Engineering topics

Keller, Jon

Publications and source records attributed to Keller, Jon.

4 records

DOE OSTI2024

Wind Turbine Design Guideline DG03: Yaw and Pitch Bearings

This design guideline describes the design criteria, calculation methods, and applicable standards recommended for use in performance and life analyses of ball and roller (rolling) bearings for yaw and pitch motion support in wind turbine applications. The formulae presented here for rolling bearing analytical methods and bearing-life ratings are consistent with methods currently used by wind turbine designers and rolling bearing manufacturers. The original yaw and pitch bearing design guideline was first drafted in 1999 by industry members and finally published in 2009 by the National Renewable Energy Laboratory. It was conceived as the third in a series of design guidelines, but it was the only one actually published by NREL and since has been known by the name "DG03." Other design guidelines were started, but instead of being published by NREL, they eventually became some of the International Electrotechnical Commission wind turbine standards in use today. This updated design guideline includes advances in research and field experiences made between 2009 and 2023. A better understanding of the operating conditions and damage mechanisms, advances in computational design, and publicly available test results facilitate more reliable yaw and pitch bearing designs.

17 WIND ENERGY↗

DOE OSTI2024

An Operations and Maintenance Roadmap for U.S. Offshore Wind: Enabling a Cost-Effective and Sustainable U.S. Offshore Wind Energy Industry Through Innovative Operations and Maintenance

The United States is currently targeting 30GW of offshore wind to be installed by 2030, and 150GW by 2050. Even considering future turbine sizes, this represents thousands of new turbines installed in a diverse set of environments, each with their unique design, installation, and maintenance challenges. While much can be learned from European and Asian experience with offshore wind over the past two decades, it is important to understand the unique circumstances of the U.S. This document explores operations and maintenance of offshore wind energy, specific to the U.S. and attempts to lay out a roadmap for needed activities to ensure reliability of future installations. The roadmap was informed through dozens of interviews with a wide cross-section of the industry, including representatives from OEMs, owner/operators, service companies, certification agencies, service providers, and researchers. The roadmap first describes the problem by component - blades, drivetrain and nacelle, structures and foundations, and electrical systems - through a look at current practices and opportunities for improvement in the areas of Failure Mode Analysis and Mitigation; Monitoring, Sensing, and Inspection; and Maintenance Execution. Crosscutting areas of Digitalization, Robotics and Automation, Prognostics and Health Management and O&M Optimization, Experimentation and Demonstration, Standardization, and Design Optimization Considering Reliability and O&M are then discussed. Finally, the roadmap summarizes all of these topics with recommendations for short (1-3 years), medium (4-7 years), and long term (8-12 years) activities, with a description of needed public and private sector contributions.

17 WIND ENERGY↗

DOE OSTI2024

Instrumentation for the Investigation of Pitch Bearing Design and Reliability

Recently, there has been an increasing level of industry interest in pitch system and pitch bearing reliability. Pitch bearings are used in wind turbines to connect the blade root to the hub. Some populations of pitch bearings have demonstrated a 12% failure rate in 20 years. As rotor diameters continue to increase for tall land-based and offshore wind turbines, pitch bearings are becoming even larger in diameter, which can make them vulnerable to deflections and consequent stress concentrations. There is an increased need to more accurately study pitch bearing deformations, misalignment, load distributions, and contact stresses. A significant body of work has investigated fatigue lives and wear characteristics of pitch bearings on ground-based test rigs. NREL has also recently begun a research program related to pitch bearing reliability, recognizing its growing importance for wind turbines. The purpose of this paper is to describe a set of instrumentation that was recently installed on a 1.5 MW wind turbine at the NREL Flatirons Campus and provide an example data set. To the authors' knowledge, this will be the first publicly available pitch bearing data collection campaign on an operational wind turbine.

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↗