This document serves both as a guide and a record for requirements management associated with design of retrofit rotors for the Sandia SWiFT turbines. The rotors will support a long-term experimental campaign. Data gathered during the campaign will support formal verification and validation of complex flow numerical models for prediction of metrics deemed important for wind energy plant efficiency. These integrated projects involve multiple years of effort, dozens of engineers and collaborators, and dozens of stakeholders in the form of the research community, National Lab staff, and DOE staff. Creating of formal, written requirements will ensure flow-down of activities from high-level goals, aid communication, and enable clear verification of activities. A custom requirements schema is created and described. Commercial requirements management software —IBM Rational DOORS—is used to organize the information and ensure traceability. This document serves as a record of the process as well as a record of the exported, detailed contents of the DOORS database.
The total energy produced by a wind farm depends on the complex interaction of many wind turbines operating in proximity with the turbulent atmosphere. Sometimes, the unsteady forces associated with wind negatively influence power production, causing damage and increasing the cost of producing energy associated with wind power. Wakes and the motion of air generated by rotating blades need to be better understood. Predicting wakes and other wind forces could lead to more effective wind turbine designs and farm layouts, thereby reducing the cost of energy, allowing the United States to increase the installed capacity of wind energy. The Wind Energy Technologies Department at Sandia has collaborated with the University of Minnesota to simulate the interaction of multiple wind turbines. By combining the validated, large-eddy simulation code with Sandia’s HPC capability, this consortium has improved its ability to predict unsteady forces and the electrical power generated by an array of wind turbines. The array of wind turbines simulated were specifically those at the Sandia Scaled Wind Farm Testbed (SWiFT) site which aided the design of new wind turbine blades being manufactured as part of the National Rotor Testbed project with the Department of Energy.
New blade designs are planned to support future research campaigns at the SWiFT facility in Lubbock, Texas. The sub-scale blades will reproduce specific aerodynamic characteristics of utility-scale rotors. Reynolds numbers for megawatt-, utility-scale rotors are generally vary from 2-8 million. The thickness of inboard airfoils for these large rotors are typically as high as 35-40%. The thickness and the proximity to three-dimensional flow of these airfoils present design and analysis challenges, even at the full scale, but more than a decade of experience with the airfoils in numerical simulation, in the wind tunnel, and in the field has generated confidence in their performance. When used on a sub-scale rotor, Reynolds number regimes are significantly lower for the inboard blade, ranging from 0.7 to 1 million. Performance of the thick airfoils in this regime is uncertain because of the lack of wind tunnel data and the inherent challenge associated with associated numerical simulations. This report documents efforts to determine the most capable analysis tools to support these simulations and to improve understanding of the aerodynamic properties of thick airfoils in this Reynolds number regime. Numerical results from various codes of four airfoils are verified against previously published wind tunnel results where data at those Reynolds numbers are available. Results are then computed for other Reynolds numbers of interest.
In this paper, the effect of two different turbine blade designs on the wake characteristics was investigated using large-eddy simulation with an actuator line model. For the two different designs, the total axial load is nearly the same but the spanwise (radial) distributions are different. The one with higher load near the blade tip is denoted as Design A; the other is Design B. From the computed results, we observed that the velocity deficit from Design B is higher than that from Design A. The intensity of turbulence kinetic energy in the far wake is also higher for Design B. The effect of blade load distribution on the wind turbine axial and tangential induction factors was also investigated.
This report serves as documentation of the information and considerations involved in creation of the latest version of the SWIFT turbines aeroelastic model. Information used to create the model came from a variety of sources including original Vestas drawings and hardware characterization during construction of turbines at the site. Much of the original Vestas drawings remain proprietary and are not available to the public, though they have been referenced and included in the bibliography. The tower and blades of the turbine model were first created using available design information and then were calibrated to match experimental characterizations performed during construction. Some model inputs, such as airfoil polar data and estimated blade material properties, were computed. A basic controller is created to represent the basic operation of the modified SWiFT turbines.
A reduction in cost of energy from wind is anticipated when maximum allowable tip velocity is allowed to increase. Rotor torque decreases as tip velocity increases and rotor size and power rating are held constant. Reduction in rotor torque yields a lighter weight gearbox, a decrease in the turbine cost, and an increase in the capacity for the turbine to deliver cost competitive electricity. The high speed rotor incurs costs attributable to rotor aero-acoustics and system loads. The increased loads of high speed rotors drive the sizing and cost of other components in the system. Rotor, drivetrain, and tower designs at 80 m/s maximum tip velocity and 100 m/s maximum tip velocity are created to quantify these effects. Component costs, annualized energy production, and cost of energy are computed for each design to quantify the change in overall cost of energy resulting from the increase in turbine tip velocity. High fidelity physics based models rather than cost and scaling models are used to perform the work. Results provide a quantitative assessment of anticipated costs and benefits for high speed rotors. Finally, important lessons regarding full system optimization of wind turbines are documented.
Sandia is designing a set of modern, research-quality blades for use on the V27 turbines at the DOE/SNL SWiFT site at Texas Tech University in Lubbock, Texas. The new blades will replace OEM blades and will be a publicly available resource for subscale rotor research. Features of the new blades do not represent the optimal design for a V27 rotor, but are determined by aeroelastic scaling of relevant parameters and design drivers from a representative megawatt-scale rotor. Scaling parameters and design drivers are chosen based two factors: 1) retrofit to the existing SWiFT turbines and 2) replicate rotor loads and wake formation of a utility scale turbine to support turbine -turbine interaction research at multiple scales. The blades are expected to provide a publicly available baseline blade design which will enable increased participation in future blade research as well as accelerated hardware manufacture and test for demonstration of innovation. This paper discusses aeroelastic scaling approaches, a rotor design process and a summary of design concepts.
The Wind Energy Technologies department at Sandia National Laboratories has developed and field tested a wind turbine rotor with integrated trailing-edge flaps designed for active control of rotor aerodynamics. The SMART Rotor project was funded by the Wind and Water Power Technologies Office of the U.S. Department of Energy (DOE) and was conducted to demonstrate active rotor control and evaluate simulation tools available for active control research. This report documents the design, fabrication, and testing of the SMART Rotor. This report begins with an overview of active control research at Sandia and the objectives of this project. The SMART blade, based on the DOE / SNL 9-meter CX-100 blade design, is then documented including all modifications necessary to integrate the trailing edge flaps, sensors incorporated into the system, and the fabrication processes that were utilized. Finally the test site and test campaign are described.
Offshore wind turbines are an attractive source for clean and renewable energy for reasons including their proximity to population centers and higher capacity factors. One obstacle to the more widespread installation of offshore wind turbines in the USA, however, is that recent projections of offshore operations and maintenance costs vary from two to five times the land-based costs. One way in which these costs could be reduced is through use of a structural health and prognostics management (SHPM) system as part of a condition-based maintenance paradigm with smart loads management. Our paper contributes to the development of such strategies by developing an initial roadmap for SHPM, with application to the blades. One of the key elements of the approach is a multiscale simulation approach developed to identify how the underlying physics of the system are affected by the presence of damage and how these changes manifest themselves in the operational response of a full turbine. A case study of a trailing edge disbond is analysed to demonstrate the multiscale sensitivity of damage approach and to show the potential life extension and increased energy capture that can be achieved using simple changes in the overall turbine control and loads management strategy. Finally, the integration of health monitoring information, economic considerations such as repair costs versus state of health, and a smart loads management methodology provides an initial roadmap for reducing operations and maintenance costs for offshore wind farms while increasing turbine availability and overall profit.
A basic structural concept of the blade design that is associated with the frequently utilized %E2%80%9CNREL offshore 5-MW baseline wind turbine%E2%80%9D is needed for studies involving blade structural design and blade structural design tools. The blade structural design documented in this report represents a concept that meets basic design criteria set forth by IEC standards for the onshore turbine. The design documented in this report is not a fully vetted blade design which is ready for manufacture. The intent of the structural concept described by this report is to provide a good starting point for more detailed and targeted investigations such as blade design optimization, blade design tool verification, blade materials and structures investigations, and blade design standards evaluation. This report documents the information used to create the current model as well as the analyses used to verify that the blade structural performance meets reasonable blade design criteria.
Sixty-three years of aero-hydro-elastic loads simulations are demonstrated for a 5 MW offshore wind turbine deployed in shallow water. This large amount of simulation was made possible through the use of a high-performance computing cluster. The resulting one-hour extreme load distributions are examined; the extensive number of one-hour realizations allows for direct estimation of fifty-year return loads, without resorting to extrapolation. This type of simulation study opens up new possibilities for developing wind turbine design standards and discovering physical mechanisms that lead to extreme loads on wind turbine components.
Operations and maintenance costs for offshore wind plants are expected to be significantly higher than the current costs for onshore plants. One way in which these costs may be able to be reduced is through the use of a structural health and prognostic management system as part of a condition based maintenance paradigm with smart load management. To facilitate the creation of such a system a multiscale modeling approach has been developed to identify how the underlying physics of the system are affected by the presence of damage and how these changes manifest themselves in the operational response of a full turbine. The developed methodology was used to investigate the effects of a candidate blade damage feature, a trailing edge disbond, on a 5-MW offshore wind turbine and the measurements that demonstrated the highest sensitivity to the damage were the local pitching moments around the disbond. The multiscale method demonstrated that these changes were caused by a local decrease in the blade's torsional stiffness due to the disbond, which also resulted in changes in the blade's local strain field. Full turbine simulations were also used to demonstrate that derating the turbine power by as little as 5% could extend the fatigue life of a blade by as much as a factor of 3. The integration of the health monitoring information, conceptual repair cost versus damage size information, and this load management methodology provides an initial roadmap for reducing operations and maintenance costs for offshore wind farms while increasing turbine availability and overall profit.
A high-performance computer was used to simulate ninety-six years of operation of a five megawatt wind turbine. Over five million aero-elastic simulations were performed, with each simulation consisting of wind turbine operation for a ten minute period in turbulent wind conditions. These simulations have produced a large database of wind turbine loads, including ten minute extreme loads as well as fatigue cycles on various turbine components. In this paper, the extreme load probability distributions are presented. The long total simulation time has enabled good estimation of the tails of the distributions down to probabilities associated with twenty-year (and longer) return events. The database can serve in the future as a truth model against which design-oriented load extrapolation techniques can be tested. The simulations also allow for detailed examination of the simulations leading to the largest loads, as demonstrated for two representative cases.