Transcript Review of Bushland LIST Program

Innovations in Blade Technology
For Multi-Mega Watt Turbines
Presented by
Jose R. Zayas
Authored by Tom Ashwill, Jose Zayas, and Paul Veers
Sandia National Laboratories
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.
Outline
 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 2
U.S. DOE Wind Program
DOE Headquarters
•
•
•
•
Stan Calvert
Jack Cadogan
• Phil Dougherty
Linda Silverman
• Jim Ahlgrimm
Dennis Lin
• Laura Miner-Nordstrom
Steve Lindenberg
• Ian Baring-Gould (M&O)
Sandia Labs
NREL
Paul Veers
R. Thresher, B. Smith
Technology Research & Development
Program
Goals
Low Wind
Speed
Technology
Offshore
Wind
Technology
Distributed
Wind
Technology
SR&T*
SR&T
SR&T
By 2014, COE from
large
systems
By 2012,
COE in
from
Class 6 winds
large systems in Class
3.6 cents/kWh
4 winds
3 cents/kWh
onshore
onshore
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
*SR&T – Supporting Research and Testing
March 1, 2006
By 2007, COE from
distributed wind
systems 10-15
cents/kWh in Class 3
Technology Application
Wind Grid
Integration
Technology
Acceptance &
Coordination
SE&A**
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.
SE&A
By 2010, at
MW
Byleast
2010,100
at least
installed in 30
states.
**SE&A – Supporting Engineering and Analysis
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Figure 1. Quick reference to program structure
Page 3
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 4
Blade Design Advances &
New Concepts
 Lightweight Designs
 Slender planform
 New materials
 Load Alleviation
 Passive
 New airfoils
 Very thick (high t/c)
 Flatbacks
 Active devices
 Manufacturing
 Sweep
 Off-axis fibers
 Active control
 Individual blade pitch
control
 Embedded devices
March 1, 2006
 Enhanced Performance
 Remote build
 Coupon testing
 Manufacturing process




Hand lay-up
RTM
Pre-preg
Infusion
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 5
Numerical 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
Micon 65 – ADAMS Model
 NASTRAN - SNL
NuMAD FEA Model
 Flutter analysis and predictions
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 6
CFD Capabilities
 CFD Codes
 ARC2D
 OVERFLOW 2.0y
 Applications for CFD
 Airfoil performance
predictions
 Understanding of the effects of
embedded devices
Three-dimensional
Compressible RaNS
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 7
Advance Airfoils with Highly
Efficient Structure
Flatback
Airfoil
Traditional
Airfoil
Flatback Airfoils
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 8
Passive and Active Blade Control
Passive Bend-Twist Coupling
Active Devices
Courtesy: NREL
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 9
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 10
Applications 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
Subscale Blade Design
& Fabrication
 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
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 11
CX-100 – Carbon Spar Cap
Manufactured by TPI Composites
Carbon Spar Cap
Root Stud Inserts
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 12
TX-100 Carbon Tri-ax Skin &
Glass Spar-Cap
Manufactured by
TPI Composites
Passive Bend-Twist Coupling – Off Axis Carbon Fiber
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 13
BSDS – Flatback Airfoils
Manufactured by TPI Composites
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 14
Blade Test Site
ROAD
 3 Micon 65/13 (modified)
2.5 Dia Lateral Spacing




RESERVOIR
34-m Pad
r
Te
CTL B
Turbine
el
nn
ha
eC
c
a
r
Anemometer Tower
ce
rr a
Te




RO
AD
AY
W
ER
AT
W
March 1, 2006
Te
rra
ce
Ch
an
ne
l
Prevailing
Wind
115 kW generator
Stall regulated
55 RPM
Heavily Instrumented
N
0
100
200
15 rotor strain gauges
Rotor speed and position
Nacelle acceleration
Tower instrumentation
 Inflow Array
Scale, ft
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 15
Active Flow/Load Control




Blade incidence angle (pitch)
Flow velocity (modification in RPM)
Blade length
Blade aerodynamic characteristics through:
CL
• Active Load Control on Blade/Turbine can be
Achieved by Modifying:
 Changes in section shape (aileron, smart
materials, microtab)
 Surface blowing/suction
 Other flow control techniques (VG’s, surface
heating, plasma)
CL
 SNL Focus on Fast-Acting, Low Actuation
Energy Devices
α
 Will operate within the boundary layer of the
blade
 Must be rugged and easily implemented
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
α
Page 16
Sensors
 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 17
Fiber 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
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 18
Future 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 19
Summary
 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 20
Questions ???
March 1, 2006
EWEC 2006 - Innovative Turbines, Components, Systems and Techniques
Page 21