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Transcript of Presented by Jose R. Zayas Authored by Tom Ashwill, Jose Zayas, and Paul Veers Sandia National...
Presented by
Jose R. Zayas
Authored by Tom Ashwill, Jose Zayas, and Paul VeersSandia National Laboratories
Innovations in Blade Technology For Multi-Mega Watt Turbines
Innovations in Blade Technology For Multi-Mega Watt Turbines
Sandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin Company,for the United States Department of Energy under contract DE-AC04-94AL85000.
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 2
OutlineOutline
DOE Wind Program Structure SNL Research Focus Numerical Analysis Tools Sub-Scale Blades Active Flow Control and Sensors Future Work
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 3
U.S. DOE Wind ProgramU.S. DOE Wind Program
DOE HeadquartersStan Calvert
• Jack Cadogan• Linda Silverman• Dennis Lin• Steve Lindenberg
• Phil Dougherty • Jim Ahlgrimm • Laura Miner-Nordstrom • Ian Baring-Gould (M&O)
Sandia LabsPaul Veers
NRELR. Thresher, B. Smith
Technology Research & Development Technology Application
ProgramGoals
By 2012, COE from large systems in Class 4 winds 3 cents/kWh
onshore
By 2007, COE from distributed wind systems 10-15
cents/kWh in Class 3
By 2014, COE in shallow water (<30 m depth) with Class 6
winds of 5 cents/kWh;
By 2016, COE in transitional water depths (30-60 m
depth) with Class 6 winds of 5 cents/kWh
By 2012, complete program activ ities addressing
electric power market rules, interconnection impacts, operating strategies, and
system planning needed for wind energy to compete without disadv antage to
serve the Nation's energy needs.
By 2010, at least
By 2010, at least 100 MW installed in 30
states.
By 2014, COE from large systems in
Class 6 winds3.6 cents/kWh
onshore
Low Wind Speed
Technology
Distributed Wind
Technology
SR&T
Offshore Wind
Technology
SR&T
Wind GridIntegration
SE&A**
TechnologyAcceptance & Coordination
SE&ASR&T*
*SR&T – Supporting Research and Testing
Figure 1. Quick reference to program structure
**SE&A – Supporting Engineering and Analysis
Technology Research & Development Technology Application
ProgramGoals
By 2012, COE from large systems in Class 4 winds 3 cents/kWh
onshore
By 2007, COE from distributed wind systems 10-15
cents/kWh in Class 3
By 2014, COE in shallow water (<30 m depth) with Class 6
winds of 5 cents/kWh;
By 2016, COE in transitional water depths (30-60 m
depth) with Class 6 winds of 5 cents/kWh
By 2012, complete program activ ities addressing
electric power market rules, interconnection impacts, operating strategies, and
system planning needed for wind energy to compete without disadv antage to
serve the Nation's energy needs.
By 2010, at least
By 2010, at least 100 MW installed in 30
states.
By 2014, COE from large systems in
Class 6 winds3.6 cents/kWh
onshore
Low Wind Speed
Technology
Distributed Wind
Technology
SR&T
Offshore Wind
Technology
SR&T
Wind GridIntegration
SE&A**
TechnologyAcceptance & Coordination
SE&ASR&T*
*SR&T – Supporting Research and Testing
Figure 1. Quick reference to program structure
**SE&A – Supporting Engineering and Analysis
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 4
Sandia National Labs Research Focus
Sandia National Labs Research Focus
SNL Blade Technology Research Design innovations Design tools Materials & manufacturing Sub-scale blade design & fabrication Laboratory and field testing
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 5
Blade Design Advances & New Concepts
Blade Design Advances & New Concepts
Lightweight Designs Slender planform New materials
Load Alleviation Passive
Sweep Off-axis fibers
Active control Individual blade pitch
control Embedded devices
Enhanced Performance New airfoils
Very thick (high t/c) Flatbacks
Active devices Manufacturing
Remote build Coupon testing Manufacturing process
Hand lay-up RTM Pre-preg Infusion
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 6
Numerical Analysis ToolsNumerical Analysis Tools
NuMAD - SNL ANSYS FEA preprocessor Linear and non-linear buckling
Dynamic Simulation Tools FAST (Fatigue, Aerodynamics, Structures, and
Turbulence) – NREL, SNL Modal representation Limited degrees of freedom Used as a preprocessor to ADAMS
ADAMS (Automatic Dynamic Analysis of Mechanical Systems) – NREL, SNL Commercial multi body dynamic
simulation software Virtually unlimited degrees of freedom
NASTRAN - SNL Flutter analysis and predictions
Micon 65 – ADAMS ModelNuMAD FEA Model
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 7
CFD CapabilitiesCFD Capabilities
CFD Codes ARC2D OVERFLOW 2.0y
Applications for CFD Airfoil performance
predictions Understanding of the effects of
embedded devices
Three-dimensionalCompressible RaNS
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 8
Advance Airfoils with Highly Efficient Structure
Advance Airfoils with Highly Efficient Structure
Flatback Airfoils
FlatbackAirfoil
TraditionalAirfoil
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 9
Passive and Active Blade ControlPassive and Active Blade Control
Active DevicesPassive Bend-Twist Coupling
Courtesy: NREL
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 10
Materials & Manufacturing Research Materials & Manufacturing Research
Carbon Coupon Tests New Forms – Large & Medium Carbon Tows
Large Database in Collaboration with Montana State University
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 11
Applications of InnovationsApplications of Innovations
Prototype Sub-scale Blades Manufactured (9 meters) CX-100
Carbon spar cap Glass skin and shear web
TX-100 Carbon triax in skin for bend-twist Constant spar cap thickness
BSDS (Blade System Design Study) Flatback airfoils Carbon spar cap Slenderized planform Large scale architecture Highly efficient structural design
LWST Phase II Components Knight & Carver
25m blade sweep twist Replacement blades
Subscale Blade Design & Fabrication
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 12
CX-100 – Carbon Spar CapCX-100 – Carbon Spar Cap
Carbon Spar Cap
Manufactured by TPI Composites
Root Stud Inserts
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 13
TX-100 Carbon Tri-ax Skin & Glass Spar-Cap
TX-100 Carbon Tri-ax Skin & Glass Spar-Cap
Passive Bend-Twist Coupling – Off Axis Carbon Fiber
Manufactured by TPI Composites
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 14
BSDS – Flatback AirfoilsBSDS – Flatback Airfoils
Manufactured by TPI Composites
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 15
Blade Test SiteBlade Test Site
34-m Pad
CTL B
RESERVOIR
ROAD
N
0 100 200
Scale, ft
Prevailing Wind
2.5 Dia Lateral Spacing
Turbine
Anemometer Tower
3 Micon 65/13 (modified) 115 kW generator Stall regulated 55 RPM Heavily Instrumented
15 rotor strain gauges Rotor speed and position Nacelle acceleration Tower instrumentation
Inflow Array
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 16
Active Flow/Load ControlActive Flow/Load Control
• Active Load Control on Blade/Turbine can be Achieved by Modifying: Blade incidence angle (pitch) Flow velocity (modification in RPM) Blade length Blade aerodynamic characteristics through:
Changes in section shape (aileron, smart materials, microtab)
Surface blowing/suction Other flow control techniques (VG’s, surface
heating, plasma) SNL Focus on Fast-Acting, Low Actuation
Energy Devices Will operate within the boundary layer of the
blade Must be rugged and easily implemented
α
CL
αC
L
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 17
SensorsSensors
Focus on Cost Effective Sensors (for lab and field environments) Strain sensors Pressure sensors for airflow measurements Fiber optic sensors Piezo-ceramic Displacement and proximity (blade tip deflection)
Sensor Networks Control inputs Damage detection and health monitoring
Embedded Sensors Composite structures Exploring possibilities with SNL MEMS facility
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 18
Fiber Optics (FO) ResearchFiber Optics (FO) Research
Goal: Develop new fiber optic interrogating method to reduce
system cost Use FO’s to measure flap and edge bending, as well as twist Relies on using
tunable filter and
superluminescent diode
- Eliminates costly interferometer
Temperature compensated Currently under development
Partnership with UCDavis
“Edge Bending”
“Flap Bending” “Twist”
Blade Structure
Fiberglass I-Beam
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 19
Future WorkFuture Work
Offshore SeaCon – Seabased Concepts
O&M Smarter blades Embedded sensor networks
Advanced Controls Materials for Offshore Applications
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 20
SummarySummary
Efforts underway to reduce blade weight growth for larger blades Active control may prove beneficial for future blade designs Coupon testing and sub-scale blades show advantages of carbon
hybrid materials New airfoils enable structural and manufacturing improvements in
blade designs 3 Sets of sub-scale blades have been manufactured – demonstrate
improvements Static testing complete – all blades met or exceeded design goals Fatigue and field testing scheduled
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 21
Questions ???Questions ???