EWEC 2010 - Warsaw

1. ECO100 prototype - extreme wind turbine measurements and development of a hybrid strength assessment EWEC 2010 - Warsaw Albert Fisas, Carles Gayán, Manel Martín Warsaw, 23 April 2010

2. Contents Hybrid structural assessment Fatigue assessment Ultimate loads assessment Dynamic assessment Conclusions ECO100 prototype - extreme wind turbine measurements and development of a hybrid strength assessment 23.April.2010 2

3. Conceptual model ECO YYY Conceptual model ECO ZZZ Virtual Prototype release Physical Prototype release Tests improvements Tests improvements Quantitative comparison and validation Simulation improvements Simulation improvements Experimental database Experimental database Design and methodology guidelines Design and methodology guidelines Hybrid structural assessment SIMULATIONS Simulation Model Simulation Model Simulation outcomes Simulation Model Simulation Results Simulation Results Tests design Tests design Experimental outcomes Tests design Experimental data Experimental data ECO100 prototype - extreme wind turbine measurements and development of a hybrid strength assessment 23.April.2010 MEASUREMENTS 3

4. Hybrid structural assessment Hybrid approach advantages: • Reduction of development lead times. • Improving simulation methodology. • Minimizing inherent uncertainties. • Improving the experimental strategy. • Improving the understanding of experimental results. • Assessment of design variants with validated models. • Taking into account process disturbances. • Encouraging interdisciplinary work. • Increase the experimental database. Benefits of the hybrid structural assessment ECO100 prototype - extreme wind turbine measurements and development of a hybrid strength assessment 23.April.2010 4

5. Fatigue assessment ECO100 prototype - extreme wind turbine measurements and development of a hybrid strength assessment 23.April.2010 5

6. Fatigue assessment ECO100 prototype - extreme wind turbine measurements and development of a hybrid strength assessment 23.April.2010 6

7. Fatigue assessment Structural analysis points (strain gages) Concrete-steel Transition: 20 measurement points (concrete and reinforcement) Blades: Moments Gearbox support: 4 measurement points Front and Central frame: 9 measurement points Low speed shaft: Mx HF Hub: 5 measurement points Rear mainframe: 11 measurement points Yaw crown adapter: 3 measurement points Front frame: My Mz HF Tower: Moments TT,TB Elastic coupling: 2 measurement points 159 measurement channels on the prototype ECO100 prototype - extreme wind turbine measurements and development of a hybrid strength assessment 23.April.2010 7

8. Fatigue assessment Validation test: Blade assembly Each step of the assembly is recorded and correlated with FEM First validation of models/measuremets with quasistatic tests ECO100 prototype - extreme wind turbine measurements and development of a hybrid strength assessment 23.April.2010 8

9. Connection zone 10m-concrete tower Foundation Fatigue assessment Validation test: Steel-Concrete Tower Connection • Instrumentation of connection zone: perfobond connectors, concrete at the 10m-tower and reinforcement steel bars. • Correlation of measurements during full power operation regime of the Wind Turbine. • Strain compatibility between the embedded steel section and concrete. Good accuracy of results. Steel bars and concrete Strain gages Perfobond connectors Concrete-steel tower connection (Patent protected) First validation of models/measurements with quasistatic tests ECO100 prototype - extreme wind turbine measurements and development of a hybrid strength assessment 23.April.2010 9

10. BC5 Idling with a mean WS=36m/s Fatigue assessment Fatigue analysis: consistent relationships between moments and local stress Relationships between loads and stresses are consistent ECO100 prototype - extreme wind turbine measurements and development of a hybrid strength assessment 23.April.2010 10

11. Fatigue analysis: damage, turbulence intensity and wind speed Damage and turbulence Damage and WS (m/s) Damage, WS (m/s) and turbulence Dam Dam Dam WS(m/s) Turbulence Intensity WS(m/s) WS (m/s) and turbulence WS(m/s) WS(m/s) Turbulence Intensity Turbulence Intensity Fatigue assessment Relationship between damage, wind speed and turbulence ECO100 prototype - extreme wind turbine measurements and development of a hybrid strength assessment 23.April.2010 11

12. Fatigue assessment Fatigue analysis: Output file ECO100 prototype - extreme wind turbine measurements and development of a hybrid strength assessment 23.April.2010 12

13. Moderate correlation. Experimental FSFs are slightly higher Fatigue assessment Fatigue analysis: Comparison Moderate correlation. Simulation is slightly conservative. 13

14. Ultimate loads assessment Wind storm: Mean wind speed 36m/s with gusts over 50m/s (Idling): Tower assessment Ultimate moments in tower according simulations ECO100 prototype - extreme wind turbine measurements and development of a hybrid strength assessment 23.April.2010 14

15. Ultimate loads assessment Wind storm: Transition events with 22m/s mean WS: Nacelle and Tower assessment Mx Max. Ppal.Stress (BC4) Ultimate loads in tower and nacelle according simulations 15 ECO100 prototype - extreme wind turbine measurements and development of a hybrid strength assessment 23.April.2010

16. Dynamic assessment Modal analysis correlation and simplification of simulation models FEM (MA) TEST (EMA) Eigenfrequencies of subsystems outside exclusion bands (rotor/tower eigenfrequencies) Validated Simple models allow faster calculation cycles (design optimization) ECO100 prototype - extreme wind turbine measurements and development of a hybrid strength assessment 23.April.2010 16

17. Conclusions • Structural simulations and experimental analysis confirm the structural reliability of the ALSTOM new platform ECO100 prototype. • The hybrid structural assessment integrates the simulation approach and experimentation approach. This method minimizes the limitations and drawbacks of each approach and improves the quality of the analysis and technical decisions. • Hybrid approach needs an interdisciplinary style of work. Training on cross cutting themes and tools are needed. • Validation of structural simulation results is performed via correlation with physical tests. Numerical and experimental uncertainties are analysed in this process. • Hybrid approach reduces uncertainties in subsequent optimization and weight reduction design loops. Next steps: Automated correlation of simulated and experimental power and transition time series. Advanced analysis tools frequency domain. Operational Modal analysis. ECO100 prototype - extreme wind turbine measurements and development of a hybrid strength assessment 23.April.2010 17

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