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Sandy Butterfield 2006 Wind Program Peer Review May 10, 2006

Overview of the Technology & Opportunities. Sandy Butterfield 2006 Wind Program Peer Review May 10, 2006. Outline of Presentation. What have we learned in the past 30 years What’s working What’s not How can we meet DOE COE goals? Gaps. Evolution of Commercial U.S. Wind Technology.

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Sandy Butterfield 2006 Wind Program Peer Review May 10, 2006

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  1. Overview of the Technology & Opportunities Sandy Butterfield 2006 Wind Program Peer Review May 10, 2006

  2. Outline of Presentation • What have we learned in the past 30 years • What’s working • What’s not • How can we meet DOE COE goals? • Gaps

  3. Evolution of Commercial U.S. Wind Technology

  4. What have we learned? • Couldn’t predict fatigue loads • Light weight & flexible didn’t work without good design tools • Heavy didn’t work much better • Machines still failed, especially the gearboxes • Testing was required to understand source of loads • Codes must be tuned with test data • Standards codified design process & experience • Reliability is critical

  5. Reliability starts in the design Full-Scale Testing Reduced Failure Rates Improved O&M Appropriate Environmental Conditions Condition Monitoring High-Reliability Systems Accurate Loads & Design Requirements O&M Data Base System Reliability Analysis Capability Designed-in Maintainability Designed-in Reliability

  6. Iterative analysis/test design process Performed at system level and component level Verification Tests Full system Blade Controller Drive train Simulate Design Detail “Tune” Model Analyze Loads

  7. A Few Words about StandardsStandards remind us of past mistakes Standards Intimately Linked to all Product Development Phases Design and Analysis Phase Test and Verification Phase Type Testing Certification Documentation Power Performance Dynamic Behavior Noise Safety Test Power Quality Maintenance Manual Installation Manual Operating Manual Personal Safety Manufacturing Quality Design Refinements Type Certification Reliability Tests Load Verification Dynamic Behavior Final Design Performance and Prototype Loads Tests Structural Detailed Design Mech. & Electrical Design Certification Loads Test Detailed Design and Analysis Component Qualification Tests Load Case Analysis Control & Protection System Preliminary Design and Analysis Define Certification Requirements Conceptual Design PRODUCT VERIFICATION DESIGN REFINEMENT

  8. NREL/DOE Standards Support • NREL/SNL Participation in most IEC standards committees • Support AWEA standards program • AWEA standards support contract • IEC Technical Advisory Group • AWEA national standards • Small turbine standards • Siting standard • AGMA gearing standard

  9. Need new strategy and design tools to meet DOE Cost goals

  10. Trends • Lifelong O&M (“unscheduled maintenance” becoming critical) • Lighter rotors, higher tip speeds, more flexible blades (lower loads) • Twist/flap coupling • Drivetrain innovation • Controls for load reduction • Offshore design concepts incorporated into onshore turbines (load control, component placement, design for reliability, condition monitoring)

  11. Can rotor improvements help the rest of the system? • WindPact Rotor study shows benefits of: • Controlling tower dynamics • Passive blade load relief through twist/flap coupling • High tip speed/low solidity blades • Need follow up system study • SeaCon Turbine study • Perform system optimization • Apply practical implementation experience

  12. Can we meet the COE goals? Offshore Turbines Path to 3.5 cents/kwh, DOE onshore goal

  13. What will it take? • Design code enhancements • Advanced controls • System and subsystem innovation • Rotor • Blades • Drivetrain • SeaCon system optimization conceptual studies (WindPact) • Testing

  14. Gaps(according to Sandy) • Aeroacoustics (limits high speed flexible rotors & downwind option) • Aerodynamics - More accurate steady & unsteady aero models • Increasing flexibility w/o complexity, cost & failure rates • Accurate prediction of coupled dynamic rotor loads • Greater fidelity between loads codes and component design codes • MIMO Control of turbulent & extreme loads without firm measure of inputs (need robust sensor technology) • More accurate inflow characterization, especially greater than 100m. • Greater drivetrain reliability while reducing cost and weight. • Offshore dynamics codes • Offshore design basis

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