628 Design, Performance, and Economics of 50-kW and 500-kW Vertical Axis Wind Turbines 1983 MALCOLM
628 Design, Performance, and Economics of 50-kW and 500-kW Vertical Axis Wind Turbines 1983 MALCOLM
Production
DAF Indal Ltd. has been actively engaged in the design, 50-kW units and their measured performance, the con-
development, manufacturing, and testing of Darrieus type figuration and expected performance of the 500 kW VAWT,
vertical axis wind turbines since 1974. The company has and the economics of both machines based on installed costs
designed and manufactured twelve 50-kW units (16.8 m X in both remote and wind farm applications.
11.2 m, 55.0 X 36.7 ft.) now installed in Canada, the United The ability to accurately predict the natural frequencies and
States, Australia, and Ireland, and the large 36.6 m by 24.4 m modes of vibration of the rotor is a key element in the suc-
(120 ft. x 80 ft.) 230-kW research machine installed on the cessful design and safe operation of the VAWTs. The paper
lies de la Madeleine in the Gulf of St. Lawrence. includes comparisons between predicted and measured
Most of the 50-kW wind turbines are being used by elec- responses for the two machines.
trical utilities for "hands on" demonstration of VAWT
technology, operating in parallel with either large networks 50-kW VAWT. A photograph of DAF Indal's advanced
or relatively small diesel generator plants. One of the original 50-kW VAWT at the San Luis Reservoir, California, is shown
units has been in service since 1978 with the U.S. Department in Fig. 1. The main characteristics of this machine are given in
of Agriculture at Bushland, Texas. It has been mechanically Table 1.
coupled to both an electric pump motor and a diesel engine Power Module. The first 50-kW units were delivered in
for deep well irrigation pumping experiments. An advanced 1978. Since that time, design changes have concentrated on
50-kW unit began operation in February 1982, in the the lower bearing, the brake, the gearbox, the rotor support
mechanical assist configuration, as part of a prototype 100-
kW, wind-turbine-assisted diesel generator plant near Sud-
bury, Canada. Table 1 Description of the DAF Indal 50-kW VAWT
DAF Indal has concluded that for large-scale (wind farm) operating at the San Luis Reservoir, California
applications, the lowest cost of wind-generated electricity will
Generic description Physical characteristics
be delivered by wind turbines having rated outputs of at least
several hundred kilowatts. Therefore, the design of a Series Vertical axis wind turbine Number of blades Two
6400 VAWT with a 500 kW rating, was started in 1981. It is generator, Darrieus type Rotor height 16.8 m (55 ft)
with Troposkien blade Rotor diameter 11.2 m2 (36.7 ft)
expected that this series of VAWTs will meet the short to shape Capture area 121m
medium term demand for both wind farm and wind diesel (1,330 ft 2 )
applications. Rotor weight 3,100 kg
(6,8201b)
Small machines, such as the 50-kW VAWT, may continue System weight 3,650 kg
to fill the need for technology demonstration units because (8,0301b)
they are relatively inexpensive and easy to install. However,
the most promising future for these machines may be in small Overall Configuration
wind turbine diesel hybrids serving isolated communities, Rotor supported by power Blade material Extruded
farms, and industrial installations. module and three guy wires aluminum alloy
terminating at the upper
This paper reviews the design features of the 50-kW and bearing housing. Rotor
500-kW VAWTs, the operating experience with two advanced drives a 56-kW (75-hp), Blade profile NACA0015 36cm
three-phase induction (14 in) chord
Contributed by the Solar Energy Division for publication in the JOURNAL OF generator through a 15:1
SOLAR ENERGY ENGINEERING. Manuscript received by the Solar Energy Division ratio single mesh spur Rotor column steel pipe 60-cm
Novembers, 1982.
gear and pinion gearbox. (2-ft) dia.
GEAR COUPLING
HYDRAULIC AOTOR
SUPPORT CHAMBER
SPRAY
~_ _ ~ LUBRICATION
"D~'lI-- BEARINGS
~~@]i!mIJI!I!iD-*---PINION
BRAKED
POSITION
HYORAULIC
OUMP VALVE ---1-+-1---+1'0
GEAR
t:::::l-1-- COUPLINGS
poweR MOCULE
I
HYDRAULIC PUMPS
AND RESERVOIR
300 o
uj 0-30-
o
160
WIND SPEED AT THE ROTOR EQUATOR (m/s)
Fig. 5 Comparison of wind energy distribution at Sable Island,
140 Canada and 50-kW VAWT efficiency
120
a significant effect on energy production for average annual
Cutoff Wind Speed 17 9 m / s windspeeds in excess of about 7 m/s with the Rayleigh
(40mph.)
° 100 distribution.
>- The operating speed of 80 rpm is close to the optimum
CD
rr speed for maximizing the energy output for Rayleigh wind-
y 80 speed distributions with average speeds of about 7 m/s. This
is illustrated in Fig. 5 where the measured efficiency at 80 rpm
and the measured wind energy probability distribution at
< 60- Sable Island (average windspeed 7.2 m/s) are shown plotted
against windspeed. Although the annual energy output for a
< given windspeed distribution can be maximized by selecting
40 Rotor Speed = 8 0 Rpm.
the best rotor speed, VAWTs can only be operated at a few
Rotor Equator Height = 114 m
rotor speeds where the natural modes of vibration of the rotor
Rayleigh Distribution will not be excited.
20
Wind Shear Exponent = 016 The Rayleigh distribution (a special case of the Weibull
distribution) has been found to be an accurate model for
many sites. However, data from many other locations, such
5 6 7 8 9 10 II as sites in Hawaii, have been found to fit other Weibull shape
AVERAGE ANNUAL WIND SPEED m / s
parameters. Figure 6 shows the effect of the shape parameters
MEASURED AT 10 m on the annual energy output for the 50-kW VAWT operating
Fig. 4 Energy output versus average annual wind speed for the 50-kW at 80 rpm. Figure 6 is useful for determining the effect of the
VAWT Weibull shape parameter on the cost of energy calculated for
a Rayleigh distribution. It may be noted that for an average
(approximately 3 kW) is attributed to the drag associated with annual windspeed of about 7 m/s, the annual energy output
the aerodynamic spoilers in the latched position. (The San reaches the maximum for the Rayleigh distribution (K = 2).
Luis machine is not equipped with spoilers.)
Most of the 50-kW machines now in service operate at 80 Frequency Prediction. The problem of exciting resonance
rpm. Although insufficient data have been gathered to ac- in this and other Darrieus rotors has been of much concern to
curately define the power output performance beyond about designers. Although the rotor structure, even with in-
15 m/s, spot power output readings taken on three machines termediate struts, is simple, the structural response is made
indicate that the peak electrical output is in excess of 50 kW, more complex by the influence of centrifugal stiffening of the
with or without spoilers. blades and by other effects of the rotating frame. The blades
Figure 4 shows the calculated annual energy outputs for the are forced to deflect in the plane of the rotor which is itself
50-kW VAWT based on the San Luis performance curve rotating, and due to the Coriolis forces, motion is therefore
shown in Figure 3 with extrapolation at higher windspeeds. excited normal to the rotor plane and vice versa. There is,
(These results are used in the cost of energy calculations.) The therefore, coupling between pairs of natural modes, each
results in Fig. 4 show that the choice of cut-off windspeed has having a 90 deg phase difference from the other.
N
f-
or
UJ B = BUTTERFLY
X
T=TOWER
>-"
o F= FLATWISE
2 S= SYMMETRIC
UJ
a A= ASYMMETRIC
UJ
rr P-PROPELLER
Q=EXPERIMENTAL
DATA
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
WIND SPEED ( m / s ) AT CENTRE OF ROTOR
5 10 15 20 25 30 35 4 0 45 50 55 6 0 65 70
WIND SPEED (MPH) AT CENTRE OF ROTOR
Fig. 8 DAF Indal 500-kW VAWT predicted performance curves
Table 2 Description of the DAF Indal Series 6400 model Table 3 Predicted electrical energy output versus average
500-kW vertical axis wind turbine annual windspeed for the 500 kW VAWT
Rotor height 36.6 m (120 ft) Average annual wind- Annual energy output
Rotor equator diameter 24.4 m (80 ft) speed measured at 10 m (MWh) for Rayleigh
Blade chord 73.7 cm (29 in) (m/s) distributions
Blade profile NACA0015 5 261
Blade root elevation 3.8 m 2(12.3 ft) 2
Capture area 595 m (6400 ft ) 6 502
Rotor column diameter 91.5 cm to 152.4 cm 7 792
(3 to 5 ft) tapered 8 1094
Rotor weight 15,340 kg (33,740lb) 9 1374
Rated electrical power output 522 kW 10 1604
Rated windspeed at rotor equator 19 m/s (42.5 mph) 11 1774
Rotor speed 45 rpm Cutoff windspeed is 24 m/s measured at the rotor equator
Braking torque capacity 272,000 Nm Wind shear power law coefficient of 0.16 is assumed
(200,000 ft. lbf) Standard sea level air density
Electrical generators 2 at 261 kW (350 HP) each 100 percent availability
three phase, 60 Hz,
NemaB
required to dispatch field service personnel from Ontario to 500-kW VAWT. An immediate market for wind turbines
California to service the machine under warranty. The design in the first generation of wind farms has developed in North
of future machines will benefit from this operating ex- America, especially in the State of California. In order to
perience, and higher reliability can be expected. meet this need, DAF Indal has started a manufacturing
The advanced 50-kW VAWT installed at the Southern program for a 500-kW VAWT.
California Edison test site (Devers Substation) near Palm Some basic details of this machine, which is geometrically
Springs has supplied 75,242 kWh to the SCE network between similar to the 50-kW machine, are listed in Table 2. The
March 10, 1982 (startup) and March 31, 1983. The unit was dimensions of the rotor are identical to the 230-kW ex-
on-line for 3,950 hours; the availability during that period perimental machine located on the lies de la Madeleine, but
was 92.1 percent. the blade chord is increased from 0.61 (24 in.) to 0.74 m (29
The VAWT down time was the result of the following in.), and the operating speed is increased from 36.5 to 45 rpm.
problems: Predicted Performance. The predicted performance curve
1 The upper bearings failed as a result of lack of grease for the 500-kW rating is shown in Fig. 8. This curve is based
lubrication. This was traced to a factory error. The bearings on the use of the latest double multiple stream tube
were replaced without lowering the rotor. aerodynamic performance model [6].
2 The strut to blade connection pins exhibited excessive Other power output ratings, obtained by changing the
wear due to an assembly error. The pins were replaced. operating speed, may provide lower costs of energy in low
3 Hydraulic pressure exhibited instability. The pressure windspeeds and very high windspeed regimes. Predicted
regulating valve was found to be defective. It was replaced. energy outputs for the 500 kW are given in Table 3.
4 Below normal network voltage resulted in the wind
turbine failing to reach the required rotor speed in the preset Design Criteria. The following criteria for the design of
time during start-up. This problem was corrected by in- the 500-kW VAWT were established:
creasing the preset starting time to allow for occasional below 1 All components sensitive to cyclic loads must sustain 10
normal network voltage. cycles (about 20 years) at rated power.
T_B
STRUTS
LOCKED
N FA-B
B = BUTTERFLY
T=TOWER
>-
o F= FLATWISE
z S= SYMMETRIC
UJ
o A= ASYMMETRIC
UJ P«PROPELLER
rr
u. ©-EXPERIMENTAL
DATA
Table 4 Cost of energy for the 50-kW VAWT Table 5 Cost of energy for the 500-kW VAWT
Average annual Cost of energy (cents/kWh) Average annual Cost of energy (cents/kWh)
windspeed (m/s) Fixed charge rate windspeed (m/s) Fixed charge rate
0.20 0.25 0.20 0.25
5 133.1 (146.5) 162.8 (179.0) 5 67.0 (71.8) 81.9 (87.8)
6 74.1 (81.5) 90.5 (99.6) 6 34.9 (37.4) 42.6 (45.7)
7 49.7 (54.7) 60.7 (66.7) 7 22.1 (23.7) 27.0 (28.9)
8 37.6 (41.3) 45.9 (50.5) 8 16.0 (17.1) 19.6 (20.9)
9 30.9 (34.0) 37.8 (41.5) 9 12.7 (13.6) 15.6 (16.7)
10 27.1 (29.8) 33.1 (36.4) 10 10.9 (11.7) 13.3 (14.3)
11 24.8 (27.3) 30.3 (33.4) 11 9.9 (10.6) 12.1 (12.9)
Cost of energy for remote applications shown in parenthesis Cost of energy for remote applications shown in parenthesis
Erected cost: remote applications 220,000 dollars Erected cost: remote applications 750,000 dollars
wind farms 200,000 dollars wind farms 700,000 dollars
Energy outputs from Fig. 4 (22.4 m/s cutoff) Energy outputs from Table 4
2 The "survival wind" on the stationary rotor is 67 m/s parameters such as central column stiffness, guy cable stiff-
(150 mph) at the rotor equator. ness, flexibility and mass of the blades, and position of the
3 The operating speed is to be 45 rpm, and the maximum horizontal struts. It is therefore possible to tune the rotor
power is generated at about 19 m/s (42.5 mph) measured at structure to make the required "window" clear of natural
the rotor equator. frequencies.
4 Design is to consider a 10 percent overspeed (to 49.5 rpm)
with a corresponding equator windspeed of 20.9 m/s (46.7
mph) and a 21 percent increase in drive train torque. Economics of the 50-kW and 500-kW VAWTS
5 The maximum gust speed in operating or overspeed
conditions is to be 35.8 m/s (80 mph). Cost of Energy. Costs of energy produced by the DAF
6 The maximum braking torque is to be two times the Indal 50-kW and 500-kW VAWTs were calculated for average
torque at rated power. annual windspeeds of between 5.0 and 11.0 m/s, assuming the
Rayleigh windspeed frequency distribution and using the
7 No natural frequencies should coincide with the one or
annual energy outputs shown in Fig. 4 and Table 3. The
three per revolution frequencies between the operating and
results are shown in Tables 4 and 5.
overspeed conditions.
The aforementioned criteria are based on experience and The costs of energy were calculated using the fixed charge
experimental data. rate method where the cost of energy is given as
(FCR + O&M) X COST
Natural Frequency Prediction. The same methods that COE =
were used on the 50-kW VAWT, based on NASTRAN with EOVTxA
the addition of rotating frame effects, have been applied to where FCR is the fixed charge rate, O&M is the levelized
the experimental turbine on the lies de la Madeleine, with the operation and maintenance cost expressed as a percent of the
results shown in Fig. 9. This prediction agrees well with the installed cost, COST is the installed cost of the VAWT,
existing experimental data (also shown on Fig. 9). EOUT is the ideal annual VAWT energy output, and A is a
It has been found that the basic in-plane and out-of-plane factor (less than one) which accounts for availability and
natural frequencies depend in a predictable manner upon control system efficiency.