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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↗

NASA NTRS1977

ERDA/NASA 100 kilowatt mod-o wind turbine operations and performance

The ERDA/NASA 100 kW Mod-0 wind turbine is operating at the NASA Plum Brook Station near Sandusky, Ohio. The operation of the wind turbine has been fully demonstrated and includes start-up, synchronization to the utility network, blade pitch control for control of power and speed, and shut-down. Also, fully automatic operation has been demonstrated by use of a remote control panel, 50 miles from the site, similar to what a utility dispatcher might use. The operation systems and experience with the wind turbine loads, electrical power and aerodynamic performance obtained from testing are described.

Thomas, R. L.↗

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↗

NASA NTRS1981

Dynamics and stability of wind turbine generators

Synchronous and induction generators are considered. A comparison is made between wind turbines, steam, and hydro units. The unusual phenomena associated with wind turbines are emphasized. The general control requirements are discussed, as well as various schemes for torsional damping such as speed sensitive stabilizer and blade pitch control. Integration between adjacent wind turbines in a wind farm is also considered.

Hinrichsen, E. N.↗

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 OSTI2019

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 plan of new capabilities in OpenFAST to model floating substructure flexibility and member-level loads, including the functional requirements and modeling approaches needed to understand and apply them correctly.

17 WIND ENERGY↗

NASA NTRS1998

Proposed Wind Turbine Aeroelasticity Studies Using Helicopter Systems Analysis

Advanced systems for the analysis of rotary wing aeroelastic structures (helicopters) are being developed at NASA Ames by the Rotorcraft Aeromechanics Branch, ARA. The research has recently been extended to the study of wind turbines, used for electric power generation Wind turbines play an important role in Europe, Japan & many other countries because they are non polluting & use a renewable source of energy. European countries such as Holland, Norway & France have been the world leaders in the design & manufacture of wind turbines due to their historical experience of several centuries, in building complex wind mill structures, which were used in water pumping, grain grinding & for lumbering. Fossil fuel cost in Japan & in Europe is two to three times higher than in the USA due to very high import taxes. High fuel cost combined with substantial governmental subsidies, allow wind generated power to be competitive with the more traditional sources of power generation. In the USA, the use of wind energy has been limited mainly because power production from wind is twice as expensive as from other traditional sources. Studies conducted at the National Renewable Energy Laboratories (NREL) indicate that the main cost in the production of wind turbines is due to the materials & the labor intensive processes used in the construction of turbine structures. Thus, for the US to assume world leadership in wind power generation, new lightweight & consequently very flexible wind turbines, that could be economically mass produced, would have to be developed [4,5]. This effort, if successful, would result in great benefit to the US & the developing nations that suffer from overpopulation & a very high cost of energy.

Ladkany, Samaan G.↗

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 OSTI2019

Substructure Flexibility and Member-Level Load Capabilities for Floating Offshore Wind Turbines in OpenFAST: Preprint

OpenFAST is an open-source, physics-based engineering tool applicable to the loads 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-let along newer designs that are more streamlined, flexible, and cost-effective. This paper presents the development plan of new capabilities in OpenFAST to model floating substructure flexibility and member-level loads, including the functional requirements and modeling approaches needed to understand and apply it correctly.

17 WIND ENERGY↗

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↗

NASA NTRS1978

Employing static excitation control and tie line reactance to stabilize wind turbine generators

An analytical representation of a wind turbine generator is presented which employs blade pitch angle feedback control. A mathematical model was formulated. With the functioning MOD-0 wind turbine serving as a practical case study, results of computer simulations of the model as applied to the problem of dynamic stability at rated load are also presented. The effect of the tower shadow was included in the input to the system. Different configurations of the drive train, and optimal values of the tie line reactance were used in the simulations. Computer results revealed that a static excitation control system coupled with optimal values of the tie line reactance would effectively reduce oscillations of the power output, without the use of a slip clutch.

Hwang, H. H.↗

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↗

NASA NTRS1984

Mod-2 wind turbine field operations experience

The Mod-2 wind turbine is now in a 2-year research/experimental operations phase which offers a unique opportunity to study the effects of single and multiple wind turbines interacting with each other, the power grid, and the environment. This paper addresses the field operations and research testing experienced at the Mod-2 Cluster Goodnoe Hills Research Test Site near Goldendale, WA. Field operation, both routine and nonroutine, are discussed as well as the role of the participating utility. Technical areas discussed pertain to system performance and loads. Specific research tests relating to acoustics, TV interference, and wake effects are also discussed.

Gordon, L. H.↗

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↗