Condition Monitoring and Wind Turbine Blades - Sandia...
Transcript of Condition Monitoring and Wind Turbine Blades - Sandia...
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2009 Wind Turbine Reliability Workshop“Di i D f R li bilit ”“Digging Down for Reliability”
Condition Monitoringand Wind Turbine Blades
Mark A RumseyMark A. RumseyWind Energy Technology Department
Sandia National LaboratoriesAlbuquerque, NM
505 844 3910 @ di505-844-3910 [email protected]
June 18, 2009
Sandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin Company,for the United States Department of Energy’s National Nuclear Security Administration
under contract DE-AC04-94AL85000.
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Presentation Outline
• S di L b Wh• Sandia Labs – Who we are
• Reliability RefresherReliability Refresher
• Condition Monitoring Challengesg g
• Condition Monitoring at the Labs
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Sandia Wind Energy Technology Focus
Blade Technology• Materials and Manufacturing• Structural, Aerodynamic, and Full
System Modeling• Sensors and Structural Health
Monitoring• Advanced Blade Concepts• Lab - Field Testing and Data
AcquisitionSystem Reliability• Industry Data Collection• Improve reliability of the existingImprove reliability of the existing
technology and future designsSystem Integration & Outreach• DOE/Wind M&O
slider
base
extender
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Sensor Tasks at Sandia Labs
• Laboratory and field diagnostics
• Smart blades – Active-aero Project (Lead: Dale Berg)– Sensor Blade Project (Lead: Mark Rumsey)
• Address sensor-in-blade issues– Manufacturability (egress/ingress, surface-mount/embed,
maintenance accessibility, material compatibility, costs)– Reliability
Acti e Aero Controls and Sensor Lab• Active Aero Controls and Sensor Lab– Determine sensor requirements (accuracy, reliability, cost)– Evaluate various sensing technologies– Model and validate sensor/actuation performance
B ild d t t b l t t– Build and test subscale structures
• Blade Manufacturing QA tools
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Working with Industry
System analysis identifies research initiatives with increasing industry involvement as it gets
l t th i l d t
SNL Program ActivitiesIndustry Activities
closer to the commercial product
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Validation Loop for Design,Models & Manufacturing Processg
Design
FabricateValidate FabricateValidate
Test
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Blade Testing in the Laboratory(Condition Monitoring)( g)
Static Test Setup
Fatigue Test Setup
NREL/National Wind Technology CenterBoulder, Colorado
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Condition Monitoring is only part of the solution
Source: Hill and Butterfield, 2006 Blade Reliability Workshop
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If Condition Monitoring is used
Condition Monitoring needs to be Reliable, too!If Condition Monitoring is used,
it needs to be Reliable… and Cost Effective.
Source: Wikipedia
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Blades have “issues”Source!: Veers, 2008 Blade Workshop (http://www.sandia.gov/wind)
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“Digging Down for Reliability”Challenges of Blade Condition Monitoring
Digging Down for Reliability
Sense What?Strains, loads, cracks, dry-spots, voids, operational dynamics, temperature gradients, lightning, …gradients, lightning, …
Sense Where? (location, location, location)Manufacturing defects, joints, bond lines, spar/shear-web interface, impacts, …
Sense with What?Piezoelectric sensor/actuators, acoustic emission sensors, optical strain gages (fiber Bragg gratings), metal-foil strain gages, IR thermography, …( gg g g ) g g g y
Sense How?Sensor specification, integration method, redundancy, interrogation, maintenance, …
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Challenges of Blade Condition Monitoring“Digging Down for Reliability”Digging Down for Reliability
Sense What?Strains, loads, cracks, dry-spots, voids, operational dynamics, temperature gradients, lightning, …gradients, lightning, …
Sense Where? (location, location, location)Manufacturing defects, joints, bond lines, spar/shear-web interface, impacts, …
Sense with What?Piezoelectric sensor/actuators, acoustic emission sensors, optical strain gages (fiber Bragg gratings), metal-foil strain gages, IR thermography, …( gg g g ) g g g y
Sense How?Sensor specification, integration method, redundancy, interrogation, maintenance,
Condition Monitoring (“Feature Extraction and Indicators” and what to do with them):
with good data
…
Condition Monitoring ( Feature Extraction and Indicators and what to do with them):data post-processing, information utilization, data management, ..., Prognostics
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Sandia Labs’ Research Blade DesignsBlade Geometry and Major Laminate RegionsBlade Geometry and Major Laminate Regions
Source: Josh Paquette
Photo of inside skin surface of TX-100 blade.
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Defects … cosmetic or not?
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Condition Monitoring during Lab Tests
Tension Side during Blade Test
List of Sensors shown in the photos:• Macro Fiber Composite (MFC)
piezoelectric sensors/actuators,• acoustic emission NDI sensorsacoustic emission NDI sensors,• metal foil strain gages,• photoelastic panel,• single axis accelerometer,• two multi-axis accelerometers,
f
Compression Side during Blade Test
• force actuator• and a force transducer
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Typical Response from Strain Gagesduring a Fatigue Test
1.75
1.00
1.25
1.50
d S
tiffn
ess
0.25
0.50
0.75
Nor
mal
ized
G21G23G25G27
CX-100 Strain Gage Layout
1.0
1.1
s
0.000.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6
Millions of Cycles
G27
0.7
0.8
0.9
Nor
mal
ized
Stif
fnes
s
G17
0.5
0.6
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6M illions of Cycles
G17G18G19G20
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Acoustic Emission NDT
Source: Paquette, “Structural Testing of 9 m Carbon Fiber Wind Turbine Research Blades “
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Active Damage Detectionusing Accelerometry
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Photoelastic and Infrared Thermography
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Sandia Sensor Blade Project
Goal: Increase the viability of windGoal: Increase the viability of wind energy by implementing sensing technologies in blades to enable advance wind turbine control strategies
Approach:• Submit a competitive solicitation
• Implement sensing technologies in a p g gblade • Obtain operational loads and blade shape• Static and fatigue test blade to failureg• Sensor system reliability• … quickly
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Sensor Blade Team
Mark Rumsey, Joshua Paquette and Wesley Johnson – Sandia National Laboratories (Wind Energy Tech. Dept.)Key colleagues in the department
Jason Kiddy and Chris Baldwin – Aither Engineering IncJason Kiddy and Chris Baldwin – Aither Engineering, Inc.Sensor Blade shape using embedded fiberoptic-based strain sensors
Alan Turner and Tom Graver – Micron Optics, Inc.Sensor Blade operational loads and temperature distribution using surface mounted fiberoptic-based sensors
Jonathan White and Douglas Adams – Purdue UniversitySensor Blade loads, shape, and Structural Health Monitoring using accelerometry
Steve Nolet and Derek Berry TPI Composites IncSteve Nolet and Derek Berry – TPI Composites, Inc.Sensor Blade manufacture in an open-shop floor environment
Jeff Carlson and Kevin Brink – Sandia National Laboratories (Energy Systems Analysis Dept.)Sensor Blade tip deflections using processed video images
Nolan Clark, Adam Holman, Byron Neal and Donnie Cagle – USDA-ARSSensor Blade field test on an operational wind turbine
Scott Hughes Jeroen van Dam and Mike Jenks NREL/NWTCScott Hughes, Jeroen van Dam and Mike Jenks – NREL/NWTCSensor Blade static and fatigue tests in the laboratory
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Sensor Blade Project(Sequence of Events)
• Build a Sensor Blade (TPI Composites, Inc., Warren, Rhode Island)• Incorporate sensors in a blade during blade manufacture• Sensor list:
E b dd d FBG ( t i d t t bl d h )– Embedded FBG sensors (strain and temperature, blade shape)– Inner-surface mounted FBG sensors (strain and temperature, loads)– Inner-surface mounted accelerometers (blade shape, loads, SHM)– Metal foil strain gages (strain, loads)– RTD (temperature)– Streaming video on rotor (blade shape)Streaming video on rotor (blade shape)
• Field Test Sensor Blade (U.S. Department of Agriculture – Agriculture Research Service, Bushland, Texas)
• On-the-ground checkouts and calibrations• In-the-air checkouts and calibrations• Obtain sensor datasets, measure loads and blade deflections during turbine operation• Real-time video monitoring
• Static and Fatigue Test Sensor Blade (National Renewable Energy Laboratory /Static and Fatigue Test Sensor Blade (National Renewable Energy Laboratory / National Wind Technology Center, Boulder, Colorado)
• AE NDT and SHM• Static Proof Test• Fatigue test to SBlade failure
• Analyze datasets and report results
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Thank You!
Mark A. RumseyWind Energy Technology Department
Sandia National LaboratoriesSandia National Laboratories
www.sandia.gov/wind