jacques nader - large wind turbine blade design challenges and r&d needs
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Large Wind turbine blade design challenges and R&D NeedsJacques Nader - Siemens Wind Power
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Outline
q Introduction
q Historic overview
q Trends in blade design
q Future challenges
q Long term outlook
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Wind Power and Renewables DivisionFacts at a glance
One of the world’s leading suppliers of wind power solutions
Acquired Danish wind turbine manufacturer Bonus Energy A/S in 2004
Installed Base: > 17,400 turbines with ~ 34 GW capacity
Installed in FY 2015: > 1,970 turbines with > 5.6 GW capacity
~12,800 employees globally incl. Wind Service
Siemens Wind Power facts
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Onshore Wind – Siemens with considerable experience and track record of installed projects
ON installed base as of June 2016: >26 GW
20161980
1979: 2 x 22 kW (10.2m)Vindeby, Denmark
1998: 17 x 1.0-54Wilsikow, Germany
2009: 62 x 2.3-82Wellington, New Zealand
2011: 3 x 3.0-101Lejbølle, Denmark
Installed base
201020001990
First project First 1MW turbines First Commercial DDFirst project w/o subsidies
Cumulated Siemens onshore installations (GW)
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Offshore Wind – Leading player with >7,3 GW installed base in strongest growing market
1991: 5 MW Vindeby, DK
2000: 40 MW Middelgrunden, DK
2011: 630 MWLondon Array, UK
First project MW turbines Master Agreement
2012: 1.8 GW DONG Master Agreement
GW project
202020151990
450 kW(ø35m)
(8 MW(ø154m)
Cumulated Siemens offshore installations (GW)
OF installed base as of June 2016: >7,3 GW
Installed base
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Wind Turbine Blade R&D Competence Center in Boulder, Colorado
• Established in 2008
• Currently 30 full-time engineers
• Will be 45 by end of this year
• Rotor research, design and technology
• 30% PhD & 70% Masters
• Investing in American engineering
NISTNOAA
UCAR
NCAR
SWP
CU
Boulder
Attractive Location for Top Talent:
• Forbes: “Boulder Tops List of America’s Smartest Cities”
• Money: “Louisville Best Places to Live”
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SWP 8.0-154 with 75 m bladesOne of the world’s largest fiberglass component cast in one piece
• 75 m long blades and a rotor diameter of 154 m.
• Blade weight of 25 tons equal to 16 mid-sized cars.
• The rotors swept area is equivalent to 2½ soccer fields.
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Fundamental changes in shape and design30 years of blade development scaled to the same size
5 m blade from Bonus 27 kW
B75 m blade for SWT 8.0 MW
We have come a long way…
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Fundamental changes in shape and design30 years of blade development scaled to the same size
5 m blade from Bonus 27 kW
B75 m blade for SWT 8.0-154
Two blades scaled to same size
• Profiles changed from 1930s aircraft types to modern custom-made types
• Solidity changed from ~10% to much less than 5%
• A75 m scaled version of the 27KW blade would weight over 50 Tones
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PAST achievements: Aerodynamic shape designG2 Planform: from B45 to B59Designed 10 years apart
Dinoshell®
Dinotail®Flatback airfoils
Aeroelastic tailored blade
Pre-bend
Sweep
45 m blade
59 m blade
SWT-2.3-93
SWT-2.3-120
Stiff blade
Vortex Generators
High thickness airfoils
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Add-ons: simple designed kits providing AEP increase, support the blade aerodynamics, reduce the blade soiling and noise emission.
.
Dinoshells®
Lift enhancing device applied at the root section of the blade
Vortex Generators
Vortex generators (VGs) are used from root to tip to increase aerodynamic performance and reduce impact of blade soiling
Dinotail®
A device applied at the trailing edge to reduce trailing edge sound emissions.
• Add-on are used to reduce noise, increase AEP and robustness
• Very popular and widely used
• Add-on can be included in the design from the beginning
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IPC technology is to blades what is used to control a helicopter –rotor imbalance is reduced!
ATB technology is to blades what shock absorption is to a car – turbulent loads are reduced!
Tends in Loads & Controls intelligenceLoad reduction techniques
Pitc
hFl
ap M
omen
t
----- Baseline----- IPC
“IPC primarily compensates for 1P load imbalances (e.g. shear) resulting in lower fatigue loads”
Angle = 2.9 deg
200 400 600 800 1000 1200 1400 1600 1800 2000
0
200
400
600
800
1000
1200
“ATB passively compensates for gust loads resulting in lower fatigue loads”
q Aero-elastic Tailored Blade (ATB)
q Individual Pitch Control (IPC)
q Real Time Condition Monitoring
q Active flaps
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Tip deflection challenge Trade-Offs: Material vs Shape
Airfoil thickness
Spar cap thickness Spar cap width Material stiffness
∆∝𝑭𝑳𝟑
𝑬𝑰
Design element Desired trends Possible limiting factor
Airfoil Thickness Aero performance
Spar cap thickness Mass penalty, manufacturability
Spar cap width Mass penalty, manufacturability
Material Stiffness Cost increase, manufacturability
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Tip deflection challengeMaterial vs. Shape, E vs. I, which one to invest in ?
glass
glass
carbon
carbon
Material Stiffness, E
Airfoil Thickness, I
• How much risk are we willing to take?• Is there a limit to airfoil thickness?• Is carbon an enabler or does it also limit us?• Depends on in-house design philosophy• Depends on manufacturing concepts• Structural topology
• A 75 m blade can have over 15m tip deflection
40 50 60 70 80
Theoretical cantilever tip deflection
Actual SWP trend
Tip
defle
ctio
n (m
)∆∝
𝐹𝐿3
𝐸𝐼
∆∝ 𝑳
Blade length (m)
Tip deflection challenge
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Summary - Size
“Advancements in blade shape and structural designs combined
with optimized material selection and load reduction techniques
allow us to overcome the limitation imposed by the square-cube law”
“This enables additional AEP to the customer”
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Future challenges
Leading edge erosion
Testing
Transportation
Manufacturing/automation
AEP
Tip deflection
Size
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Generic long term outlook
Competitive wind energy LCOE
Cost efficient turbines Smart wind turbines and
farms
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Thank you for your attention
Jacques NaderHead of Blade DesignSiemens Wind Power
1050 Walnut St, suite 303
Boulder, CO, 80303
E-mail:[email protected]