An official website of the United States government
Wind turbine blade leading edge erosion (LEE) reduces energy production and increases wind energy operation and maintenance costs. Degradation of the blade coating and ultimately damage to the underlying blade structure are caused by collisions of falling hydrometeors with rotating blades. The selection of optimal methods to mitigate/reduce LEE are critically dependent on the rates of coating fatigue accumulation at a given location and the time variance in the accumulation of material stresses. However, no such assessment currently exists for the United States of America (USA). To address this research gap, blade coating lifetimes at 883 sites across the USA are generated based on high-frequency (5-min) estimates of material fatigue derived using a mechanistic model and robust meteorological measurements. Results indicate blade coating failure at some sites in as few as 4 years, and that the frequency and intensity of material stresses are both highly episodic and spatially varying. Time series analyses indicate that up to one-third of blade coating lifetime is exhausted in just 360 5-min periods in the Southern Great Plains (SGP). Conversely, sites in the Pacific Northwest (PNW) exhibit the same level of coating lifetime depletion in over three times as many time periods. Thus, it may be more cost-effective to use wind turbine deregulation (erosion-safe mode) for damage reduction and blade lifetime extension in the SGP, while the application of blade leading edge protective measures may be more appropriate in the PNW. Annual total precipitation and mean wind speed are shown to be poor predictors of blade coating lifetime, re-emphasizing the need for detailed modeling studies such as that presented herein.
more »
« less
This content will become publicly available on December 1, 2025
Prioritizing Research for Enhancing the Technology Readiness Level of Wind Turbine Blade Leading-Edge Erosion Solutions
An enhanced understanding of the mechanisms responsible for wind turbine blade leading-edge erosion (LEE) and advancing technology readiness level (TRL) solutions for monitoring its environmental drivers, reducing LEE, detecting LEE evolution, and mitigating its impact on power production are a high priority for all wind farm owners/operators and wind turbine manufacturers. Identifying and implementing solutions has the potential to continue historical trends toward lower Levelized Cost of Energy (LCoE) from wind turbines by reducing both energy yield losses and operations and maintenance costs associated with LEE. Here, we present results from the first Phenomena Identification and Ranking Tables (PIRT) assessment for wind turbine blade LEE. We document the LEE-relevant phenomena/processes that are deemed by this expert judgment assessment tool to be the highest priorities for research investment within four themes: atmospheric drivers, damage detection and quantification, material response, and aerodynamic implications. The highest priority issues, in terms of importance to LEE but where expert judgment indicates that there is a lack of fundamental knowledge, and/or implementation in measurement, and modeling is incomplete include the accurate quantification of hydrometeor size distribution (HSD) and phase, the translation of water impingement to material loss/stress, the representation of operating conditions within rain erosion testers, the quantification of damage and surface roughness progression through time, and the aerodynamic losses as a function of damage morphology. We discuss and summarize examples of research endeavors that are currently being undertaken and/or could be initiated to reduce uncertainty in the identified high-priority research areas and thus enhance the TRLs of solutions to mitigate/reduce LEE.
more »
« less
- Award ID(s):
- 2329911
- PAR ID:
- 10613935
- Publisher / Repository:
- mdpi
- Date Published:
- Journal Name:
- Energies
- Volume:
- 17
- Issue:
- 24
- ISSN:
- 1996-1073
- Page Range / eLocation ID:
- 6285
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
More Like this
-
-
The primary goal in designing wind turbine blades is to maximize aerodynamic efficiency. One promising approach to achieve this is by modifying the blade geometry, with winglets to the tip. Winglets are intended to reduce the strength of the tip vortices, thereby reducing induced drag, increasing torque, and, ultimately, improving the power output of the wind turbines. In this study, computational fluid dynamics (CFD) simulations were utilized to assess the aerodynamic performance of wind turbine blades with and without winglets at various wind speeds (5, 7, 10, 13, 15, 20, and 25 m/s). The results indicate that winglets have a limited effect at low (5 and 7 m/s) and high (20 and 25 m/s) wind speeds due to fully attached and separated flows over the blade surface. However, within the 10–15 m/s range, winglets significantly enhance torque and power output. While this increased power generation is beneficial, it is essential to consider the potential impact of the associated increase in thrust force on turbine stability.more » « less
-
Abstract Quantification of the performance degradation on the annual energy production (AEP) of a wind farm due to leading‐edge (LE) erosion of wind turbine blades is important to design cost‐effective maintenance plans and timely blade retrofit. In this work, the effects of LE erosion on horizontal axis wind turbines are quantified using infrared (IR) thermographic imaging of turbine blades, as well as meteorological and SCADA data. The average AEP loss of turbines with LE erosion is estimated from SCADA and meteorological data to be between 3% and 8% of the expected power capture. The impact of LE erosion on the average power capture of the turbines is found to be higher at lower hub‐height wind speeds (peak around 50% of the turbine rated wind speed) and at lower turbulence intensity of the incoming wind associated with stable atmospheric conditions. The effect of LE erosion is investigated with IR thermography to identify the laminar to turbulent transition (LTT) position over the airfoils of the turbine blades. Reduction in the laminar flow region of about 85% and 87% on average in the suction and pressure sides, respectively, is observed for the airfoils of the investigated turbines with LE erosion. Using the observed LTT locations over the airfoils and the geometry of the blade, an average AEP loss of about 3.7% is calculated with blade element momentum simulations, which is found to be comparable with the magnitude of AEP loss estimated through the SCADA data.more » « less
-
A field campaign was carried out to investigate ice accretion features on large turbine blades (50 m in length) and to assess power output losses of utility-scale wind turbines induced by ice accretion. After a 30-h icing incident, a high-resolution digital camera carried by an unmanned aircraft system was used to capture photographs of iced turbine blades. Based on the obtained pictures of the frozen blades, the ice layer thickness accreted along the blades’ leading edges was determined quantitatively. While ice was found to accumulate over whole blade spans, outboard blades had more ice structures, with ice layers reaching up to 0.3 m thick toward the blade tips. With the turbine operating data provided by the turbines’ supervisory control and data acquisition systems, icing-induced power output losses were investigated systematically. Despite the high wind, frozen turbines were discovered to rotate substantially slower and even shut down from time to time, resulting in up to 80% of icing-induced turbine power losses during the icing event. The research presented here is a comprehensive field campaign to characterize ice accretion features on full-scaled turbine blades and systematically analyze detrimental impacts of ice accumulation on the power generation of utility-scale wind turbines. The research findings are very useful in bridging the gaps between fundamental icing physics research carried out in highly idealized laboratory settings and the realistic icing phenomena observed on utility-scale wind turbines operating in harsh natural icing conditions.more » « less
-
The aerodynamic shapes of the blades are of great importance in wind turbine design to achieve better overall turbine performance. Fluid–structure interaction (FSI) analyses are normally carried out to take into consideration the effects due to the loads between the air flow and the turbine structures. A structural integrity check can then be performed, and the structural/material design can be optimized accordingly. In this study, three different tip shapes are investigated based on the original blade of the test wind turbine (Phase VI) from the National Renewable Energy Laboratory (NREL). A one-way coupled simulation of FSI is conducted, and results with a focus on stresses and deformations along the span of the blade are investigated. The results show that tip modifications of the blade have the potential to effectively increase the power generation of wind turbines while ensuring adequate structural strength. Furthermore, instead of using more complicated but computationally expensive techniques, this study demonstrates an effective approach to making quality observations of this highly nonlinear phenomenon for wind turbine blade design.more » « less
