STRUCTURE AND MECHANICAL PROPERTIES OF 21HMF STEEL STEAM TURBINE ROTOR MATERIALS AFTER LONG-TERM OPERATION FOR A TIME SIGNIFICANTLY EXCEEDING THE DESIGN TIME

The article presents the results of tests of materials for steam turbine rotors with various degrees of depletion in order to determine the suitability of these components for further operation after significantly exceeding the design working time on the basis of the assessment of the microstructure condition and a set of functional properties.

Land-based wind turbines with flexible rail-transportable blades – Part 1: Conceptual design and aeroservoelastic performance

This work investigates the conceptual design and the aeroservoelastic performance of land-based wind turbines whose blades can be transported on rail via controlled bending. The turbines have a nameplate power of 5 MW and a rotor diameter of 206 m, and they aim to represent the next generation of land-based machines. Three upwind designs and two downwind designs are presented, combining different design goals together with conventional glass and pultruded carbon fiber laminates in the spar caps. One of the five blade designs is segmented and serves as a benchmark to the state of the art in industry. The results show that controlled flexing requires a reduction in the flapwise stiffness of the blades, but it represents a promising pathway for increasing the size of land-based wind turbine rotors. Given the required stiffness, the rotor can be designed either downwind with standard rotor preconing and nacelle uptilt angles or upwind with higher-than-usual angles. A downwind-specific controller is also presented, featuring a cut-out wind speed reduced to 19 m s−1 and a pitch-to-stall shutdown strategy to minimize blade tip deflections toward the tower. The flexible upwind and downwind rotor designs equipped with pultruded carbon fiber spar caps are found to generate the lowest levelized cost of energy, 2.9 % and 1.3 %, respectively, less than the segmented design. The paper concludes with several recommendations for future work in the area of large flexible wind turbine rotors.

A computationally efficient engineering aerodynamic model for non-planar wind turbine rotors

In the present work, a computationally efficient engineering model for the aerodynamic load calculation of non-planar wind turbine rotors is proposed. The method is based on the vortex cylinder model, and can be used in two ways: either as a correction to the currently widely used blade element momentum (BEM) method, or used as the main model, replacing the BEM method in the engineering modelling complex. The proposed method needs the same order of computational effort as the ordinary BEM method, which makes it ideal for time-domain aero-servo-elastic simulations. The results from the proposed method are compared with results from two higher-fidelity aerodynamic models: a lifting-line method and a Navier-Stokes solver. For planar rotors, the aerodynamic loads are identical to the current BEM model when the drag force is excluded during the calculation of the induced velocities. For non-planar rotors, the influence of the blade out-of-plane shape, measured by the difference of the load between the non-planar rotor and the planar rotor, is in very good agreement with higher-fidelity models. Meanwhile, the existing BEM methods, even with a correction of radial induction included, show relatively large deviations from the higher-fidelity method results.

Aeromechanical Optimization of Scalloping in Mixed Flow Turbines

Scalloping of radial and mixed flow turbocharger turbine rotors has been commonplace for many years as a means of inertia reduction and stress relief. The interest in turbine rotor inertia reduction is driven by transient loading requirements of turbocharged internal combustion engines, as this is a key factor in the time taken to meet transient engine torque requirements. Due to the high density materials used in turbine rotors, any material removal from the turbine wheel has a significant impact on turbocharger inertia, and thus the transient response of the engine. It is well known that scalloping not only reduces inertia, but also efficiency. This study aimed to identify if it was possible to produce a new scallop design which reduced the scalloping efficiency penalty without increasing inertia, or compromising mechanical constraints. This was carried out with the aim of developing design recommendations for scalloping where a complete minimization of inertia is not the design goal. A multipoint, multi-physics numerical optimization, with constraints on inertia and back disc stress, was carried out to determine what efficiency benefit could be realized by aerodynamically designing mixed flow turbine scalloping. An efficiency benefit was identified across the entire turbocharger operating line, with increased benefit at low engine load, whilst not exceeding the design constraints. Scalloping losses for the baseline design were found to be greatest at low engine load, where the turbine experienced low expansion ratio, mass flow and speed. This explains why an aerodynamic redesign yields the greatest benefit under those operating conditions. These performance predictions were experimentally validated on the cold flow test rig at Queen’s University Belfast, with good agreement between simulated and measured data. To conclude the study, a detailed loss audit was carried out to identify key loss generating flow structures, and to understand how changes in geometry affected the formation and development of these flow structures throughout the passage. A large vortex which entered the passage from the scalloped region and interacted with the tip leakage vortex along the suction surface of the blade was identified as the main source of loss due to scalloping. The optimized design was found to better control the location of entry of this vortex into the blade passage, thus reducing the associated loss, and facilitating a performance improvement. Geometric design guidelines were then proposed based on these findings.

Land-based wind turbines with flexible rail transportable blades – Part I: Conceptual design and aeroservoelastic performance

This work investigates the conceptual design and the aeroservoelastic performance of land-based wind turbines whose blades can be transported on rail via controlled bending. The turbines have a nameplate power of 5 MW and a rotor diameter of 206 m, and they aim to represent the next generation of land-based machines. Three upwind designs and two downwind designs are presented, combining different design goals together with conventional glass and pultruded carbon fiber laminates in the spar caps. The results show that controlled flexing requires a reduction in the flapwise stiffness of the blades, but it represents a promising pathway to increase the size of land-based wind turbine rotors. Given the required stiffness, the rotor can be designed either downwind with standard rotor preconing and nacelle uptilt angles or upwind with higher-than-usual angles. A downwind-specific controller is also presented, featuring a cut-out wind speed reduced to 19 m per second and a pitch-to-stall shutdown strategy to minimize blade-tip deflections toward the tower. The flexible upwind and downwind rotor designs equipped with pultruded carbon fiber spar caps are found to generate the lowest levelized cost of energy, 2.9 % and 1.3 %, respectively, less than the segmented design. The paper concludes with several recommendations for future work in the area of large flexible wind turbine rotors.

On the scaling of wind turbine rotors

This paper formulates laws for scaling wind turbine rotors. Although the analysis is general, the article primarily focuses on the subscaling problem, i.e., on the design of a smaller-sized model that mimics a full-scale machine. The present study considers both the steady-state and transient response cases, including the effects of aerodynamic, elastic, inertial, and gravitational forces. The analysis reveals the changes to physical characteristics induced by a generic change of scale, indicates which characteristics can be matched faithfully by a subscaled model, and states the conditions that must be fulfilled for desired matchings to hold. Based on the scaling laws formulated here, the article continues by considering the problem of designing scaled rotors that match desired indicators of a full-scale reference. To better illustrate the challenges implicit in scaling and the necessary tradeoffs and approximations, two different approaches are contrasted. The first consists in a straightforward geometric zooming. An analysis of the consequences of zooming reveals that, although apparently simple, this method is often not applicable in practice, because of physical and manufacturing limitations. This motivates the formulation of scaling as a constrained optimal aerodynamic and structural matching problem of wide applicability. Practical illustrations are given considering the scaling of a large reference 10 MW wind turbine of about 180 m in diameter down to three different sizes of 54, 27, and 2.8 m. Results indicate that, with the proper choices, even models characterized by very significant scaling factors can accurately match several key performance indicators. Additionally, when an exact match is not possible, relevant trends can at least be captured.