Optimal selection of autoregressive model coefficients for early damage detectability with an application to wind turbine blades

Piotr Omenzetter and Simon Hoell's work within the Lloyd's Register Foundation Centre for Safety and Reliability Engineering at the University of Aberdeen is supported by Lloyd’s Register Foundation. The Foundation helps to protect life and property by supporting engineering-related education, public engagement and the application of research.

Improved damage detectability in a wind turbine blade by optimal selection of vibration signal correlation coefficients

Piotr Omenzetter and Simon Hoell’s work within the Lloyd’s Register Foundation Centre for Safety and Reliability Engineering at the University of Aberdeen is supported by Lloyd’s Register Foundation. The Foundation helps to protect life and property by supporting engineering-related education, public engagement and the application of research.

Physical Insights, Steady Aerodynamic Effects, and a Design Tool for Low-Pressure Turbine Flutter

The successful, efficient, and safe turbine design requires a thorough understanding of the underlying physical phenomena. This research investigates the physical understanding and parameters highly correlated to flutter, an aeroelastic instability prevalent among low pressure turbine (LPT) blades in both aircraft engines and power turbines. The modern way of determining whether a certain cascade of LPT blades is susceptible to flutter is through time-expensive computational fluid dynamics (CFD) codes. These codes converge to solution satisfying the Eulerian conservation equations subject to the boundary conditions of a nodal domain consisting fluid and solid wall particles. Most detailed CFD codes are accompanied by cryptic turbulence models, meticulous grid constructions, and elegant boundary condition enforcements all with one goal in mind: determine the sign (and therefore stability) of the aerodynamic damping. The main question being asked by the aeroelastician, ``is it positive or negative?'' This type of thought-process eventually gives rise to a black-box effect, leaving physical understanding behind. Therefore, the first part of this research aims to understand and reveal the physics behind LPT flutter in addition to several related topics including acoustic resonance effects. A percentage of this initial numerical investigation is completed using an influence coefficient approach to study the variation the work-per-cycle contributions of neighboring cascade blades to a reference airfoil. The second part of this research introduces new discoveries regarding the relationship between steady aerodynamic loading and negative aerodynamic damping. Using validated CFD codes as computational wind tunnels, a multitude of low-pressure turbine flutter parameters, such as reduced frequency, mode shape, and interblade phase angle, will be scrutinized across various airfoil geometries and steady operating conditions to reach new design guidelines regarding the influence of steady aerodynamic loading and LPT flutter. Many pressing topics influencing LPT flutter including shocks, their nonlinearity, and three-dimensionality are also addressed along the way. The work is concluded by introducing a useful preliminary design tool that can estimate within seconds the entire aerodynamic damping versus nodal diameter curve for a given three-dimensional cascade.

Dynamic effects of anchor positional tolerance on tension moored floating wind turbine

For water depths greater than 60m floating wind turbines will become the most economical option for generating offshore wind energy. Tension mooring stabilised units are one type of platform being considered by the offshore wind energy industry. The complex mooring arrangement used by this type of platform means that the dynamics are greatly effected by offsets in the positioning of the anchors. This paper examines the issue of tendon anchor position tolerances. The dynamic effects of three positional tolerances are analysed in survival state using the time domain FASTLink. The severe impact of worst case anchor positional offsets on platform and turbine survivability is shown. The worst anchor misposition combinations are highlighted and should be strongly avoided. Novel methods to mitigate this issue are presented.

Description of an 8 MW reference wind turbine

An 8 MW wind turbine is described in terms of mass distribution, dimensions, power curve, thrust curve, maximum design load and tower configuration. This turbine has been described as part of the EU FP7 project LEANWIND in order to facilitate research into logistics and naval architecture efficiencies for future offshore wind installations. The design of this 8 MW reference wind turbine has been checked and validated by the design consultancy DNV-GL. This turbine description is intended to bridge the gap between the NREL 5 MW and DTU 10 MW reference turbines and thus contribute to the standardisation of research and development activities in the offshore wind energy industry.

Wind Shear, Gust, and Yaw-Induced Dynamic Stall on Wind-Turbine Blades

This study examined the effect of a spanwise angle of attack gradient on the growth and stability of a dynamic stall vortex in a rotating system. It was found that a spanwise angle of attack gradient induces a corresponding spanwise vorticity gradient, which, in combination with spanwise flow, results in a redistribution of circulation along the blade. Specifically, when modelling the angle of attack gradient experienced by a wind turbine at the 30% span position during a gust event, the spanwise vorticity gradient was aligned such that circulation was transported from areas of high circulation to areas of low circulation, increasing the local dynamic stall vortex growth rate, which corresponds to an increase in the lift coefficient, and a decrease in the local vortex stability at this point. Reversing the relative alignment of the spanwise vorticity gradient and spanwise flow results in circulation transport from areas of low circulation generation to areas of high circulation generation, acting to reduce local circulation and stabilise the vortex. This circulation redistribution behaviour describes a mechanism by which the fluctuating loads on a wind turbine are magnified, which is detrimental to turbine lifetime and performance. Therefore, an understanding of this phenomenon has the potential to facilitate optimised wind turbine design.

Sustainability Enhancement of a Turbine Vane Manufacturing Cell through Digital Simulation based Design

Modern manufacturing systems should satisfy emerging needs related to sustainable development. The design of sustainable manufacturing systems can be valuably supported by simulation, traditionally employed mainly for time and cost reduction. In this paper, a multi-purpose digital simulation approach is proposed to deal with sustainable manufacturing systems design through Discrete Event Simulation (DES) and 3D digital human modelling. DES models integrated with data on power consumption of the manufacturing equipment are utilized to simulate different scenarios with the aim to improve productivity as well as energy efficiency, avoiding resource and energy waste. 3D simulation based on digital human modelling is employed to assess human factors issues related to ergonomics and safety of manufacturing systems. The approach is implemented for the sustainability enhancement of a real manufacturing cell of the aerospace industry, automated by robotic deburring. Alternative scenarios are proposed and simulated, obtaining a significant improvement in terms of energy efficiency (−87%) for the new deburring cell, and a reduction of energy consumption around −69% for the coordinate measuring machine, with high potential annual energy cost savings and increased energy efficiency. Moreover, the simulation-based ergonomic assessment of human operator postures allows 25% improvement of the workcell ergonomic index.

Investigation of the effects of flow conditions at rotor inlet on mixed flow turbine performance for automotive applications

Current trends in the automotive industry have placed increased importance on engine downsizing for passenger vehicles. Engine downsizing often results in reduced power output and turbochargers have been relied upon to restore the power output and maintain drivability. As improved power output is required across a wide range of engine operating conditions, it is necessary for the turbocharger to operate effectively at both design and off-design conditions. One off-design condition of considerable importance for turbocharger turbines is low velocity ratio operation, which refers to the combination of high exhaust gas velocity and low turbine rotational speed. Conventional radial flow turbines are constrained to achieve peak efficiency at the relatively high velocity ratio of 0.7, due the requirement to maintain a zero inlet blade angle for structural reasons. Several methods exist to potentially shift turbine peak efficiency to lower velocity ratios. One method is to utilize a mixed flow turbine as an alternative to a radial flow turbine. In addition to radial and circumferential components, the flow entering a mixed flow turbine also has an axial component. This allows the flow to experience a non-zero inlet blade angle, potentially shifting peak efficiency to a lower velocity ratio when compared to an equivalent radial flow turbine.
This study examined the effects of varying the flow conditions at the inlet to a mixed flow turbine and evaluated the subsequent impact on performance. The primary parameters examined were average inlet flow angle, the spanwise distribution of flow angle across the inlet and inlet flow cone angle. The results have indicated that the inlet flow angle significantly influenced the degree of reaction across the rotor and the turbine efficiency. The rotor studied was a custom in-house design based on a state-of-the-art radial flow turbine design. A numerical approach was used as the basis for this investigation and the numerical model has been validated against experimental data obtained from the cold flow turbine test rig at Queen’s University Belfast. The results of the study have provided a useful insight into how the flow conditions at rotor inlet influence the performance of a mixed flow turbine.

Investigation expérimentale du décollement dans l’aspirateur d’une turbine bulbe

La présente thèse propose une étude expérimentale du décollement dans le diffuseur d’un modèle de turbine hydroélectrique bulbe. Le décollement se produit quand la turbine est opérée à forte charge et il réduit la section effective de récupération du diffuseur. La diminution de la performance du diffuseur à forte charge engendre une baisse brusque de l’efficacité de la turbine et de la puissance extraite. Le modèle réduit de bulbe est fidèle aux machines modernes avec un diffuseur particulièrement divergent. Les performances de la turbine sont mesurées sur une large gamme de points d’opération pour déterminer les conditions les plus intéressantes pour l’étude du décollement et pour étudier la distribution paramétrique de ce phénomène. La pression est mesurée le long de l’aspirateur par des capteurs dynamiques affleurants alors que les champs de vitesse dans la zone de décollement sont mesurés avec une méthode PIV à deux composantes. Les observations à la paroi sont pour leur part faites à l’aide de brins de laine. Pour un débit suffisant, le gradient de pression adverse induit par la géométrie du diffuseur affaiblit suffisamment la couche limite, entraînant ainsi l’éjection de fluide de la paroi le long d’une large enveloppe tridimensionelle. Le décollement instationnaire tridimensionnel se situe dans la même zone du diffuseur indépendamment du point d’opération. L’augmentation du débit provoque à la fois une extension de la zone de décollement et une augmentation de l’occurrence de ses manifestations. La position et la forme du front de décollement fluctue significativement sans périodicité. L’analyse topologique et celle des tourbillons des champs de vitesse instantanés montrent une topologie du front de décollement complexe qui diffère beaucoup d’une réalisation à l’autre. Bien que l’écoulement soit turbulent, les tourbillons associés aux foyers du front sont clairement plus gros et plus intenses que ceux de la turbulence. Cela suggère que le mécanisme d’enroulement menant aux tourbillons du décollement est clairement distinct des mécanismes de la turbulence.

Étude expérimentale de l'écoulement en entrée d'aspirateur d'une turbine bulbe

Ce mémoire présente l’étude expérimentale de l’écoulement d’entrée d’un aspirateur d’une turbine bulbe présentant une chute abrupte de performance. Des mesures par vélocimétrie laser à effet Doppler (LDV) ont été réalisées sur deux axes soit en aval des pales de la roue et en aval du moyeu de la roue. Une particularité de cette étude est la conception d’un montage permettant de mesurer la vitesse axiale proche de la paroi du cône. De plus, une méthode d’estimation de la vitesse radiale moyenne a été développée. Ces mesures ont permis de caractériser l’écoulement primaire et les écoulements secondaires et d’analyser leur évolution entre les deux axes. De plus, l’évolution de ces écoulements est analysée en fonction de la chute de performance de la turbine. Les principales particularités de l’écoulement sont la présence d’une recirculation sous le moyeu, d’une zone contrarotative, des sillages des directrices et des tourbillons de bout de pale.

Detached eddy simulation of unsteady turbulent flows in the draft tube of a bulb turbine

Les aspirateurs de turbines hydrauliques jouent un rôle crucial dans l’extraction de l’énergie disponible. Dans ce projet, les écoulements dans l’aspirateur d’une turbine de basse chute ont été simulés à l’aide de différents modèles de turbulence dont le modèle DDES, un hybride LES/RANS, qui permet de résoudre une partie du spectre turbulent. Déterminer des conditions aux limites pour ce modèle à l’entrée de l’aspirateur est un défi. Des profils d’entrée 1D axisymétriques et 2D instationnaires tenant compte des sillages et vortex induits par les aubes de la roue ont notamment été testés. Une fluctuation artificielle a également été imposée, afin d’imiter la turbulence qui existe juste après la roue. Les simulations ont été effectuées pour deux configurations d’aspirateur du projet BulbT. Pour la deuxième, plusieurs comparaisons avec des données expérimentales ont été faites pour deux conditions d’opération, à charge partielle et dans la zone de baisse rapide du rendement après le point de meilleur rendement. Cela a permis d’évaluer l’efficacité et les lacunes de la modélisation turbulente et des conditions limites à travers leurs effets sur les quantités globales et locales. Les résultats ont montrés que les structures tourbillonnaires et sillages sortant de la roue sont adéquatement résolus par les simulations DDES de l’aspirateur, en appliquant les profils instationnaires bidimensionnels et un schéma de faible dissipation pour le terme convectif. En outre, les effets de la turbulence artificielle à l’entrée de l’aspirateur ont été explorés à l’aide de l’estimation de l’intermittence du décollement, de corrélations en deux points, du spectre d’énergie et du concept de structures cohérentes lagrangiennes. Ces analyses ont montré que les détails de la dynamique de l’écoulement et de la séparation sont modifiés, ainsi que les patrons des lignes de transport à divers endroits de l’aspirateur. Cependant, les quantités globales comme le coefficient de récupération de l’aspirateur ne sont pas influencées par ces spécificités locales.

Performance assessment of a vertical axis turbine in a marine current flume tank and CFD modelling

As advances in numerical modelling techniques support the increased confidence in predictions from computer simulations, the need remains to have experimental verification built into the design process. This paper outlines the experimental investigation carried out on a shielded vertical axis turbine in a marine environment. The experiments consist of performance measurements and the use of particle image velocimetry on a small scale device in a marine current flume. The results demonstrate that the performance of the device can be modelled numerically; in particular, the results show that the numerical model used can correctly predict the increase in performance with Reynolds number.

Probabilistic design optimization of horizontal axis wind turbine rotors

Considerable interest in renewable energy has increased in recent years due to the concerns raised over the environmental impact of conventional energy sources and their price volatility. In particular, wind power has enjoyed a dramatic global growth in installed capacity over the past few decades. Nowadays, the advancement of wind turbine industry represents a challenge for several engineering areas, including materials science, computer science, aerodynamics, analytical design and analysis methods, testing and monitoring, and power electronics. In particular, the technological improvement of wind turbines is currently tied to the use of advanced design methodologies, allowing the designers to develop new and more efficient design concepts. Integrating mathematical optimization techniques into the multidisciplinary design of wind turbines constitutes a promising way to enhance the profitability of these devices. In the literature, wind turbine design optimization is typically performed deterministically. Deterministic optimizations do not consider any degree of randomness affecting the inputs of the system under consideration, and result, therefore, in an unique set of outputs. However, given the stochastic nature of the wind and the uncertainties associated, for instance, with wind turbine operating conditions or geometric tolerances, deterministically optimized designs may be inefficient. Therefore, one of the ways to further improve the design of modern wind turbines is to take into account the aforementioned sources of uncertainty in the optimization process, achieving robust configurations with minimal performance sensitivity to factors causing variability. The research work presented in this thesis deals with the development of a novel integrated multidisciplinary design framework for the robust aeroservoelastic design optimization of multi-megawatt horizontal axis wind turbine (HAWT) rotors, accounting for the stochastic variability related to the input variables. The design system is based on a multidisciplinary analysis module integrating several simulations tools needed to characterize the aeroservoelastic behavior of wind turbines, and determine their economical performance by means of the levelized cost of energy (LCOE). The reported design framework is portable and modular in that any of its analysis modules can be replaced with counterparts of user-selected fidelity. The presented technology is applied to the design of a 5-MW HAWT rotor to be used at sites of wind power density class from 3 to 7, where the mean wind speed at 50 m above the ground ranges from 6.4 to 11.9 m/s. Assuming the mean wind speed to vary stochastically in such range, the rotor design is optimized by minimizing the mean and standard deviation of the LCOE. Airfoil shapes, spanwise distributions of blade chord and twist, internal structural layup and rotor speed are optimized concurrently, subject to an extensive set of structural and aeroelastic constraints. The effectiveness of the multidisciplinary and robust design framework is demonstrated by showing that the probabilistically designed turbine achieves more favorable probabilistic performance than those of the initial baseline turbine and a turbine designed deterministically.