5/25/12

Give Power =10e13 kW/hr

Globe

Sun

3 % of Solar
Power change
to the wind

To the world electricity Grid Connect

Dr.Wirachai Roynarin
Director of Wind Water and Solar
Research Centre RMUTT, Thailand

Thai Wind Class of Wind Power Density

3 % of the whole wind energy

WHAT IS THE APPROPRAITED MODEL FOR THAILAND WIND MACHINE

-Small wind machine 1-250 KW low speed

wind machine
- Low wind speed zone
-Special Design wind machine
-Appropriated generator (PMG)
-Special airfoil design
-High tip speed ratio airfoil
-Low rpm controller
-High temperature and humidity
-High turbulent and gust with roughness
-Protection from pouring rain (very wet)
-Low maintenance
-High performance at low wind speed
-Light and strong blade
-Dusty and salty
-Strom and lighting in depression season
-low cut in and rated wind speed
(rated could not over 9 m/s)
etc...

How Model of Wind turbine

for Low Wind Speed
-Longer blade design ,Higher Tip
speed ratio
-Low Cut in wind speed, Low Cut out
wind speed
-High Temp. Design
-High Moisture design and Protection
-Near Coast?. Anti rusty Material, Easy
to install,
-Easy to maintenance, More Localize
made and repairable
-Low speed Generator develop,
-Medium size scale not more than 100

Trend of small Wind Turbine Business low Wind Speed Zones

Small Wind Turbine machine seem to be more

popular than medium-large size due to cost of
investment and location + 70 % of world Wind
resource.
Low wind speed design is the suitable technology for
Thailand and many countries start to develop.
Base on the oil price, if > 150 USD/Gal., using of
wind machine and solar panel will be the right
solution.
Government stimulus plan and Global warming is the
key factor.
Local Content and after service of after sale is the
Keys factor of using wind machines

5/25/12

Type of Wind
Turbine
2. Horizontal Axis Wind

Type of Wind
Turbine

1. Vertical Axis Wind

Turbines(HAWTs)

Turbines (VAWTs)

Wind Water and Solar Research Centre

Mechanical Engineering Department, Engineering Faculty

Renewable Research Centre

RMUTT

WWW.PRAPAI.CO.TH DEDE

Wind Turbine Laboratory ,RMUTT

1. Control System

2. Data monitoring

5. Generator Testing Lab

3. Mechanical testing
4. Power control

Tools and Licensed

Software
CFD, CF-Design for Fluid and Heat investigation
3 D Computer Aid Design, Solid Works CAD
Data monitoring system
Finite Element Program, 2 D and 3 D
Apparatus
- Water turbine test rig
- Wind turbine test rig
- Solar module test rig
- Micro Controller for Power Control testing unit
- Inverter testing unit
Including majors instruments in energy and environment
measurements

Dr. Wirachai Roynarin

5/25/12

Step of Design and Making Prototypes

(Factors to the wind machine Design)
Properties:
-Low density ~1.22 kg/m^3 (High Temp.)
-More fluctuate (Forrest and Mountains)
-High Moistures
-Dusty
-Salty
-2 Direction (Northeast and Southwest)
- Average Wind speed @15 - 30 Height ~ 5 m/s

Betz Limit
All wind power cannot be
captured by rotor or air
would be completely still
behind rotor and not allow
more wind to pass through.
Theoretical limit of rotor
efficiency is 59%
Most modern wind turbines
are in the 35 45% range

Performance Over Range of Tip

Speed Ra4os
Power Coecient Varies with Tip Speed Ra4o
Characterized by Cp vs Tip Speed Ra4o Curve

1. KW Requires
2. Blade design
3. Generator design
4. Blade prototyping
5. Blade Ground Testing
6. Yaws and Nacelle design
7. Controller design and testing
8. Tower and Foundation Design
9. Assembly and Prototype Testing
10.Data record and Analyzing
11.1 years testing and modification
12.data sheet spec. and commercial

Rotor Solidity
Solidity is the ratio of total rotor
platform area to total swept area
R

Low solidity (0.10) = high speed, low torque

A

High solidity (>0.80) = low speed, high torque

Solidity = 3a/A

Twist & Taper

Speed through the air of
a point on the blade
changes with distance
from hub
Therefore, tip speed
ratio varies as well
To optimize angle of
attack all along blade, it
must twist from root to
tip

Fastest
Faster
Fast

5/25/12

Tip-Speed Ratio
Tip-speed ratio is the ratio of the
speed of the rotating blade tip to
the speed of the free stream wind.

Selecting the blades:

Airfoil Standard ?

There is an optimum angle of attack

which creates the highest lift to
drag ratio.
Because angle of attack is
dependant on wind speed, there is
an optimum tip-speed ratio

TSR =

R
V

Where,

= rotational speed in radians /sec

R = Rotor Radius

V = Wind Free Stream Velocity

New blade design required ; Investigate

performance airfoil by CFD

Lift & Drag Forces

The Lift Force is
perpendicular to the
direction of motion. We
want to make this force
BIG.

The Drag Force is

parallel to the direction
of motion. We want to
make this force small.

= low
Mesh around airfoil by
ICEM mesh creator

= medium
<10 degrees

The model elements

created ready to study
and to investigate in CFD

= High
Stall!!

Example of the performances prediction by Analytical Models

Selection the right airfoil for low speed wind machine

The performance comparison using 40 different airfoil sections

Airfoil Section: Clark Y

40 Airfoils:
ClarkY, E 387, S 6062, SD 7037, NACA 2414, S 822, SD 6060, RG 15, S823, SG6042, Goe417a, SG6040, LRN1007 (B), CR-001,
SA7035, Trainer 60, S6063, RG14, E231, SD 7032, SD 7062, SG 6041, USNPS-4, S1223, E423, MO6-13-128, Davis3R, LD-79,
MH32

Put Cl and Cd

Analytical Models
program

Compute

NACA 0006,NACA 661-212,NACA66 (215-016), NACA4421, NACA 23024,NACA23021, NACA1421, NACA2412, NACA4418, and
NACA23012.

Results

5/25/12

The investigation of blade chord ratio (c/r)

Blade Profile Design for 3 Dimensions

STEP OF CFD
PROCESS

Blade Design Theory

1.Momentum Theory
2.Blade Element Theory
(BET)
3.Blade ElementMomentum (BEM) Theory
4.Strip Theory

Type of element onTetrahedral

Discretization

Numerical
Solver

MATHEMATICA
L
MODEL

CFD PreProcessing

CFD
model
CFD
Solution

CFD
results

CFD PostProcessing

Scope of Study

Node

Element

Beam
(1D)

Plate
(2D)

Solid
(3D)

5/25/12

Computational Mesh

Properties of Material in CFD

Air Properties

Boundary
Conditions

Result from CFD

Moment of Inertia of Blade

In Solidwork

Results Velocity Vectors"

Airfoil Shape and Structure Design

Just like the wings of an
airplane, wind turbine
blades use the airfoil
shape to create lift and
maximize efficiency.

5/25/12

PROTOTYPE BLADE STRUCTURE

STRENGTH TEST at LAB.

Mold of
Prototype

Prototype Testing

Prototype BLADE
GROUND TEST

Prototype Testing

Deflection Blade
Test results

Deflection
Blade

. 10kW PMSG
10kW PMSG Developing Focus and Objects
Electrical
For very high electrical efficiency, a 3 generator using Skew-NdFeB magnets
has been specially designed for the turbine.
Mechanical
The generator is designed to work at low rpm and so can be directly driven
by the rotor-gearless. thus eliminating a source of inefficiency, noise and
potential
Mechanical Strong
Easy Heating release
Low inertia
&
Strong- Durability.

Wind turbine tower manufacturing and inspection

Rated Power
rpm
Efficiency
Rotor
Stator

Specification
12 kW
120 rpm
Over 90%
Skew, Permanent Magnet
lamination core sheet

42

5/25/12

. 10kW PMSG_ Progress(2)

. 10kW PMSG_ Progress(3)

10kW PMSG- Magnet and Rotor

10kW PMSG- Magnet and NdFeB Price

Cogging Torque Reduction

<Spacer Mold

- 90 slot/30 pole, Air Gap: Min.1.5mm

With a large number of slots/pole slightly skewing is
usually sufficient to eliminate most of the cogging.

43

. 10kW PMSG_ Progress(4)

Core Design and Winding

44

. 10kW PMSG_ Progress(5)

slot opening width; cogging Torque ripple

10kW PMSG Al Housing and Cover

Housing material is Al.
Easy to heat dissipation, corrosion resistant.

A+
A+

BB-

C+
C+

AA-

B+
B+

CC-

Distributed full pitch windings(Double layer)

90-slot-30-pole (q = 1)
A, -B, C, -A, B, -C

Housing Mold

45

. 10kW PMSG_ Progress

46

. 10kW PMSG_ Progress

10kW PMSG Assembly

10kW PMSG M&G TEST

Symbol

Split Slot core

+
Coli winding
+
Housing

units

Output power

Po

kW

Rated speed

rpm

120

Output Voltage

3phase, 360(Line-Line)

Max. Efficiency

Number of Pole

30

Speed Constant

KE

Vdc/rpm

4.6

Resistance at 20 C(Line-Line)

RT

1.79

Inductance ( Line-Line)
Rotor Inertia

Stator
+
Rotor

Maximum Temperature

47

mH

Kg-m2

CMax

oC

24.9
1.47
150
Wye

Winding
Starting Torque

Nm

< 10

Shaft Play-Axial

mm

< 0.2

Kg

210

Gen. Weight

The manufactured
PMSG

94
Permanent magnet

Rotor

M&G SET

12

PMSG: High efficiency, Duration

NdFe-B Magnet design
Direct Drive
Multi Pole, Distribution Winding
Split core,
Skew Magnet type: Low cogging Torque

Wg

No load, Load
Output power vs. rpm
Insulation Resistance Examination
Starting Torque

5/25/12

. 10kW PMSG_ Progress(8)

. 10kW Grid Inverter_ Progress(1)

10kW PMSG M&G TEST

10kW Grid Inverter

Rated Power range : 10kW@100rpm ~

20kW@ 200rpm
Application: SWT, Hydro, etc.

10kW OVP, E/B, Grid Inverter

. 10kW Grid Inverter_ Progress(2)

10kW Grid Inverter
Dump
IGBT&
Heat Fin ASSY

Air Blower
Reactor

Monitor
Transformer
CPU ASSY

OVP

Wiring
ASSY

Electric Brake(E/B)- ON
Over power, Over Voltage, Over Temperature etc.
Generator Temp. : > 110C
Rectified DC Voltage: > 500Vdc
Emergency : Manual S/W

. 10kW Grid Inverter_ Progress(6)

10kW Grid Inverter

5/25/12

. 10kW Yawing System_ Progress(2)

Yawing and Nacelle

. 10kW Yawing System_ Progress(4)

Electric Brake-E/B

. 10kW Yawing System_ Progress(6)

Nacelle and Nose Cone Mold

. 10kW Yawing System_ Progress(3)

Slip Ring

. 10kW Yawing System_ Progress(5)

Yawing and Tail

. 10kW Wind Turbine Project- Summary(1)

10kW@9m/s-Wind Turbine

PMSG: 12kW-120rpm, Low cogging torque, High efficiency and Duration.

Grid inverter: Built-In(OVP and Dump), Transformer type, MPPT, High efficiency.
Composite: Low weight, Waterproof
Anti-corrosion- FRP, Stainless steel, coating and Painting
Yawing error- efficiency
Safety and reliability: Side Furling, E/B, Short Circuit Breaker

For use for low wind speed- 9 m/s

Power restricted in strong wind; Side Furling+ E/B
Warrantee and Guarantee over 5 yrs

10

5/25/12

Installation for prototype test

Engineering inspection

Teaching and instruction of installation

Ready to test and colleting

data of the prototype

10 kw prototype test at Wind testing centre Samutsakorn Thailand

10 KW P-TECH
Technical Specification:

Cut- in 2.5 m/s

Rated power @9 m/s
Rotor Diameter: 8 m
Strom protection:@ 15 m/s
Auto furling with E-brake
Blade: Carbon fiber+ fiberglass
reinforced
Nacelle weight: 700 kg
Rotor weight: 90 kg
Design for average wind speed 4.5 m/s

Data monitoring and

investigation process

Tower Height: 18 m
Grid inverter outdoor type IP 54
380 Volts 3 phases 50 Hz.

11

5/25/12

Plant design

Design of Grid Connected Wind Turbine

Generation in Thailand

Grid Connected

Designing of 100 kw/Plant for Low Speed Mini Wind Farm

WTG 5 KW x 3

WTG 5 KW x 3

Mini Wind Farm for Low Wind Zone King RAMA IX Farm
Project Located @Thayang, Pecthaburi

WTG 5 KW x 4
Designed for Low Wind Speed Zone
(Wind Class I- II @ 4-7 m/s)

S
WTG
Controller

0- 200 VAC

(Blade Length)
~ 3.2 m
(Rated Power)
~ 5000 W @ 9 m/s
(Cut-in)
~ 2.5 m/s
(Cut-out)
~ No: With Auto Furling System
(Hub Height)
~ 18 m. based on site
(Rotor Speed)
~ Variable 100-200 rpm
(Rotor Speed Control) ~ Fixed Pitch With optimum Output PWM Control
(Yaw Mechanism ) ~ Active system by tailing
(Noise Emission at 50 m. distance) ~ < 30 dBA

WTG
Controller
0-300 VDC

Grid
Connect
Inverter

Grid
Connect
Inverter
0- 220 +-5% VAC 50 Hz.

MDB

100 KW mini wind farm grid connected

3 Phases
Electric Meter

- 5 kw x 20 Unit Low Wind Speed Design

- Rated @ 8.5 m/s of 5 Kw

380 VAC
3 Phases

TR; 380 VAC- 22 KVA

Grid line 22 KVa

Wind Turbine Designed by Dr.Wirachai Roynarin

100 KW MINI WIND FARM USING LOW WIND SPEED MACHINE

@ King Rama IX project , Thayang , Petchaniburi Province

Result of Low wind speed wind Farm

(Case study king farm project, Thailand)

- Monthly average 4500 units electricity production

- Making 20 % plant factor at wind speed average 4.5 m/s
-Very good for low wind speed areas
-Investment return of about 7 years of 8

/kwh adder cost

12

5/25/12

Research success and commercial

Research for rst small wind farm wind machine in Low wind speed areas

Research for automa2cs wind machine low speed zones

Research for real implementa2on king farm project

Mini Wind Farm for Low Wind Zone King RAMA IX Farm
Project Located @Thayang, Pecthaburi

100 KW mini wind farm grid connected

13

5/25/12

2 kw 2 arms low wind speed machines

Ko-Lahn Wind Farm Project

Case Study for the Queen Project at remote area for Electricity

5 kw small wind with high speed wind machine

14

5/25/12

The Visiting from Bangkok City

Governor team

Research of High and Low Speed Wind

Machine (Appropriated Technology)

Sponsored by DEDE

Canon Marketing Thailand Support and donate 1 kw wind

machine to 15 Primary School for Renewable Energy and
Education

Wind Turbine 10 kW

Now 10 kw Release to commercial

Thank you
for your Co-Operation
More info at

www.thaiwindy.com

www.prapai.com
e-mail: wirachairoynarin@yahoo.com

COST ~ 3 USD /W /UNITS

Dr.Wirachai Roynarin
PhD. Mechanical Engineering Dept.
Rajamangala university of technology Thanyaburi, RMUTT
Thailand 12110

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