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Operating loads and structural damage were monitored during operation of the MOD-OA electric generating system. The turbine was damaged locally between stations 48 and 125 after 2.8 million rotations. Loads due to degraded yaw stiffness and fretting at rib station 48 were identified as primary to this distress. The repaired blades operated an additional 4.8 million rotations without problems.
External configuration, environmental, and internal design requirements for the 300 foot diameter MOD-2 rotor are discussed, with emphasis on design details, significance of fatigue strength, design development test results, and conclusions of the preliminary design efforts.
The MOD-1 detail design is appended. The supporting analyses presented include a parametric system trade study, a verification of the computer codes used for rotor loads analysis, a metal blade study, and a definition of the design loads at each principal wind turbine generator interface for critical loading conditions. Shipping and assembly requirements, composite blade development, and electrical stability are also discussed.
Results of tests conducted using the MOD-0 100 kW experimental wind turbine are evaluated. The teetered rotor significantly decreased loads on the yaw drive mechanism and reduced blade cyclic flapwise bending moments by 25 percent at the 20 percent span location when compared to the rigid hub rotor. The teetered hub performed well, but impacted the teeter stops on occasion as wind speed and/or direction varied rapidly. The tip-controlled rotor performed satisfactorily with some expected loss of control when compared to the full span pitchable blade. The performance results indicate that a review of techniques used to calculate rotor power is in order.
The Mod-1 machine was assembled without the blades, tested, and sent to the site at Boone, North Carolina for erection. The blades were transported directly to the site. A series of checkout tests were then conducted to evaluate performance and loads. The results of these tests compared well with the design data.
A failure modes and effects analysis (FMEA) was directed primarily at identifying those critical failure modes that would be hazardous to life or would result in major damage to the system. Each subsystem was approached from the top down, and broken down to successive lower levels where it appeared that the criticality of the failure mode warranted more detail analysis. The results were reviewed by specialists from outside the Mod 1 program, and corrective action taken wherever recommended.
The activities leading to the completion of detail design of the MOD-1 wind turbine generator are described. Emphasis is placed on the description of the design as it finally evolved. However, the steps through which the design progressed are also traced in order to understand the major design decisions.
The Advanced High Resolution Radiometer, Mod 2 (AVHRR/2) is a modification of the original AVHRR (AVHRR/1) to expand the number of channels from four to five and provide additional sensing in the infrared region. A comparison of the spectral regions employed in the two instruments is given. Three of the channels are the same on both instruments. The difference in instruments is in the long wave IR region where a single channel was replaced by two channels. The modification from AVHRR/1 to AVHRR/2 was done with a minimum of changes. The areas of change are highlighted and the modifications by module are summarized. It is seen that the primary changes are in the relay optics and in the cooler. In this development program only two models are involved. The first model, the Optical Test Model was constructed and tested to prove the performance and structural integrity of the optical system and the modified cooler. The second model constructed is the Protoflight. Only the areas of the AVHRR/2 which were modified from the AVHRR/1 design are discussed.
The dynamics of single and multiple 2.5 ME, Boeing MOD-2 wind turbine generators (WTGs) connected to utility power systems were investigated. The analysis was based on digital simulation. Both time response and frequency response methods were used. The dynamics of this type of WTG are characterized by two torsional modes, a low frequency 'shaft' mode below 1 Hz and an 'electrical' mode at 3-5 Hz. High turbine inertia and low torsional stiffness between turbine and generator are inherent features. Turbine control is based on electrical power, not turbine speed as in conventional utility turbine generators. Multi-machine dynamics differ very little from single machine dynamics.
The performance and loading of a large wind rotor, 38.4 m in diameter and composed of two low-cost steel spar blades were examined. Two blades were fabricated at Lewis Research Center and successfully operated on the Mod-0 wind turbine at Plum Brook. The blades were operated on a tower on which the natural bending frequency were altered by placing the tower on a leaf-spring apparatus. It was found that neither blade performance nor loading were affected significantly by this tower softening technique. Rotor performance exceeded prediction while blade loads were found to be in reasonable agreement with those predicted. Seventy-five hours of operation over a five month period resulted in no deterioration in the blade.
Sound measurements were made for the MOD-2 wind turbine generator for wind conditions of 7.6 to 13.4 m/sec and for output power ratings of about 1 to 2 NW. Both broad band and narrow band data wre obtained for a range of distances and azimuth angles from the machine. The rotor sound spectra are random in character and peak in the frequency ranges 30 to 50 Hz and 800 to 1300 Hz. Both peaks are predictable from experience with helicopter rotors and propellers. Results suggest that the lower frequency peak is due to the effects of inflow turbulence and the higher frequency peak is due to the interactions of the turbulent boundary layers with the trailing edges of the blades. The boundary layer related sound is the dominant component in the audible frequency range and determines the detectability of the machine. It could be detected at a distance of 1350 m in the upwind direction where the background noise was 30 dB (A) and at distances in excess of 2100 m in the downwind direction. Discrete frequency sound components associated with the power generation equipment are measurable in the direction normal to the axis of rotation but are not believed to be significant for detection or community response.
The Safety, Reliability, and Quality Assurance (R&QA) approach developed for the largest wind turbine generator, the Mod 2, is described. The R&QA approach assures that the machine is not hazardous to the public or to the operating personnel, is operated unattended on a utility grid, demonstrates reliable operation, and helps establish the quality assurance and maintainability requirements for future wind turbine projects. The significant guideline consisted of a failure modes and effects analysis (FMEA) during the design phase, hardware inspections during parts fabrication, and three simple documents to control activities during machine construction and operation.
The microprocessor system and program used to control the operation of the 200-kW Mod-OA wind turbines is described. The system is programmed to begin startup and shutdown sequences automatically and to control yaw motion. Rotor speed and power output are controlled with integral and proportional control of the blade pitch angle. Included in the report are a description of the hardware and a discussion of the software programming technique. A listing of the PL/M software program is given.
Noise studies of the MOD-1 Wind Turbine Generator are summarized, and a simple mathematical noise is presented which is adequate to correlate the sound levels found near the machine. A simple acoustic measure is suggested for use in evaluating far field sound levels. Use of this measure as input to a currently available sound complaint prediction program is discussed. Results of a recent statistical survey relative to the far field variation of this acoustic measure because of atmospheric effects are described.
The auxiliaries and the control system for the ASE MOD I: (1) provide the required fuel and air flows for a well controlled combustion process, generating heat to the Stirling cycle; (2) provide a driver acceptable method for controlling the power output of the engine; (3) provide adequate lubrication and cooling water circulation; (4) generate the electric energy required for engine and vehicle operation; (5) provide a driver acceptable method for starting, stopping and monitoring the engine; and (6) provide a guard system, that protects the engine at component or system malfunction. The control principles and the way the different components and sub-systems interact are described as well as the different auxiliaries, the air fuel system, the power control systems and the electronics. The arrangement and location of auxiliaries and other major components are also examined.
The machine configuration and its advantages and disadvantages, particularly as it affects reliability are discussed. The machine performance, both availability and power output characteristics are described. The Mod-OA operational experience is documented. The characteristics of the wind energy generated, the machine performance, and the subsystem strengths and weaknesses are discussed. An assessment of the project success in fulfilling its goals and objectives is also presented.
The project requirements, approach, system description, design requirements, design, analysis, system tests, installation safety considerations, failure modes and effects analysis, data acquisition, and initial performance for the MOD-OA 200 kw wind turbine generator are discussed. The components, the rotor, driven train, nacelle equipment, yaw drive mechanism and brake, tower, foundation, electrical system, and control systems are presented. The rotor includes the blades, hub and pitch change mechanism. The drive train includes the low speed shaft, speed increaser, high speed shaft, and rotor brake. The electrical system includes the generator, switchgear, transformer, and utility connection. The control systems are the blade pitch, yaw, and generator control, and the safety system. Manual, automatic, and remote control and Dynamic loads and fatigue are analyzed.
The windpowered generator, Mod-0A, and its advantages and disadvantages, particularly as it affects reliability, are discussed. The machine performance with regard to power availability and power output is discussed.