Mark A. Rumsey

Structural Health Monitoring of Wind Turbine Blades

As electric utility wind turbines increase in size, and correspondingly, increase in initial capital investment cost, there is an increasing need to monitor the health of the structure. Acquiring an early indication of structural or mechanical problems allows operators to better plan for maintenance, possibly operate the machine in a de-rated condition rather than taking the unit off-line, or in the case of an emergency, shut the machine down to avoid further damage. This paper describes several promising structural health monitoring (SHM) techniques that were recently exercised during a fatigue test of a 9 meter glass-epoxy and carbon-epoxy wind turbine blade. The SHM systems were implemented by teams from NASA Kennedy Space Center, Purdue University and Virginia Tech. A commercial off-the-shelf acoustic emission (AE) NDT system gathered blade AE data throughout the test. At a fatigue load cycle rate around 1.2 Hertz, and after more than 4,000,000 fatigue cycles, the blade was diagnostically and visibly failing at the out-board blade spar-cap termination point at 4.5 meters. For safety reasons, the test was stopped just before the blade completely failed. This paper provides an overview of the SHM and NDT system setups and some current test results.

Modal Analysis of CX-100 Rotor Blade and Micon 65/13 Wind Turbine

At the end of 2008 the United States became the largest producer of wind energy with 25,369 MW of electricity. This accounts for 1.25% of all U.S. electricity generated and enough to power 7 million homes. As wind energy becomes a key player in power generation and in the economy, so does the performance and reliability of wind turbines. To improve both performance and reliability, smart rotor blades are being developed that collocate reference measurements, aerodynamic actuation, and control on the rotor blade. Towards the development of a smart blade, SNL has fabricated a sensored rotor blade with embedded distributed accelerometer measurements to be used with operational loading methods to estimate the rotor blade deflection and dynamic excitation. These estimates would serve as observers for future smart rotor blade control systems. An accurate model of the rotor blade was needed for the development of the operational monitoring methods. An experimental modal analysis of the SNL sensored rotor blade (a modified CX-100 rotor blade) with embedded DC accelerometers was performed when hung with free boundary conditions and when mounted to a Micon 65/13 wind turbine. The modal analysis results and results from a static pull test were used to update an existing distributed parameter CX-100 rotor analytical blade model. This model was updated using percentage error estimates from cost functions of the weighted residuals. The model distributed stiffness parameters were simultaneously updated using the static and dynamic experimental results. The model updating methods decreased all of the chosen error metrics and will be used in future work to update the edge-wise model of the rotor blade and the full turbine model.

Inspection and monitoring of wind turbine blade-embedded wave defects during fatigue testing

The research presented in this article focuses on a 9-m CX-100 wind turbine blade, designed by a team led by Sandia National Laboratories and manufactured by TPI Composites Inc. The key difference between the 9-m blade and baseline CX-100 blades is that this blade contains fabric wave defects of controlled geometry inserted at specified locations along the blade length. The defect blade was tested at the National Wind Technology Center at the National Renewable Energy Laboratory using a schedule of cycles at increasing load level until failure was detected. Researchers used digital image correlation, shearography, acoustic emission, fiber-optic strain sensing, thermal imaging, and piezoelectric sensing as structural health monitoring techniques. This article provides a comparison of the sensing results of these different structural health monitoring approaches to detect the defects and track the resultant damage from the initial fatigue cycle to final failure.

Impact Loading and Damage Detection in a Carbon Composite TX-100 Wind Turbine Rotor Blade

An experimental 9-m composite rotor blade with integrated carbon-carbon features and an outer fiber direction of 20o was fatigued to failure. The blade initially developed a crack at 65o on the high pressure side near the 4.6-m station at 2.5 M cycles and the crack then coalesced to the 20o fiber direction until the test was stopped at 4 M cycles. An array of highsensitivity triaxial accelerometers, low-frequency capacitive accelerometers, and piezoelectric actuators with force sensors was distributed over the surface of the blade to monitor the loading and blade damage. A triaxial accelerometer at the tip was used to measure the tip deflection in the flap, lead-lag, and root-tip directions throughout the test. In-plane displacement measurements between the damage and the root were found to be sensitive to the crack growth and direction. The dynamic features of the rotor blade were sensitive to the variation in ambient temperature. Active diagnostics with the method of virtual forces was sensitive to the damage for in-plane measurements following adjustment for thermal effects. Impact identification was demonstrated with 93% accuracy of the location and within 1.3% accuracy of the magnitude. Modal filtering provided a means of monitoring the fatigue loading in near-real time. Second-order harmonics excited by the fatigue system were shown to exist at the tip in the lead-lag and root-tip directions. Findings of this test will be instrumental in future development of accelerometer-based wind turbine rotor blade monitoring.

Hardware and software developments for the Accurate Time-Linked Data Acquisition System

Wind-energy researchers at Sandia National Laboratories have developed a new, light-weight, modular data acquisition system capable of acquiring long-term, continuous, multi-channel time-series data from operating wind-turbines. New hardware features have been added to this system to make it more flexible and permit programming via telemetry. User-friendly Windows-based software has been developed for programming the hardware and acquiring, storing, analyzing, and archiving the data. This paper briefly reviews the major components of the system, summarizes the recent hardware enhancements and operating experiences, and discusses the features and capabilities of the software programs that have been developed.

Operational load estimation of a smart wind turbine rotor blade

Rising energy prices and carbon emission standards are driving a fundamental shift from fossil fuels to alternative sources of energy such as biofuel, solar, wind, clean coal and nuclear. In 2008, the U.S. installed 8,358 MW of new wind capacity increasing the total installed wind power by 50% to 25,170 MW. A key technology to improve the efficiency of wind turbines is smart rotor blades that can monitor the physical loads being applied by the wind and then adapt the airfoil for increased energy capture. For extreme wind and gust events, the airfoil could be changed to reduce the loads to prevent excessive fatigue or catastrophic failure. Knowledge of the actual loading to the turbine is also useful for maintenance planning and design improvements. In this work, an array of uniaxial and triaxial accelerometers was integrally manufactured into a 9m smart rotor blade. DC type accelerometers were utilized in order to estimate the loading and deflection from both quasi-steady-state and dynamic events. A method is presented that designs an estimator of the rotor blade static deflection and loading and then optimizes the placement of the sensor(s). Example results show that the method can identify the optimal location for the sensor for both simple example cases and realistic complex loading. The optimal location of a single sensor shifts towards the tip as the curvature of the blade deflection increases with increasingly complex wind loading. The framework developed is practical for the expansion of sensor optimization in more complex blade models and for higher numbers of sensors.

Design, Fabrication, Assembly and Initial Testing of a SMART Rotor 1

Sandia National Laboratories has designed and built a full set of three 9m blades (based on the Sandia CX-100 blade design) equipped with active aerodynamic blade load control surfaces on the outboard trailing edges. The design and fabrication of the blades and active aerodynamic control hardware and the instrumentation are discussed and the plans for control development are presented. , Albuquerque, NM 87185-1124

Experimental Results of Structural Health Monitoring of Wind Turbine Blades

A 9 meter TX-100 wind turbine blade, developed under a Sandia National Laboratories R&D program, was recently fatigue tested to blade failure at the National Renewable Energy Laboratories, National Wind Technology Center. The fatigue test provided an opportunity to exercise a number of structural health monitoring (SHM) techniques and nondestructive testing (NDT) systems. The SHM systems were provided by teams from NASA Kennedy Space Center, Purdue University and Virginia Tech (VT). The NASA and VT impedance-based SHM systems used separate but similar arrays of Smart Material macro-fiber composite actuators and sensors. Their actuator activation techniques were different. The Purdue SHM setup consisted of several arrays of PCB accelerometers and exercised a variety of passive and active SHM techniques, including virtual and restoring force methods. A commercial off-the-shelf Physical Acoustics Corporation acoustic emission (AE) NDT system gathered blade AE data throughout the test. At a fatigue cycle rate around 1.2 Hertz, and after more than 4,000,000 fatigue cycles, the blade was diagnostically and visibly failing at the blade spar cap termination point at 4.5 meters. For safety reasons, the test was stopped just before the blade completely failed. This paper provides an overview of the SHM and NDT system setups, and some test results.

Non-destructive evaluation of wind turbine blades using an infrared camera

The use of a digital infrared as a non-destructive evaluation thermography camera (NDE) tool was ex- plored in two separate wind turbine blade fatigue tests. The fwst test was a fatigue test of part of a 13.1 meter wood-epoxy-composite blade. The second test was on a 4.25 meter pultruded fiber glass blade section driven at several mechanical resonant frequencies. The digital infrared camera can produce images of either the static temperature distribution on the surface of the specimen, or the dynamic temperature distribution that is in phase with a specific frequency on a vibrating specimen. The dynamic temperature distribution (due to thermoplastic effects) gives a measure of the sum of the principal stresses at each point on the surface. In the wood- epoxy-composite blade fatigue test, the point of ultimate failure was detected long before failure occurred. The mode shapes obtained with the digital infrared camera, from the resonant blade tests, were in very good agree- ment with the finite-element calculations. In addition, the static temperature images of the resonating blade showed two areas that contained cracks. Close-up dy- namic inf%red images of these areas showed the crack structure that agreed with subsequent dye-penetrant analysis.

An Evaluation of Sensing Technologies in a Wind Turbine Blade: Some Issues Challenges and Lessons-Learned.

The Department of Energy and the Sandia National Laboratories Wind Power Technology Department have initiated a number of wind turbine blade sensing technology projects with a major goal of understanding the issues and challenges of incorporating new sensing technologies in wind turbine blades. The projects have been highly collaborative with teams from several commercial companies, universities, other national labs, government agencies and wind industry partners. Each team provided technology that was targeted for a particular application that included structural dynamics, operational monitoring, non-destructive evaluation and structural health monitoring. The sensing channels were monitored, in some or all cases, during blade fabrication, field testing of the blade on an operating wind turbine, and lab testing where the life of the blade was accelerated to blade failure. Implementing sensing systems in wind turbine blades is an engineering challenge and solutions often require the collaboration with a diverse set of expertise. This report discusses some of the key issues, challenges and lessons-learned while implementing sensing technologies in wind turbine blades. Some of the briefly discussed topics include cost and reliability, coordinate systems and references, blade geometry, blade composites, material compatibility, sensor ingress and egress, time synchronization, wind turbine operation environments, and blade failure mechanisms and locations.