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Large Blade Testing Facility LARGE WIND TURBINES Rahul Yarala Executive Director, Wind Technology Testing Center May 12, 2011

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  • WHY OFFSHORE WIND?Resource near load centersMinimize greenhouse gas emissions from electricity generationMinimal water consumption for electricity generationEnergy IndependenceGreen Jobs and local economic development

    Higher Capacity FactorsLow shear and turbulenceHigher wind speedsTurbines can spin at higher tip speeds and hence higher energy production

    A POWERFUL RESOURCE IN US

  • WHY LARGER TURBINES?

  • CHALLENGES and OPPORTUNITIESRotor Blade StructureNew materialsTwo-pieceLarger Chords

    New Tower conceptsComposite materialsLighter and corrosion resistanceDrivetrainDirect drive or low speed

    Foundations

  • Corrosion protection

    Site specific wind data collection and correlation with mesoscale weather prediction models for wind assessment.Further research and data collection using newer offshore friendly technology like LIDAR, SODAR etc is very important

    Demonstration platforms or prototype farms are required for offshore wind specific technology development and long term cost competitiveness of offshore wind. This is similar to land based turbine testing at NREL and UKs (public-private) initiative to have 100MW offshore wind farm available for prototyping and testing.

    CHALLENGES and OPPORTUNITIES

  • Static strength testing and accelerated fatigue testing of wind turbine blades are required for Turbine certification Reduce the risk of widespread failuresImprove blade reliabilityReduce COEBlades over 50m can not be fatigue tested in the United StatesBlades 62m long are in production and longer blades are being designedThis project will reduce COE by Reducing frequency of blade failuresLowering machine costIntroducing more efficient bladesReducing technical and financial risk of large-scale deploymentProviding industry with low cost test facilities to comply with certification requirements and support value engineering

    BLADES - Statement of the ProblemSlide courtesy of Jason Cotrell of NREL

    Chart3

    91989

    199319

    1934

    241999

    372002

    50.752004

    200550

    61.52006

    NWTC IUF Blade Test Facility built for blades up to 34m

    NWTC Blade Test Facility modified to test blades up to 50m

    .1 MW

    .5 MW

    .75 MW

    3.6 MW

    5 MW

    1.5 MW

    7 MW Clipper Offshore)

    Blade Length (m)

    Sheet1

    Onshore Blade LengthOnshore Rating (MW)Offshore Blade LengthOffshore Rating (MW)Onshore & Offshore Blade LengthsBlade Test FacilitiesLM

    198990.190.1198814.5

    199319251

    1996190.5190.534IUF199821

    1999240.75240.75200233

    2002371.5371.5200462.5

    2004452.5513.6512.5

    200550IUF

    2006625625

    PROJECTIONS

    402.1151431027

    503.3049110979

    604.759071981

    706.4776257519

    808.4605724106

    9010.7079119572

    10013.2196443916

    Sheet1

    NWTC IUF Blade Test Facility built for blades up to 34m

    NWTC Blade Test Facility modified to test blades up to 50m

    .1 MW

    .5 MW

    .75 MW

    3.6 MW

    5 MW

    1.5 MW

    7 MW Clipper Offshore)

    Blade Length (m)

    Sheet2

    NWTC IUF Blade Test Facility built for blades up to 34m

    NWTC Blade Test Facility modified to test blades up to 50m

    .1 MW

    .5 MW

    .75 MW MW

    3.6 MW

    5 MW

    1.5 MW

    Blade Length (m)

    Sheet3

  • Development of Test EquipmentProcuring a state of the art hydraulic based static test system from MTSWorking with MTS to scale up NREL UREX Fatigue Test SystemDesigning and procuring a new generation of the NREL data acquisition hardwareDeveloping a new version of data acquisition software

    Schematic of MTS Static Test SystemCourtesy of MTS websiteTechnical ApproachSlide courtesy of Jason Cotrell of NREL

  • Picture courtesy of MTS and NRELStatic and Fatigue TestingLatest hydraulic actuators/winches will allow matching various specified bending moment distributions.

    Dual-axis resonant test system (NREL patent pending)

  • THANK YOU

    *****