddy Model
ABSTRACT Fast and accurate large‐eddy simulation (LES) of the atmospheric boundary layer plays a crucial role in advancing wind energy research. Long‐duration wind farm studies at turbine‐resolving scales have become increasingly important to understand the intricate interactions between large wind farms and the atmospheric boundary layer. However, the prohibitive computational cost of these turbulence‐ and turbine‐resolving simulations has precluded such modeling to be exercised on a regular basis. To that end, we implement and validate the generalized actuator disk (GAD) model in the computationally efficient, graphics processing unit (GPU)–resident, LES model FastEddy. We perform single‐turbine simulations under three atmospheric stabilities (neutral, unstable, and stable) and compare them against observations from the Scaled Wind Farm Technology (SWiFT) facility and other LES codes from the recent Wakebench turbine wake model benchmark. Our idealized LES results agree well with observed wake velocity deficit and downstream recovery across stability regimes. Turbine response in terms of rotational speed, generated power, torque, and thrust coefficient are well predicted across stability regimes and are consistent with the LES results from the benchmark. The FastEddy simulations are found to be at least two orders of magnitude more efficient than the traditional CPU‐based LES models, opening the door for realistic LES simulations of full wind plants as a viable standard practice.
17 WIND ENERGY↗
Experimental determination of transient strain in a thermally-cycled simulated turbine blade utilizing a non-contact technique
A type of noncontacting electro-optical extensometer was used to measure the displacement between parallel targets mounted on the leading edge of a simulated turbine blade throughout a complete heating and cooling cycle. The blade was cyclically heated and cooled by moving it into and out of a Mach 1 hot gas stream. The principle of operation and measurement procedure of the electro-optics extensometer are described.
Calfo, F. D.↗
Environmental and Mechanical Stability of Environmental Barrier Coated SA Tyrannohex SiC Composites Under Simulated Turbine Engine Environments
The environmental stability and thermal gradient cyclic durability performance of SA Tyrannohex composites were investigated for turbine engine component applications. The work has been focused on investigating the combustion rig recession, cyclic thermal stress resistance and thermomechanical low cycle fatigue of uncoated and environmental barrier coated Tyrannohex SiC SA composites in simulated turbine engine combustion water vapor, thermal gradients, and mechanical loading conditions. Flexural strength degradations have been evaluated, and the upper limits of operating temperature conditions for the SA composite material systems are discussed based on the experimental results.
Low cycle fatigue↗
Crack-Detection Experiments on Simulated Turbine Engine Disks in NASA Glenn Research Center's Rotordynamics Laboratory
The development of new health-monitoring techniques requires the use of theoretical and experimental tools to allow new concepts to be demonstrated and validated prior to use on more complicated and expensive engine hardware. In order to meet this need, significant upgrades were made to NASA Glenn Research Center s Rotordynamics Laboratory and a series of tests were conducted on simulated turbine engine disks as a means of demonstrating potential crack-detection techniques. The Rotordynamics Laboratory consists of a high-precision spin rig that can rotate subscale engine disks at speeds up to 12,000 rpm. The crack-detection experiment involved introducing a notch on a subscale engine disk and measuring its vibration response using externally mounted blade-tip-clearance sensors as the disk was operated at speeds up to 12 000 rpm. Testing was accomplished on both a clean baseline disk and a disk with an artificial crack: a 50.8-mm- (2-in.-) long introduced notch. The disk s vibration responses were compared and evaluated against theoretical models to investigate how successful the technique was in detecting cracks. This paper presents the capabilities of the Rotordynamics Laboratory, the baseline theory and experimental setup for the crack-detection experiments, and the associated results from the latest test campaign.
Woike, Mark R.↗
A 100 kW experimental wind turbine: Simulation of starting, overspeed, and shutdown characteristics
The ERDA/NASA 100 kW experimental wind turbine is modeled on a digital computer in order to study the performance of a wind turbine under operating conditions. Simulation studies of starting, overspeed, and shutdown performance were made. From these studies operating procedures, precautions, and limitations are prescribed.
Gilbert, L. J.↗
High-temperature erosion of plasma-sprayed, yttria-stabilized zirconia in a simulated turbine environment
A series of rig calibration and high temperature tests simulating gas path seal erosion in turbine engines were performed at three impingement angles and at three downstream locations. Plasma sprayed, yttria stablized zirconia specimens were tested. Steady state erosion curves presented for 19 test specimens indicate a brittle type of material erosion despite scanning electron microscopy evidence of plastic deformation. Steady state erosion results were not sensitive to downstream location but were sensitive to impingement angle. At difference downstream locations specimen surface temperature varied from 1250 to 1600 C (2280 to 2900 F) and particle velocity varied from 260 to 320 m/s (850 to 1050 ft/s). The mass ratio of combustion products to erosive grit material was typically 240.
Hanschuh, R. F.↗
High-temperature erosion of plasma-sprayed, yttria-stabilized zirconia in a simulated turbine environment
A series of rig calibration and high temperature tests simulating gas path seal erosion in turbine engines were performed at three impingement angles and at three downstream locations. Plasma sprayed, yttria stabilized zirconia specimens were tested. Steady state erosion curves presented for 19 test specimens indicate a brittle type of material erosion despite scanning electron microscopy evidence of plastic deformation. Steady state erosion results were not sensitive to downstream location but were sensitive to impingement angle. At different downstream locations specimen surface temperature varied from 1250 to 1600 C (2280 to 2900 F) and particle velocity varied from 260 to 320 m/s (850 to 1050 ft/s). The mass ratio of combustion products to erosive grit material was typically 240.
Handschuh, R. F.↗
Impact of Limited Degree of Freedom Drag Coefficients on a Floating Offshore Wind Turbine Simulation
The worldwide effort to design and commission floating offshore wind turbines (FOWT) is motivating the need for reliable numerical models that adequately represent their physical behavior under realistic sea states. However, properly representing the hydrodynamic quadratic damping for FOWT remains uncertain, because of its dependency on the choice of drag coefficients (dimensionless or not). It is hypothesized that the limited degree of freedom (DoF) drag coefficient formulation that uses only translational drag coefficients causes mischaracterization of the rotational DoF drag, leading to underestimation of FOWT global loads, such as tower base fore-aft shear. To address these hydrodynamic modeling uncertainties, different quadratic drag models implemented in the open-source mid-fidelity simulation tool, OpenFAST, were investigated and compared with the experimental data from the Offshore Code Comparison Collaboration, Continued, with Correlation (OC5) project. The tower base fore-aft shear and up-wave mooring line tension were compared under an irregular wave loading condition to demonstrate the effects of the different damping models. Two types of hydrodynamic quadratic drag formulations were considered: (1) member-based dimensionless drag coefficients applied only at the translational DoF (namely limited-DoF drag model) and (2) quadratic drag matrix model (in dimensional form). Based on the results, the former consistently underestimated the 95th percentile peak loads and spectral responses when compared to the OC5 experimental data. In contrast, the drag matrix models reduced errors in estimates of the tower base shear peak load by 7–10% compared to the limited-DoF drag model. The underestimation in the tower base fore-aft shear was thus inferred be related to mischaracterization of the rotational pitch drag and the heave motion/drag by the limited-DoF model.
17 WIND ENERGY↗
Unsteady, Cooled Turbine Simulation Using a PC-Linux Analysis System
The fist stage of the high-pressure turbine (HPT) of the GE90 engine was simulated with a three-dimensional unsteady Navier-Sokes solver, MSU Turbo, which uses source terms to simulate the cooling flows. In addition to the solver, its pre-processor, GUMBO, and a post-processing and visualization tool, Turbomachinery Visual3 (TV3) were run in a Linux environment to carry out the simulation and analysis. The solver was run both with and without cooling. The introduction of cooling flow on the blade surfaces, case, and hub and its effects on both rotor-vane interaction as well the effects on the blades themselves were the principle motivations for this study. The studies of the cooling flow show the large amount of unsteadiness in the turbine and the corresponding hot streak migration phenomenon. This research on the GE90 turbomachinery has also led to a procedure for running unsteady, cooled turbine analysis on commodity PC's running the Linux operating system.
List, Michael G.↗