Wind turbine

This article discusses wind-powered electrical generators. See windmill for wind-powered machinery used to grind grain or pump water.

Wind farm in the North Sea off Belgium

A wind turbine is a rotary device that extracts energy from the wind. If the mechanical energy is used directly by machinery, such as for pumping water, cutting lumber or grinding stones, the machine is called a windmill. If the mechanical energy is instead converted to electricity, the machine is called a wind generator, wind turbine, wind turbine generator (WTG), wind power unit (WPU), wind energy converter (WEC), or aerogenerator.

History

Wind turbines near Aalborg, Denmark

The world's first automatically operated wind turbine was built in Cleveland in 1888 by Charles F. Brush. It was 60 feet tall, weighed four tons and had a 12kW turbine.^[1]

Wind machines were used in Persia as early as 200 B.C.^[2] The windwheel of Heron of Alexandria marks one of the first known instances of wind powering a machine in history.^[3]^[4] However, the first practical windmills were built in Sistan, a region between Afghanistan and Iran, from the 7th century. These were vertical axle windmills, which had long vertical driveshafts with rectangle-shaped blades.^[5] Made of six to twelve sails covered in reed matting or cloth material, these windmills were used to grind corn and draw up water, and were used in the gristmilling and sugarcane industries.^[6]

By the 14th century, Dutch windmills were in use to drain areas of the Rhine River delta. In Denmark by 1900, there were about 2500 windmills for mechanical loads such as pumps and mills, producing an estimated combined peak power of about 30 MW. The first known electricity generating windmill operated, was a battery charging machine installed in 1887 by James Blyth in Scotland.^[7] The first windmill for electricity production in the United States was built in Cleveland, Ohio by Charles F Brush in 1888, and in 1908 there were 72 wind-driven electric generators from 5 kW to 25 kW. The largest machines were on 24 m (79 ft) towers with four-bladed 23 m (75 ft) diameter rotors. Around the time of World War I, American windmill makers were producing 100,000 farm windmills each year, mostly for water-pumping.^[8] By the 1930s, windmills for electricity were common on farms, mostly in the United States where distribution systems had not yet been installed. In this period, high-tensile steel was cheap, and windmills were placed atop prefabricated open steel lattice towers.

A forerunner of modern horizontal-axis wind generators was in service at Yalta, USSR in 1931. This was a 100 kW generator on a 30 m (100 ft) tower, connected to the local 6.3 kV distribution system. It was reported to have an annual capacity factor of 32 per cent, not much different from current wind machines.^[9] In the fall of 1941, the first megawatt-class wind turbine was synchronized to a utility grid in Vermont. The Smith-Putnam wind turbine only ran for 1100 hours. Due to war time material shortages the unit was not repaired.

The first utility grid-connected wind turbine operated in the UK was built by John Brown & Company in 1954 in the Orkney Islands. It had an 18 meter diameter, three-bladed rotor and a rated output of 100 kW.

Resources

Main article: Wind power

Wind turbines in locations with constantly high wind speeds bring best return on investment. With a wind resource assessment it is possible to estimate the amount of energy the wind turbine will produce.

A quantitative measure of the wind energy available at any location is called the Wind Power Density (WPD) It is a calculation of the mean annual power available per square meter of swept area of a turbine, and is tabulated for different heights above ground. Calculation of wind power density includes the effect of wind velocity and air density. Color-coded maps are prepared for a particular area described, for example, as "Mean Annual Power Density at 50 Meters." In the United States, the results of the above calculation are included in an index developed by the U.S. National Renewable Energy Lab and referred to as "NREL CLASS." The larger the WPD calculation, the higher it is rated by class. Classes range from Class 1 (200 watts/square meter or less at 50 meters altitude) to Class 7 (800 to 2000 watts/square meter). Commercial wind farms generally are sited in Class 3 or higher areas, although isolated points in an otherwise Class 1 area may be practical to exploit.^[10]

Types

Wind turbines can rotate about either a horizontal or a vertical axis, the former being both older and more common.^[11]

The 3 primary types of HAWT and VAWT as they appear in operation.

Horizontal axis

Components of a horizontal axis wind turbine (gearbox, rotor shaft and brake assembly) being lifted into position

Horizontal-axis wind turbines (HAWT) have the main rotor shaft and electrical generator at the top of a tower, and must be pointed into the wind. Small turbines are pointed by a simple wind vane, while large turbines generally use a wind sensor coupled with a servo motor. Most have a gearbox, which turns the slow rotation of the blades into a quicker rotation that is more suitable to drive an electrical generator.^[12]

Since a tower produces turbulence behind it, the turbine is usually pointed upwind of the tower. Turbine blades are made stiff to prevent the blades from being pushed into the tower by high winds. Additionally, the blades are placed a considerable distance in front of the tower and are sometimes tilted forward into the wind a small amount.

Downwind machines have been built, despite the problem of turbulence (mast wake), because they don't need an additional mechanism for keeping them in line with the wind, and because in high winds the blades can be allowed to bend which reduces their swept area and thus their wind resistance. Since cyclic (that is repetitive) turbulence may lead to fatigue failures most HAWTs are upwind machines.

Subtypes

Doesburger windmill, Ede, The Netherlands.

12th-century windmills

These squat structures, typically (at least) four bladed, usually with wooden shutters or fabric sails, were developed in Europe. These windmills were pointed into the wind manually or via a tail-fan and were typically used to grind grain. In the Netherlands they were also used to pump water from low-lying land, and were instrumental in keeping its polders dry.

In Schiedam, the Netherlands, a traditional style windmill (the Noletmolen) was built in 2005 to generate electricity.^[13] The mill is one of the tallest Tower mills in the world, being some 42.5 metres (139 ft) tall.

19th-century windmills

The Eclipse windmill factory was set up around 1866 in Beloit, Wisconsin and soon became successful building mills for pumping water on farms and for filling railroad tanks. Other firms like Star, Dempster, and Aeromotor also entered the market. Hundreds of thousands of these mills were produced before rural electrification and small numbers continue to be made.^[8] They typically had many blades, operated at tip speed ratios not better than one, and had good starting torque. Some had small direct-current generators used to charge storage batteries, to provide power to lights, or to operate a radio receiver. The American rural electrification connected many farms to centrally generated power and replaced individual windmills as a primary source of farm power by the 1950s. They were also produced in other countries like South Africa and Australia (where an American design was copied in 1876^[14]). Such devices are still used in locations where it is too costly to bring in commercial power.

Modern wind turbines

Three bladed wind turbine

Turbines used in wind farms for commercial production of electric power are usually three-bladed and pointed into the wind by computer-controlled motors. These have high tip speeds of over 320 km/h (200 miles per hour), high efficiency, and low torque ripple, which contribute to good reliability. The blades are usually colored light gray to blend in with the clouds and range in length from 20 to 40 metres (65 to 130 ft) or more. The tubular steel towers range from 60 to 90 metres (200 to 300 feet) tall. The blades rotate at 10-22 revolutions per minute. At 22 rotations per minute the tip speed exceeds 300 ft per second.^[15]^[16] A gear box is commonly used to step up the speed of the generator, although designs may also use direct drive of an annular generator. Some models operate at constant speed, but more energy can be collected by variable-speed turbines which use a solid-state power converter to interface to the transmission system. All turbines are equipped with shut-down features to avoid damage at high wind speeds.

Advantages

Variable blade pitch, which gives the turbine blades the optimum angle of attack. Allowing the angle of attack to be remotely adjusted gives greater control, so the turbine collects the maximum amount of wind energy for the time of day and season.
The tall tower base allows access to stronger wind in sites with wind shear. In some wind shear sites, the wind speed can increase by 20% and the power output by 34% for every 10 metres in elevation.
High efficiency, since the blades always move perpendicular to the wind, receiving power through the whole rotation. In contrast, all vertical axis wind turbines, and most proposed airborne wind turbine designs, involve various types of reciprocating actions, requiring airfoil surfaces to backtrack against the wind for part of the cycle. Backtracking against the wind leads to inherently lower efficiency.
The face of a horizontal axis blade is struck by the wind at a consistent angle regardless of the position in its rotation. This results in a consistent lateral wind loading over the course of a rotation, reducing vibration and audible noise coupled to the tower or mount.

Disadvantages

Turbine blade convoy passing through Edenfield in the UK

The tall towers and blades up to 45 meters long are difficult to transport. Transportation can now amount to 20% of equipment costs.
Tall HAWTs are difficult to install, needing very tall and expensive cranes and skilled operators.
Massive tower construction is required to support the heavy blades, gearbox, and generator.
Reflections from tall HAWTs may affect side lobes of radar installations creating signal clutter, although filtering can suppress it.
Their height makes them obtrusively visible across large areas, disrupting the appearance of the landscape and sometimes creating local opposition.
Downwind variants suffer from fatigue and structural failure caused by turbulence when a blade passes through the tower's wind shadow (for this reason, the majority of HAWTs use an upwind design, with the rotor facing the wind in front of the tower).
HAWTs require an additional yaw control mechanism to turn the blades and nacelle toward the wind.
In order to minimize fatigue loads due to wake turbulence, wind turbines are usually sited a distance of 5 rotor diameters away from each other, but the spacing depends on the manufacturer and the turbine model.

Cyclic stresses and vibration

Cyclic stresses fatigue the blade, axle and bearing resulting in material failures that were a major cause of turbine failure for many years. Because wind velocity often increases at higher altitudes, the backward force and torque on a horizontal-axis wind turbine (HAWT) blade peaks as it turns through the highest point in its circle. The tower hinders the airflow at the lowest point in the circle, which produces a local dip in force and torque. These effects produce a cyclic twist on the main bearings of a HAWT. The combined twist is worst in machines with an even number of blades, where one is straight up when another is straight down. To improve reliability, teetering hubs have been used which allow the main shaft to rock through a few degrees, so that the main bearings do not have to resist the torque peaks.

The rotating blades of a wind turbine act like a gyroscope. As it pivots along its vertical axis to face the wind, gyroscopic precession tries to twist the turbine disc along its horizontal axis. For each blade on a wind generator's turbine, precessive force is at a minimum when the blade is horizontal and at a maximum when the blade is vertical. The cyclic loading affects the design of the mechanical elements, structure, and foundation of the wind turbine.

Vertical axis design

Vertical-axis wind turbines (or VAWTs) have the main rotor shaft arranged vertically. Key advantages of this arrangement are that the turbine does not need to be pointed into the wind to be effective. This is an advantage on sites where the wind direction is highly variable.

With a vertical axis, the generator and gearbox can be placed near the ground, so the tower doesn't need to support it, and it is more accessible for maintenance. Drawbacks are that some designs produce pulsating torque.

It is difficult to mount vertical-axis turbines on towers, meaning they are often installed nearer to the base on which they rest, such as the ground or a building rooftop. The wind speed is slower at a lower altitude, so less wind energy is available for a given size turbine. Air flow near the ground and other objects can create turbulent flow, which can introduce issues of vibration, including noise and bearing wear which may increase the maintenance or shorten the service life. However, when a turbine is mounted on a rooftop, the building generally redirects wind over the roof and this can double the wind speed at the turbine. If the height of the rooftop mounted turbine tower is approximately 50% of the building height, this is near the optimum for maximum wind energy and minimum wind turbulence.