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At least 361 records · Page 20

Constrained power reference control for wind turbines

The cost of wind energy can be reduced by controlling the power reference of a turbine to increase energy capture, while maintaining load and generator speed constraints. We apply standard torque and pitch controllers to the direct inputs of the turbine and use their set points to change the power output and reduce generator speed and blade load transients. A power reference controller increases the power output when conditions are safe and decreases it when problematic transient events are expected. Transient generator speeds and blade loads are estimated using a gust measure derived from a wind speed estimate. A hybrid controller decreases the power rating from a maximum allowable power. Compared to a baseline controller, with a constant power reference, the proposed controller results in generator speeds and blade loads that do not exceed the original limits, increases tower fore-aft damage equivalent loads by 1%, and increases the annual energy production by 5%.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Intracycle RPM control for vertical axis wind turbines

The wind energy market is currently dominated by horizontal axis wind turbines (HAWTs); however, vertical axis wind turbines (VAWTs) are emerging as a design alternative, especially for deep-water offshore siting due to their low center of gravity, ease of access to drivetrain components, and overall simplicity. Due to the absence of a pitch mechanism in large-scale Darrieus VAWTs, stall control has often been used to manage power and loads. Introducing a pitching mechanism in H-type VAWTs has been studied, but this diminishes the mechanical simplicity advantage, and the use of a pitching mechanism in a large-scale Darrieus-type VAWT is not practical. This work examines an innovative, alternative method to control the rotor dynamics of a large-scale 5 MW VAWT to maximize power while constraining loads without introducing any new or complex mechanical elements. This control strategy is termed intracycle revolution per minute (RPM) control, where the rotational speed of the turbine is allowed to vary in an optimal fashion with the azimuthal location of blades as opposed to typical constant RPM operation. An optimization framework is formulated for an open-loop optimal control problem and solved to maximize power subject to constraints on aerodynamic design loads. Results are presented to demonstrate the benefits and the performance limits of intracycle RPM control for large-scale 5 MW Darrieus VAWTs, namely, (1) power production (quantified in terms of AEP) that can be increased subject to baseline load limits and (2) opportunities to significantly increase AEP or decrease loads via intracycle RPM control that are examined for both two-bladed and three-bladed VAWTs.

17 WIND ENERGY↗

Novel thermal energy storage component: Development, performance, and phase transition diagnosis

Thermal energy storage (TES) using phase change materials (PCMs) is a promising technology for capturing and storing excess thermal energy for later use. However, challenges such as poor heat transfer efficiency and a lack of modular, scalable designs have limited widespread adoption of TES in real-world applications. This study developed and evaluated modular brick-type and blade-type TES prototypes featuring an aluminum housing, an embedded serpentine coil for active or passive thermal exchange, and a cost-effective metal mesh to enhance PCM thermal conductivity. The blade-type TES achieved notable geometric efficiency, with a thickness-to-length ratio of 0.03 and a thickness-to-width ratio of 0.08, enabling highly compact and modular thermal storage suitable for space-constrained applications. The paper presents a detailed evaluation of the TES prototypes’ performance. The comparative analysis indicated that the TES prototypes provide a highly cost-effective, thermally optimized alternative for compact energy storage and load shifting. A novel diagnostic technique was also introduced: using a portable endoscope to capture real-time visualizations of PCM phase transitions inside the TES. This method provides critical insights into internal heat transfer mechanisms, identifies potential issues, and offers valuable support for optimizing the TES design and developing the control algorithm. Overall, the modular brick-type and blade-type TES designs demonstrated in this work provide a scalable, efficient, and economically viable solution for advancing TES across residential, commercial, and industrial sectors. The designs’ compact structure, enhanced thermal performance, and integrated diagnostic capabilities make them strong candidates for future deployment in energy-efficient systems.

Gao, Zhiming [ORNL] (ORCID:0000000271397995)↗

Modeling deformation and failure in AlSi-polyester abradable sealcoating material using microstructure-based finite element simulation

A plasma-sprayed aluminum-silicon (AlSi)/polyester coating is applied in modern gas turbine engines as an abradable sealcoating to maintain tight clearances between the rotating blades and the static casing. While running the engine, the rotating blades “rub” with the abradable coating, which results in extreme strain rate (up to 10 6 ) dynamics and a high-temperature environment. Due to the difficulty of collecting direct measurements, predictive computational models are important for analyzing the deformation and failure of the abradable material, to help meet the design target of avoiding damage to the blade tip and maintaining high fuel efficiency. In this research, a microstructure-based finite element (FE) computational model was developed to capture the complex mechanical behavior of the AlSi/polyester microstructure. The model is based on a virtual representative-volume-element (RVE) of a metal-polymer microstructure, reconstructed from x-ray computed tomography. It models the plastic deformation of, and damage to, each AlSi and polyester constituents, as well as the failure at their interface. The model was calibrated and validated with uniaxial tension and compression experiments, conducted at two temperatures (298 K and 533 K) at an applied strain rate of 10 3 - 10 4 s -1 . The material exhibited strongly asymmetric tension-compression behavior and a sensitivity to temperature, which was well captured by the model. The model was further applied to investigate changes in mechanical behavior due to variations in constituents’ volume fractions, which provides guidance to the microstructural design of AlSi/polyester abradable materials. The model is expected to facilitate the development of improved abradable materials by bypassing the conventional trial-and-error approach and extensive testing requirements.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Advanced manufacturing of 3D custom boron-carbide collimators designed for complex environments for neutron scattering

Scattered-beam collimation is a very useful method to reduce unwanted backgrounds and to boost the desired sample signal instead. This approach is of particular interest for samples contained within a complex environment that gives rise to much unwanted parasitic scatter. As neutron scattering instrument and techniques advances, small samples are becoming of more and more interest, which necessitates optimized collimation. Here, in this work, we describe a concept for the design and fabrication of advanced scattered-beam collimation 3D printed from B 4 C specifically tailored for samples contained within a complex environment. This concept is demonstrated through the use of a diamond anvil cell for high pressure experimentation, a technique that very typically requires small samples. The collimators here are designed through a modeling procedure via Monte Carlo neutron ray tracing that encompasses the entire system: the instrument, the complex environment and the collimator. Since the first approach of simply scaling up of the print-size was not successful, a novel concept of a multi-part alternate-blade collimator was developed. This approach addresses printing constraints but gives greater flexibility in design. Its performance is computationally compared against an unprintable progressively tighter blade collimator to assess the effect of alternating blades. No strong difference was observed. Its performance was validated through experimentation at the Spallation Neutron Source. The results emphasize the critical importance of ultra-high precision alignment while showing good overall agreement between simulation and experiment and underscore the feasibility of the method and its real-world application.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Aerodynamic characterization of two tandem wind turbines under yaw misalignment control using actuator line model

Yaw control has proven to be promising in alleviating the wake effects that plague the efficiency of wind farms. In this work, the actuator line modeling (ALM) method is adopted to simulate the flows over two tandem turbines distanced by 3–7 rotor diameters, with the yaw angle of the upstream rotor varying from γ 1 = 0° to 50°. The aim is to provide a comprehensive aerodynamic characterization of this simple wind farm under yaw misalignment control. With increasing yaw angle, the power generated by the downstream rotor increases, compensating the power loss in the upstream rotor, and resulting in significantly higher total power of the two turbines than that without yaw control. The maximum power output is achieved as the upstream wake of the yawed rotor is redirected away from the downstream rotor plane. Behind the downstream rotor, the secondary steering phenomenon is observed, where the wake is also redirected from the centerline. The use of the actuator line model also reveal unsteady aerodynamic characteristics that cannot be captured by lower-fidelity models. For the upstream rotor, the yaw misalignment results in time-varying change in the local angle of attack on the blade, giving rise to unsteady loading. The downstream rotor is partially submerged in the deflected wake incurred by the yawed upstream rotor. As the blade revolves into and out of the wake deficit, the blade experiences cyclic loading, leading to even stronger fluctuations in the aerodynamic loads than the upstream rotor. These analysis provides a comprehensive understanding of the yaw control effects on the two tandem rotors from the perspectives of aerodynamic performance, wake profiles, and unsteady characteristics. In conclusion, the insights gained from the present study can aid the design of collective yaw control strategies of wind farms, and lay the foundation for assessing the fatigue damage associated with yaw misalignment.

17 WIND ENERGY↗

Performance and wake flow characterization of a 1:8.7-scale reference USDOE MHKF1 hydrokinetic turbine to establish a verification and validation test database

As hydrokinetic turbine technologies continue to advance towards commercialization, public datasets on the performance characteristics for these devices and their flow field effects are invaluable to advance our understanding of these technologies and to validate analytical and numerical models. The Applied Research Laboratory at The Pennsylvania State University (ARL Penn State) collaborated with Sandia National Laboratories and the University of California at Davis to design, fabricate (at a 1:8.7 scale), and experimentally test a novel hydrokinetic turbine rotor design to provide an open platform and dataset for further study and development. The water tunnel test of this three-bladed, horizontal-axis rotor recorded power production, blade loading, the near-wake flow, cavitation effects, and noise generation. These state-of-the-art measurements demonstrate much of the complex physics associated with the flow through an unducted, horizontal-axis turbine, and they elucidate the performance characteristics and flow field effects at an unprecedented fidelity, accuracy and resolution. Measurements of powering coefficients (power, torque and thrust) as a function of tip-speed-ratio were performed. The dataset also includes unsteady measurements of driveshaft loading, blade strain, tower pressures, and radiated noise. Detailed flow mapping using laser Doppler velocimetry, and planar and stereo particle image velocimetry includes measurements of mean velocity and Reynolds stresses. Although the wake measurements are limited to less than half a diameter, they reveal the complex flow patterns in the near-wake structure of the rotor. The full database, available at the United States Department of Energy’s marine and hydrokinetic data repository, includes tunnel and model Computer Aided Design geometry files and inflow data sufficient for a “Model-the-Test” computational Verification and Validation study.

13 HYDRO ENERGY↗

Mechanisms of Dynamic Near-Wake Modulation of a Utility-Scale Wind Turbine

The current study uses large eddy simulations to investigate the transient response of a utility-scale wind turbine wake to dynamic changes in atmospheric and operational conditions, as observed in previous field-scale measurements. Most wind turbine wake investigations assume quasi-steady conditions, but real wind turbines operate in a highly stochastic atmosphere, and their operation (e.g. blade pitch, yaw angle) changes constantly in response. Furthermore, dynamic control strategies have been recently proposed to optimize wind farm power generation and longevity. Therefore, improved understanding of dynamic wake behaviours is essential. First, changes in blade pitch are investigated and the wake expansion response is found to display hysteresis as a result of flow inertia. The time scales of the wake response to different pitch rates are quantified. Next, changes in wind direction with different time scales are explored. Under short time scales, the wake deflection is in the opposite direction of that observed under quasi-steady conditions. Finally, yaw changes are implemented at different rates, and the maximum inverse wake deflection and time scale are quantified, showing a clear dependence on yaw rate. To gain further physical understanding of the mechanism behind the inverse wake deflection, the streamwise vorticity in different parts of the wake is quantified. The results of this study provide guidance for the design of advanced wake flow control algorithms. The lag in wake response observed for both blade pitch and yaw changes shows that proposed dynamic control strategies must implement turbine operational changes with a time scale of the order of the rotor time scale or slower.

flow-structure interactions↗

Material Characterization-Based Wear Mechanism Investigation for Biomass Hammer Mills

Biomass, as harvested, is composed of inorganic compounds both intrinsically and extrinsically and can be abrasive. The present study investigates the wear modes and mechanisms of two types of blades of hammer mills used in biomass size reduction (impacting the particle size and distribution) and densification (impacting the size, shape, and density). The dominant wear modes for the stage 1 steel blades are determined to be erosive and polishing wear. For the stage 2 blades with a carbide weld overlay, the main wear mechanisms are erosion and fracture. Partial replacement of Co by Fe in the outer layer of the carbide grits, likely induced by diffusion during high-temperature welding, has been correlated to the observed microcracking. Finally, the microcracking is believed to weaken the grit strength and fracture toughness to make the overlay prone to fracture and erosion due to repetitive contact with the inorganic contents in chopping biomass.

42 ENGINEERING↗

CFD-based design optimization of ducted hydrokinetic turbines

Abstract Hydrokinetic turbines extract kinetic energy from moving water to generate renewable electricity, thus contributing to sustainable energy production and reducing reliance on fossil fuels. It has been hypothesized that a duct can accelerate and condition the fluid flow passing the turbine blades, improving the overall energy extraction efficiency. However, no substantial evidence has been provided so far for hydrokinetic turbines. To investigate this problem, we perform a CFD-based optimization study with a blade-resolved Reynolds-averaged Navier–Stokes (RANS) solver to explore the design of a ducted hydrokinetic turbine that maximizes the efficiency of energy extraction. A gradient-based optimization approach is utilized to effectively deal with the high-dimensional design space of the blade and duct geometry, with gradients being calculated through the adjoint method. The final design is re-evaluated through higher-fidelity unsteady RANS (URANS) simulations. Our optimized ducted turbine achieves an efficiency of about 54% over a range of operating conditions, higher than the typical 46% efficiency of unducted turbines.

13 HYDRO ENERGY↗

Validation of FAST.Farm Against Full-Scale Turbine SCADA Data for a Small Wind Farm

FAST.Farm is a new midfidelity engineering tool developed by the National Renewable Energy Laboratory targeted at accurately and efficiently predicting wind turbine power production and structural loading in wind farm settings, including wake interactions between turbines. FAST.Farm is based on some of the principles of the Dynamic Wake Meandering model—including passive tracer modeling of wake meandering—but addresses many of the limitations of previous Dynamic Wake Meandering (DWM) implementations. Previous FAST.Farm verification studies show the similarities and differences between FAST.Farm and large-eddy simulations for rigid and flexible turbines. In this validation study, FAST.Farm turbine responses are compared to multiturbine measurements from a subset of a full-scale wind farm. FAST.Farm predictions of turbine generator power, rotor speed, and blade pitch for five-turbine simulations are compared to supervisory control and data acquisition results. Results reveal that FAST.Farm generator power mean and standard deviation results reasonably match measured data for upstream and downstream turbines, as well as the mean rotor speed and blade pitch above rated wind speeds. However, FAST.Farm generally underpredicts the mean rotor speed and overpredicts the mean blade pitch below rated operation. These errors are likely related to inaccuracies in the generic controller simulated. Despite controller differences, FAST.Farm predicts the same overall relative rotor power trends for all waked turbines at all wind speeds.

17 WIND ENERGY↗

Closed-Loop Wind Turbine Controllers for Active Wake Mixing Strategies

Wind turbine active wake mixing (AWM) is an exciting new field of research where dynamic actuation, usually on the blade pitch angles, is used to increase wind farm-wide power production. From a controls perspective, the current state-of-the-art AWM strategies are very simple: a dynamic, usually periodic, reference signal is prescribed to actuators in an open-loop (OL) fashion. The actuation is then presumed to have a certain desired effect on the system, i.e., the wind turbine and the flow it affects. However, this system is highly nonlinear and experiences disturbances in the form of wind variations that are not known a priori. As a result, the OL approach might not yield optimal results. In this article, a novel approach is presented, which closes the loop on AWM controllers. A feedback loop is implemented, which uses measurements of the individual blade bending moments that are widely available on modern wind turbines to determine the individual blade pitch angles. A proof of concept of this implementation is presented in this article, and a thorough comparison with the OL method is executed using high-fidelity flow simulations. These simulations show that the novel closed-loop controller does not substantially increase wake mixing but achieves similar performance as the OL controller while reducing fatigue loads on the controlled turbine.

17 WIND ENERGY↗

Measurements of the Flow in the Vicinity of an Additively Manufactured Turbine Leading-Edge Using X-Ray Particle Tracking Velocimetry

X-ray particle tracking velocimetry (PTV) is performed, for the first time, to measure the velocity field inside a leading-edge of a turbine blade made by laser-additive-manufacturing (LAM) process. The traditional showerhead holes were replaced by a porous matrix in the leading-edge. The flow through such a leading-edge piece cannot be faithfully recreated by traditional prototype testing methods due to the surface roughness and imperfections caused by LAM process. Hence, direct measurement is the only option. However, it is difficult to measure flow inside such pieces with traditional velocimetry measurements due to the existence of metallic walls. Moreover, small internal size and high flow speeds call for a measurement technique with high spatial and temporal resolutions. To address these issues, we performed time-resolved X-ray PTV using the Advanced Photon Source (APS) synchrotron facility at the Argonne National Laboratory (ANL). A hydraulic system was constructed to run water, mixed with seeding particles, through the leading-edge piece. A high-speed camera captured the images of the seeding particles, which were later processed to create particle tracks. The time-averaged velocity field showed distinct pairs of vortices located in front of the porous outlet inside the leading-edge piece. The inlet channel showed reversed flow due to partial obstruction by the porous inlet of the test piece. Such knowledge of the flow field inside a leading-edge of a turbine blade will help us to design better cooling paths leading to higher cooling efficiency and increased life-span of a turbine blade.

42 ENGINEERING↗

Experimental and Numerical Study on the Effect of Annular Combustor Design on Thermal Uniformity Jet in Crossflow

Abstract Non-uniformity of the exit flow temperature represents one of the significant damages to gas-turbine components, particularly turbine blades. This may occur in the course of gas-turbine operation. This paper aims to provide passive techniques by modifying the combustor design rather than changing the flow parameters to improve the thermal uniformity and turbine blades to reduce thermal stresses and increase turbine blades’ life span. An acceptable agreement between the numerical and experimental results has been achieved, and the agreement includes the velocity and temperature profile. Four different angles have been tested numerically and experimentally with a maximum error of 5% at two different Reynolds numbers. Designing the outer combustor surface with a 45-deg angle bend can give a more uniform temperature distribution of 37% higher than the basic design with only a 0.5% higher pressure drop.

Energy & Fuels↗

Direct Numerical Simulation of Transitional and Turbulent Flows Over Multi-Scale Surface Roughness—Part I: Methodology and Challenges

Abstract High-fidelity simulation of transitional and turbulent flows over multi-scale surface roughness presents several challenges. For instance, the complex and irregular geometrical nature of surface roughness makes it impractical to employ conforming structured grids, commonly adopted in large-scale numerical simulations due to their high computational efficiency. One possible solution to overcome this problem is offered by immersed boundary methods, which allow wall boundary conditions to be enforced on grids that do not conform to the geometry of the solid boundary. To this end, a three-dimensional, second-order accurate boundary data immersion method (BDIM) is adopted. A novel mapping algorithm that can be applied to general three-dimensional surfaces is presented, together with a newly developed data-capturing methodology to extract and analyze on-surface flow quantities of interest. A rigorous procedure to compute gradient quantities such as the wall shear stress and the heat flux on complex non-conforming geometries is also introduced. The new framework is validated by performing a direct numerical simulation (DNS) of fully developed turbulent channel flow over sinusoidal egg-carton roughness in a minimal-span domain. For this canonical case, the averaged streamwise velocity profiles are compared against results from the literature obtained with a body-fitted grid. General guidelines on the BDIM resolution requirements for multi-scale roughness simulation are given. Momentum and energy balance methods are used to validate the calculation of the overall skin friction and heat transfer at the wall. The BDIM is then employed to investigate the effect of irregular homogeneous surface roughness on the performance of an LS-89 high-pressure turbine blade at engine-relevant conditions using DNS. This is the first application of the BDIM to realize multi-scale roughness for transitional flow in transonic conditions in the context of high-pressure turbines. The methodology adopted to generate the desired roughness distribution and to apply it to the reference blade geometry is introduced. The results are compared to the case of an equivalent smooth blade.

Engineering↗

An Experimental Investigation of Heat Transfer for Supercritical Carbon Dioxide Cooling in a Staggered Pin Fin Array

Pin fin geometry in the trailing edge as turbulators in tur-bine blades has been a subject thoroughly researched for the past several decades. To improve the efficiency of turbomachinery, higher turbine inlet temperatures are necessary, introducing the need for internal cooling channel features, such as pin fin arrays. These solutions are necessary to avoid material failure at higher operating conditions by enhancing the heat transfer of the blade. Over the past decade, a shift toward applying supercritical carbon dioxide or sCO2 cycles has shown increased potential compared to the industry standard air cycles. Promising higher cycle ef¬ficiency, smaller footprints, and zero greenhouse gas emissions, sCO2 has become an attractive alternative to well-established air cycles. This alternative cycle introduces the need to re-visit the heat transfer capabilities of internal cooling geometries within this novel operating fluid environment. The first objective of this paper is to experimentally demonstrate the heat transfer charac-teristics of sCO2 as the secondary internal cooling fluid environ¬ment through testing a pin fin array in a closed loop at 200 bar and 400 Celsius inlet conditions, which stands well within the supercritical region of sCO2. Secondly, the experimental process aims to validate numerical simulation methodology for studying sCO2 environments for internal cooling of turbine blades in a matching pin fin geometry.

Wardell, Ryan J↗

WRF Modelling of Deep Convection and Hail for Wind Power Applications

Deep convection and the related occurrence of hail, intense precipitation and wind gusts represent a hazard to a range of energy infrastructure including wind turbine blades. Wind turbine blade leading edge erosion (LEE) is caused by the impact of falling hydrometeors onto rotating wind turbine blades. It is a major source of wind turbine maintenance costs and energy losses from wind farms. In the United States Southern Great Plains (SGP), where there is widespread wind energy development, deep convection and hail events are common, increasing the potential for precipitation-driven LEE. A 25-day Weather Research and Forecasting (WRF) model simulation conducted at convection-permitting resolution and using a detailed microphysics scheme is carried out for the SGP to evaluate the effectiveness in modelling the wind and precipitation conditions relevant to LEE potential. WRF output for these properties is evaluated using radar observations of precipitation (including hail) and reflectivity, in situ wind speed measurements and wind power generation. This research demonstrates some skill for the primary drivers of LEE. Wind speeds, rainfall rates and precipitation totals show good agreement with observations. Here, the occurrence of precipitation during power producing wind speeds is also shown to exhibit fidelity. Hail events frequently occur during periods when wind turbines are rotating and are especially important to LEE in the SGP. The presence of hail is modelled with a mean proportion correct of 0.77 and an odds ratio 4.55. Further research is needed to demonstrate sufficient model performance to be actionable for the wind energy industry and there is evidence for positive model bias in cloud reflectivity.

17 WIND ENERGY↗

Structural design and optimization of a series of 13.2 MW downwind rotors

The quest for reduced LCOE has driven significant growth in wind turbine size. A key question to enable larger rotor designs is how to configure and optimize structural designs to constrain blade mass and cost while satisfying a growing set of challenging structural design requirements. In this paper, we investigate the performance of a series of three two-bladed downwind rotors with different blade lengths (104.3-m, 122.9-m, and 143.4-m) all rated at 13.2 MW. The primary goals are to achieve 25% rotor mass and 25% LCOE reduction. A comparative analysis of the structural performance and economics of this family rotors is presented. To further explore optimization opportunities for large rotors, we present new results in a root and spar cap design optimization. In summary, we present structural design solutions that achieve 25% rotor mass reduction in a SUMR13i design (104.3-m) and 25% LCOE reduction in a SUMR13C design (143.4-m).

Yao, Shulong↗