Montana State University Wind Turbine Technology Bozeman, Montana November 29, 2007 Wind Turbine Technology Mark A. Rumsey Wind Energy Technology Department Sandia National Laboratories (SNL) Albuquerque, NM Sandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin Company, for the United States Department of Energy’s National Nuclear Security Administration under contract DE-AC04-94AL85000.

US Wind Resource Map Wind Power Density at 10 meters above ground The return button will take you back to the menu slide for this file. Wind Power Density at 10 meters above ground

Wind Industry Trends 1985 1995 2000 2003 2006 2007 . . . All US electrical generation in 2005 was 1,067,019 MW (Source: DOE/EIA)

Wind Turbine Technology Trends and Challenges Wind Turbine specifications: Electrical Power: 1.5-5.0 MW Turbine Weight: 150-500 tons Tower Height: 65-100 meters Blade Length: 34-60 meters Blade Weight: 6-23 tons Costs: System < $3/lb Blades < $5/lb ~$1.40/Watt * $0.03-0.06/kWh * (Cost Of Energy) - Volatility in the cost of steel and copper - Variable currency exchange rate - Few domestic manufacturers

Wind Turbine Lifecycle WECS ≡ Wind Energy Conversion Systems

Sandia Wind Energy R&D Program Blade Technology Materials and Manufacturing Structural, Aerodynamic, and Full Turbine Modeling Lab and Field Testing, and specialized Data Acquisition Systems Advanced Blade Concepts Sensors, Smart Structures and Structural Health Monitoring System Reliability Industry Data Collection Improve reliability of the existing technology and future designs TPI Composites, RI NREL/NWTC, Boulder, CO USDA-ARS, Amarillo, TX

Laboratory and Field Testing FAA-SNL AANC, Albuquerque, NM USDA-ARS, Bushland, TX NREL/NWTC, Boulder, CO NREL/NWTC, Boulder, CO

Materials Testing Sandia National Labs and Montana State University Composite Material Testing (1989-present) PI: Prof. John Mandell Material Properties (10000+ tests for 175 Materials) Database updated once per year (Last update 04/2007) http://www.sandia.gov/wind/

Characterization of Carbon (for instance) Examine Data Trends N SAERTEX

Fine-tuning the Goodman Diagram Loss of Service Lifetime Small Cycles Very Important Very Severe in Tension Compression May be Worse Loss of Residual Strength High Load at Beginning of Service Lifetime Severe Loss of Strength

Manufacturing Uncertainty - Big Issue! As designed As built

Blade Innovations Prototype Sub-scale Blades Manufactured (9 meters) CX-100 Carbon spar cap Glass skin and shear web TX-100 Carbon triax in skin for bend-twist coupling Constant spar cap thickness BSDS (Blade System Design Study) Flatback airfoils Slenderized planform Large scale architecture Highly efficient structural design

Blade Design Improvements Time Property  ERS-100 CX-100 TX-100 BSDS Weight (lb) 426 383 361 289 % of Design Load at Failure 110% 105% 197% 310% Root Failure Moment (kN-m) 122.8 117.0 121.4 203.9 Max. Carbon Tensile Strain at Failure(%) NA 0.31% 0.59% 0.73% Max. Carbon Compressive 0.30% 0.87% Maximum Tip Displacement (m) 1.43 1.05 1.80 2.79 Integrated aero/structural design process resulted in lighter, less expensive, stronger blade

… for more information: Mark A. Rumsey 505-844-3910 marumse@sandia.gov Wind Energy Technology Department Sandia National Laboratories www.sandia.gov/wind Good web sites: http://www.awea.org/ http://www.eere.energy.gov/windandhydro/