Infrastructure Access Report

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1 Marine Renewables Infrastructure Network Infrastructure Access Report Infrastructure: CNR-INSEAN Circulating Water Channel User-Project:DIRMO Double Inline Rotor Marine turbine Optimization. Analysis of a double inline rotor marine current turbine performance, global performance optimization and cavitation risk avoiding in presence of turbine wake. CNV NAVAL ARCHITECTS S.L. Status: Final Version: [Type versionnumber, e.g. 01] Date: [Pick the version date] EC FP7 Capacities Specific Programme Research Infrastructure Action

2 ABOUT MARINET MARINET (Marine Renewables Infrastructure Network for emerging Energy Technologies) is an EC-funded network of research centres and organisations that are working together to accelerate the development of marine renewable energy - wave, tidal & offshore-wind. The initiative is funded through the EC's Seventh Framework Programme (FP7) and runs for four years until The network of 29 partners with 42 specialist marine research facilities is spread across 11 EU countries and 1 International Cooperation Partner Country (Brazil). MARINET offers periods of free-of-charge access to test facilities at a range of world-class research centres. Companies and research groups can avail of this Transnational Access (TA) to test devices at any scale in areas such as wave energy, tidal energy, offshore-wind energy and environmental data or to conduct tests on cross-cutting areas such as power take-off systems, grid integration, materials or moorings. In total, over 700 weeks of access is available to an estimated 300 projects and 800 external users, with at least four calls for access applications over the 4-year initiative. MARINET partners are also working to implement common standards for testing in order to streamline the development process, conducting research to improve testing capabilities across the network, providing training at various facilities in the network in order to enhance personnel expertise and organising industry networking events in order to facilitate partnerships and knowledge exchange. The aimof the initiative isto streamline the capabilities of test infrastructures in order to enhance their impact and accelerate the commercialisation of marine renewable energy. See for more details. Partners Ireland University College Cork, HMRC (UCC_HMRC) Coordinator Sustainable Energy Authority of Ireland (SEAI_OEDU) Denmark Aalborg Universitet (AAU) Danmarks Tekniske Universitet (RISOE) France Ecole Centrale de Nantes (ECN) Institut Français de Recherche Pour l'exploitation de la Mer (IFREMER) United Kingdom National Renewable Energy Centre Ltd. (NAREC) The University of Exeter (UNEXE) European Marine Energy Centre Ltd. (EMEC) University of Strathclyde (UNI_STRATH) The University of Edinburgh (UEDIN) Queen s University Belfast (QUB) Plymouth University(PU) Spain Ente Vasco de la Energía (EVE) Tecnalia Research & Innovation Foundation (TECNALIA) Belgium 1-Tech (1_TECH) Netherlands Stichting Tidal Testing Centre (TTC) Stichting Energieonderzoek Centrum Nederland (ECNeth) Germany Fraunhofer-Gesellschaft Zur Foerderung Der Angewandten Forschung E.V (Fh_IWES) Gottfried Wilhelm Leibniz Universität Hannover (LUH) Universitaet Stuttgart (USTUTT) Portugal Wave Energy Centre Centro de Energia das Ondas (WavEC) Italy Universitàdegli Studi di Firenze (UNIFI-CRIACIV) Universitàdegli Studi di Firenze (UNIFI-PIN) Università degli Studi della Tuscia (UNI_TUS) Consiglio Nazionale delle Ricerche (CNR-INSEAN) Brazil Instituto de Pesquisas Tecnológicas do Estado de São Paulo S.A. (IPT) Norway Sintef Energi AS (SINTEF) Norges Teknisk-Naturvitenskapelige Universitet (NTNU) Rev. [Version Number, e.g. 01], [Pick the version date] Page 2 of 17

3 DOCUMENT INFORMATION Title Double Inline Rotor Marine turbine Optimization. Analysis of a double inline rotor marine current turbine performance, global performance optimization and cavitation risk avoiding in presence of turbine wake. Distribution Public Document Reference MARINET-TA1-DIRMO User-Group Leader, Lead Ana Pérez Fernández CNV Navals SL Author [Optional: Insert address and contact details] User-Group Members, Adriano Marques de Magallanes Contributing Authors Infrastructure Accessed: CNR-INSEAN Circulating Water Channel Infrastructure Manager Dr. Fabio Di Felice as Facility manager, whereas F. Salvatore is project manager (or Main Contact) REVISION HISTORY Rev. Date Description Prepared by (Name) Approved By Infrastructure Manager Status (Draft/Final) 01 18/02/2015 Ocument draft Adriano Marques draft Page 3 of 17

4 ABOUT THIS REPORT One of the requirements of the EC in enabling a user group to benefit from free-of-charge access to an infrastructure is that the user group must be entitled to disseminate the foreground (information and results) that they have generated under the project in order to progress the state-of-the-art of the sector. Notwithstanding this, the EC also state that dissemination activities shall be compatible with the protection of intellectual property rights, confidentiality obligations and the legitimate interests of the owner(s) of the foreground. The aim of this report is therefore to meet the first requirement of publicly disseminating the knowledge generated through this MARINET infrastructure access project in an accessible format in order to: progress the state-of-the-art publicise resulting progress made for the technology/industry provide evidence of progress made along the Structured Development Plan provide due diligence material for potential future investment and financing share lessons learned avoid potential future replication by others provide opportunities for future collaboration etc. In some cases, the user group may wish to protect some of this information which they deem commercially sensitive, and so may choose to present results in a normalised (non-dimensional) format or withhold certain design data this is acceptable and allowed for in the second requirement outlined above. ACKNOWLEDGEMENT The work described in this publication has received support from MARINET, a European Community - Research Infrastructure Action under the FP7 Capacities Specific Programme. LEGAL DISCLAIMER The views expressed, and responsibility for the content of this publication, lie solely with the authors. The European Commission is not liable for any use that may be made of the information contained herein.this work may rely on data from sources external to the MARINET project Consortium. Members of the Consortium do not accept liability for loss or damage suffered by any third party as a result of errors or inaccuracies in such data. The information in this document is provided as is and no guarantee or warranty is given that the information is fit for any particular purpose. The user thereof uses the information at its sole risk and neither the European Commission nor any member of the MARINET Consortium is liable for any use that may be made of the information. Page 4 of 17

5 EXECUTIVE SUMMARY The tests done at the CNR-INSEAR facility are part of a set of tests guided to optimize a contra-rotative double inline rotor for a marine current turbine. The objective of the test is to obtain relevant data for the characterization of the rotor designed by the DIRMO in terms of efficiency, torque and the presence of signs of cavitation in a range of different pitch settings, inflow-water velocity and rotor angular velocity. The outcome of the test will help to improve the design of the rotor s blade optimizing the efficiency and avoid cavitation effects. Page 5 of 17

6 CONTENTS 1 INTRODUCTION& BACKGROUND INTRODUCTION DEVELOPMENT SO FAR Stage Gate Progress OUTLINE OF WORK CARRIED OUT SETUP TESTS Test Plan RESULTS ANALYSIS & CONCLUSIONS MAIN LEARNING OUTCOMES PROGRESS MADE Progress Made: For This User-Group or Technology Progress Made: For Marine Renewable Energy Industry KEY LESSONS LEARNED APPENDICES STAGE DEVELOPMENT SUMMARY TABLE ANY OTHER APPENDICES Page 6 of 17

7 1 INTRODUCTION& BACKGROUND 1.1 INTRODUCTION CNV Naval Architects is and independent design & engineering company whose activities consists on elaborating preliminary and full designs relative to naval field. collaborating with other Spanish companies and Research Groups in the development of a novel tidal device inside the so called ProyectoMagallanes. This big industry led project will finish with the building of a full scale 40 meters long floating device carrying two turbines of 1 MW each. This platform has two in-line counter-rotating rotors. These rotors have a variable pitch system, which adjust the pitch angle for optimal efficiency in a range of inflow water velocity and rotational speed. Until now, a 1:10 scale prototype has been built and tested in the Galician fjord like Ría of the river Miño (6/2013), by towing the scale device and by a permanent installation with a slack mooring configuration. This test had allowed us to verify the platform stability and the PTO robustness; unfortunately there was no clear way to validate the design of scalable turbine blades. The objective of the test done at the CNR-INSEAR facility was focus in obtaining relevant data for the characterization of the rotor designed by the DIRMO in terms of efficiency, torque and the presence of signs of cavitation in a range of different pitch settings, inflow-water velocity and rotor angular velocity. The outcome of the test will help to improve the design of the rotor s blade optimizing the efficiency. 1.2 DEVELOPMENT SO FAR Stage Gate Progress Previously completed: Planned for this project: STAGE GATE CRITERIA Stage 1 Concept Validation Linear monochromatic waves to validate or calibrate numericalmodels of the system ( waves) Finite monochromatic waves to include higher order effects ( waves) Hull(s) sea worthiness in real seas (scaled duration at 3 hours) Restricted degrees of freedom (DofF) if required by the earlymathematical models Provide the empirical hydrodynamic co-efficient associated withthe device (for mathematical modelling tuning) Investigate physical process governing device response. May notbe well defined theoretically or numerically solvable Real seaway productivity (scaled duration at minutes) Initially 2-D (flume) test programme Short crested seas need only be run at this early stage if thedevices anticipated performance would be significantly affected bythem Evidence of the device seaworthiness Initial indication of the full system load regimes Status Stage 2 Design Validation Accurately simulated PTO characteristics Performance in real seaways (long and short crested) Survival loading and extreme motion behaviour. Active damping control (may be deferred to Stage 3) Page 7 of 17

8 STAGE GATE CRITERIA Device design changes and modifications Mooring arrangements and effects on motion Data for proposed PTO design and bench testing (Stage 3) Engineering Design (Prototype), feasibility and costing Site Review for Stage 3 and Stage 4 deployments Over topping rates Status Stage 3 Sub-Systems Validation To investigate physical properties not well scaled & validate performance figures To employ a realistic/actual PTO and generating system & develop control strategies To qualify environmental factors (i.e. the device on the environment and vice versa) e.g. marine growth, corrosion, windage and current drag To validate electrical supply quality and power electronic requirements. To quantify survival conditions, mooring behaviour and hull seaworthiness Manufacturing, deployment, recovery and O&M (component reliability) Project planning and management, including licensing, certification, insurance etc. Stage 4 Solo Device Validation Hull seaworthiness and survival strategies Mooring and cable connection issues, including failure modes PTO performance and reliability Component and assembly longevity Electricity supply quality(absorbed/pneumatic power-converted/electrical power) Application in local wave climate conditions Project management, manufacturing, deployment, recovery, etc Service, maintenance and operational experience [O&M] Accepted EIA Stage 5 Multi-Device Demonstration Economic Feasibility/Profitability Multiple units performance Device array interactions Power supply interaction & quality Environmental impact issues Full technical and economic due diligence Compliance of all operations with existing legal requirements Page 8 of 17

9 2 OUTLINE OF WORK CARRIED OUT 2.1 SETUP A 1:30 scale model rotor (600mm-diameter rotor) was chosen to prevent any blockage effect from the basin. Blades and test ring were manufactured in Spain using a high-accurate CNC procedure and with a tolerance of 15 micros, allowing an accurate representation of the blade geometry. Forebody cap and inner ring were prepared by INSEAN, so the model rotor could be fixed in the dynamometer structure that the facility has ready to use. The data acquisition system and the velocity control system used for this test belong to INSEAN and they are mounted in a fixed support structure. A long shaft between the rotor and dynamometer minimize the blockage effect on the rotor. This system employs a motor for adjusting the angular speed so it can obtain an expected TSR for an inflow water velocity (U). A dynamometer is used for data acquisition allowing to monitor parameters as angular velocity, axial thrust power and torque generated. The support structure can modify the yaw angle within the range expected for this test. Page 9 of 17

10 Ilustración 1: Rotor display in CNR-Insean Pitch setting is manually regulated, the rotor hub has two parts, when unmounted blades can be clamped and pitch angle could be fixed. For an easier fixing the pitch angle, rotor hub and root blades have a mark as in the next figure. Ilustración 2: Detail of the marks for blades positioning Page 10 of 17

11 The final disposition is the usual use in a circulation test. Some pictures are display: Ilustración 3: Pictures of the rotor in CNR-Insean Page 11 of 17

12 2.2 TESTS Test Plan This is the test plan followed for the test: Day 1: set-up - Installation of the model turbine into the CWC, blade pitch setting - Calibration of instruments Day 2-4: turbine performance tests - Determination of performance (thrust, torque, power) curves over a range of TSR values(max conditions) at given: - Inflow current speed, V0 (to be defined at set-up) 2,25 m/s - Turbine yaw angle, Gamma (0, 10, 15, 20) - Blade pitch setting, Phi (15, 20, 22.5, 25) - Test section pressure, P0 (1 atm) - Based on time available during days 2-4, more performance curves can be determined by varying parameter Gamma and/or blade pitch setting, Phi Day 5: - Rotor dummy characterization: - Measurement of rotor dummy axial force (drag) and passive Torque to determine pure rotor loads - model decommissioning and removal of set-up from facility test Section DIRMO device is a double contra-rotating rotor system. Despite this fact, tests were focused on characterizing the performance on a single rotor in an upstream configuration (that is, dynamometer gondola and strut downstream the rotor). The rotor dummy is obtained by removing blades from the hub and replacing the hub with a closed cylinder of same dimensions of the hub InflowVelocity (U) Pitch Setting TSR Set-Up 1-2,5 m/s (0,25 steps) + 15º 3-9 Performance Test 2,25 m/s +/- 25º 3-9 Dummy Char 1-2,5 m/s (0,25 steps) Page 12 of 17

13 2.3 RESULTS We are still working on the data analysis. Some initial analysis shows a low efficiency of the blades tested so it is expected to continue with the designing process in order to achieve a blade with a better behaviour at the speed tested. Next picture shows the difference between the data obtained by computational analysis (blue) and the results obtained in Rome (red) by our rotor. The loss of efficiency can be produced by the appearance of cavitation at low velocities of water. This cavitation appears a TSR lower that expected, starting at TSR 5.5. Maximum cavitation appears at r = 0.8. This effect causes the loss of efficiency of the blade and increase the velocity of blade s deterioration as it was revealed by blade surface painting that was partially removed after short time of testing. This has been explained with the occurrence of erosive cavitation over a significant part of blade surface. Page 13 of 17

14 Ilustración 4: Effects of cavitation on DIRMO rotor 2.4 ANALYSIS & CONCLUSIONS With data analysis still in progress, initial conclusions of the test appear that the rotor model tested does not achieve the level of efficiency required. The appearance of cavitation could compromise the structural integrity of the rotor. It is suggested redesigning the rotor blade, using the data from the test done at INSEAN as feedback to our numerical methods, allowing a better performance prediction. 3 MAIN LEARNING OUTCOMES 3.1 PROGRESS MADE The outcome from the circulation test done at INSEAN has helped us to understand the blade we are designing and to take into account other effects that can affect significantly in the efficiency of the rotor. Further redesign and tank test will be done. This test allows us to improve our blade design increasing its efficiency and the efficiency of the whole project Progress Made: For This User-Group or Technology The data gathered during the test is vital importance on order to validate the numerical methods used in the blade design and will help to improve rotor design Next Steps forresearch or Staged Development Plan Exit/Change & Retest/Proceed? Page 14 of 17

15 As the initial results suggest that the blade design needs a redesign process. With the data gathered during the test, numeric methods used for designing stage will be validated, helping to achieve a more reliable result on the predictions of efficiency for the rotor at all pitch configurations. In the close future it will be necessary to manufacture new blades with the result of the new designing process to increase the performance of our rotor Progress Made: For Marine Renewable Energy Industry 3.2 KEY LESSONS LEARNED - Tank test is of vital importance in order to validate numerical methods and final design. - Numerical methods in some configurations could significantly vary from obtained in test tanks. - Blade performance doesn t reach the designed parameters, with a significant loss of efficiency and appearance of cavitation. - Further test needs to be done until the design blade reach the designed parameters. 4 APPENDICES 4.1 STAGE DEVELOPMENT SUMMARY TABLE The table following offers an overview of the test programmes recommended by IEA-OES for each Technology Readiness Level. This is only offered as a guide and is in no way extensive of the full test programme that should be committed to at each TRL. Page 15 of 17

16 Page 16 of 17 Infrastructure Access Report: DIRMO

17 4.2 ANY OTHER APPENDICES Page 17 of 17