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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

CalWave's xWave Design for PacWave (Final Technical Report)

CalWave Inc. (CalWave) is developing a wave energy converter (WEC) technology that can generate electricity from ocean waves. CalWave’s design offers a unique approach to wave energy conversion that operates fully submerged and can actively adjust the wave excitation. This capability gives the architecture enhanced survivability in ocean storms without adding significant costs. Prior to this project, CalWave had completed a demonstration of a fully functional WEC system in an open ocean demonstration at nominal 1:5 scale under FOA 1663. The goal of this project was the detailed design, following relevant standards and industry best-practices, of a variant of the xWave WEC technology that can safely and efficiently operate at the DOE’s PacWave South test site for a targeted deployment of up two years. The WEC design and associated review processes proceeded in two distinct project phases: a ‘Preliminary’ and a ‘Final’ design phase. The first phase of the project consisted of the systematic design of the WEC’s key features with regards to appropriate IEC standards. The work resulted in a preliminary design of the xWave hull including structural and Power Take-Off (PTO) load estimates, as well as performance estimates for all ocean conditions the WEC would operate in at PacWave South. Following the first open-water demonstration of CalWave’s small-scale “x1” device under FOA 1663, lessons learned were fed directly into a comprehensive review of the xWave design in the second design phase of this FOA project. CalWave’s work was supported by Sandia National Lab (SNL) and the National Renewable Energy Lab (NREL) on the holistic WEC design, and detailed feedback from specialized partners on hull design, mooring and anchoring specification, and electrical grid interconnection. Optimization of the WEC system was performed using a novel numerical optimization tool developed by Sandia and optimization trends were confirmed via an experimental model scale tank test campaign. Performance estimates for PacWave and a detailed xWave design including integration of all relevant system components were concluded. The mooring design was also concluded in the Final design phase using the most up to date sea floor characterization (CPT) data.

16 TIDAL AND WAVE POWER↗
DOE OSTI2016

Investigating the process of white etching crack initiation in bearing steel

White etching cracks (WECs) have been identified as a dominant mode of premature failure within wind turbine gearbox bearings. Though WECs have been reported in the field for over a decade, the conditions leading to WECs, and the process by which this failure culminates, are both highly debated. In previously published work, the generation of WECs on a benchtop scale was linked to sliding at the surface of the test sample, it was also postulated that the generation of WECs was dependent on the cumulative energy that had been applied to the sample over the entirety of the test. In this paper, a three ring on roller bench top test rig is used to systematically alter the cumulative energy that a sample experiences through changes in normal load, sliding, and run time, in an attempt to correlate cumulative energy with the formation of WECs. It was determined that, in the current test setup, the presence of WECs can be predicted by this energy criterion. The authors then used this information to study the process by which WECs initiate. Lastly, it was found that, under the current testing conditions, the formation of a dark etching microstructure precedes the formation of a crack, and a crack precedes the formation of white etching microstructure.

17 WIND ENERGY↗
DOE OSTI2019

Numerical analysis and wave tank validation on the optimal design of a two-body wave energy converter

To improve the performance of a ‘point absorber’ type wave energy converter (WEC), an additional submerged body can be deployed. The submerged body can be used to increase the equivalent excitation force on the WEC, as well as provide resonance tuning. This paper presents numerical analysis and experimental validation of a two-body point absorber type WEC using a mechanical motion rectifier (MMR) based power takeoff. The two-body point absorber consists of a floating buoy connected to a neutrally buoyant submerged body via the power-takeoff. The mechanical motion rectifier and a ball screw translate the relative heave motion of the two bodies into unidirectional rotation, which in turn spins a generator. Frequency domain analysis suggests there is an optimal submerged body mass for maximum WEC power absorption. Regular wave simulations in the time domain are compared to the results obtained in the frequency domain. While the time domain and frequency domain results predict the same optimal mass ratio, time domain analysis provides a more complex and accurate power result. To validate the time domain model, experimental wave tank testing is conducted using a 1:30 scale model WEC. The experiment shows the two-body WEC can produce twice the amount of power as the single-body WEC with same floating buoy and can be further increased by PTO design and power electronics optimization. Furthermore, wave tank testing shows the two-body WEC has a capture width ratio up to 58% at 59 kW/m and 51% at 36 kW/m.

16 TIDAL AND WAVE POWER↗
DOE OSTI2025

From TPL assessment to design optimization: Wave energy converter control co-design applied to the RM3

The Reference Model (RM) project developed six marine energy converter concepts using a sequential design methodology, which, while widely adopted in the industry, often overlooks interactions between system components, resulting in suboptimal designs. One such example is the Reference Model 3 (RM3), a two-body point absorber wave energy converter (WEC). An assessment using the Technology Performance Level (TPL) revealed that RM3’s low power-to-cost ratio, partly due to expensive steel construction, limits its techno-economic performance. Here, this study aims to redesign RM3 by reducing its scale and employing control co-design to integrate WEC and Power Take-Off (PTO) dynamics, constraints, and cost considerations within an optimization framework. We demonstrate the limitations of RM3’s current PTO design and explore the benefits of scaling down to enhance techno-economic viability by lowering material costs. Using WecOptTool, we conduct a parameter sweep over gear ratios and spring stiffnesses for various Commercial Off-The-Shelf generators in irregular wave conditions. Our findings emphasize the importance of aligning PTO components with WEC dynamics, showing that control co-design and strategic scaling can improve RM3’s power-to-cost ratio. This study presents a transferable example of applied control co-design for other WECs, supporting early-stage developers in their design decisions.

Off the shelf components↗
DOE OSTI2021

Reliability-based hull geometry optimisation of a point-absorber wave energy converter with power take-off structural reliability objectives

Recent studies have focused on optimising wave energy converter (WEC) designs, maximising their power performance and techno-economic feasibility. Reliability has yet to be fully considered in these formulations, despite its impact on cost and performance. In this study, this gap is addressed by developing a reliability-based design optimisation framework for WEC hull geometries to explore the trade-off between power performance and power take-off (PTO) system damage equivalent loading (DEL). Optimised hull geometries for two sites are considered (from the centre of the North Sea and off the west coast of Norway), and two directions of motions (heave and surge). Results indicate that site characteristics affect the potential power production and DEL for an optimal WEC design. These are also affected by the direction of motion for power extraction, which also significantly changes optimal hull shape characteristics. Optimal surging WEC designs have edges facing oncoming wave directions, while heaving WECs have pointed bottoms, both to streamline movement. Larger, more convex WECs result in greater power production and DEL, while smaller, more concave WECs result in lesser power production and DEL. These findings underline the importance of considering WEC hull geometry in early design processes to optimise cost, power production, and reliability.

16 TIDAL AND WAVE POWER↗
DOE OSTI2016

Application of the Most Likely Extreme Response Method for Wave Energy Converters: Preprint

Extreme loads are often a key cost driver for wave energy converters (WECs). As an alternative to exhaustive Monte Carlo or long-term simulations, the most likely extreme response (MLER) method allows mid- and high-fidelity simulations to be used more efficiently in evaluating WEC response to events at the edges of the design envelope, and is therefore applicable to system design analysis. The study discussed in this paper applies the MLER method to investigate the maximum heave, pitch, and surge force of a point absorber WEC. Most likely extreme waves were obtained from a set of wave statistics data based on spectral analysis and the response amplitude operators (RAOs) of the floating body; the RAOs were computed from a simple radiation-and-diffraction-theory-based numerical model. A weakly nonlinear numerical method and a computational fluid dynamics (CFD) method were then applied to compute the short-term response to the MLER wave. Effects of nonlinear wave and floating body interaction on the WEC under the anticipated 100-year waves were examined by comparing the results from the linearly superimposed RAOs, the weakly nonlinear model, and CFD simulations. Overall, the MLER method was successfully applied. In particular, when coupled to a high-fidelity CFD analysis, the nonlinear fluid dynamics can be readily captured.

16 TIDAL AND WAVE POWER↗
DOE OSTI2019

Extreme Load Computational Fluid Dynamics Analysis and Verification for a Multibody Wave Energy Converter

A wave energy converter (WEC) must be designed to survive the extreme sea states that it will be subject to throughout its lifetime. Although there are many analysis methods and codes available to accomplish this, there are currently several engineering challenges to WEC survival design. Foremost, the computational design approach will typically involve a trade-off between accuracy and computational efficiency. Additionally, most computational fluid dynamics (CFD) codes are not ideally suited to modeling extreme events for WECs with multibody dynamics, power-take-off systems, and mooring systems. Finally, although WEC design standards and CFD guidelines are emerging, with the current immaturity of the WEC industry, they are not yet well established. In this study, loads on a 1:35-scale, moored, multibody WEC are evaluated with CFD. The CFD results are compared with results obtained from a computationally efficient, midfidelity model based on linearized potential flow hydrodynamics. For these model verification comparisons, both operational and survival configurations are considered. The extreme load results obtained, using both codes, indicate that the survival configuration successfully sheds loads during extreme sea states. It is also found that WEC-Sim, when appropriately applied, can provide reasonable load results, at a fraction of the computational expense of CFD. However, for the more extreme sea states, and for higher-order effects not included in the WEC-Sim model, the linear-based results have significant errors in comparison to the CFD-based results, and should be used judiciously.

16 TIDAL AND WAVE POWER↗
DOE OSTI2020

Umbilical Fatigue Analysis for a Wave Energy Converter

Unique umbilical designs for wave energy converters (WECs), including the ability to handle significantly larger motions and loads over long deployments, are often required when conventional marine umbilical designs for offshore oil and gas and offshore wind may not meet the design and cost needs of wave energy technologies. This study details a fatigue analysis of a dynamic power umbilical attached to a two-body floating point absorber WEC system, using the sea states provided for the PacWave testing facilities. The 6 degrees of freedom motion time history for the WEC was simulated, and the motions of the attachment point for the umbilical on the WEC and respective sea states were used to analyze the dynamic motions and fatigue of the connected power umbilical to predict the fatigue life. The results show that the fatigue damage observed is more significant in shallow water, and extensive fatigue damage may occur because of the larger curvature response of the umbilical. The umbilical configurations departing at 90 deg off incoming waves were found to have the highest fatigue life attributed to less extension or compression of the umbilical. However, additional bend stiffener/limiter features may need to be incorporated into the buoyancy section and touchdown regions to minimize curvature-induced fatigue.

50 EE - Wind and Water Power Program - Water (EE-4↗
DOE OSTI2015

Economic Impact of Large-Scale Deployment of Offshore Marine and Hydrokinetic Technology in Oregon Coastal Counties

To begin understanding the potential economic impacts of large-scale WEC technology, the Bureau of Ocean Energy Management (BOEM) commissioned the National Renewable Energy Laboratory (NREL) to conduct an economic impact analysis of largescale WEC deployment for Oregon coastal counties. This report follows a previously published report by BOEM and NREL on the jobs and economic impacts of WEC technology for the entire state (Jimenez and Tegen 2015). As in Jimenez and Tegen (2015), this analysis examined two deployment scenarios in the 2026-2045 timeframe: the first scenario assumed 13,000 megawatts (MW) of WEC technology deployed during the analysis period, and the second assumed 18,000 MW of WEC technology deployed by 2045. Both scenarios require major technology and cost improvements in the WEC devices. The study is on very large-scale deployment so readers can examine and discuss the potential of a successful and very large WEC industry. The 13,000-MW is used as the basis for the county analysis as it is the smaller of the two scenarios. Sensitivity studies examined the effects of a robust in-state WEC supply chain. The region of analysis is comprised of the seven coastal counties in Oregon—Clatsop, Coos, Curry, Douglas, Lane, Lincoln, and Tillamook—so estimates of jobs and other economic impacts are specific to this coastal county area.

16 TIDAL AND WAVE POWER↗
DOE OSTI2023

Investigating the Longevity of Hydraulic Power Take-Off Piston Seals in Wave Energy Converters

Wave energy converters (WECs) utilize hydraulic power take-off (PTO) systems. Hydraulic cylinder seals, which are commonly made from thermoplastic or elastomeric polymers, play a vital role in PTO system functionality as they are responsible for containing and isolating high-pressure fluids. However, manufacturers of WECs have identified a significant concern regarding the longevity of hydraulic piston seal wear due to a combination of stressors, such as high pressure, elevated temperature, chemical corrosion, and/or environmental conditions. Seal failure can result in a loss of tightness and fluid leakage, and consequently a reduction in the efficiency of WECs. Seal manufacturers do not typically provide durability data as the materials are not specifically designed for WEC applications, nor do they account for real-world conditions that the materials may be exposed to. Additionally, there is no comparative performance data available between different seal manufacturers, creating uncertainty in hydraulic PTO designs for WECs. This paper reviews the current state of available seal materials for WEC hydraulic PTO systems, seal selection criteria for WEC applications, potential seal degradation mechanisms, and also material properties of the seals, such as density, hardness, tensile strength, and operating temperature. In addition, this paper also examines current evaluation procedures for estimating the durability of WEC PTO seals. Lastly, additional research on estimating the lifespan of piston and rod polymer seals used in hydraulic PTO systems is proposed.

Elen, Muthu↗
DOE OSTI2018

Numerical Modeling and Dynamic Analysis of a Wave-Powered Reverse-Osmosis System

A wave energy converter (WEC) system has the potential to convert the wave energy resource directly into the high-pressure flow that is needed by the desalination system to pump saltwater to the reverse-osmosis membrane and provide the required pressure level to generate freshwater. In this study, a wave-to-water numerical model was developed to investigate the potential use of a wave-powered desalination system (WPDS) for water production. The model was developed by coupling a time-domain radiation-and-diffraction method-based numerical tool (WEC-Sim) for predicting the hydrodynamic performance of WECs with a solution-diffusion model that was used to simulate the reverse-osmosis (RO) process. The objective of this research is to evaluate the WPDS dynamics and the overall efficiency of the system. To evaluate the feasibility of the WPDS, the wave-to-water numerical model was applied to simulate a desalination system that used an oscillating surge WEC device to pump seawater through the system. The hydrodynamics WEC-Sim simulation results for the oscillating surge WEC device were validated against existing experimental data. The RO simulation was verified by comparing the results to those from the Dow Chemical Company’s reverse osmosis system analysis (ROSA) model, which has been widely used to design and simulate RO systems. The wave-to-water model was then used to analyze the WPDS under a range of wave conditions and for a two-WECs-coupled RO system to evaluate the influence of pressure and flow rate fluctuation on the WPDS performance. The results show that the instantaneous energy fluctuation from waves has a significant influence on the responding hydraulic pressure and flow rate, as well as the recovery ratio and, ultimately, the water-production quality. Nevertheless, it is possible to reduce the hydraulic fluctuation for different sea states while maintaining a certain level of freshwater production, and a WEC array that produces water can be a viable, near-term solution to the nation’s water supply. A discussion on the dynamic impact of hydraulic fluctuation on the WPDS performance and potential options to reduce the fluctuation and their trade-offs is also presented.

16 TIDAL AND WAVE POWER↗
DOE OSTI2020

Comparison of Numerical Methods for Modeling the Wave Field Effects Generated by Individual Wave Energy Converters and Multiple Converter Wave Farms

This numerical study compares the wave field generated by the spectral wave action balance code, SNL-SWAN, to the linear-wave boundary-element method (BEM) code, WAMIT. The objective of this study is to assess the performance of SNL-SWAN for modeling wave field effects produced by individual wave energy converters (WECs) and wave farms comprising multiple WECs by comparing results from SNL-SWAN with those produced by the BEM code WAMIT. BEM codes better model the physics of wave-body interactions and thus simulate a more accurate near-field wave field than spectral codes. In SNL-SWAN, the wave field’s energy extraction is modeled parametrically based on the WEC’s power curve. The comparison between SNL-SWAN and WAMIT is made over a range of incident wave conditions, including short-, medium-, and long-wavelength waves with various amounts of directional spreading, and for three WEC archetypes: a point absorber (PA), a pitching flap (PF) terminator, and a hinged raft (HR) attenuator. Individual WECs and wave farms of five WECs in various configuration were studied with qualitative comparisons made of wave height and spectra at specific locations, and quantitative comparisons of the wave fields over circular arcs around the WECs as a function of radial distance. Results from this numerical study demonstrate that in the near-field, the difference between SNL-SWAN and WAMIT is relatively large (between 20% and 50%), but in the far-field from the array the differences are minimal (between 1% and 5%). The resultant wave field generated by the two different numerical approaches is highly dependent on parameters such as: directional wave spreading, wave reflection or scattering, and the WEC’s power curve.

16 TIDAL AND WAVE POWER↗
DOE OSTI2019

Extreme Load Computational Fluid Dynamics Analysis and Verification for a Multibody Wave Energy Converter: Preprint

A wave energy converter (WEC) must be designed to survive the extreme sea states that it will be subject to throughout its lifetime. Although there are many analysis methods and codes available to accomplish this, there are currently several engineering challenges to WEC survival design. Foremost, the computational design approach will typically involve a trade-off between accuracy and computational efficiency. Additionally, most computational fluid dynamics (CFD) codes are not ideally suited to modeling extreme events for WECs with multibody dynamics, power-take-off systems, and mooring systems. Finally, although WEC design standards and CFD guidelines are emerging, with the current immaturity of the WEC industry, they are not yet well established. In this study, loads on a 1:35-scale, moored, multibody WEC are evaluated with CFD. The CFD results are compared with results obtained from a computationally efficient, midfidelity model based on linearized potential flow hydrodynamics. For these model verification comparisons, both operational and survival configurations are considered. The extreme load results obtained, using both codes, indicate that the survival configuration successfully sheds loads during extreme sea states. It is also found that WEC-Sim, when appropriately applied, can provide reasonable load results, at a fraction of the computational expense of CFD. However, for the more extreme sea states, and for higher-order effects not included in the WEC-Sim model, the linear-based results have significant errors in comparison to the CFD-based results, and should be used judiciously.

16 TIDAL AND WAVE POWER↗
DOE OSTI2023

Understanding the Uncertainty in the Technical Performance Level Assessment for Wave Energy

In recent years, the design and development of wave energy converters (WECs) has been explored with intense interest, with highly varying design concepts emerging globally across both research enterprises and industry. The design space for WECs is vast - many concepts ranging in functionality, control systems, power development systems, materials, and scale have been ideated and prototyped, but WEC technology has yet to converge. One critical element of the technology trajectory that governs the speed of adoption is the performance of a WEC concept. In analogous but more-established industries (such as aerospace, and environmentally sustainable electronics design), performance assessment is a quantitative method, based on historical data, that is used as an iterative tool to improve the design of these systems early on in the design process. Though more nascent than these approaches, in wave energy R&D, WEC performance has been assessed using the Technology Performance Level (TPL) assessment, which provides designers with a quantitative score, situating a grid-scale WEC concept on a scale from 1-9 (1 being the lowest performance, and 9 being the highest, trending with the oft-used Technology Readiness Level, or TRL). The TPL assessment is designed to be used during design iteration, when a WEC concept is fully ideated, to enable designers to consider potential means of improving the downstream performance of the concept. One concern that may be slowing the adoption of TPL among WEC developers is the inherent uncertainty in the assessment, and how uncertainty in the individual questions asked as part of the assessment may contribute to perceived inaccuracies in the final score. In this work, we explore the uncertainty present in the assessment and quantify this uncertainty using both traditional mathematical operations and a Monte Carlo simulation. Results imply areas of improvement of the TPL assessment, where reducing uncertainty will be most helpful to end users, enabling both TPL practitioners and users to understand with more accuracy those design elements that can be improved to impact device performance most substantively.

techno-economic analysis↗
DOE OSTI2019

Analysis on the Influence of an Energy Storage System and its Impact to the Grid for a Wave Energy Converter

Reducing power fluctuations is essential for controlling the integration impacts of wave energy converter (WEC) plants in both distribution and transmission grids, and in stand-alone isolated power systems. This paper presents an analysis on the cost of and how a battery storage system can be used to further reduce the variation of power generated from the WEC due to the fluctuating nature of waves and its impact to the grid. The electrical power output from WEC-Sim simulations for the six sea states used in the Wave Energy Prize was analyzed to compute the peak power and power time history. The results were used to evaluate the battery storage capacity that is needed for a WEC system to provide reasonable power flow to the grid and estimate its cost based on the latest cost information for battery technologies published by the U.S. Energy Information Administration. Finally, a preliminary grid integration analysis was performed to demonstrate how WEC-generated power would contribute to a small island electricity system. As shown in the study, the instantaneous peak power is the primary cost driver for the battery storage and the power take-off system, and reducing the power fluctuations is essential for reducing the overall levelized cost of energy (LCOE). The power flow variation from WECs can be significantly reduced using battery storage without adding significant overall system costs, and the implementation of battery storage is essential for grid integration applications. There may also be additional opportunities to further investigate energy storage technologies that are specific to WEC applications to reduce these costs even further.

16 TIDAL AND WAVE POWER↗
DOE OSTI2015

The Influence of Sliding and Contact Severity on the Generation of White Etching Cracks

White etching cracks (WECs) have been identified as the dominant mechanism of premature failure for bearings within wind turbine gearboxes. Though WECs have been observed in the field for over a decade, the exact mechanisms which lead to this failure are still debated, and benchtop replication has proven difficult. In previously published work, WECs have been replicated only through the use of component level test rigs, where complete bearings are tested. In these tests, the factors that are thought to drive the formation of WECs, such as slide-to-roll ratio (SRR) and lubricant film thickness, cannot not be easily altered or controlled. In this paper, WECs have been replicated on a three rings on roller, benchtop test rig, which allowed for a direct investigation into the influence that SRR magnitude, sliding direction, and the lubricant film thickness have on surface failures and WEC generation. It was determined that WEC were formed in samples that experienced -30% SRR at various lubrication conditions, however, at lower levels of negative SRR and positive SRR up to 30% no white-etching cracks were observed.

17 WIND ENERGY↗
DOE OSTI2024

Shared mooring system designs and cost estimates for wave energy arrays

For floating renewable energy devices to become more cost-efficient and commercially scalable, their mooring system designs must be low-cost and suited for large-scale installations. Large arrays of floating devices, such as wave energy converters (WECs), will likely be designed with an individual mooring system for each device in the array. However, new mooring technology advancements provide options to use shared mooring lines to connect adjacent devices to one another, reducing the total number of anchors in the array, thereby reducing material use and cost. Here, this paper explores the design, modeling, and cost analysis of shared mooring systems for various sizes of arrays consisting of heaving oscillating water column (OWC) WECs. Shared mooring systems for WEC arrays sized in 2 x N and N x N grid layouts are designed to meet the relevant design standards, checking their performance with a nonlinear time-domain dynamic simulation, and the costs of each are calculated and compared. Several assumptions are taken in the design process to produce efficient results, providing a preliminary optimization for guidance on design decisions rather than a full, detailed design analysis. Mooring system costs per WEC were found to decrease as the number of WECs in the array increase, up to certain array sizes. The 2 x 3 array had the lowest mooring system cost per WEC out of all arrays considered, with a 60% cost reduction relative to using individual mooring systems. The 3 x 3 and 4 x 4 arrays achieved a 50% cost per WEC reduction. In addition to these significant cost reductions, the shared mooring system designs can provide advantages through smaller mooring system footprints, lower installation times, and less seabed disturbance.

16 TIDAL AND WAVE POWER↗
DOE OSTI2014

SNL-SWAN

Sandia National Laboratories has modified Simulating WAves Nearshore (SWAN), the Delft University of Technology code,, to include functionality to better model wave energy converters (WECs). The code modified by SNL has been named SNL-SWAN. SNL-SWAN includes a frequency dependent WEC Module that builds upon the traditional obstacle module in SWAN. In SNL-SWAN, a frequency dependent transmission coefficient is calculated to model power absorbed by WEC devices. The power transmission coefficients are calculated based on the WEC's power performance, which is defined by the user in the input text files. Two methods of defining WEC power performance have been implemented: a user-specified power matrix, and a user-specified relative capture width. These methods allow the user to define the WEC's frequency dependent energy absorption as a function of period and/or wave height. SWAN test cases were run to verify the compiled code's functionality, and verification of the frequency dependent WEC Module in SNL-SWAN has also been performed. SNL-SWAN code is will be released as open source code and will be made publicly available.

Chartrand, Chris↗