Utility-scale Wind Turbine Blades Research Articles

Analyzing the Effects of Atmospheric Turbulent Fluctuations on the Wake Structure of Wind Turbines and Their Blade Vibrational Dynamics

In recent trends, a rising demand for renewable energy has driven wind turbines to larger proportions, where lighter blade designs are often adopted to reduce the costs associated with logistics and production. This causes modern utility-scale wind turbine blades to be inherently more flexible, and their amplified aeroelastic sensitivity results in complex multi-physics reactions to variant atmospheric conditions, including dynamic patterns of aerodynamic loading at the rotor and vortex structure evolutions within the wake. In this paper, we analyze the influence of inflow variance for wind turbines with large, flexible rotors through simulations of the National Rotor Testbed (NRT) turbine, located at Sandia National Labs’ Scaled Wind Farm Technology (SWiFT) facility in Lubbock, Texas. The Common Ordinary Differential Equation Framework (CODEF) modeling suite is used to simulate wind turbine aeroelastic oscillatory behavior and wind farm vortex wake interactions for a range of flexible NRT blade variations, operating in differing conditions of variant atmospheric flow. CODEF solutions of turbine operation in Steady-In-The-Average (SITA) wind conditions are compared to SITA wind conditions featuring a controlled gust-like pulse overimposed, to isolate the effects of typical wind fluctuations. Finally, simulations of realistic time-varying wind conditions from SWiFT meteorological tower measurements are compared to the solutions of SITA wind conditions. These increasingly complex atmospheric inflow variations are tested to show the differing effects evoked by various patterns of spatiotemporal atmospheric flow fluctuations. An analysis is presented for solutions of wind turbine aeroelastic response and vortex wake evolution, to elucidate the consequences of variant inflow, which pertain to wind turbine dynamics at an individual and farm-collective scale. The comparisons of simulated farm flow for SITA and measured fluctuating wind conditions show that certain regions of the wake contain up to a 12% difference in normalized axial velocity, due to the introduction of wind fluctuations. The findings of this study prove valuable for practical applications in wind farm control and optimization strategies, with particular significance for modern utility-scale wind power plants operating in variant atmospheric conditions.

Analysis of the Aeroelastic Dynamics of Lightweight Flexible Variations of the SNL-NRT Turbine

Current trends show that wind turbines are growing in size to meet a rising demand for renewable energy generation, and their upscaled rotors have inherently become more flexible to maintain a proportionally lighter design. This is because larger rotors must be less massive relative to their diameter to minimize the levelized cost of energy (LCOE), which means that blades that are notably less stiff are produced as a result. These structural changes to blades are often reflected in their compromised aeroelastic stability and amplified deformation during operation, which has the potential to decrease the blade’s expected lifetime and the performance of the machine overall. Variations in blade flexibility are also known to influence vortex-wake structures downstream of the turbine, causing patterns of velocity deficit to evolve in ways that affect the performance of other turbines in the farm. This research explores how the increased flexibility of modern utility-scale wind turbine blades influences rotor aeroelastic behavior and interactions with farm flow. High-fidelity simulations of Sandia National Laboratories’ (SNL) National Rotor Testbed (NRT) wind turbine are presented. Flexible variations of the NRT baseline blade are simulated in a variety of realistic operational conditions typically expected at the SNL’s SWiFT facility in Lubbock, Texas. Solutions are then compared to investigate how specific changes to the structural properties of the NRT baseline blade’s design and construction can influence its aeroelastic response at the rotor and the evolution of the turbine’s wake.

Bending moment characteristic analysis of utility-scale onshore wind turbine blades based on monitoring data

Bending moment is an important parameter in structural design of the wind turbine blades. The purpose of the present study is to accurately determine the actual bending moments on the blades of wind turbine in service and study the characteristics. It can be helpful to provide supports for the design load of wind turbine blades. For this purpose, a blade load monitoring system was developed and installed on a 2 MW onshore wind turbine to measure bending moments at the blade root. A simulation model which is consistent with the monitoring wind turbine was used to verify the availability of the system. Based on the monitored bending moments and operational conditions of the wind turbine, the characteristics and fatigue load of blade root bending moments were analyzed. Meanwhile, the relationship between bending moments of blade root and operational parameters was discussed. A thrust estimation method based on monitored bending moments of blade root was presented which will help to assess the loads on the tower and foundation of the wind turbine. At last, a calculation method of equivalent fatigue load based on wind speed-rotor speed joint distribution was established which will contribute to the fatigue design of blades.

An experimental investigation into passive acoustic damage detection for structural health monitoring of wind turbine blades

This article details the implementation of a novel passive structural health monitoring approach for damage detection in wind turbine blades using airborne sound. The approach utilizes blade-internal microphones to detect trends, shifts, or spikes in the sound pressure level of the blade cavity using a limited network of internally distributed airborne acoustic sensors, naturally occurring passive system excitation, and periodic measurement windows. A test campaign was performed on a utility-scale wind turbine blade undergoing fatigue testing to demonstrate the ability of the method for structural health monitoring applications. The preliminary audio signal processing steps used in the study, which were heavily influenced by those methods commonly utilized in speech-processing applications, are discussed in detail. Principal component analysis and K-means clustering are applied to the feature-space representation of the data set to identify any outliers (synonymous with deviations from the normal operation of the wind turbine blade) in the measurements. The performance of the system is evaluated based on its ability to detect those structural events in the blade that are identified by making manual observations of the measurements. The signal processing methods proposed within the article are shown to be successful in detecting structural and acoustic aberrations experienced by a full-scale wind turbine blade undergoing fatigue testing. Following the assessment of the data, recommendations are given to address the future development of the approach in terms of physical limitations, signal processing techniques, and machine learning options.

A Numerical Model for the Analysis of Leading-Edge Protection Tapes for Wind Turbine Blades

This paper presents results of a numerical study on the effect of a standard leading-edge protection (LEP) tape on the aerodynamics of a NACA 64-618 airfoil. Two numerical models are used in STAR-CCM+ to estimate the impact of LEP tapes on airfoil c l and c d . The objective is to determine which numerical model resolves the physical mechanisms responsible for the aerodynamic degradation observed with standard LEP tapes. Experimental c d data are collected for LEP tapes applied to the tip section of an utility-scale wind turbine blade for numerical validation. For a standard LEP tape, experiments indicate laminar-to-turbulent boundary-layer transition occurs at the LEP tape edge, resulting in a 62% increase in c d . To capture the boundary-layer transition at the LEP step, transition modeling is required in STAR-CCM+. This is an important finding as the mesh techniques developed in this work can be used for future LEP tape design to prevent early transition, thereby reducing the associated adverse impact on wind-turbine tip-section airfoil aerodynamics and annual energy production.

Passive acoustic damage detection of structural cavities using flow-induced acoustic excitations

Cavities with different geometries represent the internal volumes of various engineering applications such as cabins of passenger cars, fuselages and wings of aircraft, and internal compartments of wind turbine blades. Transmissibility of acoustic excitation to and from these cavities is affected by material and cross-sectional properties of the structural cavity, as well as potential damage incurred. A new structural damage detection methodology that relies on the detectability of the changes in acoustic transmissibility across the boundaries of structural cavities is proposed. The methodology is described with a specific focus on the passive damage detection approach applied to cavity internal acoustic pressure responses under external flow-induced acoustic excitations. The approach is realized through a test plan that considers a wind turbine blade section subject to various damage types, severity levels, and locations, as well as wind speeds tested in a subsonic wind tunnel. A number of statistics-based metrics, including power spectral density estimates, band power differences from a known baseline, and the sum of absolute difference, were used to detect damage. The results obtained from the test campaign indicated that the passive acoustic damage detection approach was able to detect all considered hole-type damages as small as 0.32 cm in diameter and crack-type damages 1.27 cm in length. In general, the ability to distinguish damage from the baseline state improved as the damage increased in severity. Damage type, damage location, and flow speed influenced the ability to detect damage, but were not significant enough to prevent detection. This article serves as an overall proof of concept of the passive-based damage detection approach using flow-induced acoustic excitations on structural cavities of a wind turbine blade. The laboratory-scale results reveal that acoustic-based monitoring has great potential to be used as a new structural health monitoring technique for utility-scale wind turbine blades.

Experimental modal analysis of a utility-scale wind turbine blade using a multi-camera approach

Utility-scale wind turbine blades (WTBs) require proper certification to ensure that they meet the design specifications and for safe operation throughout their lifetime. Instrumentation during testing involves using wire-based sensors such as strain gauges and accelerometers. These systems are expensive, time-consuming to install, difficult to deploy on large-sized structures, require additional instrumentations (e.g., power amplifiers and data acquisitions), and produce results at only a discrete number of points. In this study, a multicamera based measurement system is implemented and experimentally evaluated to estimate the modal parameters of a ∼60-meter long utility-scale WTB. The measurement areas of the stereo-vision systems are limited based on the field of view (FOV) of the cameras. Therefore, two sets of cameras were used to increase the measurement area. The performance of the optical sensing system in identifying the modal parameters of the WTB was validated by using the multi-camera approach to measure the dynamic response of the blade subjected to impulse inputs (i.e., impacts). The multi-camera stereo vision system in conjunction with a data stitching algorithm enables the photogrammetry technique to cover larger areas for expanded measurements. From an analysis of processed data, it was observed that the multi-camera system allows for detecting the first five operating mode shapes with an error below 2% as compared with traditionally wired accelerometers. For higher order modes, an estimation is possible, but the accuracy of the system decreases and miscorrelation in the mode shapes up to ∼10% resulted.

Temperature effects on vision measurement system in long-term continuous monitoring of displacement

Videogrammetry has been recognized as a promising method for monitoring the dynamics of wind turbines. On the way forward, the environmental effects on the measurement accuracy of the videogrammetry are key issues should be solved. This study therefore carried out an investigation into the temperature-induced measurement error of the videometric technique in long-term continuous monitoring of displacement. First, videometric measurement tests specifically targeted for improving the applicability of the videogrammetry to wind turbine blade monitoring were conducted. Making use of the measurement data, the characteristics of the temperature-induced measurement errors were obtained by examining them as a whole as well as their wavelet decomposed components. Comprehensive correlation analyses were performed to quantify the degree of correlation between measurement error and temperature change. It is found that the vertical displacement measurement error and temperature change have a satisfactory linear relationship, while the relationship between horizontal displacement measurement error and temperature change is more scattered. Making use of the unique features of the deformation and thermal expansion of a utility-scale wind turbine blade, it is likely to subtract the temperature-induced measurement error from the measured displacement with the help of the relationship between measurement error and temperature change or a time-frequency approach.

Similitude analysis of thin-walled composite I-beams for subcomponent testing of wind turbine blades

In this study, the I-beam structure of a utility-scale blade is used as the basis for the design of a small-scale subcomponent emulating the same type of structural element of a utility-scale wind turbine blade. Governing equations for the bending of a shear deformable thin-walled composite I-beam are considered. Similitude theory is applied to derive the corresponding scaling laws. Accuracy of the derived scaling laws in predicting the strain and displacement fields of the full-scale I-beam is considered as a design criterion for small-scale I-beams. Both complete and partial similarity cases are discussed. A novel approach is proposed to design partially similar scaled I-beams with totally different layups from those of the full-scale I-beam. Using the proposed technique, scaled-down composite I-beams are designed that predict the strain and displacement fields of their full-scale parent I-beam with very good accuracy.

Large-area photogrammetry based testing of wind turbine blades

An optically based sensing system that can measure the displacement and strain over essentially the entire area of a utility-scale blade leads to a measurement system that can significantly reduce the time and cost associated with traditional instrumentation. This paper evaluates the performance of conventional three dimensional digital image correlation (3D DIC) and three dimensional point tracking (3DPT) approaches over the surface of wind turbine blades and proposes a multi-camera measurement system using dynamic spatial data stitching. The potential advantages for the proposed approach include: (1) full-field measurement distributed over a very large area, (2) the elimination of time-consuming wiring and expensive sensors, and (3) the need for large-channel data acquisition systems. There are several challenges associated with extending the capability of a standard 3D DIC system to measure entire surface of utility scale blades to extract distributed strain, deflection, and modal parameters. This paper only tries to address some of the difficulties including: (1) assessing the accuracy of the 3D DIC system to measure full-field distributed strain and displacement over the large area, (2) understanding the geometrical constraints associated with a wind turbine testing facility (e.g. lighting, working distance, and speckle pattern size), (3) evaluating the performance of the dynamic stitching method to combine two different fields of view by extracting modal parameters from aligned point clouds, and (4) determining the feasibility of employing an output-only system identification to estimate modal parameters of a utility scale wind turbine blade from optically measured data. Within the current work, the results of an optical measurement (one stereo-vision system) performed on a large area over a 50-m utility-scale blade subjected to quasi-static and cyclic loading are presented. The blade certification and testing is typically performed using International Electro-Technical Commission standard (IEC 61400-23). For static tests, the blade is pulled in either flap-wise or edge-wise directions to measure deflection or distributed strain at a few limited locations of a large-sized blade. Additionally, the paper explores the error associated with using a multi-camera system (two stereo-vision systems) in measuring 3D displacement and extracting structural dynamic parameters on a mock set up emulating a utility-scale wind turbine blade. The results obtained in this paper reveal that the multi-camera measurement system has the potential to identify the dynamic characteristics of a very large structure.

Design and Fatigue Performance of Large Utility-Scale Wind Turbine Blades

Aeroelastic design and fatigue analysis of large utility-scale wind turbine blades have been performed to investigate the applicability of different types of materials in a fatigue environment. The blade designs used in the study are developed according to an iterative numerical design process for realistic wind turbine blades, and the software tool FAST is used for advanced aero-servo-elastic simulations. Elementary beam theory is used to calculate strain time series from these simulations, and the material fatigue is evaluated using established methods. Following wind turbine design standards, the fatigue evaluation is based on a turbulent wind load case. Fatigue damage is estimated based on 100% availability and a site-specific annual wind distribution. Rainflow cycle counting and Miner's sum for cumulative damage prediction is used together with constant life diagrams tailored to actual material S-N data. Material properties are based on 95% survival probability, 95% confidence level, and additional material safety factors to maintain conservative results. Fatigue performance is first evaluated for a baseline blade design of the 10 MW NOWITECH reference wind turbine. Results show that blade damage is dominated by tensile stresses due to poorer tensile fatigue characteristics of the shell glass fiber material. The interaction between turbulent wind and gravitational fluctuations is demonstrated to greatly influence the damage. The need for relevant S-N data to reliably predict fatigue damage accumulation and to avoid nonconservative conclusions is demonstrated. State-of-art wind turbine blade trends are discussed and different design varieties of the baseline blade are analyzed in a parametric study focusing on fatigue performance and material costs. It is observed that higher performance material is more favorable in the spar-cap construction of large blades which are designed for lower wind speeds.

Occupational Exposures to Styrene Vapor in a Manufacturing Plant for Fiber-Reinforced Composite Wind Turbine Blades

A utility-scale wind turbine blade manufacturing plant requested assistance from the National Institute for Occupational Safety and Health (NIOSH) in controlling worker exposures to styrene at a plant that produced 37 and 42 m long fiber-reinforced wind turbine blades. The plant requested NIOSH assistance because previous air sampling conducted by the company indicated concerns about peak styrene concentrations when workers entered the confined space inside of the wind turbine blade. NIOSH researchers conducted two site visits and collected personal breathing zone and area air samples while workers performed the wind turbine blade manufacturing tasks of vacuum-assisted resin transfer molding (VARTM), gelcoating, glue wiping, and installing the safety platform. All samples were collected during the course of normal employee work activities and analyzed for styrene using NIOSH Method 1501. All sampling was task based since full-shift sampling from a prior Occupational Safety and Health Administration (OSHA) compliance inspection did not show any exposures to styrene above the OSHA permissible exposure limit. During the initial NIOSH site visit, 67 personal breathing zone and 18 area air samples were collected while workers performed tasks of VARTM, gelcoating, glue wipe, and installation of a safety platform. After the initial site visit, the company made changes to the glue wipe task that eliminated the need for workers to enter the confined space inside of the wind turbine blade. During the follow-up site visit, 12 personal breathing zone and 8 area air samples were collected from workers performing the modified glue wipe task. During the initial site visit, the geometric means of the personal breathing zone styrene air samples were 1.8 p.p.m. (n = 21) for workers performing the VARTM task, 68 p.p.m. (n = 5) for workers installing a safety platform, and 340 p.p.m. (n = 14) for workers performing the glue wipe task, where n is the number of workers sampled for a given mean result. Gelcoating workers included job categories of millers, gelcoat machine operators, and gelcoaters. Geometric mean personal breathing zone styrene air samples were 150 p.p.m. (n = 6) for millers, 87 p.p.m. (n = 2) for the gelcoat machine operators, and 66 p.p.m. (n = 19) for gelcoaters. The geometric mean of the personal breathing zone styrene air samples from the glue wipe task measured during the follow-up site visit was 31 p.p.m. (n = 12). The closed molding VARTM process was very effective at controlling worker exposures to styrene. Personal breathing zone styrene air samples were reduced by an order of magnitude after changes were made to the glue wipe task. The company used chemical substitution to eliminate styrene exposure during the installation of the safety platform. Recommendations were provided to reduce styrene concentrations during gelcoating.

Could thermoplastics be the answer for utility-scale wind turbine blades?

The manufacture of wind turbine blades has been based on thermoset composite technology, but thermoplastic composites could offer recyclability and other advantages. George Marsh reports on the current research going on into thermoplastic turbine blades.