WIXLIB

Testing Facilities andCapabilities at NWTCProject ID # T1Dave SimmsNRELPhoto by Dennis Schroeder, NREL 38270U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY1

FY17-FY18 Wind Office Project Organization“Enabling Wind Energy Options Nationwide”Technology DevelopmentMarket Acceleration & DeploymentAtmosphere to ElectronsStakeholder Engagement, WorkforceDevelopment, and Human Use ConsiderationsOffshore WindEnvironmental ResearchDistributed WindGrid IntegrationTesting InfrastructureRegulatory and SitingStandards Support and InternationalEngagementAdvanced Components, Reliability, andManufacturingAnalysis and Modeling (cross-cutting)U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY2

Project OverviewT1: Testing Facilities and Capabilities at NWTCProject SummaryProject Attributes Safely operate and maintain reliable performance ofDOE’s world-class research facilities and capabilities atthe National Wind Technology Center (NWTC). Support fundamental research, development,experimentation, and validation of components andsystems, and understand operation and failure modes. Support evolving DOE and industry research needs.Project Principal Investigator(s)Dave SimmsDavid.simms@nrel.gov303-384-6942DOE LeadGary NowakowskiProject Objective & Impact Maintain mission readiness and operational expertise ofspecialized research facilities and capabilities, includinghighly-skilled staff, advanced state-of-the-art researchmethods, acquisition of research data, and developmentof data processing and analysis tools. Formal agreements with 75 partner organizationsannually with staff involved in projects that utilized NWTCresearch facilities.U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYProject Partners/SubsManyProject DurationThrough FY193

Approach and MethodologyPhotos clockwise from top by Dennis Schroeder, NREL 22073, 19010, 19012, 22132, 25889U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY4

Approach and MethodologyOperations & Maintenance (O&M): Specialized NWTC research facilities and capabilities,associated equipment and systems, qualified operators andtechnical experts––To keep them “Mission Ready” for safe use by DOE researchers andindustry partnersMaintained in a defined baseline configuration. Note that: –Photo by Dennis Schroeder, NREL 19010Enhancements (e.g., specific to supporting new research or customers)funded elsewhereCustomers pay NREL to install/set-up/take down their research projectsand operate DOE equipment as needed to conduct their experimentsIncludes associated research needs: Photo by DennisSchroeder, NREL38281Control systems, data acquisition, instrumentation, calibrations, dataanalysis, and processing systems and tools.Organized into the following areas:1.2.3.4.5.Field: Turbines, met towers, sitesStructural: blade static and fatigue loadingDynamometers: Drivetrains and componentsGrid Integration: Centered around Controllable Grid Interface (CGI)Overarching Safety, O&MPhoto by Dennis Schroeder, NREL 31775Photo by Mark McDade, NREL 29069U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY5

Approach and MethodologyPhoto Pat Corkery,NREL 16562Leverage WETO investments 2-4X Approximately 15M-- 25M annual DOE, NREL, and industry fundingassociated with operating, maintaining, developing, improving, andutilizing specialized NWTC research facilities and capabilitiesMany projects underway concurrently, requires careful planning andscheduling, understanding of critical-path items, risk mitigation, andtimeline to achieving desired outcomes:––Research validation projects and experiments ( 30-60)Sitewide projects including new capabilities, construction, renovation, andupgrade ( 10-20)–Projects to inspect, maintain, and repair research facilities and equipment.Ensure compliance with DOE requirements: Facility management, extensive rigorous integrated projectplanning, enables efficient sharing and optimization ofresources (facilities, equipment, people)Develop and retain qualified workers, operators, cognizantsystem engineers and technicians,documentation and recordkeepingSafety per DOE, OSHA, NFPAQuality, security, environmental,property per applicable requirementsEducate and support industry partners,especially smaller companies.Photo by Dennis Schroeder, NREL 40375Photo by Lee Jay Fingersh, NREL 16270U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYPhoto by Dennis Schroeder, NREL 190676

Approach and Methodology1. Field Research Facilities and CapabilitiesO&M:CART-3maintenance– DOE-owned research wind turbines: DOE 1.5 (1.5 MW, Site 4.0), CART-2 (600 kW, Site 4.3), CART-3 (600 kW,Site 4.2), NW-100 (100 kW, Site 1.2), Skystream (3 kW, Site entrance).– Instrumented meteorological research towers: 135 m (2, Site 4.0 & 4.4) , 80 m (Site M2, includes interactive display andarchive), upwind of each CART machine (Sites 4.2 & 4.3).– Also supports A2e, Reliability, Environmental R&D,Grid Integration, Solar Program.Installing instrument boomson 135-m Met TowerCART-3 (600kW)Photo by Dennis Schroeder, NREL 26643135-m MetTowerCART-2 (600 kW)Photo by Lee Jay Fingersh, NREL 18494DOE 1.5 MWPhoto by Lee JayFingersh, NRELU.S. DEPARTMENT OF ENERGYPhoto by Lee Jay Fingersh, NREL 16387OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYPhoto by Lee Jay Fingersh, NREL 16388Photo by Dennis Schroeder, NREL 190237

Approach and Methodology2. Structural Research Facilities andCapabilities O&M:– 3 structural research facilities with teststands: STL: up to 50-m length test articles 251: up to 21 m A60: up to 19 m.– Also supports Advanced ManufacturingOffice, Water Power ProgramPhoto by Mike Jenks, NREL 17641U.S. DEPARTMENT OF ENERGYPhoto by Mike Jenks, NREL 14707OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYPhoto by Mark McDade, NREL 29072Photo by Mike Jenks, NREL 138898

Approach and Methodology3. Dynamometer ResearchFacilities and Capabilities O&M:– 3 dynamometer research facilities 225 kW 2.5 MW 5 MW with nontorque loading systemPhoto by Dennis Schroeder NREL 32785Photo by Mark McDade, NREL 40432– Also supports Water Power ProgramPhoto by Mark McDade, NREL 28218U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYPhoto by Mark McDade, NREL 272499

Approach and Methodology4. Grid Integration ResearchFacilities and Capabilities O&M:– 6.3-MW Controllable Grid Interface (CGI)grid simulator Expose power device(s) to precisely created andcontrolled grid power anomalies (e.g., grid faults,transients, frequency fluctuations) under safeconditions on research grid isolated from utility– Electrical interconnections to all plausibleconfigurations of grid integration researchassets (e.g,. loads, generators, storage)– Also supports Water Power, Solar, and GridModernization ProgramsGraphic by Josh Bauer, NRELNWTC Grid Integration Research Assets Photo by Mark McDade, NRELU.S. DEPARTMENT OF ENERGYDOE-owned turbines: DOE 1.5 2 600-kW CARTsIndustry-owned turbines: Siemens 2.3 MW Gamesa 2 MW GE/Alstom 3 MW (researchcompleted, removed FY18)Dynos: 2.5 MW 5 MW“Grid-friendly” ancillary service controlcapabilities of DOE 1.5Research pads (3@4 MW each, for power,storage devices, NREL-funded)Industry-owned PV Solar arrays (480 kWand 250 kW, new FY18)1-MW/1-MW-hr Battery Energy StorageSystem (new FY17, NREL-funded)Photo by Dennis Schroeder, NREL 47212OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY10

Approach and Methodology5. Overarching Safety, O&M– Research operations in accordance with DOE IntegratedSafety Management System, comprehensive projectplanning and scheduling– Qualified operation and scheduled preventativemaintenance of general use equipment– Specialized training and mentoring– Quality assurance (accreditation, audits, procedurerevisions, software validation, etc.)– Government property management, inventory, equipmentdatabase– Site-wide environmental compliance and reporting,assessments, NEPA, etc.Photos by Dave Jager, NRELU.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY11

Accomplishments and Progress Exemplary safety recordAll DOE milestones completed on time and within budgetMaintained steady queue of 2.5-MW and 5-MW dyno researchprojects, and CGI/grid integration research projectsSupported A2e:– Developed and verified turbine instrumentation systems (e.g.,loads, LIDARs) prior to wind farm deployment– Supported Sandia colleagues at the SWiFT facility in Lubbock, TXwith field testing and instrumentation expertise Supporting upgrade of NWTC electrical utility interconnection(Xcel) from 10-MW distribution grid to 19.9-MW transmissioninfrastructureMaintained ISO 17025 accreditation by A2LA to many IECstandardsWorked with DOE to establish process to use UASs(drones) to support R&DPhoto by Jerry Hur, NRELPhoto by Werner Slocum NREL 51763Photo by Steve Nixon, NRELU.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY12

NWTC R&D Project ExamplesDOE 1.5-MW research wind turbine at NWTC retrofitted with highlyinstrumented gearbox to support DOE’s Drivetrain Reliability Program. Field experiments are now underway to provide researchers and industry partners withresearch data needed to better understand drivetrain physics and develop improveddrivetrain models.Photo by Jon Keller, NRELNWTC experts install specializedinstrumentation on gearbox componentsprior to factory assemblyPhoto by Dennis Schroeder, NREL 49409Photo by Dennis Schroeder, NREL 49413The DOE 1.5-MW turbine’s OEM gearbox is replaced with new research gearbox.U.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY13

NWTC R&D Project ExamplesDOE’s two 600-kW research wind turbines (CART-2 and CART-3) utilized toconduct full-scale aerodynamics research experiments in partnership with: Rensselaer Polytechnic Institute (RPI)–CART-3 retrofitted with customized blade tip configured with RPI’s active synthetic jetblowing devices designed to control blade loading ts/smart-blades-enhance-wind-turbine DLR–CART-3 retrofitted with three innovative “Smartblades” designed to adapt towind conditions using bending-torsion coupling in accordance with theobjectives of the German Aerospace Center (DLR) research spx/tabid-10501/826 read-25338/#/gallery/29286 ARPA-e–CART-2 retrofitted with two highly flexible “Segmented Ultralight Morphing Rotor” (SUMR)blades that were designed in accordance with the objectives of the University of Virginia’sARPA-e research project:https://arpa-e.energy.gov/?q slick-sheet-project/ultra-large-wind-turbineTo enable this research, the CART-2 will be operated downwindPhoto by Dennis Schroeder, NREL 53933U.S. DEPARTMENT OF ENERGYPhoto by Andy Scholbrock, NRELOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGYPhoto by Dennis Schroeder, NREL 53511Photo by Jee Jay Fingersh, NREL 5423214

NWTC Transition Supported transition of NWTC from single program tomultiprogram to address anticipated future needs(called NWTC 2.0) :oDue to NWTC synergies of capabilities to support otherEERE ProgramsPhoto by Dennis Schroeder, NREL 51625– Especially Water Power, Solar, Advanced Manufacturing,Grid ModernizationSignificant grid integration investments generated newwork and interest, benefits to EERE and industryo Providing NWTC 2.0 planning and analysis forNREL and DOE management, including:o– 2nd CGI– 3 additional grid research pads– MW-scale load bank and other assets formicrogrid R&D– Electrical infrastructure upgrades to supportnew Distributed Wind MIRACL projectPhoto by Dennis Schroeder, NREL 41830Photo by Jee Jay Fingersh, NRELU.S. DEPARTMENT OF ENERGYOFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY15