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Tuesday, 11 March 2014
11:15 - 12:45 Advanced rotor technologies
Hardware Technology  


Room: Tramuntana
Session description

The Rotor is the key item for development of wind turbines. This includes e.g. power curve / production, turbine loads, safety and noise. In this session three developers / manufactures will contribute their know-how on research, development and validation of the new developments, i.e. CFD and measurements. The session will be completed by an outlook for the future trends within the Rotor technologies.

Learning objectives

  • State-of-the-art rotor technologies
  • Outlook for future rotor technologies
Lead Session Chair:
Ole Kjær, DNV GL Renewables Certification, Denmark
Jeppe Kirkegaard Siemens Wind Power, Denmark
Co-authors:
Jeppe Kirkegaard (1) F P Peder Enevoldsen (1) Henrik Paulsen (1)
(1) Siemens Wind Power, Brande, Denmark

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Presenter's biography

Biographies are supplied directly by presenters at EWEA 2014 and are published here unedited

Mr. Kirkegaard has been with Siemens Wind Power for 3 years as a project manager in Blades department.
He studied mechanical engineering and manufacturing at the University of Aalborg. After his studies he had a one year contract as a research assistant at the university for Novo Nordisk and went on to become Design Engineer and later Technology Manager at Composhield A/S specializing in advanced materials related to military vehicle armor technology.
His work at Siemens Wind Power is focused on power curve upgrade kits improving the performance of its wind turbines.

Abstract

Aerodynamic Power Curve Upgrade Kits for Wind Turbines

Introduction

Siemens Wind Power (SWP) has improved the power production of its wind turbines with aerodynamic Power Curve Upgrade Kits (PCUK) applied both to new sales and as aftersales retrofits. The Annual Energy Production (AEP) of the targeted turbine types has been raised by up to 4% with noise emissions at the same time being lowered by up to 1 dB. This has been done within the design load envelope for all turbine components. Bringing academic technology research into fullscale commercial operation requires many competences within the company brought together and allows future focus on more paradigme changing technologies.

Approach

The task of updating a complete turbine with technology, which academically has been known for more than a decade, is effectively the design of a new design process and requires many diverse competences in design, implementation and validation. Maturing of the technology together with the increasing involvement of the organization has been a learning process for SWP as the technology has been brought to market. The relevant technologies and the required competence buildup are herein described together with the implications for future developments.

Main body of abstract

The design phase of a PCUK is based on computational fluid dynamics (CFD) and aeroelastic load calculations. The blade induction level is analyzed and then optimized by adding aerodynamic components while the load consequences are analyzed to ensure that turbine and component design loads are not surpassed. Well-known aerodynamic components such as DinoTails® and DinoShells® are used together with the latest developments such as passive load mitigation devices, winglets and raked tips. This is an iterative process that continues until the target AEP increase is reached with a load release that can be certified by a 3rd party.
The implementation phase starts when the aerodynamic design is frozen. The complexity can vary between reusing existing components designed for other blades, alterations of these, to completely new component families. Design for manufacture begins in the early design stage and now has to be realized as teamwork with Procurement and blade Manufacturing. The new design is HALT tested for 20 years of lifetime in harsh offshore environments and larger components also undergo separate 3rd party structural certification.
The final phase for a PCUK project is the validation phase. It starts together with the implementation phase using 3D printed components to upgrade rotors for internal array based noise measurements and side-by-side power curve measurements. The final noise and power curve validations are done by 3rd party as soon as the production components can be installed on a suitable turbine. Side-by-side power curve measurements also add further confidence to the calculated AEP gain.

Conclusion

The decision to actively take academic research and commercialize it has driven a change of the organization of SWP to a structure that can apply the needed competences to succeed. This has enabled SWP to rapidly deploy new power curve revisions while providing the foundation for further improvements using still more advanced technologies.


Learning objectives
To:
Give an overview of the available technologies to drive aerodynamic upgrades of wind turbines
Demonstrate the true complexity involved when upgrading a wind turbine
Describe core competences needed to implement aerodynamic upgrades