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CHAPTER 6 Design and Development of Megawatt Wind Turbines CHAPTER 6 Design and development of megawatt wind turbines Lawrence D. Willey General Electric Energy Wind, USA. Electric power generation is the single most important factor in the prosperity of modern man. Yet, increasing concerns over carbon emissions from burning fossil fuels have brought large-scale renewable energy technologies to the forefront of technological development. Framework for the successful design and develop- ment of large wind turbines (WTs) addresses the world’s power generation needs. The motivation for this work, the broad framework for success, the best approach for product design, various techniques and special considerations, and develop- ment aspects are presented. Horizontal axis WTs operating inland or in near-shore applications are specifi cally addressed. 1 Introduction Supplies of fossil fuels are inadequate to meet the growing need for more power generation, which is driven by increasing demand for electricity [ 1, 2 ]. The hori- zontal axis wind turbine (HAWT) is one of the most economical forms of modern power generation. HAWTs have numerous benefi ts: they conserve dwindling fos- sil fuel resources, reduce harmful emissions, and support a sustainable electric energy infrastructure for posterity. Large wind turbines (WTs) are an engineering challenge; they must endure some of the largest numbers of fatigue cycles for structures while meeting size and cost constraints [49]. New WTs must maximize reliability, availability, maintenance, and serviceability (RAMS) while having the lowest cost of energy (CoE) and highest net present value (NPV) for a customer and an original equipment manufacturer (OEM) [50]. One of the biggest motiva- tions for accelerating technological development of WTs is in support for the U.S. 20% wind energy by 2030 initiative [ 3 ]. WIT Transactions on State of the Art in Science and Engineering, Vol 44, © 2010 WIT Press www.witpress.com, ISSN 1755-8336 (on-line) doi:10.2495/978-1-84564-205-1/06 188 Wind Power Generation and Wind Turbine Design 1.1 All new turbine design What design decisions will make a new multi-megawatt (MMW) WT successful in today’s power generation market? How big should it be? What are the governing parameters that drive its design and ensure that it operates without failure and for the budgeted cost? These are just a few of the many questions at the beginning of any new turbine design [54]. Providing the lowest CoE in the power generation market is a challenge to the WT industry, but ever-improving designs are meeting the challenge. MMW turbines often operate for over 20 years and are among some of the largest manmade structures, especially from the perspective of controllable moving parts. An all-new MW WT begins with conceptual design and follows a rigorous technology building block and toll gate approach for component and sys- tems development, and then undergoes a validation process involving prototypes and pre-series projects prior to entering full production. Value analysis or value engineering drives this process [4 − 6], where cost and fi nancial return are continually assessed to ensure success for the customer and the OEM. 1.1.1 Technology readiness levels (TRLs) MW WT technology is advancing quickly, and concepts need to be character- ized in a way that enables everyone to immediately understand the maturity of a particular technology. The TRL system (used by NASA and U.S. Government agencies) provides a common basis for assessing new concepts [ 7 ]. • TRL-1: Basic principles observed and reported • TRL-2: Technology concept and/or application formulated • TRL-3: Analytical and experimental critical function and/or characteristic proof of concept • TRL-4: Component and/or breadboard validation in laboratory environment • TRL-5: Component and/or breadboard validation in relevant environment • TRL-6: System/sub-system model or prototype demonstration in a relevant environment (ground or space) • TRL-7: System prototype demonstration in a space environment • TRL-8: Actual system completed and “fl ight qualifi ed” through test and demonstration (ground or space) • TRL-9: Actual system “fl ight proven” through successful mission operations (space) 1.1.2 Technology proofs required (TRL-1, 2, 3, 4 and 5) − early phase New turbine development cannot be undertaken effectively using unproven com- ponent technologies. The best development strategy for new technologies involves devoted internal research and development (IRD) programs. To mitigate risk, these programs should be completed before embarking on a new product introduction. New products released before proper validation and refi nement may result in the OEM having to mitigate problems later in the fi eld, which can cost the OEM a factor WIT Transactions on State of the Art in Science and Engineering, Vol 44, © 2010 WIT Press www.witpress.com, ISSN 1755-8336 (on-line) Design and Development of Megawatt Wind Turbines 189 of 10 or more relative to doing it correctly up front. A roadmap of technologies and products relative to the marketplace and other manufacturers helps keep upfront costs down and minimizes overall development cycles. Organizations need not necessarily have their own IRD departments. There are examples of broad-based collaborative research programs among industry, university and government par- ticipants. Value analysis is critically important in understanding research priorities and where to apply funding. Regular re-evaluation is required to ensure market changes are refl ected in re-direction or termination of programs. 1.1.3 Technologies in-hand (TRL-6, 7, 8 and 9) − late phase Having a broad range of component technologies from wind or other sectors (that are well understood and scalable) is an important aspect of new WT design. Even with this, system integration readiness should not be underestimated. During the product development cycle, early assumptions about the suitability of a component technology may come under question, and new validation steps or even the invention of new component technology may become necessary. Again, continuous and ever- improving value analysis is the key activity for assessing technologies in-hand and identifying new development opportunities. Carrying the value analysis cycles throughout the development phases will help identify where additional technology proofs are needed and will ultimately yield the very best product. 1.2 Incremental improvements to existing turbine designs Once a product is introduced, later market entrants force competition and cause a need for the original product to improve. Incremental product improvements can be more tractable for some risk adverse organizations from the perspectives of quick return on investment (ROI) funding allocation and minimizing investment. There comes a point in every WT design when up-scaling component technol- ogy, improving performance or further cost reduction are not possible, and a new breakthrough design is required to begin the cycle anew [46]. Continual value analysis provides the foresight needed to know which route to take and when, and it helps build a comprehensive multi-generation technology plan (MGTP) that is regularly reviewed and updated. 1.3 The state of technology and the industry Thirty-fi ve years into the modern WT era, less than half of this experience is in today’s large utility scale machines. More than 27 GW of new wind capacity was commissioned worldwide in 2008, a 36% increase over 2007. By the end of 2008, global wind capacity grew nearly 29% reaching 121 −123.5 GW with turbine and wind power plant (WPP) investments worth about US$47.5B (€36.5B) [ 8 , 9 ]. The state of WT design today is similar to the state of automobile design in the 1920s and 1930s. Even the most advanced WTs are relatively immature when consid- ering future advances for component integration, dry nanotechnology, quantum wires and advanced digital controls [ 1 ]. There are many choices to be made today, WIT Transactions on State of the Art in Science and Engineering, Vol 44, © 2010 WIT Press www.witpress.com, ISSN 1755-8336 (on-line) 190 Wind Power Generation and Wind Turbine Design Figure 1: Megawatt-size WTs are large structures. and with tighter R&D budgets and a shortage of qualifi ed wind engineers and specialists in the industry, there is great opportunity for those who recognize this view of the future today. The need for more electrical energy is driving installa- tion of more wind energy. Rapidly increasing numbers of government, university and industry collaborations are becoming involved with wind energy. All of these groups are quickly recognizing the importance of value analysis to set R&D priorities and guide innovation [55]. 2 Motivation for developing megawatt-size WTs Modern WTs have become very large structures that push the limits for structural engineering and require the use of lightweight, low-cost materials ( Fig. 1 ) [52]. From fi rst principles, the net power rating and size of a turbine grows with swept area; i.e. rotor diameter raised to the second power. At the same time, the amount of material (i.e. mass or cost) increases as the cube of the diameter. This is known as the square-cube law [10 ]. Aside from improving energy capture by accessing stronger winds at higher hub heights (HHs), the original motivation for going larger in power rating and rotor size was to lower the CoE through econo- mies of scale. Today’s most common turbine size is within the 2 − 3 MW rating, and perhaps as high as 4 −5 MW for some of the newest designs. Larger machines beyond 5 MW should become economically viable with further advances in material and design technology, but a sudden change is unlikely over the next 5-year period. To better understand where the large WT market is today in terms of size, an “industry study set” of key design parameters for more than 150 utility scale tur- bines is used to characterize trends and provide a basis for setting targets for new WT designs [ 11].
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