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DOE OSTI2025

HPC for optimizing process parameters to control material evolution in seamless induction hardening of wind turbine main shaft bearings

Work proposed in this project focused on understanding the effect of martensitic transformation in the steel on the potential for cracking during seamless induction hardening (SIH) as a function of process conditions to allow the process to optimally scale up. Large-scale, three-dimensional phase-field simulations of martensitic transformation were performed using MEUMAPPS-SS (Microstructure Evolution Using Massively Parallel Phase-field Simulations – Solid State) code developed at Oak Ridge National Laboratory. The simulations were guided by location-specific thermal history generated by experimental measurements of time-temperature history generated at The Timken Company. The simulations were able to capture the morphological evolution of the martensite variants in an Fe-1.0C-1.5Cr steel based on the Nishiyama-Wasserman (NW) orientation relationship. The simulations were also able to quantify the stress-state at the interface between impinging martensite variants. The simulations indicated that the magnitude of the various stress and strain components were dependent on the sizes of the impinging plates with a reduction in these quantities with reduced plate size in agreement with experimental findings. The results obtained from the simulations will be used to guide the optimization of the alloy thermal conditions to eliminate quench cracking during SIH of bearing steels.

17 WIND ENERGY↗

DOE OSTI2021

Wyandotte Integrated Renewable Energy Strategy (WIRES 2) (Final Technical Report)

Wyandotte Municipal Services (WMS), a Michigan Municipal Utility offering electric generation, transmission & distribution, water filtration & distribution and Broadband/Video sought to deploy a set of renewable energy projects for their Electric Utility that contributed to reducing the City’s environmental and energy impact, provided examples that would encourage businesses and citizens to adopt cleaner energy practices and help WMS meet the required renewable energy standards of the State of Michigan (10% in 2015, 15% in 2021). WMS generates and delivers roughly 280,000 megawatt hours (MWh) of electricity annually to more than 10,000 homes and 1,000 businesses within the City of Wyandotte. The Wyandotte Integrated Renewable Energy Strategy – WIRES 2 resulted in deployment of a set of community-scale micro-wind turbines, evaluation and installation of energy-efficient and low-maintenance light-emitting diode (LED) street lights and park lights in highly visible locations in the City and expansion of the geothermal heating and cooling district that already included residential geothermal systems, to include larger scale business/institutional systems at the Utility’s largest electric customer and at the City Library. Finally, WMS identified the need for job training in energy efficiency and renewable energy technologies to further develop a local skilled workforce in these areas. Partially funded by the grant, the wind turbine project provides a benchmark for WMS, local businesses and residents in the evaluation of utility-scale wind v. micro-wind in an urban environment as a renewable energy strategy. Also partially funded by the grant, the LED project benefited the City of Wyandotte by reducing load on the electric system for the public utility but also reduced City costs for streetlighting, parking lot lighting and park lighting without a compromise in security. The project also resulted in a visual success that has led to additional approvals for non-Grant related LED lighting installations resulting in further reduction in the electric load in the City. Commercial Geothermal installations resulted in the Utility being able to eliminate steam customers who formerly utilized the byproduct of steam from WMS electric production. Due to the reduction in natural gas prices and the overall reduction in market purchased power, it was no longer feasible for WMS to operate its Power Plant as a base load plant and to only operate on a market dispatch philosophy when market prices dictated that WMS could produce electricity cheaper than the market purchase price. This has resulted in fewer operating days for the WMS Power Plant, resulting in less environmental impact. WMS has now completely exited the steam business and the ability to offer a geothermal option to two (2) former steam customers (BASF-Wyandotte and the Bacon Memorial Library) allowed for that. In addition, peak loads have been shaved for these two (2) large customers due to the consistent temperature offered by geothermal heating and cooling, reducing the swings associated with thermostat changes caused by outside temperature changes during extreme high and low temperatures. Finally, energy efficiency and renewable energy college-level classes at Wayne County Community College allowed a group of interested students to pursue studies in those technologies through grant provided tuition, books and course materials. This effort provided a foundation of potential future employees not only for WMS but other energy efficiency/renewable energy employers such as Franklin Energy, a partner with WMS in energy optimization efforts with Wyandotte businesses.

17 WIND ENERGY↗

DOE OSTI2022

Nonsteady Load Responses to Daytime Atmospheric Turbulence Eddies on the DOE 1.5 MW Wind Turbine at NREL

Field data collected from the NREL/GE 1.5MW wind turbine (WT) and met tower (MetT) at the NREL Wind Technology Center near Boulder, CO June-October 2018 were analyzed to quantify the impacts of turbulence eddies on the load responses measured from sensors on the main shaft, blade and tower. The passage of individual mountain-generated eddies from the met tower to the WT were critically determined by correlating the optimal time shifts in signal between MetT and nacelle anemometers with mean advection time. Loading responses from mountain eddy passage were compared with atmospheric eddies from the north/south, unimpeded by the mountains, and found to be similar. Whereas time variations in torque were highly correlated with time changes in horizontal eddy velocity, the out-of-plane bending moments on the main shaft (directly forcing the main bearing) were uncorrelated with horizontal eddy velocity. This result is consistent with a previous LES study indicating that the main bearing is forced by asymmetrical interactions between the WT rotor and turbulence eddies, while power fluctuations respond primarily to advective eddy velocity. Surprisingly, the nacelle anemometer produced statistics very similar to the MetT.

ENGINEERING,WIND ENERGY↗

NASA NTRS1976

Aeroacoustics: Acoustic wave propagation; Aircraft noise prediction; Aeroacoustic instrumentation

The papers in this volume deal with recent research into acoustic-wave propagation through the atmosphere and progress in aeroacoustic instrumentation, facilities, and test techniques. Topics include the propagation of aircraft noise over long distances in the lower atmosphere, measured effects of turbulence on the rise time of a weak shock, sound scattering from atmospheric turbulence, saturation effects associated with sound propagation in a turbulent medium, and a computer model of the lightning-thunder process. Other papers discuss the development of a computer system for aircraft noise prediction; aircraft flyover noise measurements; and theories and methods for the prediction of ground effects on aircraft noise propagation, for the prediction of airframe aerodynamic noise, for turbine noise prediction, and for combustion noise prediction. Attention is also given to the use of Hartmann generators as sources of high-intensity sound in a large absorption flow-duct facility, an outdoor jet noise facility, factors in the design and performance of free-jet acoustic wind tunnels, and the use of a laser shadowgraph for jet noise diagnosis.

Schwartz, I. R.↗

DOE OSTI2021

A systematic evaluation of wind's capacity credit in the Western United States

Abstract The degree to which wind energy can contribute to the capacity needed to meet resource adequacy requirements, also known as capacity credit (CC), can be impacted by many factors. The CC varies regionally with wind resource and correlation to net load and may also vary with wind technology (land‐based versus offshore) and turbine specifications. We use a probabilistic resource adequacy tool to systematically assess the CC of multiple technologies for near‐term wind deployment across the Western US power system to help inform planning decisions. We find that wind CC varies by weather year and location but averages 16% for land‐based turbines and 41% for offshore turbines, with large regional variations. The average wind CC increases to 20% for land‐based and 53% for offshore when considering only the sites in the top 25th percentile of capacity factor. The CC of land‐based wind is generally lower than its capacity factor, which indicates a low correlation of generation to system needs. However, offshore wind shows a substantially higher CC, which is driven by not only a higher capacity factor but also a greater correlation with system needs.

17 WIND ENERGY↗

DOE OSTI2024

Coupled aero-hydro-geotech real-time hybrid simulation of offshore wind turbine monopile structures

Real-time hybrid simulation (RTHS) divides a structural system into an analytical and experimental substructure. The former is based on a well-established analytical model while the latter consists of a physical model in the laboratory, for which there is not a well-established analytical model. This paper extends real-time hybrid simulation to monopile-type Offshore Wind Turbines (OWTs) to enable the investigation of their behavior considering the response of pile foundations under operational and more severe conditions. The embedded foundation and surrounding soil of the OWT are modeled physically in a soil box in the laboratory while the remaining parts of the system and loading are modeled analytically. The program OpenFAST, developed by the National Renewable Energy Laboratory (NREL), is linked to the RTHS coordinator to determine the hydrodynamic and aerodynamic loads acting on the OWT, along with modeling the dynamics of the electric power generation equipment and associated controller for the OWT. The RTHS framework along with its initial implementation and validation are described in this paper. RTHSs of a 5 MW OWT subjected to operational and more severe conditions are performed to experimentally validate the framework. The framework offers a realistic approach to investigate the behavior of OWT structures supported on monopiles. Furthermore, this approach accounts for the coupled response of the OWT structure with its foundation, while experimentally capturing the nonlinearities of the soil-foundation interaction in real-time.

17 WIND ENERGY↗

DOE OSTI2026

Key Drivers for Offshore Wind Deployment in the Western United States

The western coast of the United States has abundant natural resources, including wind, sun, and water. Despite strong ocean winds, offshore wind energy (OSW) in the Western United States is in the early stages of technology development due largely to the deep water off the coast, which requires floating platforms rather than fixed‐bottom turbines. Floating OSW increases the technical difficulty of installation and thus the cost relative to both fixed‐bottom OSW and land‐based turbines. OSW is a potential generation option to help meet increasing demand on the west coast of the United States because it likely has fewer land‐use conflicts than other technologies and complements sources in the existing electricity supply by providing energy during times of high system stress. This paper examines the possible drivers and barriers to OSW deployment on the West Coast using the National Laboratory of the Rockies' state‐of‐the‐art capacity expansion model and the Regional Energy Deployment System (ReEDS) model. We use ReEDS to explore a multitude of future scenarios looking at key drivers for OSW deployment, including variations on the cost of OSW, electricity demand growth, and the availability of competing technologies to examine the factors that may play a role in OSW growth. Assuming coastal state policies such as renewable portfolio and clean energy standards remain in place, we find that OSW can play a role in meeting electricity demand and provide energy during stressful grid conditions and find that deployment from the least‐cost investment model ranges from 7.6 to 38 GW by 2045.

17 WIND ENERGY↗

DOE OSTI2022

The impact of swirl and wake strength on turbulent axisymmetric wake evolution

Here, an experimental investigation of swirl and wake strength influence on axisymmetric turbulent wake evolution was conducted. A novel wake generator design wire mounted in a wind tunnel test section with low free-stream turbulence produced wake Reynolds numbers based on momentum thickness and free-stream velocity in excess of 14000 and swirl numbers up to 0.4 with minimal blockage. Steady-state blade element momentum simulations of reference wind turbine designs indicated that wind turbines operate in the flow regimes studied, indicating the practical aspects of this work. Stereoscopic particle image velocimetry was used to acquire three components of velocity in the swirling wake at locations up to approximately ten diameters downstream. Quantitative measures of wake growth and decay were deduced using available equilibrium similarity scaling for the swirling wake. The results show an increase above 50% in growth and axial velocity decay rate constants over the range of swirl strength studied compared to those of the non-swirling wake. Tangential velocity decay constants were shown to decrease with swirl strength over the range of conditions studied. Notably, changes in wake strength have little influence on growth and decay rates when compared to changes in swirl strength for the flow regimes studied in this work.

17 WIND ENERGY↗

DOE OSTI2020

Variability in Wind Energy Generation across the Contiguous United States

ERA5 provides high-resolution, high-quality hourly wind speeds at 100 m and is a unique resource for quantifying temporal variability in likely wind-derived power production across the United States. Gross capacity factors (CF) in seven independent system operators (ISOs) are estimated using the location and rated power of each wind turbine, a simplified power curve, and ERA5 output from 1979 to 2018. Excluding the California ISO, the marginal probability of a calm (zero power production) is less than 0.1 in any ERA5 grid cell. When a calm occurs, the mean co-occurrence across wind-turbine-containing grid cells ranges from 0.38 to 0.39 for ISOs in the Midwest and central plains [Midcontinent (or Midwest) ISO (MISO), Southwest Power Pool (SPP), and the Electric Reliability Council of Texas (ERCOT) region], increasing to 0.54–0.58 for ISOs in the eastern United States [Pennsylvania–New Jersey–Maryland interconnection (PJM), New York ISO (NYISO), and New England ISO (NEISO)]. Periods with low gross CF have a median duration of ≤6 h, except in California, and are most likely during summer. Additionally, gross CF exhibit highest variance at periods of 1 day in ERCOT and SPP; on synoptic scales in MISO, NEISO, and NYISO; and on interannual time scales in PJM. This implies differences in optimal strategies for ensuring resilience of supply. Theoretical scenarios show adding wind energy capacity near existing wind farms is advantageous even in areas with high existing installed capacity (IC), while expanding into areas with lower IC is more beneficial to reducing ramps and the probability of gross CF falling below 20%. These results emphasize the benefits of large balancing areas and aggregation in reducing wind power variability and the likelihood of wind droughts.

17 WIND ENERGY↗

DOE OSTI2021

Control-Oriented Model for Secondary Effects of Wake Steering

This paper presents a model to incorporate the secondary effects of wake steering in large arrays of turbines. Previous models have focused on the aerodynamic interaction of wake steering between two turbines. The model proposed in this paper builds on these models to include yaw-induced wake recovery and secondary steering seen in large arrays of turbines when wake steering is performed. Turbines operating in yaw-misaligned conditions generate counter-rotating vortices that entrain momentum and contribute to the deformation and deflection of the wake at downstream turbines. Rows of turbines can compound the effects of wake steering that benefit turbines far downstream. This model quantifies these effects and demonstrates that wake steering has greater potential to increase the performance of a wind farm due to these counter-rotating vortices especially for large rows of turbines. This is validated using numerous large-eddy simulations for three-turbine, five-turbine, and wind farm scenarios.

17 WIND ENERGY↗

DOE OSTI2024

Resource Assessment for Distributed Wind Energy: An Evaluation of Best-Practice Methods in the Continental US

Current wind resources within the United States (US) indicate a potential to profitably install nearly 1,400 gigawatts of distributed wind (DW) capacity. This amount is equivalent to over half of the United States’ current energy demand from electricity, making it enough to power millions of homes and businesses and replace countless fossil fuel-based generating plants. Despite the potential growth of DW in the US, deployments are presently hindered by a lack of confidence in resource estimation methods. One potential challenge is that smaller-scale turbines, with hub heights of 40 meters or less, are disproportionately impacted by obstacles such as buildings and vegetation. These obstacles may produce complex wake effects, best modeled with high-fidelity complex fluid dynamics (CFD) models that are too computationally expensive to use for routine siting and resource assessment. Thus, installers today make use of heuristics and simple equations to approximate the impact of obstacles while also leveraging long-term resource data from commercial or publicly available atmospheric models. This study evaluates these historical and commonly used methods alongside new lower-order obstacle models produced from CFD simulations and measurement-based bias correction. The preliminary results from this study show the importance of taking care in the choice and application of mesoscale atmospheric models and the significant value of bias correction using measurements from nearby meteorological towers. Detailed obstacle modeling provides only modest additional gains in performance and, in some cases, can add error, especially at sites where turbines have already been located to avoid obvious impact from upwind obstacles. These findings reinforce the importance of collecting in situ measurements and suggest that obstacle models may be better applied in practice to automated or computer-aided siting, rather than in economic wind resource assessments.

17 WIND ENERGY↗

DOE OSTI2025

Spatiotemporal Variability in Wind Turbine Blade Leading Edge Erosion

Wind turbine blade leading edge erosion (LEE) reduces energy production and increases wind energy operation and maintenance costs. Degradation of the blade coating and ultimately damage to the underlying blade structure are caused by collisions of falling hydrometeors with rotating blades. The selection of optimal methods to mitigate/reduce LEE are critically dependent on the rates of coating fatigue accumulation at a given location and the time variance in the accumulation of material stresses. However, no such assessment currently exists for the United States of America (USA). To address this research gap, blade coating lifetimes at 883 sites across the USA are generated based on high-frequency (5-min) estimates of material fatigue derived using a mechanistic model and robust meteorological measurements. Results indicate blade coating failure at some sites in as few as 4 years, and that the frequency and intensity of material stresses are both highly episodic and spatially varying. Time series analyses indicate that up to one-third of blade coating lifetime is exhausted in just 360 5-min periods in the Southern Great Plains (SGP). Conversely, sites in the Pacific Northwest (PNW) exhibit the same level of coating lifetime depletion in over three times as many time periods. Thus, it may be more cost-effective to use wind turbine deregulation (erosion-safe mode) for damage reduction and blade lifetime extension in the SGP, while the application of blade leading edge protective measures may be more appropriate in the PNW. Annual total precipitation and mean wind speed are shown to be poor predictors of blade coating lifetime, re-emphasizing the need for detailed modeling studies such as that presented herein.

Pryor, Sara C. (ORCID:0000000348473440)↗

DOE OSTI2020

American WAKE experimeNt (AWAKEN)

The American WAKE experimeNt (AWAKEN) is an international multi-institutional wind energy field campaign to better understand wake losses within operational wind farms. Wake interactions are among the least understood physical interactions in wind plants today, leading to unexpected power and profit losses. For example, Ørsted, the world’s largest offshore wind farm developer, recently announced a downward revision in energy estimates across their energy generation portfolio, primarily caused by underprediction of energy losses from wind farm blockage and wakes. In their announcement, they noted that the standard industry models used for their original energy estimates were inaccurate, and this was likely an industry-wide issue. To help further improve and validate wind plant models across scales from individual turbines as well as interfarm interactions between plants, new observations, such as those planned for AWAKEN, are critical. These model improvements will enable both improved layout and more optimal operation of wind farms with greater power production and improved reliability, ultimately leading to lower wind energy costs.

17 WIND ENERGY↗

DOE OSTI2025

HPC for Optimizing Process Parameters to Control Material Evolution in Seamless Induction Hardening of Wind Turbine Main Shaft Bearings

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2020

20% of US electricity from wind will have limited impacts on system efficiency and regional climate

Abstract Impacts from current and future wind turbine (WT) deployments necessary to achieve 20% electricity from wind are analyzed using high resolution numerical simulations over the eastern USA. Theoretical scenarios for future deployments are based on repowering (i.e. replacing with higher capacity WTs) thus avoiding competition for land. Simulations for the contemporary climate and current WT deployments exhibit good agreement with observed electricity generation efficiency (gross capacity factors (CF) from simulations = 45–48%, while net CF for WT installed in 2016 = 42.5%). Under the scenario of quadrupled installed capacity there is a small decrease in system-wide efficiency as indicated by annual mean CF. This difference is approximately equal to that from the two simulation years and may reflect saturation of the wind resource in some areas. WT modify the local near-surface climate in the grid cells where they are deployed. The simulated impact on near-surface climate properties at both the regional and local scales does not increase with increasing WT installed capacity. Climate impacts from WT are modest compared to regional changes induced by historical changes in land cover and to the global temperature perturbation induced by use of coal to generate an equivalent amount of electricity.

17 WIND ENERGY↗

NASA NTRS1989

Composite blade structural analyzer (COBSTRAN) user's manual

The installation and use of a computer code, COBSTRAN (COmposite Blade STRuctrual ANalyzer), developed for the design and analysis of composite turbofan and turboprop blades and also for composite wind turbine blades was described. This code combines composite mechanics and laminate theory with an internal data base of fiber and matrix properties. Inputs to the code are constituent fiber and matrix material properties, factors reflecting the fabrication process, composite geometry and blade geometry. COBSTRAN performs the micromechanics, macromechanics and laminate analyses of these fiber composites. COBSTRAN generates a NASTRAN model with equivalent anisotropic homogeneous material properties. Stress output from NASTRAN is used to calculate individual ply stresses, strains, interply stresses, thru-the-thickness stresses and failure margins. Curved panel structures may be modeled providing the curvature of a cross-section is defined by a single value function. COBSTRAN is written in FORTRAN 77.

Aiello, Robert A.↗

DOE OSTI2022

Land-Based Wind Market Report: 2022 Edition

The U.S. Department of Energy's 2022 edition of its Land-Based Wind Market Report provides an overview of key trends in the U.S. wind power market, with a focus on 2021. You can find a report, data file and presentation on the Files tab, below. Additionally, several data visualizations are available on the Visualizations tab. Despite ongoing supply chain challenges, wind energy in 2021 continued to see strong growth, technology improvements, and low prices in the U.S. Key highlights include: Wind comprises a growing share of electricity supply: U.S. wind power capacity grew at a strong pace in 2021, with the 13.4 GW of new additions representing a $\$20$ billion investment and 32% of all newly added U.S. generation capacity. Wind energy output rose to account for more than 9% of the entire nation’s electricity supply. At least 247 GW of wind are seeking transmission interconnection; 77 GW of this capacity are offshore wind and 19 GW are hybrid plants that pair wind with storage or solar PV. Wind project performance has increased over the decades: The average capacity factor among recently built projects was nearly 40%, considerably higher than projects built earlier. The highest capacity factors are seen in the interior ‘wind belt’ of the country. Turbines continue to get larger: Improved plant performance has been driven by larger turbines mounted on taller towers and featuring longer blades. In 2011, no turbines employed blades that were 115 meters in diameter or larger, but in 2021, 89% of newly installed turbines featured such rotors. Proposed projects indicate that total turbine height will continue to rise. Low wind turbine pricing has pushed down installed project costs over the last decade: Wind turbine prices averaged $\$800$–$\$950$/kW in 2021, a 5% to 10% increase from the year prior but substantially lower than in 2010. The average installed cost of wind projects in 2021 was $\$1,500$/kW, down more than 40% since the peak in 2010, though relatively stable in recent years. The lowest costs were found in Texas and the (non-ISO) West. Wind energy prices are on the rise, but generally remain low, around $\$20$/MWh in the interior of the country with higher prices in the West and East. After topping out above $\$75$/MWh for power purchase agreements (PPAs) executed in 2009, the national average price of wind PPAs has dropped—though supply-chain pressures have resulted in increased prices in recent years. In the interior ‘wind belt’ of the country, recent pricing is around $\$20$/MWh. In the West and East, prices tend to average above $\$30$/MWh. These prices, which are possible in part due to federal tax support, fall below the projected future fuel costs of gas-fired generation. Wind PPA prices are often attractive compared to wind’s grid-system market value: The value of wind in wholesale power markets is affected by the location of wind plants, their hourly output profiles, and how those characteristics correlate with real-time electricity prices and capacity markets. The market value of wind increased in 2021, averaging $\$16$/MWh in MISO, $\$19$/MWh in SPP, $\$23$/MWh in NYISO, $\$31$/MWh in ERCOT, $\$33$/MWh in PJM, $\$44$/MWh in ISO-NE, and $\$48$/MWh in CAISO. The average levelized cost of wind energy was $\$32$/MWh for plants built in 2021: Levelized costs, which exclude the impacts of federal tax incentives, vary across time and geography. The national average stood at $\$32$/MWh in 2021—down substantially historically, though relatively stable in recent years. Levelized costs were lowest in ERCOT, SPP, and the (non-ISO) West. The health and climate benefits of wind in 2021 were larger than its grid-system value, and the combination of all three far exceeds the current levelized cost of wind: Wind generation reduces power-sector emissions of carbon dioxide, nitrogen oxides, and sulfur dioxide. These reductions, in turn, provide public health and climate benefits that vary regionally, but together are economically valued at an average of over $\$90$/MWh-wind for plants built in 2021.

17 WIND ENERGY↗

NASA NTRS1980

Some calculated effects of non-uniform inflow on the radiated noise of a large wind turbine

Far field computations were performed for a large wind turbine to evaluate the effects of non-uniform aerodynamic loading over the rotor disk. A modified version of the Farassat/Nystrom propeller noise prediction program was applied to account for the variations in loading due to inflow interruption by the upstream support tower. The computations indicate that for the uniform inflow case, relatively low noise levels are generated and the first rotational harmonic dominated the spectrum. For cases representing wake flow deficiences due to the tower structure, subtantially increased noise levels for all harmonics are indicated, the greatest increases being associated with the higher order harmonics.

Greene, G. C.↗