On design,modelling, and analysis of a 10‐MW medium‐speed drivetrain for offshore wind turbines

The design of a medium‐speed drivetrain for the Technical University of Denmark (DTU) 10‐MW reference offshore wind turbine is presented. A four‐point support drivetrain layout that is equipped with a gearbox with two planetary stages and one parallel stage is proposed. Then, the drivetrain components are designed based on design loads and criteria that are recommended in relevant international standards. Finally, an optimized drivetrain model is obtained via an iterative design process that minimizes the weight and volume. A high‐fidelity numerical model is established via the multibody system approach. Then, the developed drivetrain model is compared with the simplified model that was proposed by DTU, and the two models agree well. In addition, a drivetrain resonance evaluation is conducted based on the Campbell diagrams and the modal energy distribution. Detailed parameters for the drivetrain design and dynamic modelling are provided to support the reproduction of the drivetrain model. A decoupled approach, which consists of global aero‐hydro‐servo‐elastic analysis and local drivetrain analysis, is used to determine the drivetrain dynamic response. The 20‐year fatigue damages of gears and bearings are calculated based on the stress or load duration distributions, the Palmgren‐Miner linear accumulative damage hypothesis, and long‐term environmental condition distributions. Then, an inspection priority map is established based on the failure ranking of the drivetrain components, which supports drivetrain inspection and maintenance assessment and further model optimization. The detailed modelling of the baseline drivetrain model provides a basis for benchmark studies and support for future research on multimegawatt offshore wind turbines.     

Condition monitoring of spar‐type floating wind turbine drivetrain using statistical fault diagnosis

Operation and maintenance costs are significant for large‐scale wind turbines and particularly so for offshore. A well‐organized operation and maintenance strategy is vital to ensure the reliability, availability, and cost‐effectiveness of a system. The ability to detect, isolate, estimate, and perform prognoses on component degradation could become essential to reduce unplanned maintenance and downtime. Failures in gearbox components are in focus since they account for a large share of wind turbine downtime. This study considers detection and estimation of wear in the downwind main‐shaft bearing of a 5‐MW spar‐type floating turbine. Using a high‐fidelity gearbox model, we show how the downwind main bearing and nacelle axial accelerations can be used to evaluate the condition of the bearing. The paper shows how relative acceleration can be evaluated using statistical change‐detection methods to perform a reliable estimation of wear of the bearing. It is shown in the paper that the amplitude distribution of the residual accelerations follows a t‐distribution and a change‐detection test is designed for the specific changes we observe when the main bearing becomes worn. The generalized likelihood ratio test is extended to fit the particular distribution encountered in this problem, and closed‐form expressions are derived for shape and scale parameter estimation, which are indicators for wear and extent of wear in the bearing. The results in this paper show how the proposed approach can detect and estimate wear in the bearing according to desired probabilities of detection and false alarm.     

Evaluation of PMSG‐based drivetrain technologies for 10‐MW floating offshore wind turbines: Pros and cons in a life cycle perspective

This paper presents an in depth evaluation and comparison of three different drivetrain choices based on permanent‐magnet synchronous generator (PMSG) technology for 10‐MW offshore wind turbines. The life cycle approach is suggested to evaluate the performance of the different under consideration drivetrain topologies. Furthermore, the design of the drivetrain is studied through optimized designs for the generator and gearbox. The proposed drivetrain analytical optimization approach supported by numerical simulations shows that application of gearbox in 10‐MW offshore wind turbines can help to reduce weight, raw material cost, and size and simultaneously improve the efficiency. The possibility of resonance with the first torsional natural frequency of drivetrain for the different designed drivetrain systems, the influence of gear ratio, and the feasibility of the application for a spar floating platform are also discussed. This study gives evidence on how gearbox can mitigate the torque oscillation consequences on the other components and how the latter can influence the reliability of drivetrain.     

Availability,operation and maintenance costs of offshore wind turbines with different drive train configurations

Different configurations of gearbox, generator and power converter exist for offshore wind turbines. This paper investigated the performance of four prominent drive train configurations over a range of sites distinguished by their distance to shore. Failure rate data from onshore and offshore wind turbine populations was used where available or systematically estimated where no data was available. This was inputted along with repair resource requirements to an offshore accessibility and operation and maintenance model to calculate availability and operation and maintenance costs for a baseline wind farm consisting of 100 turbines. The results predicted that turbines with a permanent magnet generator and a fully rated power converter will have a higher availability and lower operation and maintenance costs than turbines with doubly fed induction generators. This held true for all sites in this analysis. It was also predicted that in turbines with a permanent magnet generator, the direct drive configuration has the highest availability and lowest operation and maintenance costs followed by the turbines with two‐stage and three‐stage gearboxes. Copyright © 2016 John Wiley & Sons, Ltd.     

Bearing monitoring in the wind turbine drivetrain: A comparative study of the FFT and wavelet transforms

Wind turbines are often plagued by premature component failures, with drivetrain bearings being particularly subjected to these failures. To identify failing components, vibration condition monitoring has emerged and grown substantially. The fast Fourier transform (FFT) is the major signal processing method of vibrations. Recently, the wavelet transforms have been used more frequently in bearing vibration research, with one alternative being the discrete wavelet transform (DWT). Here, the low‐frequency component of the signal is repeatedly decomposed into approximative and detailed coefficients using a predefined mother wavelet. An extension to this is the wavelet packet transform (WPT), which decomposes the entire frequency domain and stores the wavelet coefficients in packets. How wavelet transforms and FFT compare regarding fault detection in wind turbine drivetrain bearings has been largely overlooked in literature when applied on field data, with non‐ideal placement of sensors and uncertain parameters influencing the measurements. This study consists of a comprehensive comparison of the FFT, a three‐level DWT, and the WPT when applied on enveloped vibration measurements from two 2.5‐MW wind turbine gearbox bearing failures. The frequency content is compared by calculating a robust condition indicator by summation of the harmonics and shaft speed sidebands of the bearing fault frequencies. Results show a higher performance of the WPT when used as a field vibration measurement analysis tool compared with the FFT as it detects one bearing failure earlier and more clearly, leading to a more stable alarm setting and avoidable, costly false alarms.     

Numerical study of a concept for major repair and replacement of offshore wind turbine blades

Repair and replacement of offshore wind turbine blades are necessary for current and future offshore wind turbines. To date, repair activities are often conducted using huge jack‐up crane vessels and by applying a reverse installation procedure. Because of the high costs associated with installation and removal of offshore wind turbine components and the low profit margin of the offshore wind industry, alternative methods for installation and removal are needed. This paper introduces a novel concept for replacement or installation of offshore wind turbine blades. The concept involves a medium‐sized jack‐up crane vessel and a tower climbing mechanism. This mechanism provides a stable platform for clamping, lowering, and lifting of a blade. A case study of a 5‐MW offshore wind turbine is shown, where common engineering practices were applied and numerical simulations of the marine operations were carried out using finite element and multibody simulation tools. Operational limits for wave and wind actions were established to demonstrate the technical feasibility of the proposed concept.     

Effect of platform disturbance on the performance of offshore wind turbine under pitch control

The aerodynamic performance of offshore floating wind turbines (OFWTs) is more complicated than onshore wind turbines due to 6‐degree of freedom (DOF) motion of the floating platform. In the current study, the aerodynamic analysis of a horizontal‐axis floating offshore wind turbine is performed with the aim of studying the effects of floating platform movement on the aerodynamic characteristics of the turbine in the presence of a pitch angle control system. The National Renewable Energy Laboratory (NREL) 5‐MW offshore wind turbine is selected as the baseline wind turbine. For this sake, the unsteady blade element momentum method with dynamic stall and dynamic inflow models have been employed to obtain the unsteady aerodynamic loads. The baseline pitch angle control system is assumed to be coupled with the aerodynamic model to maintain the rated condition of the wind turbine and also to approach a closer model of wind turbine. In case of pitching motion input, the reduction of mean power coefficient for tip speed ratios (TSRs) less that 7 is expected by an amount of 16% to 20% at pitch amplitude of 2° and frequency of 0.1 Hz. For high TSRs, the trend is reverse with respect to fixed‐platform case. The mean thrust coefficient is reduced for almost all range of TSRs with maximum loss of 37%. Moreover, the mean control pitch angle that is an index of control system effort is increased. The results also represent the importance of considering the pitch control system for aerodynamic analysis of disturbed OFWT.     

Multidisciplinary design optimization of offshore wind turbines for minimum levelized cost of energy

This paper presents a method for multidisciplinary design optimization of offshore wind turbines at system level. The formulation and implementation that enable the integrated aerodynamic and structural design of the rotor and tower simultaneously are detailed. The objective function to be minimized is the levelized cost of energy. The model includes various design constraints: stresses, deflections, modal frequencies and fatigue limits along different stations of the blade and tower. The rotor design variables are: chord and twist distribution, blade length, rated rotational speed and structural thicknesses along the span. The tower design variables are: tower thickness and diameter distribution, as well as the tower height. For the other wind turbine components, a representative mass model is used to include their dynamic interactions in the system. To calculate the system costs, representative cost models of a wind turbine located in an offshore wind farm are used. To show the potential of the method and to verify its usefulness, the 5 MW NREL wind turbine is used as a case study. The result of the design optimization process shows 2.3% decrease in the levelized cost of energy for a representative Dutch site, while satisfying all the design constraints.     

Experimental identification of modal parameters of an industrial 2‐MW wind turbine

This contribution presents modal testing of a 2‐MW wind turbine on a 100‐m tubular tower with a 93‐m rotor developed by W2E Wind to Energy GmbH. This research is part of the DYNAWIND project of the University of Rostock and W2E. Beside classical modal analysis schemes, this contribution mainly focusses on the application of operational modal analysis techniques to a wind turbine. Specific problems are addressed, and hints for modal testing on wind turbines are given. Furthermore, an effective measurement setup is proposed for identification of the modal parameters of a wind turbine. The measurement campaign is divided in two parts. First, a measurement campaign using 8 sensor positions on a rotor blade was done while the rotor is lying on ground. Second, a detailed measurement campaign was done on the entire wind turbine with the rotor locked in Y position using 61 sensor positions on the tower, the mainframe, the gearbox, the generator, and the low‐voltage unit. While the rotor blade was tested by classical and operational modal analysis techniques, the entire wind turbine was tested by operational modal analysis techniques only. The mode shapes and eigenfrequencies of the wind turbine identified within the measurement campaigns are within the expected range of the design values of the wind turbine. But in contrast, the damping ratios differ strongly from those given in guidelines and literature. Furthermore, a strong influence of aerodynamic damping compared to structural damping is observed for the first tower mode even for a parked wind turbine.     

Valuing the manufacturing externalities of wind energy: assessing the environmental profit and loss of wind turbines in Northern Europe

This study draws from a concept from green accounting, lifecycle assessment, and industrial ecology known as 'environmental profit and loss” (EP&L) to determine the extent of externalities across the manufacturing lifecycle of wind energy. So far, no EP&Ls have involved energy companies and none have involved wind energy or wind turbines. We perform an EP&L for three types of wind turbines sited and built in Northern Europe (Denmark and Norway) by a major manufacturer: a 3.2 MW onshore turbine with a mixed concrete steel foundation, a 3.0 MW offshore turbine with a steel foundation, and a 3.0 MW offshore turbine with a concrete foundation. For each of these three turbine types, we identify and monetize externalities related to carbon dioxide emissions, air pollution, and waste. We find that total environmental losses range from €1.1 million for the offshore turbine with concrete foundation to €740,000 for onshore turbines and about €500,000 for an offshore turbine with steel foundation—equivalent to almost one‐fifth of construction cost in some instances. We conclude that carbon dioxide emissions dominate the amount of environmental damages and that turbines need to work for 2.5 to 5.5 years to payback their carbon debts. Even though turbines are installed in Europe, China and South Korea accounted for about 80% of damages across each type of turbine. Lastly, two components, foundations and towers, account for about 90% of all damages. We conclude with six implications for wind energy analysts, suppliers, manufacturers, and planners. Copyright © 2015 John Wiley & Sons, Ltd.     

The dynamics of an offshore wind turbine in parked conditions: a comparison between simulations and measurements

Offshore wind turbines are complex structures, and their dynamics can vary significantly because of changes in operating conditions, e.g., rotor‐speed, pitch angle or changes in the ambient conditions, e.g., wind speed, wave height or wave period. Especially in parked conditions, with reduced aerodynamic damping forces, the response due to wave actions with wave frequencies close to the first structural resonance frequencies can be high. Therefore, this paper will present numerical simulations using the HAWC2 code to study an offshore wind turbine in parked conditions. The model has been created according to best practice and current standards based on the design of an existing Vestas V90 offshore wind turbine on a monopile foundation in the Belgian North Sea. The damping value of the model's first fore‐aft mode has been tuned on the basis of measurements obtained from a long‐term ambient monitoring campaign on the same wind turbine. Using the updated model of the offshore wind turbine, the paper will present some of the effects of the different design parameters and the different ambient conditions on the dynamics of an offshore wind turbine. The results from the simulations will be compared with the processed data obtained from the real measurements. The accuracy of the model will be discussed in terms of resonance frequencies, mode shapes, damping value and acceleration levels, and the limitations of the simulations in modeling of an offshore wind turbine will be addressed. Copyright © 2014 John Wiley & Sons, Ltd.     

Aerodynamic simulations of offshore floating wind turbine in platform‐induced pitching motion

Forfloating offshore wind turbines, rotors are under coupled motions of rotating and platform‐induced motions because of hydrodynamics impacts. Notably, the coupled motion of platform pitching and rotor rotating induces unsteadiness and nonlinear aerodynamics in turbine operations; thus having a strong effect on the rotor performances including thrust and power generation. The present work aims at developing a computational fluid dynamics model for simulations of rotor under floating platform induced motions. The rotor motion is realized using arbitrary mesh interface, and wind flows are modelled by incompressible Navier‐Stokes flow solver appended by the k  ? ω shear stress transport turbulence model to resolve turbulence quantities. In order to investigate the fully coupled motion of floating wind turbine, the six degree of freedom solid body motion solver is extended to couple with multiple motions, especially for the motion of rotor coupled with the prescribed surge‐heave‐pitch motion of floating platform. The detailed methodology of multiple motion coupling is also described and discussed in this work. Both steady and unsteady simulations of offshore floating wind turbine are considered in the present work. The steady aerodynamic simulation of offshore floating wind turbine is implemented by the multiple reference frames approach and for the transient simulation, the rotor motion is realized using arbitrary mesh interface. A rigorous benchmark of the present numerical model is performed by comparing to the reported literatures. The detailed elemental thrust and power comparisons of wind turbine are carried out by comparing with the results from FAST developed by National Renewable Energy Laboratory and various existing numerical data with good agreement. The proposed approach is then applied for simulations of National Renewable Energy Laboratory 5MW turbine in coupled platform motion at various wind speeds under a typical load case scenario. Transient effect of flows over turbines rotor is captured with good prediction of turbine performance as compared with existing data from FAST. Copyright © 2016 John Wiley & Sons, Ltd.     

Review on wind turbines with focus on drive train system dynamics

The strong growth within the wind technology market, underpinned by policy goals around the world, has highlighted the demand for advanced engineering analysis to improve wind turbine (WT) design, both in terms of reliability and design of larger turbines. This paper presents a review of the latest research that has been carried out in modeling and analysis of load transmission in WT drive train systems and their components. Common failure roots are elaborated, and probable hypotheses are presented. A modeling approach is derived by classification into engineering, mathematical and computational models with a focus on gearbox modeling efforts. Precise understanding of drive train system dynamics and load transmission is necessary for a cost efficient and robust system design to enhance reliability and reduce the maintenance costs. Design optimization of WTs and their subsystems will make future WTs more attractive compared with fossil and nuclear power plants, and it is therefore an important issue for a more sustainable environment. Copyright © 2014 John Wiley & Sons, Ltd.     

Aeroelastic analysis of a floating offshore wind turbine in platform‐induced surge motion using a fully coupled CFD‐MBD method

Modern offshore wind turbines are susceptible to blade deformation because of their increased size and the recent trend of installing these turbines on floating platforms in deep sea. In this paper, an aeroelastic analysis tool for floating offshore wind turbines is presented by coupling a high‐fidelity computational fluid dynamics (CFD) solver with a general purpose multibody dynamics code, which is capable of modelling flexible bodies based on the nonlinear beam theory. With the tool developed, we demonstrated its applications to the NREL 5 MW offshore wind turbine with aeroelastic blades. The impacts of blade flexibility and platform‐induced surge motion on wind turbine aerodynamics and structural responses are studied and illustrated by the CFD results of the flow field, force, and wake structure. Results are compared with data obtained from the engineering tool FAST v8.     

Failure rate,repair time and unscheduled O&M cost analysis of offshore wind turbines

Determining and understanding offshore wind turbine failure rates and resource requirement for repair are vital for modelling and reducing O&M costs and in turn reducing the cost of energy. While few offshore failure rates have been published in the past even less details on resource requirement for repair exist in the public domain. Based on ~350 offshore wind turbines throughout Europe this paper provides failure rates for the overall wind turbine and its sub‐assemblies. It also provides failure rates by year of operation, cost category and failure modes for the components/sub‐assemblies that are the highest contributor to the overall failure rate. Repair times, average repair costs and average number of technicians required for repair are also detailed in this paper. An onshore to offshore failure rate comparison is carried out for generators and converters based on this analysis and an analysis carried out in a past publication. The results of this paper will contribute to offshore wind O&M cost and resource modelling and aid in better decision making for O&M planners and managers. Copyright © 2015 John Wiley & Sons, Ltd.     

Aeroservoelastic design definition of a 20 MW common research wind turbine model

Wind turbine upscaling is motivated by the fact that larger machines can achieve lower levelized cost of energy. However, there are several fundamental issues with the design of such turbines, and there is little public data available for large wind turbine studies. To address this need, we develop a 20 MW common research wind turbine design that is available to the public. Multidisciplinary design optimization is used to define the aeroservoelastic design of the rotor and tower subject to the following constraints: blade‐tower clearance, structural stresses, modal frequencies, tip‐speed and fatigue damage at several sections of the tower and blade. For the blade, the design variables include blade length, twist and chord distribution, structural thicknesses distribution and rotor speed at the rated. The tower design variables are the height, and the diameter distribution in the vertical direction. For the other components, mass models are employed to capture their dynamic interactions. The associated cost of these components is obtained by using cost models. The design objective is to minimize the levelized cost of energy. The results of this research show the feasibility of a 20 MW wind turbine and provide a model with the corresponding data for wind energy researchers to use in the investigation of different aspects of wind turbine design and upscaling. Copyright © 2016 John Wiley & Sons, Ltd.     

Evaluation of different wind fields for the investigation of the dynamic response of offshore wind turbines

As the size of offshore wind turbines increases, a realistic representation of the spatiotemporal distribution of the incident wind field becomes crucial for modeling the dynamic response of the turbine. The International Electrotechnical Commission (IEC) standard for wind turbine design recommends two turbulence models for simulations of the incident wind field, the Mann spectral tensor model, and the Kaimal spectral and exponential coherence model. In particular, for floating wind turbines, these standard models are challenged by more sophisticated ones. The characteristics of the wind field depend on the stability conditions of the atmosphere, which neither of the standard turbulence models account for. The spatial and temporal distribution of the turbulence, represented by coherence, is not modeled consistently by the two standard models. In this study, the Mann spectral tensor model and the Kaimal spectral and exponential coherence model are compared with wind fields constructed from offshore measurements and obtained from large‐eddy simulations. Cross sections and durations relevant for offshore wind turbine design are considered. Coherent structures from the different simulators are studied across various stability conditions and wind speeds through coherence and proper orthogonal decomposition mode plots. As expected, the standard models represent neutral stratification better than they do stable and unstable. Depending upon the method used for generating the wind field, significant differences in the spatial and temporal distribution of coherence are found. Consequently, the computed structural design loads on a wind turbine are expected to vary significantly depending upon the employed turbulence model. The knowledge gained in this study will be used in future studies to quantify the effect of various turbulence models on the dynamic response of large offshore wind turbines.     

Identification of loading conditions resulting in roller slippage in gearbox bearings of large wind turbines

The dynamic loads on the rollers inside the bearings of large wind turbine gearboxes operating under transient conditions are presented with a focus on identifying conditions leading to slippage of rollers. The methodology was developed using a multi‐body model of the drivetrain coupled with aeroelastic simulations of the wind turbine system. A 5 MW reference wind turbine is considered for which a three‐stage planetary gearbox is designed on the basis of upscaling of an actual 750 kW gearbox unit. Multi‐body dynamic simulations are run using the ADAMS software using a detailed model of the gearbox planetary bearings to investigate transient loads inside the planet bearing. It was found that assembly and pre‐loading conditions have significant influence on the bearing's operation. Also, the load distribution in the gearbox bearings strongly depends on wind turbine operation. Wind turbine start‐up and shut‐down under normal conditions are shown to induce roller slippage, as characterized by loss of contacts and impacts between rollers and raceways. The roller impacts occur under reduced initial pre‐load on opposite sides of the load zone followed by stress variation, which can be one of the potential reasons leading to wear and premature bearing failures. Copyright © 2017 John Wiley & Sons, Ltd.     

风力机大型化发展中的总体设计技术

简单介绍当前风能利用的发展,分析风电技术发展的趋势和主要特点;主要讨论风机大型化、柔性化等趋势引起的大型风机总体设计所面临的主要问题,总体设计技术是涉及气动、气动弹性、结构设计等多个学科、多方面的综合性问题,直接决定着大型柔性风机的性能、可靠性和寿命。本文主要分析了攻克总体设计难题所必需优先解决的风力机气动弹性载荷计算、气动弹性稳定性等问题。同时简要阐述了发展海上风机需要优先解决的相关技术问题,指出海上大型风力机分析首先需要着重考虑风—波联合作用下的机组气弹分析问题和考虑到近海风力机桩基特性的波浪载荷问题。     

Improving wind turbine drivetrain bearing reliability through pre‐misalignment

Improving the reliability of wind turbines (WT) is an essential component in the bid to minimize the cost of energy, especially for offshore wind because of the difficulties associated with access for maintenance. Numerous studies have shown that WT gearbox and generator failure rates are unacceptably high, particularly given the long downtime incurred per failure. There is evidence that bearing failures of the gearbox high‐speed stage (HSS) and generator account for a significant proportion of these failures. However, the root causes of these failure data are not known, and there is therefore a need for fundamental computational studies to support the valuable ‘top down’ reliability analyses. In this paper, a real (proprietary) 2 MW geared WT was modelled to compute the gearbox–generator misalignment and predict the impact of this misalignment upon the gearbox HSS and generator bearings. At rated torque, misalignment between the gearbox and generator of 8500 µm was seen. For the 2 MW WT analysed, the computational data show that the L₁₀ fatigue lives of the gearbox HSS bearings were not significantly affected by this misalignment but that the L₁₀ fatigue lives of the generator bearings, particularly the drive‐end bearing, could be significantly reduced. It is proposed to apply a nominal offset to the generator to reduce the misalignment under operation, thereby reducing the loading on the gearbox HSS and generator bearings. The value of performing integrated system analyses has been demonstrated, and a robust methodology has been outlined. Copyright © 2013 John Wiley & Sons, Ltd.