The use of wind tunnels in the Wind Energy Industry Jesper Monrad Laursen Siemens Gamesa Renewable Energy

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1 The use of wind tunnels in the Wind Energy Industry Jesper Monrad Laursen Siemens Gamesa Renewable Energy October 24 th, 2018

2 Industrial perspective Offshore state-of-the-art 2018 Swept area m 2 ~ 3 football fields Energy production ~ house holds Mass of air through rotor at 10 m/s ~ 18 large Trucks Wind load in blade root ~ A VW Golf at the end of a 1.9 km stick 600 siblings are up and running! Siemens Gamesa Renewable Energy Peter Fuglsang Industrial perspective April 10 th 2018

3 Industrial perspective The industry challenge is the simultaneous cost pressure and global market growth Cost pressure Global market growth Low volume/short time on market Consolidation Cost focus Innovation need Short term Incremental thinking Cash constraints Short product life cycle Continuous collaboration with Universities and Research Institutions is a part of the solution

4 Industrial perspective 4 The innovation challenge for extreme-scale turbine development Blade mass scaling Scaling of a blade with 50% leads to almost 3 times the blade mass Non linear mass scaling trend with size Factory space scaling Larger blades and increased cycle time -> Need for factory space increase rapidly! Factory size for 50% additional blade length (est.) Mass Scaling law Additional innovation needed Blade x 1 Blade x 1.5 Size Radical innovation and disruption is needed to break the basic scaling laws more of the same will not work!

5 Industrial perspective 5 Blade factory in Aalborg, Denmark

6 6 Transporting 6MW nacelle to test site in Høvsøre

7 Industrial perspective 7 The innovation challenge for blade development 1979 Today Bonus 27 kw SWT m blade B75 blade Fundamental changes in shape and design > years of blade development

8 Design Approach Innovations in Aerodynamic Blade Design Vortex Generators Active flow control Tip shape Flatback airfoils High thickness airfoils Dinotail Sweep / Pre-bend Innovations in aerodynamic blade shape design has been driven by DFM & Product performance

9 Industrial perspective 9 Wind turbine airfoils. SGRE In-house Airfoil Design Robust performance in field - an Important KPI Tailored airfoils for specific functional requirements Blade surface conditions are rarely ideal! Airfoil Design Validation New airfoils are always wind tunnel validated before release for New Product Development (NPD) SGRE airfoils tailored to blade design philosophy, enabling high root performance, lower solidity and higher t/c Design for robustness favored over peak efficiency design for unlikely clean surface in field DFM approach enabling low cost light blades Flatback root airfoils Airfoil families tailored for straight, well aligned beams

10 Industrial perspective 10 Aerodynamic add-ons. Dinoshells Vortex Generators Lift enhancing device applied at the root section of the blade Vortex generators (VGs) are used to increase aerodynamic performance and reduce impact of blade soiling Dinotail A device applied at the trailing edge to reduce trailing edge sound emissions Power curve upgrade kits provide AEP increase, reduce soiling sensitivity and noise emission Add-on configuration is optimized on basis of few basic components Noise can be reduced at the same time as increasing annual energy production (AEP)

11 Industrial perspective 11 Wind turbine acoustics Quiet please! Learning from a silent hunter Overall a 1 db noise reduction over existing state of the art serrations! Systematic design approach and wind tunnel testing key to successful end result

12 Industrial perspective 12 Tip Shapes. Advanced Modeling of Tip Flow Tip flow is essentially 3D CFD 3D wind tunnel : Offers opportunities for directly modeling impact of geometry changes Wind Tunnel Validation Testing of B45 blade tip with winglet Qualitative measurements to prove design functionality Field Testing Engineers performing field validation of own concepts High level of detail can be obtained down to the level of surface finish, soiling etc. Advanced tip design can improve performance of large scale wind turbines SGRE and Risø further pursuing opportunities in this area through the Smart Tip project (Innovation Fund Denmark project) The devil is in the detail How can we use wind tunnel tests to unlock further details going forward?

13 Industrial perspective 13 Active flow control. Basic Concept Design and mature active add-ons concept Tailor blade section loading to actual need: performance increment or loads reduction? Concept Validation in Wind Tunnel Wind tunnel ideal for testing different concepts Feedback from wind tunnel used actively in optimization and maturing process Rapid Prototyping - Just do it Approach SGRE looking for next breakthrough on add-ons Early field testing essential for screening concepts Hands-on approach part of team DNA! Concepts tailored for specific need Power production below rated power? Loads alleviation? What load case is targeted? Overcoming of high design cost on large scale turbine Concept screening Rapid prototyping Testing, testing, testing

14 Industrial perspective 14 Advanced modelling We have become pretty far with our static calculations -> fits well with power curve etc. Next step is to better understand dynamic phenomena Advanced modelling of dyn. phenomena (getting started) How can we better validate model (wind tunnel testing?)? Field measurements (costly and late in development cycle) How can we combine advanced modelling and wind tunnel tests to understand dynamic phenomena better?

15 Industrial perspective 15 Computational Aero-Acoustics (CAA) Lattice-Boltzmann simulation Lambda2 Criterion visualizing vortices Acoustic waves and pressure fluctuations in BL Near field visualization of vortices rolling up on serrated trailing edge CAA can be used to pick improved design -> before going to wind tunnel The combination of advanced modelling and wind tunnel testing can be used to improve acoustic design

16 16 Technology maturity Airfoils Technological maturity? Active flow control Add-ons growing mature aging embryonic Effort / Time The wind tunnel need remains but the individual technologies change!

17 17 Technology readiness level The wind tunnel need is on component and sub system level

18 Key messages Congratulations on this great new wind tunnel We are looking forward to working with you in the AeroLoop EUDP project! Radical innovation and disruption is needed more of the same will not work! The wind tunnel need remains but the individual technologies change! Siemens Gamesa Renewable Energy Jesper Monrad Laursen Industrial perspective October 24 th 2018

19 Thank you! Jesper Monrad Laursen Chief Engineer, Offshore Blade R&D, Siemens Gamesa Renewable Energy