Post on 13-Apr-2022
© Siemens Gamesa Renewable Energy S.A Jesper Monrad Laursen | Industrial perspective October 24th 2018
The use of wind tunnels in the Wind Energy IndustryJesper Monrad LaursenSiemens Gamesa Renewable EnergyOctober 24th, 2018
© Siemens Gamesa Renewable Energy Peter Fuglsang | Industrial perspective April 10th 2018
Offshore state-of-the-art 2018
Industrial perspective
Swept area 22.000 m2 ~3 football fields
Energy production ~ +7000house holds
Mass of air through rotor at10 m/s ~ 18 large Trucks
Wind load in blade root ~ A VWGolf at the end of a 1.9 km stick
600 siblings are up and running!
© Siemens Gamesa Renewable Energy S.A Jesper Monrad Laursen | Industrial perspective October 24th 2018
• Cost pressure
• Global market growth
• Low volume/short time on market
• Consolidation
• Cost focus
• Innovation need
• Short term Incremental thinking
• Cash constraints
• Short product life cycle
The industry challenge is the simultaneous cost pressure and global market growth
Industrial perspective
Continuous collaboration with Universities and Research Institutions is a part of the solution
© Siemens Gamesa Renewable Energy S.A Jesper Monrad Laursen | Industrial perspective October 24th 2018
The innovation challenge for extreme-scale turbine development
Industrial perspective 4
• Larger blades and increased cycle time -> Needfor factory space increase rapidly!
Factory space scaling
Radical innovation and disruption is needed to break the basic scaling laws – “more of the same” will not work!
• Scaling of a blade with 50% leads to almost 3times the blade mass
Blade mass scaling
Size
Mass
Scalinglaw
Additionalinnovation
needed
Blade x 1.5
Blade x 1
Factory size for 50% additional blade length (est.)Non linear mass scaling trend with size
© Siemens Gamesa Renewable Energy S.A Jesper Monrad Laursen | Industrial perspective October 24th 2018
Blade factory in Aalborg, Denmark
Industrial perspective 5
© Siemens Gamesa Renewable Energy S.A Jesper Monrad Laursen | Industrial perspective October 24th 2018
Transporting 6MW nacelle to test site in Høvsøre6
© Siemens Gamesa Renewable Energy S.A Jesper Monrad Laursen | Industrial perspective October 24th 2018
The innovation challenge for blade development
Industrial perspective 7
Fundamental changes in shape and design –> 30 - 40 years of blade development
1979 Today
B75 blade
SWT 6.0-154
5 m blade
Bonus 27 kW
© Siemens Gamesa Renewable Energy S.A Jesper Monrad Laursen | Industrial perspective October 24th 2018
Innovations in Aerodynamic Blade Design
Design Approach
Dinotail®Flatback airfoils
Active flowcontrol
Vortex Generators
High thickness airfoils
Innovations in aerodynamic blade shape design has been driven by DFM & Product performance
Tip shape
Sweep / Pre-bend
© Siemens Gamesa Renewable Energy S.A Jesper Monrad Laursen | Industrial perspective October 24th 2018
Wind turbine airfoils
Industrial perspective 9
.SGRE In-house Airfoil Design
• Tailored airfoils for specific functional requirements
Robust performance in field - an Important KPI
• Blade surfaceconditions are rarelyideal!
Airfoil Design Validation • SGRE airfoils tailored to blade design philosophy, enablinghigh root performance, lower solidity and higher t/c
• Design for robustness favored over peak efficiency designfor unlikely clean surface in field
• DFM approach enabling low cost light blades• Flatback root airfoils• Airfoil families tailored for straight, well aligned beams
• New airfoils are alwayswind tunnel validatedbefore release for NewProduct Development(NPD)
© Siemens Gamesa Renewable Energy S.A Jesper Monrad Laursen | Industrial perspective October 24th 2018
Aerodynamic add-ons
Industrial perspective 10
.Dinoshells®
Lift enhancing deviceapplied at the root sectionof the blade
Vortex Generators
Vortex generators (VGs)are used to increaseaerodynamic performanceand reduce impact ofblade soiling
Dinotail®
A device applied at thetrailing edge to reducetrailing edge soundemissions
• Power curve upgrade kits provide AEP increase, reducesoiling sensitivity and noise emission
• Add-on configuration is optimized on basis of few basiccomponents
• Noise can be reduced at the same time as increasing annualenergy production (AEP)
© Siemens Gamesa Renewable Energy S.A Jesper Monrad Laursen | Industrial perspective October 24th 2018
Wind turbine acoustics
• Learning from a silent hunter…
Industrial perspective 11
Quietplease!
Overall a 1 dB noisereduction over existingstate of the art serrations!
Systematic designapproach and wind tunneltesting key to successfulend result
© Siemens Gamesa Renewable Energy S.A Jesper Monrad Laursen | Industrial perspective October 24th 2018
Tip Shapes
Industrial perspective 12
.Advanced Modeling of Tip Flow Wind Tunnel Validation
Testing of B45 blade tipwith winglet
Qualitative measurementsto prove designfunctionality
Field Testing• Advanced tip design can improve performance of large scale
wind turbines – SGRE and Risø further pursuingopportunities in this area through the Smart Tip project(Innovation Fund Denmark project)
• The devil is in the detail – How can we use wind tunnel teststo unlock further details going forward?
Engineers performing fieldvalidation of own concepts
High level of detail can beobtained – down to thelevel of surface finish,soiling etc.
Tip flow is essentially 3D
CFD “3D wind tunnel”:Offers opportunities fordirectly modeling impact ofgeometry changes
© Siemens Gamesa Renewable Energy S.A Jesper Monrad Laursen | Industrial perspective October 24th 2018
Active flow control
Industrial perspective 13
.Basic Concept Concept Validation in Wind Tunnel
Wind tunnel ideal fortesting different concepts
Feedback from windtunnel used actively inoptimization and maturingprocess
Rapid Prototyping - “Just do it” Approach • SGRE looking for next breakthrough on add-ons
• Concepts tailored for specific need• Power production below rated power?• Loads alleviation? What load case is targeted?
• Overcoming of high design cost on large scale turbine• Concept screening• Rapid prototyping• Testing, testing, testing…
Early field testing essentialfor screening concepts
Hands-on approach part ofteam DNA!
Design and mature activeadd-ons concept
Tailor blade sectionloading to actual need:performance increment orloads reduction?
© Siemens Gamesa Renewable Energy S.A Jesper Monrad Laursen | Industrial perspective October 24th 2018
Advanced modelling
Industrial perspective 14
How can we combine advanced modelling and wind tunnel tests to understand dynamic phenomena better?
We have become pretty far with our staticcalculations -> fits well with power curveetc.
Next step is to better understand dynamic phenomena• Advanced modelling of dyn. phenomena (getting started)• How can we better validate model (wind tunnel testing?)?• Field measurements (costly and late in development cycle)
© Siemens Gamesa Renewable Energy S.A Jesper Monrad Laursen | Industrial perspective October 24th 2018
Computational Aero-Acoustics (CAA)
Industrial perspective 15
The combination of advanced modelling and wind tunnel testing can be used to improve acoustic design
• Lattice-Boltzmann simulation• Lambda2 Criterion visualizing vortices• Acoustic waves and pressure fluctuations in BL
• Near field visualization of vortices rolling up onserrated trailing edge
• CAA can be used to pick improved design ->before going to wind tunnel
© Siemens Gamesa Renewable Energy S.A Jesper Monrad Laursen | Industrial perspective October 24th 2018
Technology maturity16
The wind tunnel need remains – but the individual technologies change!
Effort / Time
Tech
nolo
gica
lmat
urity
growing
mature
aging
embryonic
Airfoils
Add-ons
?
Active flowcontrol
© Siemens Gamesa Renewable Energy S.A Jesper Monrad Laursen | Industrial perspective October 24th 2018
Technology readiness level17
The wind tunnel need is on component and sub system level
© Siemens Gamesa Renewable Energy Jesper Monrad Laursen | Industrial perspective October 24th 2018
Key messages
• Congratulations on this great new wind tunnel– We are looking forward to working with youin the AeroLoop EUDP project!
• Radical innovation and disruption is needed– “more of the same” will not work!
• The wind tunnel need remains– but the individual technologies change!
© Siemens Gamesa Renewable Energy S.A Jesper Monrad Laursen | Industrial perspective October 24th 2018
Thank you!Jesper Monrad Laursen
Chief Engineer, Offshore Blade R&D, Siemens Gamesa Renewable Energy
Jesper.m.Laursen@siemensgamesa.com