Theme 2 The Turbine Dr Geoff Dutton
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1 SUPERGEN Wind Wind Energy Technology Phase 2 Theme 2 The Turbine Dr Geoff Dutton Supergen Wind Phase 2 General Assembly Meeting 21 March 2012
2 Normalized spectrum [db] Turbine blade materials The Turbine Drive train dynamics Rotor wind-field interaction Fault detection Hz Hz MODEL RIG 150 Hz Hz 212 Hz Hz Hz Hz -25 Middelgrunden wind farm photo by LM Glasfiber Hz 250 Hz 350 Hz Frequency [Hz] Subsea turbine foundations
3 Turbine blade materials The Turbine Basic materials 3D fabrics and joints Component testing Blade model
4 Materials considerations in blade design Labour, Material, Equipment Production rate Bending stiffness Cost Weight Selection of materials and manufacturing process design Maintenance and repair Reliable and cost-effective wind turbine blades Fatigue Resistance Manufacturing processes Environmental effects: UV, radar, Corrosions, Lightening
5 Novel materials: interlaminar toughness Selective interfacial reinforcement Veils Nano-additives Nano silica particles Through-thickness stitching and tufting Use of 3D fibre formats: braiding & weaving 3D Fabric
6 3D textile composites Why 3D Textiles? Current UD prepreg technology is excellent for thin flat structures But It is slow to lay up, difficult to work with complex 3D shapes, and struggles to allow load transfer in connections and across right angle shapes.
7 Strain Stitching: Digital Image Correlation Unstitched 400 cycles Unstitched 17,000 cycles Stitched 400 cycles Stitched 17,000 cycles Mean strain on stitched line Mean strain between two stitched lines Mean strain of stitched sample Mean strain of unstitched sample (a) (b) (c) (d) Log (N) Fig. Principal strain for samples. Arrows indicate the stitching lines. Fig. history of strain variations over stitched (line 1) and unstitched (line 2) areas Stitching generates high strain concentration areas along the sample. The strains on stitching line are much higher than unstitched area. The strains on stitching line are increasing gradually while the fatigue test is ongoing. However, the average strains of the stitched sample exhibit almost same values as that of the unstitched sample during the fatigue test. Slide No.7
8 Structural blade model Materials Parametric blade model: 3D coupled shell/solid element model Geometry sweeps Realistic quasi-static aerodynamic/gravity load Static failure criteria Cohesive failure model for shear web bonding line First look fatigue strength analysis Lay-up optimisation (under development)
9 Structural blade model Fully distributed aerodynamic loading
10 Rotor wind-field interaction The Turbine Vortex lattice wake model Transient rotor load model Integrated wake/rotor model Wind tunnel model testing
11 Rotor Wind Field Interaction: Unsteady Vortex Lattice Wake Model é ê ê ë ê G 1 G M ù ú ú û ú = é ê ê ë ê C 11 C M 1 C 1N C MN ù ú ú û ú -1 é ê ê ë ê V 1 V N ù ú ú û ú
12 Rotor Wind Field Interaction: Wind Tunnel Model Testing
13 Rotor Wind Field Interaction: Transient Rotor Load Model
14 Rotor Wind Field Interaction: Transient Rotor Load Model
15 Rotor Wind Field Interaction: Use model to simulate the flow conditions surrounding a turbine in an array Study the effects of upstream rotor wake interaction on downstream turbines. Investigate the effects of wind shear and incident turbulence on the rotor loads. Develop semi-empirical models for use with industry standard BEM codes to predict the impact on rotor induction factors and loading of these unsteady flow conditions.
16 Drive train dynamics The Turbine Improving controllers Flexibility of operation Control of model blade devices
17 Improving controllers Bode Plot before Gain Scheduling tower blade edge increasing size Non-linearities due to blade pitching
18 Improving controllers Bode Plot after Gain Scheduling
19 Flexibility of operation
20 Flexibility of operation General layout of the controller Outer controller (independent of the wind turbine s inner controller) Applicable to any wind turbine, regardless of the specific design of the inner controller and without any effect under normal conditions General layout of the additional power controller
21 Normalized spectrum [db] Fault detection Hz Hz MODEL RIG 150 Hz Hz 212 Hz Hz Hz Hz The Turbine Hz 250 Hz 350 Hz Frequency [Hz] Application of monitoring techniques Monitoring key sub-assemblies
22 Why is fault detection needed? Generator and gearbox failures contribute significantly to wind turbine downtime Generators and gearboxes have v. high replacement costs Spectral analysis of vibration signals commonly used in commercial condition monitoring systems for fault detection Spectral analysis of line current common in other fields for detection of motor/generator faults
23 Aims of fault detection Fundamental understanding of potential failure mechanisms and resulting fault signals in generators, drive train and frequency converters Develop practical methods of tracking fault signals under normal operating conditions Extend to all generator types and associated supply converters Mixed signal sources: current, power, vibration, temperature etc
24 Drive Train Test Rigs Synchronous wound-rotor generator and gearbox rig at Durham: - Variable speed - SKF WindCon DFIG generator and frequency converter rig at Manchester: - Fixed speed Screened test chamber for PD testing at Manchester
25 Generator Fault Wound rotor induction generator rotor electrical asymmetry eg slip-ring/brush gear fault/unbalance Raw data of generator speed, current and instantaneous power Example of fault frequency tracking the power under wind conditions 2sf component tracked : onset of rotor asymmetries clearly evident
26 Normalized spectrum [db] Normalized spectrum [db] Generator Fault DFIG induction generator stator winding fault Hz Hz Hz 450 Hz Hz Hz Hz 212 Hz Hz Hz MODEL RIG Hz Hz Hz Hz MODEL 250 Hz 350 Hz RIG Frequency [Hz] Hz 250 Hz 350 Hz Frequency [Hz] a) Healthy DFIG b) Stator winding fault Line current frequency spectra all frequency components can be identified in healthy and faulted operation using detailed generator model
![Acceleration [m/s 2 ] magnitude [normalized] I s [normalized] Induction generator - outer race bearing fault Stator current frequency spectrum, 1600 rpm 10 0 10-1 healthy faulthy 10-2 f o -fs 2f o -f](/docs-images/96/126547769/images/27-2.jpg "s f o +f s 10-3 10-4 10-5 0 50 100 150 Frequency [Hz] Conventional stator current spectrum difficult to see bearing fault signal!")
27 Acceleration [m/s 2 ] magnitude [normalized] I s [normalized] Induction generator - outer race bearing fault Stator current frequency spectrum, 1600 rpm healthy faulthy 10-2 f o -fs 2f o -f s f o +f s Frequency [Hz] Conventional stator current spectrum difficult to see bearing fault signal! 10 0 f o Vibration frequency spectrum 1600 rpm healthy faulthy 2f o x Complex envelope frequency spectrum, 1630 rpm I as I bs I cs Frequency [Hz] Vibration signal bearing fault signal clear Frequency [Hz] Modified current spectrum bearing fault signal now clear! f o Stator current see electrical faults and bearing faults! Vibration signal see bearing fault and electrical faults!
28 Ongoing work PD test facility: signal comparison for two methods: blue signal from a discharge detector Robinson M5, yellow from a MHz scan antenna Bearing faults in DFIG s Detection of converter faults Develop link from condition monitoring to maintenance Electrical fault models for other generator types (eg direct-drive/hybrid pm generators)
29 The Turbine Extend hydrodynamic solver to waves Historical data and experiment design Experimental study of wave loading Solver optimisation Numerical experiments Subsea turbine foundations
30 Wave impact on a vertical cylinder NWT outer dimensions: m 3 Water depth : h = 0.45m Diameter of cylinder : d = 0.325m wave gauges Case1 Case2 Case3 Case4 Wave amplitude (m) Wave period (s) Scattering parameter ka Experiments and Theoretical analyses conducted by D.L. Kriebel (1998) and J.R. Chaplin et al. (1997)
31 Force (N) Force (N) Force (N) Force (N) Time history of horizontal force on cylinder t (s) t (s) t (s) t (s)
32 Wave force time series for combinations of ka and kh (d/a=2.77) F/F Phase F/F Case1: ka = 0.271, kh = Case3: ka = 0.374, kh = Numerical Linear theory Second order Experimental Numerical Linear theory Second order Experimental Phase F/F 0 F/F Phase Case2: ka = 0.308, kh = Case4: ka = 0.481, kh = Numerical Linear theory Second order Experimental Numerical Linear theory Second order Experimetal Phase
33 Typical water surface around cylinder in 2 nd wave period (Case1) (1) t = 0/8 T (2) t = 1/8 T (3) t = 2/8 T (4) t = 3/8 T (5) t = 4/8 T (6) t = 5/8 T (7) t = 6/8 T (8) t = 7/8 T (9) t = 8/8 T
34 Horizontal Force (N) Extreme wave test Input wave energy spectrum t (s) Time history of horizontal force on cylinder Extreme wave impact on a vertical cylinder
35 Acknowledgements EPSRC grant nos. EP/D034566/1 & EP/H018662/1 SUPERGEN Wind Energy Technologies Consortium For further information please contact:
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