Herb Sutherland

1
Wind Energy Technology

• Herb Sutherland
• Wind Energy Technology Dept.
• Sandia National Laboratories
• www.sandia.gov/wind

2
Current Wind Industry Market

• Size
• 1.5-5.0 MW
• Towers 65-100 m
• Blades 34-50m
• Weight 150-500t

• Costs
• System lt 3/lb
• Blades lt 5/lb
• 0.75/Watt
• 0.03-0.05/kWh

3
Wind Cost of Energy is Falling
U.S. Cumulative Capacity (MW)
Cost of Energy (cents/kWh)
Year 2000 dollars
Increased Turbine Size - RD Advances -
Manufacturing Improvements
4
Some Machines Currently on the Market
These four suppliers account for 75 of the world
market
Gamesa (Spain)
Vestas NEG Micon (Denmark)
GE (US)
No. 5 Bonus/Siemens (Denmark/Germany)
Enercon (Germany)
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Size of the Global Market
6
Growth of Wind Energy Capacity Worldwide

Jan 2004 Cumulative MW Rest of World
3.897 North America 6,691 Europe
28,706
MW Installed
Updated March 2004
Sources BTM Consult Aps, March 2003
AWEA/EWEA Press Release 3/3/03
EWEA press release 10/3/04
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(No Transcript)
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RESOURCE
New Mexico
Ref. Elliott, et al, An Assessment of the
Available Windy Land Area and Wind
Energy Potential in the Contiguous United
States, August 1991, PNL-7789
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NM Wind Farms

• 204 MW PNM Wind Energy Center
• House, NM
• PNM
• 80 MW Caprock Wind Ranch
• Quay county, NM
• Cielo Wind Power/Xcel
• 120 MW San Juan Mesa
• Elida, NM
• Padoma Wind Power/Xcel

10
DOE Wind Energy Program2002 Plan
Class 6 (High Energy) Sites
Technology Application
Technology Viability
Class 4 (Good) Sites
Low Wind SpeedTechnology
SystemsIntegration
Distributed WindTechnology
TechnologyAcceptance

• Primary Program Activities
• Public/private partnerships

• Primary Program Activities
• Public/private partnerships

• Primary Program Activities
• Models
• Ancillary costs
• Utility rules
• Grid capability

• Primary Program Activities
• State outreach
• Federal loads
• Rural wind development
• Native Americans
• Power partnerships

Load Centers
Goal A By 2012, COE from large systems in Class 4
winds 3 cents/kWh onshore or5 cents/kWh
offshore (Program Strategic Performance Goal)
Goal C By 2012, complete program activities for
grid access, operating rules, ancillary service
tariffs, and transmission expansion plans that
support industrys 2020 capacity goal.
Goal D By 2010, 100 MW installed in at least16
states.
Goal B By 2007, COE from distributed wind
systems10-15 cents/kWh in Class 3
ProgramGoals
Supporting Engineeringand Analysis
Supporting Researchand Testing

• Primary Program Activities
• Standards and certification
• Field verification test support
• Technical issues analysis and communications
• Innovative technology development

• Primary Program Activities
• Enabling research
• Design Review and Analysis
• Testing Support

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Impact of Cost Goals
Current Class 4 cost 4.3 cents/kWh Class 4 goal
(2012) 3.0 cents/kWh

• Baseline (15 GW in 2020)
• No technology breakthrough
• Class 6 Plateau

• Expands resource base 20-fold
• Reduces average distance to load 5-fold
• 35 GW additional opportunity by 2020

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Offshore Wind
US DOE Program Goal 5 cents/kWh, Shallow Water
Offshore in the year 2012

• European Goal 10 GW offshore
• British Islands
• Enormous resource
• 1.4 GW in the planning stages
• US has limited shallow resource
• US Early Interest
• Cape Cod (Cape Wind)
• Long Island (LIPA)
• Deep Water Research
• Base and foundation costs
• Floating structures

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How Do We Get to Low-Cost, Low-Wind-Speed
Technology? (Thresher 5/02)
Technology Improvements
Estimated COE Improvement

• Larger-scale 2 - 5MW - (rotors up to 120m) 0
  ? 5
• Advanced rotors and controls
• (flexible, low-solidity, higher speed, hybrid
  carbon-glass -15 ? 7
• and advanced and innovative designs)
• Advanced drive train concepts -
• (Hybrid drive trains with low-speed PM
  generators and -10 ? 7
• other innovative designs including reduced cost
  PE)
• New tower concepts - (taller, modular, field
  assembled,
• load feedback control) -2 ? 5
• Improved availability and reduced losses -
  (better controls, -5 ? 3
• siting and improved availability)
• Manufacturing improvements - (new manufacturing
  methods, -7 ? 3
• volume production and learning effects)

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Wind Turbine Systems
Conventional Drive Train
Hub
Gear Box
Direct Drive System
Pitch System
Yaw System
Generator
Blade
Tower
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How Do We Get to Low-Cost, Low-Wind-Speed
Technology? (Thresher 5/02)
Technology Improvements
Estimated COE Improvement

• Larger-scale 2 - 5MW - (rotors up to 120m) 0
  ? 5
• Advanced rotors and controls
• (flexible, low-solidity, higher speed, hybrid
  carbon-glass -15 ? 7
• and advanced and innovative designs)
• Advanced drive train concepts -
• (Hybrid drive trains with low-speed PM
  generators and -10 ? 7
• other innovative designs including reduced cost
  PE)
• New tower concepts - (taller, modular, field
  assembled,
• load feedback control) -2 ? 5
• Improved availability and reduced losses -
  (better controls, -5 ? 3
• siting and improved availability)
• Manufacturing improvements - (new manufacturing
  methods, -7 ? 3
• volume production and learning effects)

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Sandia Wind Energy ResearchPrimary
Responsibility Blades

• Blades are the only uniquely wind-turbine
  component
• Blades produce all the energy
• Blades produce all the system loads

• Sandia Research Elements
• Advanced Blade Control both active and passive
  (adaptive blade)
• Materials
• Manufacturing
• Analysis Tools
• Validation Testing NDI
• Field Testing and Instrumentation
• Reliability

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Blades Are Getting Bigger
50.5 Meter Blade(GE 3.6 MW turbine)
Blade Size over Time
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Comparison of Weight Trends WindStats Data
Preliminary Designs
SAND2004-0074, Innovative Design Approaches for
Large Wind Turbine Blades Final Report, TPI
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New Materials New Issues

• Carbon fiber forms
• Cost vs. Performance
• Tow Size
• Pre-preg vs. fabrics
• Processing and fiber straightness
• Carbon/Glass hybrids
• Carbon-to-Glass Transitions
• Resin systems

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Design ToolsValidation and Testing
Design, analyze, fabricate, and test composite
material structures to develop new approaches to
design and analysis of blades
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Sandia Partners in Blade Manufacturing

• TPI Composites
• TPI and Mitsubishi have a joint venture
  Vienteck in Juarez, Mexico
• Manufacturing blades for 1-2 MW Mitsubishi
  machines
• 40m long blade now being tested
• TPI patented SCRIMP technology

22
Design Studies identify the inner-span for
thicker airfoils

• A thicker airfoil opens up new manufacturing
  opportunities
• Constant thickness spar cap
• Pre-manufactured spars (e.g., Pultrusion)
• Weights are reduced substantially without other
  (material) changes

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Examples of Flatback Airfoils
Previous extent of flat trailing edges on blades
New concepts in flatback airfoils
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Adaptive Blades

• Active
• Micro-tab Assembly Motion

Passive Bend-Twist Coupling
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Field Testing Site Monitoring and Turbine Loads
Research
ATLAS System Layout
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Wind Energy Questions
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Growth of Wind Energy Capacity Worldwide

Jan 2004 Cumulative MW Rest of World
3.897 North America 6,691 Europe
28,706
MW Installed
Updated March 2004
Sources BTM Consult Aps, March 2003
AWEA/EWEA Press Release 3/3/03
EWEA press release 10/3/04
28
Blade Size over Time
50 meter 34 meter 23 meter 20 meter 12
meter 9 meter 7.5 meter 5 meter
1978 1985 1990 1995
2000 2005
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50.5 Meter Blade(GE 3.6 MW turbine)
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Offshore Wind Development

• Germany and Denmark have limited land area and
  extensive, shallow, windy, offshore area
• The UK has onshore NIMBY and is hoping to go
  immediately offshore
• The US East Coast is the largest electrical load
  the best wind resources are offshore
• Great Lakes offer a similar opportunity
• Much of the US opportunity is in deeper water
  (gt50m)

Offshore Projection
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Wind Power Basics
Wind Power output is proportional to wind speed
cubed.
Effectively, the maximum drag-driven power
coefficient is 0.15 because only the down-wind
motion of the blade produces power
Lift-driven machines are only limited by the
Betz Limit (the maximum energy extraction
coefficient)
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Turbine Power Basics
Energy vs. Wind Speed
Power vs. Wind Speed
15 mph (6.8 m/s) average wind speed
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Wind Turbine Manufacturers
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Horns Reef, Denmark
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Why Move Offshore?

• Higher-quality wind resources
• Reduced turbulence
• Increased wind speed
• Economies of scale
• Avoid logistical constraints on turbine size
• Proximity to loads
• Many demand centers are near the coast
• Increased transmission options
• Access to less heavily loaded lines
• Potential for reducing land use and aesthetic
  concerns

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Horns Rev Offshore Wind FarmNorth Sea Off
Danish Coast
Wind turbine type Vestas V80 - 2 MW Total wind
farm output 160 MW (80 turbines) Expected
annual production 600,000,000 kWh Rotor diameter
80 m Hub height 70 m Mean wind speed (62 m)
9.7 m/s Water depth 6-14 m Distance from land
14-20 km Wind farm area 20 km2 Total project
costs DKK 2 billion (EUR 270 million)
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Northeastern U.S. Offshore Potential

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Wind ResourceWest Coast of the US
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Reverse Evolution
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GE Wind Energy 3.6 MW Turbines