National Wind Technology Center Dynamometer Upgrade Project Overview March, 2010 by Mike Derby, DOE (Brian McNiff) Presentation by Flemming Rasmussen, Risø DTU
Current NWTC 2.5 MW Dyno NWTC gearbox Adjustable table enables dynamometer motor and gearbox to be aligned to any drivetrain test article configuration Jack shaft Drivetrain under test (power converter not shown)
Current NWTC Drivetrain Testing Capabilities NWTC commissioned the 2.5MW Dyno in 1999 2.5 MW rated power capacity -power regeneration at 480/575or 4160 volts. Torque range 0-1.6 MNm. Speed range from 0-2250 RPM 488 kn force capacity for dynamic shaft bending with servo-hydraulic controls. Fully automated SCADA torque/speed controls
Shaft Power (kw) Current NWTC Power/Speed Envelope The only multi-megawatt entire-drivetrain testing capability in the U.S. Turbine drivetrains over approximately 2 MW can not be HALT tested in the U.S. today. 7000 6000 5000 Current 2.5 MW Dyno Power - Speed Envelope Practical wind turbine envelope Current 2.5 MW Dyno Existing machines HALT Test Points (30% above rated torque) Practical Envelope - High Speed Practical Envelope - Low Speed 4000 3000 2000 1000 0 2.5 MW Dyno Shaft Speed (rpm) 0 5 10 15 20 25 30 35 40
NWTC Dynamometer Upgrade Project Origins DOE Project Operating Plan, July 09 upgrade the 2.5 MW dynamometer facility to 5.0 MW NREL receives $10 M ARRA funds, Sept 09 Strict Buy-American requirements for construction Conceptual design underway Dec 09 Target date for completion June 12 5
NWTC Dynamometer Upgrade System Requirements Priority 1 mandatory (subject to change) Ability to conduct HALT, highly accelerated (gearbox) lifetime testing, on a 2.5 to 3.5-MW rated drivetrain (A range of drivetrain ratings is given because manufacturers use varying overload conditions for HALT.) Ability to apply static non-torque shaft loading with a capacity sufficient for representative loads on a 3.5-MW rated drivetrain Ability to certify wind turbine drivetrains in accordance with expected IEC testing standards for drivetrains (This standard is expected to require submitting the drivetrain to the design load cases in IEC 61400-1. It is important for this facility to have equipment capable of developing new testing technology for this purpose.) Facility design, installation and calibration of sufficient quality to support future accreditation System control capable of providing dynamometer torque transients in response to test article control commands combined with a model of rotor aerodynamic characteristics 6
NWTC Dynamometer Upgrade System Requirements Priority 2 highly desirable (subject to change) Ability to conduct performance and prototype testing of drivetrains up to 4.0 to 4.5-MW rated capacity Ability to apply static non-torque shaft loading with a capacity sufficient for representative loads on a 4 to 4.5-MW rated drivetrain Ability to apply dynamic non-torque shaft loading with a capacity sufficient for representative loads on a 4 to 4.5-MW rated drivetrain Ability to simulate a range of grid conditions sufficient to test drivetrains for compliance with existing and anticipated IEC standards Ability to test direct drive generators with diameters of up to 6.0 m 7
NWTC Dynamometer Upgrade System Requirements Priority 3 if budget allows (subject to change) Ability to conduct testing in a temperature-controlled environmental chamber Assembly, disassembly and inspection facilities with clean room environment A facility configuration that prevents tours from infringing on dynamometer intellectual property and/or test operations 8
NWTC Dynamometer Upgrade Power/Speed Capabilities (subject to change) Design Target: 5.0 MW @ 12-24 rpm LSS 9
WT Drive Train Test Facility US DOE EERE: DE-FOA-000012 : $98M Project $45M US DOE EERE, $53M Matching Funds Primary Mission: Provide (1) High Value, (2) High Quality and (3) Cost Competitive testing services, with high integrity and respect for the end users intellectual property. Secondary Mission: Establish long term partnerships with industry for work force development, research and education.
Business model based on proven CUICAR model Public /Private Partnerships focused on meeting industry s needs Research / Full Scale Testing Education: developing people for industry Collaboration with Industrial Partners
Strategically located in industrial port facility DTTF Site
Utilize Existing Port Infrastructure Former DOD Non-Haz Warehouse Built 1985, decommissioned 1992 7642 m2 14.6 m clearance Deepwater port access Detyens Shipyard 500 ton lift capacity at docks
Proposed Building Layout Future Expansion To Main RR Connector Demolished RR To DD3 and Piers External Prep Area Dedicated 115 kv feed and substation
Test Rig #1: 15 MW with Dynamic Load Applicator
Test Rig #1: Handling of Direct Drive Units
Torque Curves for 15 MW Test Stand
Dynamic Load Applicator: Sleeve Bearing Design
Test Rig #2: 7.5 MW Component Test Rig Static Load Applicator
Challenges Managing the huge torques (15 M Nm) Pushing existing proven gear box designs Systems engineering Integration of dynamic load applicator Repeatability of testing parameters Calibrating applied loads to field conditions Use of advanced sensors Ensuring protection of intellectual property Logistical handling of large test specimens Ensuring long term viability in a changing market
Proposed Capabilities Nacelles 15 MW Test Rig 7.5 MW Test Rig Complete Drivetrains Yes Yes Gear boxes Yes Yes Direct Drive Yes Yes Dynamic Load Applicator Static Load Applicator High Speed Generators Yes Yes Climatic Chamber (Future) Yes Yes Acoustic Chamber (Future) Yes Yes Low Voltage Ride Through Testing (Future) Grid Fault (Short Circuit) Testing (Future) Yes Yes Yes Yes Yes Yes Yes
Tentative Project Time-Line (Goal to Accelerate)
Key Industry Players will serve on Industrial Review Board Timken Bosch-Rexroth Winergy Hansen GE Transportation
Planetary drive train
Planetary stage
Contact loss and wedging
Impact of loads (causing double contact)