RE Feature

Testing of Small

Wind Turbines

The potential of wind energy in solving the energy crisis is

significant and the small wind turbines popularly known
as SWTs are poised to go a long way in achieving energy
empowerment for rural India. This article seeks to explain
the mechanism behind the technology of SWTs.
Rajesh Katyal

Students visiting the C-WET facility

October 2012
Volume 6 Issue 2

31

RE Feature

raditional mega-power production of electricity

is insufficient in todays scenario considering
exponential industrial growth along with higher
living standards. However mass use of battery stored
renewable energy would mitigate and even overcome peak
load demands especially in villages. It is in a scenario such
as this that micro-generation which includes technologies
like small wind turbines/aerogenerators can act as catalysts
to bring about cultural changes in consumer attitude. This
will in turn facilitate the availability of power to the rural
poor in the Indian context.
The small wind turbine (SWT) market has been
on the upswing globally for the last 2-3 years. SWTs
find application in isolated or stand alone systems,
mainly rural electrification, commercial applications
(telecommunication towers) etc. There can be different
types of small wind turbines - upwind, downwind,
horizontal axis wind turbines (HAWTs), vertical axis wind
turbines (VAWTs) and different variations of HAWTs and
VAWTs.
Most of the existing systems come under the category
of stand alone systems. Hybrid systems constitute a major
z blade
y blade

x blade

y shaft
x shaft

Fig 1. System of Axes for

HAWT
Source: IEC 61400-2
y

Mini wind farms consisting of

large number of wind turbines in
vast open spaces have become
a reality and serve as miniature
power plants. In remote places
aerogenerators meet the power
requirements.

October 2012
Volume 6 Issue 2

Types of Small Wind Turbines

Unlike large wind turbines, there are different types of

SWTs available in the market which makes the choice of
the most suitable SWT difficult. These include:
Drag and lift type SWTs
HAWT and VAWT
Upwind and downwind SWTs
Geared and direct-drive SWTs
Off-grid, on-grid and hybrid SWTs
Hence testing of SWTs has become all the more important to
mitigate the customer/investor risk of under performance
thereby increasing their confidence.

Testing of Small Wind Turbines

z shaft

32

share of these isolated systems, as they combine two or

more sources of renewable energy to ensure continuity
of supply. Mini wind farms consisting of large number of
such wind turbines in vast open spaces in cities have also
become a reality and can serve as miniature power plants.
In remote places where grid connectivity is not available
these aerogenerators are handy to meet the basic power
requirements. Also they can be employed in localities with
weak grids and high winds.
Some of the issues that have hampered the growth of
SWTs are design, grid integration, policy support from the
government and testing and standardisation. This article
focuses on the issues and methods, related to testing/
certification of small wind turbines and strategies to
accelerate the growth of the small wind turbine sector.

To cater to the standardisation of the design of these SWTs,

the international standard IEC 61400-2(2006) [3] was
formulated for small wind turbines/aerogenerators with a
swept area less than 200 m2 (i.e. rotor diameter less than
or equal to 16 m) and generating at a voltage below 1000 V
AC or 1500V DC. The standard suggests certain empirical
formulae/equations for design documentation.
After having dedicated years to the testing and
certification of large MW class wind turbines, the Centre
for Wind Energy Technology (C-WET) based at Chennai,
now has the capability even to test the SWTs and issue
quality type test reports. The test methodologies have
been standardised and the adherence to procedures is
done diligently. Presently the testing programme focuses
on engineering integrity, safety philosophy and quality
assurance so as to have a fail-safe design for SWTs.

IEC Tests for Small Wind Turbines

The different classification of tests, as per International

Electrotechnical Commission (IEC) 61400-2[3], to be
conducted on an SWT, based on which the integrity of the
turbines design is ascertained are given as follows:
a. Tests to verify design data,

RE Feature
b. Mechanical load testing,
c. Mechanical component testing,
d. Environmental testing, and,
e. Tests on electrical sub-systems.
Tests to Verify Design Data: The design of the SWT is
quantified ultimately by the dimensions and the specification
of the operation of the individual components and hence the
tests which can be performed in-house by the manufacturer
to verify:
Designed power at rated wind speed,
Designed rpm,
Designed shaft torque at rated wind speed,
Maximum rpm, and,
Maximum yaw rate.
These verifications result in the appropriate technical
specification details finalised for the designed model.
Mechanical Load Testing: Since the material used in the
construction of the SWT, by virtue of its properties, has
to be capable enough to withstand the load flow occurring
during its operations; one critical test that has to be done
is to determine the loads induced at critical locations in
the structure along with the meteorological parameters
and SWT operational data (rotor speed, electrical power,
yaw position, turbine status). The loads may include blade
root bending moments, shaft loads and loads acting on the
support structure. These tests needs to be performed as per
IEC 61400-13[5].
Mechanical Component Testing: This procedure includes
tests carried on the load carrying components such as the
blade, hub, nacelle frame, yaw mechanism and gearbox.
These tests can be performed in-house by the
manufacturer. The resulting data from these tests provide
the concise picture of the components of capabilities and
whether they live up to the design requirements envisioned
on the design stage; in effect ensuring the reliability of
components.
Environmental Testing: If the SWT is designed for
external conditions such as extreme cold, hot, desert/
dusty conditions outside the normal external conditions,
the turbine shall be subjected to tests simulating those
conditions, thus ensuring that the design adequacy in these
spheres are verified.
Tests on Electrical Sub-Systems: Tests shall be carried
on all safety critical electrical sub-systems of the turbine
such as the electrical generators/alternators, electronic
sub-systems, etc. in compliance with the relevant IEC and
national standards.

Type Tests

The present type testing programme focuses on the

following essential tests of the SWTs.
Power performance test,

Every small wind turbine has to

perform its operations, yield the
utmost benefits promised during
the commercial transaction
and yet safeguard itself for an
extended life.
Safety function test, and,
Duration tests (replacement

of load measurement test

as in the case of large wind turbines). The three elements
of type testing for the conformity statement of a SWT/
aerogenerator are as shown in Fig 2.
Power Performance Test: The productive yield of a
turbine is always quantified by the annual generation
of electrical power harnessed by the turbine. The
power performance test provides verified data for the
purpose and is to be carried in accordance with the
IEC standard, (Wind Turbine Generator Systems, Part
12: Power Performance Measurement Techniques,
IEC 61400-12-1[2]). Small wind turbines can be used as
battery charging devices, grid connected systems or can
directly run electrical loads like motors or resistive load.
For a battery charging turbine, the power performance
measurement test must take into account the effect of
battery state of charge (i.e. voltage variations in the load
including float voltage levels) on power output.
The turbines power performance characteristics
are determined by the measured power curve and the
estimated annual energy production (AEP). The measured
power curve is determined by collecting simultaneous
measurements of wind speed and power output for a period
that is long enough to establish a statistically significant
database over a range of wind speeds and under varying
wind conditions. The AEP is calculated by applying the
measured power curve to reference wind speed frequency
distributions, assuming 100 per cent availability of the
turbine.As per IEC 6140012-1, the anemometer, to measure
wind speeds, must be located between 2 - 4 times the rotor
diameter from the turbine. Another anemometer will be
located at 1.5m below the primary anemometer as a check
on the primary anemometer.
Measurement Setup for Power Performance Testing:
The measurement system involves acquisition of signals
from meteorological sensors, status signals and DC
power signals at the output of the charge controller. The
power curve of the wind turbine is plotted as a function
of wind speed at standard air conditions (air density - 1.225
kg/m3). A typical power curve of a SWT normalised to
the peak power at standard wind speed conditions is
depicted in Fig 3.

October 2012
Volume 6 Issue 2

33

RE Feature
Fig 2. Type tests of SWTs
Type test
conformity statement

Safety
function
test

Other test
environmental
(optional)

Duration
test

Source: IEC 61400-2

Safety and Function Test: Every SWT has to perform its

operations, yield the utmost benefits promised during
the commercial transaction and yet safeguard itself for
an extended life. This sole purpose is catered to through
the safety and function testing which verifies whether the
SWT under test displays the behaviour predicted in the
design and that provisions relating to personnel safety
are properly implemented and get deployed during the
appropriate time.
The purpose of the safety and function test is to ensure
a fail-safe operation of the turbine under all conditions.
It is undertaken in accordance with provisions listed
in IEC 61400-2. Unlike large wind turbines, the control
and protection systems for SWTs are very simple and
often passive. The safety and function test consists of the
following:
Emergency Shutdown Operation: Brakes will be applied
to check if the SWT shuts down at normal and high wind
speeds.
Power and Speed Control: This is to ensure that the
power and speed of the SWT remain within design
limits. The power output and the rpm of the SWT will
be measured. The maximum rpm shall be determined by
interpolation or extrapolation to Vref, corresponding to
the SWT class.
Yaw Control: This shall be verified by visual inspection.
Loss of Load: The condition shall be simulated by an
open circuit at the SWT electrical generator terminals
and the braking mechanism of the SWT shall be verified.
Over-Speed Protection: This verifies how the over speed
protection mechanism of the SWT works under fault

The purpose of the safety and

function test is to ensure a failsafe operation of the turbine
under all conditions. It is
undertaken in accordance with
provisions listed in IEC 61400-2.

34

October 2012
Volume 6 Issue 2

Duration Testing

This test is performed at the end of all the tests and is based
mostly on the visual observations at that point of time. The
Fig 3. Power Curve of a SWT
0.7
Electrical Power (P. U.)

Power
performance
test

conditions or above design cut-out wind speeds.

and Shutdown above the Rated Wind Speed:
The start up and shutdown mechanism above rated wind
speed for the SWT are monitored.
In addition to the above mentioned critical functions, the
following may also be verified if applicable.
Excessive Vibration Protection: The test verifies the
vibration protection mechanism of the SWT.
Battery Over- and Under-voltage Protection: The test
verifies the over and under voltage protection mechanism
of the SWT at battery voltages outside set points, for
battery charging systems. The battery voltage, dump load
status and load status are monitored and correlated.
Cable Twist: This is to verify whether the SWT cable
untwist influences the yawing mechanism.
Anti-islanding (for grid connections): This verifies
whether any electrical system (capacitors) that by itself
can operate the SWT shall be automatically disconnected
from the network and remain safely disconnected in the
event of loss of network power.
Start-Up

0.6
0.5
0.4
0.3
0.2
0.1
0
0

Source: SWT testing at C-WET

10

Wind Speed m/s

20

30

purpose of the duration test is to investigate the following:

Structural integrity and material degradation (corrosion,
cracks, deformations)
Quality of environmental protection of the SWT
Dynamic behaviour of the SWT.
The load measurement and blade fatigue tests of large
wind turbines are replaced with the duration test [3],[4]. As
per IEC 61400-2, the duration test requires that the SWT
has a reliable operation during the test period including at
least 6 months of operation, at least 2500 hours of power
production in winds of any velocity, at least 250 hours of
power production in winds of 1.2 Vave and above or at least

RE Feature
25 hours of power production in winds of 1.8 Vave and
above, where Vave is the annual average wind speed at
hub height. The Vave value is determined by the SWT
class under which the turbine falls. Reliable operation
means operational time fraction of at least 90 per cent
without the following events:
No major failure of the turbine or components in the
turbine system,
Significant wear, corrosion or damage to turbine
components, and,
Significant degradation of produced power at
comparable wind speeds.
Measurements that will be taken during the duration
test are power production, turbine operational time
fraction, and wind speed consisting of 10-minute
average, turbulence intensity and wind direction. Power
is measured by a power transducer at the point of
connection to the electrical load. To check any hidden
degradation in power performance, the power levels
shall be binned by wind speed every month. The binned
power levels shall be plotted as a function of time for each
wind speed and any visible trends shall be investigated.
At the completion of the duration test, a detailed
component wear and durability check for the entire
turbine will be conducted. It will include a visual
assessment of the structural integrity and material
degradation (corrosion, cracks, and deformations).

Selection of Test Site

The guidelines followed for the selection of site for

undertaking tests on SWT are as per standard IEC 6140012-1. The basic requirements for selection of test sites will
depend on the terrain conditions and minimum wind
speed requirements. Presently, the tests on SWTs are
conducted at the Wind Turbine Testing Station (WTTS),
Kayathar, Tamil Nadu. The wind speed statistics for
Kayathar are as follows:
a) Maximum average wind speed : 5-6 m/s
b) Peak wind speed : 25 m/s

Conclusion

The main drivers to the growth of SWTs are the demand

supply gap in energy, increasing fossil fuel prices, improved
small wind turbine technology and the diverse application
to which it can be used both for grid-tied and stand alone
systems. The market for SWT technology is encouraging in
India also, and may require market drivers like favourable
policies, encouragement to the net metering concept,
adoption of micro generation technologies, and reduced
costs etc., to reach a significant level. b
The author is Scientist and Unit Chief, Wind Turbine Research
Station (WTRS) Chennai. Email: katyal@cwet.res.in

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October 2012
Volume 6

Issue 2

35