(2004) Wind Turbine Technology - IsTORIE

“Wind Turbine Technology”
Presented to the Austin Chapter of the:

IEEE Power Engineering Society
by
Jules Campbell
Fellow of the Technical Staff, Motorola SPS
Advocate, American Wind Energy Association
Senior Member, IEEE
2/24/2004
Jules Campbell – 24 Feb 2004
Agenda
• Brief History of Wind Power
• Evaluating Wind Power
• U.S. & Texas Resources
• Modern Wind Turbine Technology
• Issues with Wind?
• Is Wind Economical?
• Conclusions

A Brief History of Windpower
Photos from
“Wind Turbine Technology”
by David A. Speara

First Wind Power Generator
Wind Generator
Dr. Charles Brush
Cleveland, OH
1888 – 1908
Rotor Diameter: 17m
Power Output: 12 kW

Early “Small” Wind Turbine
Jacobs Wind Electric Battery Charger

c. 1931

Early Large Scale Wind Turbines
First “Grid Tied” turbine First “ > 1 MW Turbine

Russia 1931: 30m – 100kW Putnam, VT 1941: 53m -- 1.25MW
Darrieus VAWT*
Sandia Labs: 17m, experimental

*Vertical Axis
Wind Turbine FlowWind 170kW, Altamont Pass, CA
How Wind Power got a Bad Name!
Tehachapi, CA Photo by Henry Richardson, “consultant”

Evaluating Wind Power

The Air We Breathe
Composition of Air (1m3 = 1000 liters)
Cumulative Molecular
Wt. Mass per Cumulative
Component Formula Quantity Units composition
(g/22.4l) g/m 3 mass (g/m3)
(%)
Nitrogen N2 78.0840% percent 78.0840% 28.0134 976.52 976.52
Oxygen O2 20.9470% percent 99.0310% 31.9988 299.23 1275.75
Argon Ar 0.9340% percent 99.9650% 39.948 16.66 1292.41
Carbon Dioxide CO2 0.0314% percent 99.9964% 44.0003 0.62 1293.02
Neon Ne 18.18 ppm 99.9982% 20.179 0.000367 1293.02
Helium He 5.24 ppm 99.9987% 4.026 0.000021 1293.02
Krypton Kr 1.14 ppm 99.9989% 83.8 0.000096 1293.02
Sulfur dioxide SO2 1 ppm 99.9990% 64.0628 0.000064 1293.02
Methane CH4 2 ppm 99.9992% 16.04338 0.000032 1293.02
Hydrogen H2 0.5 ppm 99.9992% 2.01594 0.000001 1293.02

Nitrous Oxide N2O 0.5 ppm 99.9993% 44.0128 0.000022 1293.02
Xenon Xe 0.087 ppm 99.9993% 131.3 0.000011 1293.02
Ozone O3 0.07 ppm 99.9993% 47.9982 0.000003 1293.02
Nitrogen Dioxide NO2 0.02 ppm 99.9993% 46.0055 0.000001 1293.02
Iodine I2 0.01 ppm 99.9993% 253.8088 0.000003 1293.02
Carbon Monoxide CO trace 99.9993% 28.0149 1293.02
Ammonia NH3 trace 99.9993% 17.03061 1293.02
99.9993% 1293.02

Weather effects on Air Density
Density of Air vs. Temperature
Temperature (F)
-50 0 50 100 150
1500 80
Water Content g/m3

1450 70
1400 60
Density g/m3
1350 50
1300 40
1250 30
1200 20
1150 10
1100 0
-40 -20 0 11 20 40 60
Conditions used for Temperature (C)
Turbine Rating.
Density of Dry Air Density of Saturated Air Max. Water Content

Computing Power in the Wind
• The mass passing through a 1 x 1 m2 surface
is proportional to the speed in m/s
– Mass = ρ (kg/m3)* v (m/s)
• The Kinetic Energy in the mass is ½ mv2
• Therefore, the power/m2 is proportional to v3
– Power/m2 = ½ ρ v3 = ½ kg/m3 * m3/s3
– Power/m2 = kg * m2/s2*1/s*1/m2 = Joules/s*1/m2 = W/m2
Χ m/s
1m3
1m2

Power in the Wind
Wind Power Density vs Wind Speed
Diesel Locomotive ~ 3MW F5 @ 318MPH = 1.7MW/m2
10,000,000 350.0 Fujita
300.0 Scale:
F5
Power Density (W/m2)
1,000,000
Tornados
100,000 F4 250.0
(miles/hour)
Wind Speed
10,000 F3 200.0
1,000 F2 150.0
100 F1 100.0
10 F0 50.0
1 0.0
1 3 10 25 100 1000
Wind Turbine
Wind Speed (meters/second)
Op Region
Energy Density Miles per Hour

Wind Power Classes
Classes of Wind Power Density at 10 m and 50 m(a)
10 m (33 ft) 50 m (164 ft)
Wind Power Wind Power Wind Power
Class Speed(b) Speed(b)
Density Density
(W/m2) m/s (mph) (W/m2) m/s (mph)
1 <100 <4.4 (9.8) <200 <5.6 (12.5)
2 100 - 150 4.4 (9.8)/5.1 (11.5) 200 - 300 5.6 (12.5)/6.4 (14.3)
3 150 - 200 5.1 (11.5)/5.6 (12.5) 300 - 400 6.4 (14.3)/7.0 (15.7)
4 200 - 250 5.6 (12.5)/6.0 (13.4) 400 - 500 7.0 (15.7)/7.5 (16.8)
5 250 - 300 6.0 (13.4)/6.4 (14.3) 500 - 600 7.5 (16.8)/8.0 (17.9)
6 300 - 400 6.4 (14.3)/7.0 (15.7) 600 - 800 8.0 (17.9)/8.8 (19.7)
7 >400 >7.0 (15.7) >800 >8.8 (19.7)

(a) Vertical extrapolation of wind speed based on the 1/7 power law
(b) Mean wind speed is based on the Rayleigh speed distribution of equivalent wind
power density. Wind speed is for standard sea-level conditions. To maintain the
same power density, speed increases 3%/1000 m (5%/5000 ft) of elevation.
(from the Battelle Wind Energy Resource Atlas)
In general, sites with a Wind Power Class rating of 4 or higher

are now preferred for large scale wind plants. Research
conducted by industry and the U.S. government is expanding
the applications of grid- connected wind technology to areas
with more moder

U.S. & Texas Resources

1987 U.S. Wind Atlas

C u m m u la tiv e A v e r a g e W in d
E n e rg y (M W )
0
200,000
400,000
600,000
800,000
1,000,000
1,200,000
1,400,000
N o rth D a k o ta
Texas
Kansas
S o u th D a k o ta
M o n ta n a
N e b ra s k a
W y o m in g
O k la h o m a
M in n e s o ta
Top 10 States!
Io w a
C o lo r a d o
N e w M e x ic o
Id a h o
M ic h ig a n
N e w Y o rk
State
Illin o is
C a lifo r n ia
W is c o n s in
M a in e
Cummulative Average Wind Energy by State
Cummulative Average Energy by State M is s o u r i

N evada
P e n n s y lv a n ia
O re g o n
States
W a s h in g to n
M a s s a c h u s e tts
V ir g in ia
W e s t V ir g in ia
V e rm o n t
U.S. DOE
U.S. Wind Power Potential
Central Plains & Rocky Mt
Tennessee
> 90% of Windpower resides in
H a w a ii
Total U.S. Generation 1999 ~ 775 GW

Wind Energy Power Potential > 1200GW
Data from AWEA &
A la s k a
Texas Wind Power & Projects
Rank 2 http://www.awea.org/projects/texas.html
Average Power Output 136,000 MW
Annual Output 1,191,360,000 kWhr Updated: Jan 12, 2004
Installed Output 1,293.24 MW
% of resource developed 0.95%
Power Purchaser/ Number Turbine
Date
Existing Project or Area Location (County) Owner MW of Rating Manufacturer
Online User
Turbines (MW)
Nichols Station Southwest Public Service 1992 0.3 Southwest Public Service 1 0.30 Carter
Deleware Mt. Culberson County Oct-95 35 LCRA 112 0.30 Kenetech
Fort Davis Wind Farm Fort Davis American Electric Power Sep-99 6 West Texas Utilities Co. 12 0.50 Zond
American Nat. Wind Power Reliant Energy, HL&P,
Deleware Mt. Culberson County Jun-99 30 40 0.75 Zond
& Orion Energy LCRA
Big Spring I Howard County York Research Apr-99 27.72 TXU 42 0.66 Vestas V-47
Big Spring II Howard County York Research Jun-99 6.6 TXU / York 1.65 Vestas
Southwest Mesa Crockett County Cielo Wind Power May-99 74.9 American Electric Power 107 0.70 NEG Micon (107)
Hueco Mt. El Paso County Cielo Wind Power Mar-01 1.32 El Paso Electric 2 0.66 Vestas V-47
76.7 Austin Energy 59
Jul-01 to 198.9 Reliant Energy 153
King Mt. I, II, & III Upton Co FPL Energy 1.30 Bonus, 60m
Dec-01 Texas-New Mexico Power
2.6 2
Co
Woodward Mt. I & II Pecos County FPL Energy Apr-01 159.7 TXU 242 0.66 Vestas V-47
Fort Stockton Pecos County Big Wind LP Jul-01 3.5 Texas - New Mexico Power
Trent Mesa Nolan & Taylor AEP Aug-01 150 TXU 100 1.50 GE Wind (Enron)
TXU (31.5MW)
Indian Mesa Pecos County National Wind Power Dec-01 82.5 125 0.66 Vestas V-47
LCRA (48.5MW)
Pecos Co near City Public Services of San
Desert Sky AEP Dec-01 160 107 1.50 GE Wind (Enron)
Iraan Antonio
Llano Estacado @ White
Carson Co Shell Wind Energy Nov-01 80 SW Public Service 80 1.00 Mitsubishi
Deer
Brazos Wind Ranch Borden& Scurry Cielo Wind Power 4Q 2003 160 TXU & Green Mt. Energy 160 1.00 Mitsubishi
Sweetwater DKR/ Babcock-Brown 4Q 2003 37.5 TXU 25 1.50 GE Wind
1293.2 1369

“Modern”
Wind Turbine Technology

Range of Turbine Sizes
Turbine Output vs Swept Area for misc. Vendors
6000
5000 Vestas
Neg-Micon
4000 Mitsubishi
Output (kW)
Gamesa Eolica
3000 GE Wind
Bonus
2000 Fuhrlander
Suzlon
1000 RePower
0
0 5000 10000 Data from
Swept Area (m^2) Vendor Websites

Common Turbine Characteristics
• Upwind Design: “into the wind”
• Tower height approximately equal to blade diameter:
– Solid or Annular, with rock fill (patented) Concrete Footing,
approx. 12-14’ in diameter, 14-20’ deep.
– Tubular Steel, usually in sections.
• Turbine “Cut-in” speed: approx. 3 m/s
• “Rated speed” (for max. power): from 11-15 m/s
– depends on rotor diameter and siting in “high” or
“low” wind speed location.
• “Cut-out” > 25 m/s, except for short bursts
– Turbine “feathers” blades and applies breaks
– Approximately 30 seconds “spin down” time.

Common Rotor Characteristics
• 3 Fiberglass Blades
– Provides Balance in both Horizontal & Vertical directions.
– Embedded conductor for lightning strikes.
– Constant RPM, depending on diameter
– Speed Regulation: Blade Stall and/or Blade Pitch
– Tip speed 130-190 mph, varies with model & manufacturer
• Yaw control:
– Wind Speed & Direction Sensors cause controller
to aim rotor into wind
– bull gear & motors at top of tower

Common Generator Characteristics
•Types:
•Assynchronous: Induction
•Double Fed Induction: Wide “slip range”
•Variable Speed: Power Electronic Output
•RPM: 1200/1800 (60 Hz)
•Output: Three Phase, 690 V
•Dual Windings 6/4 pole for low/high wind
conditions and related low/high power output
•Power: 0.66MW-3.6MW
•“Grid Tie”: usually “soft” with thyristors, plus
electro-mechanical contactor

Wind Farm Electrical Systems
• Transformer at base of turbine towers connects to
13.8-35kV distribution system within the wind farm.
• Distribution feeds a multi-MW sub-station to grid

Turbine Siting in Arrays
Sub-
XRMR XRMR XRMR
station
3d
Turbine Array 5 to 10d
Distribution Lines
XRMR XRMR XRMR
d Predominant
Wind Direction

King Mountain Wind Farm (McCamey, TX)
214, 1.3 MW Bonus Turbines 1.3 MW @ 15 m/s
providing up to 278 MW of
“Pollution Free” Power,
ter
to Austin Energy & elsewhere. m
e
D ia ers
o r et
o t m
R 6 0
Hub Height: 65 meters

Bonus 1.3 MW Nacelle
Rotor Attach Point Nacelle with Canopy Open
Main Shaft & 1 of 4 Yaw Motors Disk Brake & 1.3 MW Generator
Bonus 1.3MW Nacelle (typical of industry)
9. Gearbox
1. Spinner 10. Brake Disc
2. Rotor Hub 11. Brake Caliper
3. Blade 12. Coupling
4. Pitch Bearing 13. Generator
5. Pitch Gearbox 14. Meterological
6. Main Bearing Sensors
7. Main Shaft 15. Yaw Ring
8. Top Controller 16. Yaw Bearing
17. Yaw Gearbox
18. Nacelle Bedplate
19. Hydraulics
20. Canopy
21. Generator Fan

Rotor Components
60 meter diameter
“I can’t believe I got the whole thing!!”
Hub, Blade attach & Spinner Angled fins reduce noise, like airplanes
Suzlon 0.95 MW Drivetrain
Rotor Hub
Torque
Converter
Coupling
Removed
Main Drive Shaft & Bearing Disk Brake & Gearbox
Hydraulic Pump
0.95 MW Generator
Suzlon 0.95 MW Rotor Hub
Blade Attach
Bolt Holes
Blade Pitch Controllers
Blade Pitch Drive Motor

Suzlon 0.95MW Controls
Controller Cabinets
Vibration Vibration
Sensors Analyzers

Other Technologies
• Enercon (Germany)
– Direct Drive, no RPM step up transmission
– High Pole Count “Ring Generator” (e.g. alternator)
• The Wind Turbine Company (Washington)
– Down Wind (self yawed or powered yaw)
– Two Blade, blade tilting to reduce “root” stress
– Guyed Tower, aim to lower cost.
• Clipper Wind Turbines (California)
– Multiple (8) Generators on common drive
– reduced production loss
– Generator swapping requires smaller crane
– Not in the field yet, concept or in development

Other Technologies
The Wind Turbine Company

2 Blade, Downwind
Enercon 30 m & 112 m (4.5MW)
Clipper Drive with

8 generators
Photos from Vendor Websites

or convention booth

“Desert Sky” Photo Album
Site Plan
Turbine Control Panel
Site Control System readout of

Turbine “Cubic” power curve

Sommerset, PA
• 8 - Nordex N-60, 1.3MW

• Very Quiet Turbines!
• Built on top of old “strip mine”
(note dragline in lower right)

“Stateline” Project (WA-OR)
•459 x Vestas, V-47 / 660kW
•Covers 50 sq. mi.
•BPA Grid
AWEA Tour Group
in e C o n tr oll er Panel”
“Turb
“Field of Dreams”

Issues with Wind Power ?
Technical Issues:
• Distance from the Load
• Weak Power Grid & Capacity
• Induction Machines & Grid “Dips”
• Needs Storage Mechanism for variability
• Radio Frequency Interference & Reflections
People Issues:
G.E. 100m/3.6MW
• Must forecast vs. “dispatch”
• Environmentalists & Bird Kills? – Feral Cats are worse!
• Noise Pollution? – Most are barely perceptible!
• Visual Impact? – You be the judge!
• N.I.M.B.Y. – Senator Kennedy isn’t the only “scrooge”!!

Energy Storage Techniques
• Pumped Hydro-electric
– BPA announced plans for 500MW Wind storage
– Requires geologic formations & water source
• Compressed Air
– Typically a cavern, or pressure tanks
– Some (heat of compression) energy lost in
storage.
– Eliminates compressor losses on Gas turbine
• Flywheels?
– Present-day ~ 4MJ or 1-5 seconds vs need or
hours
• Batteries?
– Large, Heavy, Toxic Materials

Energy Storage Techniques
• PEMFC (Proton Exchange Membrane Fuel Cells)
– Reversible Electrolysis-Generation > 50% recovery
– Hydrogen Storage still an issue
• Doesn’t compress easily and only Liquefies at
~3 K
• Metal-Hydride powders have promise, but
require heat input for hydrogen “liberation”
– Probable synergy between Wind Power needing
hydrogen storage & Fuel Cell Autos needing
hydrogen infrastructure.
– Or generate Hydrogen & burn in combined cycle
Gas Turbine/Steam Turbine plant.

Small PEMFC Characteristic
Energy Input to Drive

“Liberation” of H2
Gas Generation
Energy Lost as Heat

Electricity During generation of
Generation Electricity
Data Taken by author on ~ 4 cm2 PEMFC.

Is Wind Power Economical?

2002 Power Generation Costs
Construction + Generation: Range, Cents/KWhr
Photovoltaic 15 25 Earth Friendly!
Solar (thermal) 10 15
Nuclear 10 15 Radioactive Waste
Hydro-electric 4 10 Affects Stream Ecology
Biomass 6 8
Geothermal 3 8
Coal 4 5 Polluting !
Wind 4 5
Natural Gas 3 4 Reduced CO2, toxics
Data from “The Environment” by Raven & Berg

Conclusion
Some would say…

“If it ain’t broke, don’t fix it!?”
I disagree!

Present Day U.S. Generation Sources
Chart from:
http://www.balancedenergy.org
(A Coal Industry Consortium)
70 % of U.S. Energy comes from fossil fuels:

• large discharges of CO2, e.g. “greenhouse” gas.
• large discharges of air pollutants (e.g. causing unaccounted
health problems)

Input-Output of a typical 500MW Coal Plant
• Gozintas Data from:
Union of Concerned Scientists
– 1,430,000 Tons of Coal 2002
– 146,000 Tons of Limestone
– 2.2 Billion Gallons of Water
• Gozoutas • Gozoutas (cont’d)
– 10,000 Tons of SO2
– 3.5 Billion kWhr!
– 10,200 Tons on NOX
– 3.7 Million Tons of – 500 Tons Small Particulates
CO2 – 220 Tons Hydro-Carbons
– Plus all these – 720 Tons CO
– 125,000 Tons Ash
Nasties!!! – 193,000 Tons Sludge
– As, Pb, Cd, Hg, U, etc.
– Approx. 65% Waste Heat

Deaths Attributed to Power Plants!
>1100 GW !!
Region holds > 90% of U.S. Wind Resource

Does Wind make sense?
• U.S. Electric Generation in 1999 was 775 GW.
• The Estimated U.S. Wind Resource is 1200 GW!
– 37.8E15 KWhr annually, or 37.8E19 Joule
• 1 Million Tons of Oil = 7.8 Million Barrels = 1E15 Joule
= 1 peta-Joule
• So, The Estimated U.S. Wind Resource is
equivalent to:
– 37.8 Billion Tons of Oil, or
–295 Billion Barrels of Oil !!

• E.U. & US DOE have targeted 20% electrical
generation from Wind by 2020

Acknowledgements
• American Wind Energy Association
– Souvenir Calendars for y’all!
– Excellent website information
– Wind Power Conferences & Project Tours
• Texas Renewable Energy Industry
Assoc.
– “Texas Wind” pins for y’all!
• Walter Hornaday, Pres. Cielo Windpower
• Photos by Author, unless noted.

Links to Useful Information
• http://www.awea.org American Wind Energy Association
• http://www.ewea.org European Wind Energy Association
• http://www.nrel.gov National Renewable Energy Lab
• http://www.nrel.gov/wind National Wind Technology Center
• http://www.cielowind.com Cielo Windpower, Austin, Tx. Developer
• http://www.treia.org Texas Renewable Energy Industry Assoc
• http://www.bonus.dk Bonus – Sturdy & Quiet (< 70 dBA)
• http://www.gewind.com GE Wind, LVRT, Variable Spd., Quiet
• http://www.vestas.dk Low Cost, High Volume, noisier
• http://www.nordex.de Nordex – “Built like a Beamer”,(< 70dBA)
• http://www.mhi.co.jp/power/e_power/product/idx_nature_wind.html
» Mitsubishi Wind Turbines
• http://www.suzlon.com Suzlon – Torque Converter coupling
• http://www.enercon.de Enercon – Direct Drive, noise > 100dBA
• http://www.neg-micon.dk/cm90.asp?d=1 Neg-Micon
• http://www.gamesa.es/ingles/nucleos_negocio/gamesa_eolica/presentaci
on/presentacion.htm Gamesa Eolica

Ref: Energy Equivalence
Energy Units
0.2388 cal = 1 J (joule)
1 Ws = 1 J (joule)
1 kWh = 3.60 MJ (mega-joule) M = 1.00E+06
barrels of crude oil in
7.4
primary energy
toe (tonne
barrels in total final
1 oil = 7.8
consumption
e quiva le nt)
1270 m^3 natural gas
2.3 metric tonnes of coal
Mtoe
(million
1 = 41.868 PJ (peta-joule) P = 1.00E+15
tonne oil
e quiv.)
Million Barrels in final
= 7.8
consumption
Data from European Wind Power site:

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“Wind Turbine Technology”

Presented to the Austin Chapter of the:

Jules Campbell – 24 Feb 2004

Jules Campbell – 24 Feb 2004

Jules Campbell – 24 Feb 2004

Jacobs Wind Electric Battery Charger

Jules Campbell – 24 Feb 2004

First “Grid Tied” turbine First “ > 1 MW Turbine

Sandia Labs: 17m, experimental

Tehachapi, CA Photo by Henry Richardson, “consultant”

Jules Campbell – 24 Feb 2004

Jules Campbell – 24 Feb 2004

Hydrogen H2 0.5 ppm 99.9992% 2.01594 0.000001 1293.02

Jules Campbell – 24 Feb 2004

Water Content g/m3

Jules Campbell – 24 Feb 2004

Jules Campbell – 24 Feb 2004

Energy Density Miles per Hour

Jules Campbell – 24 Feb 2004

7 >400 >7.0 (15.7) >800 >8.8 (19.7)

In general, sites with a Wind Power Class rating of 4 or higher

Jules Campbell – 24 Feb 2004

Jules Campbell – 24 Feb 2004

Jules Campbell – 24 Feb 2004

Cummulative Average Energy by State M is s o u r i

Central Plains & Rocky Mt

Jules Campbell – 24 Feb 2004

Data from AWEA &

Jules Campbell – 24 Feb 2004

Jules Campbell – 24 Feb 2004

Jules Campbell – 24 Feb 2004

Jules Campbell – 24 Feb 2004

Jules Campbell – 24 Feb 2004

Jules Campbell – 24 Feb 2004

Jules Campbell – 24 Feb 2004

XRMR XRMR XRMR

Jules Campbell – 24 Feb 2004

Hub Height: 65 meters

Jules Campbell – 24 Feb 2004

Rotor Attach Point Nacelle with Canopy Open

Jules Campbell – 24 Feb 2004

“I can’t believe I got the whole thing!!”

Blade Pitch Controllers

Blade Pitch Drive Motor

Jules Campbell – 24 Feb 2004

Jules Campbell – 24 Feb 2004

The Wind Turbine Company

Enercon 30 m & 112 m (4.5MW)

Clipper Drive with

Photos from Vendor Websites

Jules Campbell – 24 Feb 2004

Turbine Control Panel

Site Control System readout of

Jules Campbell – 24 Feb 2004

• 8 - Nordex N-60, 1.3MW

Jules Campbell – 24 Feb 2004

AWEA Tour Group

Jules Campbell – 24 Feb 2004

Jules Campbell – 24 Feb 2004

Jules Campbell – 24 Feb 2004

Jules Campbell – 24 Feb 2004

Energy Input to Drive