Publications

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Wind energy is quickly becoming a significant contributor to the United States' overall energy portfolio. Wind turbine blades pose a unique set of inspection challenges that span from very thick and attenuative spar cap structures to porous bond lines, varying core material and a multitude of manufacturing defects of interest. The need for viable, accurate nondestructive inspection (NDI) technology becomes more important as the cost per blade, and lost revenue from downtime, grows. To address this growing need, Sandia and SkySpecs collaborated to evaluate NDI methods that are suitable for integration on an autonomous drone inspection platform. A trade study of these NDI methods was performed, and thermography was selected as the primary technique for further evaluation. Based on the capabilities of SkySpecs' custom inspection drone, a miniature microbolometer IR camera was successfully selected and tested in a benchtop setting. After identifying key operating parameters for inspecting wind blade materials, hardware and software integration of the IR camera was performed, and Sandia and SkySpecs conducted initial field testing. Finally, recommendations for a path forward for drone-deployed thermography inspections were provided.

This paper discusses the broad use of rotational kinetic energy stored in wind turbine rotors to supply services to the electrical power grid. The grid services are discussed in terms of zero-net-energy, which do not require a reduction in power output via pitch control (spill), but neither do they preclude doing so. The services discussed include zero-net-energy regulation, transient and small signal stability, and other frequency management services. The delivery of this energy requires a trade-off between the frequency and amplitude of power modulation and is limited, in some cases, by equipment ratings and the unresearched long-term mechanical effects on the turbine. As wind displaces synchronous generation, the grid's inertial storage is being reduced, but the amount of accessible kinetic energy in a wind turbine at rated speed is approximately 6 times greater than that of a generator with only a 0.12% loss in efficiency and 75 times greater at 10% loss. The potential flexibility of the wind's kinetic storage is also high. However, the true cost of providing grid services using wind turbines, which includes a potential increase in operations and maintenance costs, have not been compared to the value of the services themselves.

This paper describes the process of transforming measured blade loads, with force estimation, to wind turbine quantities of interest. Uncertainty quantification on the blade load measurement and force estimation is derived and used to estimate uncertainty on aerodynamic torque and rotor thrust for sample cases. A methodology is defined for calculating mean values and quantifying the uncertainty in these important quantities of interest for wind turbines when your available data includes only blade root moment measurements. This paper is not intended to provide precise values for these uncertainties at the current stage, however, sample measurement uncertainties are defined and used along with representative mean values to identify the sensitivity of uncertainty in torque and thrust to the constituent variables and associated uncertainties. The largest contributors of the uncertainty when using blade strain gage measurements to estimate rotor loads is identified for the sample cases revealing the components that have the largest effect on the resulting quantity of interest’s uncertainty, and those which have negligible effect on the uncertainty.

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Wind turbine blades pose a unique set of inspection challenges that span from very thick and attentive spar cap structures to porous bond lines, varying core material and a multitude of manufacturing defects of interest. The need for viable, accurate nondestructive inspection (NDI) technology becomes more important as the cost per blade, and lost revenue from downtime, grows. NDI methods must not only be able to contend with the challenges associated with inspecting extremely thick composite laminates and subsurface bond lines, but must also address new inspection requirements stemming from the growing understanding of blade structural aging phenomena. Under its Blade Reliability Collaborative program, Sandia Labs quantitatively assessed the performance of a wide range of NDI methods that are candidates for wind blade inspections. Custom wind turbine blade test specimens, containing engineered defects, were used to determine critical aspects of NDI performance including sensitivity, accuracy, repeatability, speed of inspection coverage, and ease of equipment deployment. The detection of fabrication defects helps enhance plant reliability and increase blade life while improved inspection of operating blades can result in efficient blade maintenance, facilitate repairs before critical damage levels are reached and minimize turbine downtime. The Sandia Wind Blade Flaw Detection Experiment was completed to evaluate different NDI methods that have demonstrated promise for interrogating wind blades for manufacturing flaws or in-service damage. These tests provided the Probability of Detection information needed to generate industry-wide performance curves that quantify: 1) how well current inspection techniques are able to reliably find flaws in wind turbine blades (industry baseline) and 2) the degree of improvements possible through integrating more advanced NDI techniques and procedures. _____________ S a n d i a N a t i o n a l L a b o r a t o r i e s i s a m u l t i m i s s i o n l a b o r a t o r y m a n a g e d a n d o p e r a t e d b y N a t i o n a l T e c h n o l o g y a n d E n g i n e e r i n g S o l u t i o n s o f S a n d i a , L L C , a w h o l l y o w n e d s u b s i d i a r y o f H o n e y w e l l I n t e r n a t i o n a l , I n c . , f o r t h e U . S . D e p a r t m e n t o f E n e r g y ' s N a t i o n a l N u c l e a r S e c u r i t y A d m i n i s t r a t i o n u n d e r c o n t r a c t D E - N A 0 0 0 3 5 2 5 .

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The Scaled Wind Farm Technology (SWiFT) facility, operated by Sandia National Laboratories for the U.S. Department of Energy's Wind and Water Power Program, is a wind energy research site with multiple wind turbines scaled for the experimental study of wake dynamics, advanced rotor development, turbine control, and advanced sensing for production-scale wind farms. The SWiFT site currently includes three variable-speed, pitch-regulated, three-bladed wind turbines. The six volumes of this manual provide a detailed description of the SWiFT wind turbines, including their operation and user interfaces, electrical and mechanical systems, assembly and commissioning procedures, and safety systems.

This report covers the design and analysis of the hardware safety systems of the DOE/SNL Scaled Wind Farm Technology facility wind turbines. An analysis of the stopping capability of the turbines in multiple scenarios is presented. Included are calculations of braking torque, simulations of high wind speed emergency stops including multiple fault scenarios, and comparisons of predicted turbine performance to the relevant design standards.

This document describes the initial structural design for the National Rotor Testbed blade as presented during the preliminary design review at Sandia National Laboratories on October 28- 29, 2015. The document summarizes the structural and aeroelastic requirements placed on the NRT rotor for satisfactory deployment at the DOE/SNL SWiFT experimental facility to produce high-quality datasets for wind turbine model validation. The method and result of the NRT blade structural optimization is also presented within this report, along with analysis of its satisfaction of the design requirements.

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