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Offshore Wind Development Structure

Design process of Wind Turbine Generator (WTG)

Summary

All WTG activities in the Offshore Wind Development Structure are project-specific WTG Engineering. This includes:

  • Site-specific load calculations (wind class, turbulence, typhoon)
  • Seismic verification (in APAC specifically)
  • Tower height optimization
  • Control tuning for grid code
  • Transport adaptation
  • Interface geometry confirmation
  • Foundation load envelope issuance

The design described below is "OEM Platform Design" which is not part of WBS in Offshore Wind Development Structure. This design:

  • Take about 2 years
  • Is completed before Y1 in Offshore Wind Development Structure
  • Has type certificate

1. Market analysis & target definition

Define target LCOE (levelized cost of energy), rated power, rotor diameter, and hub height according to the target wind class.

2. Turbine concept & architecture selection

  1. Drivetrain: direct-drive vs medium-speed vs high-speed gearbox.
  2. Generator: PM synchronous, electrically excited synchronous, DFIG etc.
  3. Converter: full-scale vs partial-scale; DC-link sizing; filter topology.
  4. Pitch & yaw: number of actuators, redundancy philosophy, emergency pitch.
  5. Braking: aerodynamic + mechanical brake, parking strategy, fail-safe behaviour.
  6. Tower/support: steel tubular, hybrid, concrete; offshore jacket/monopile; floating substructure type.

3. Preliminary design

  1. Aerodynamic rotor design:
    1.1 Aerofoil family selection, chord/twist distribution, root design constraint.
    1.2 Optimize for AEP to loads, noise, transport constraints, and control stability.

  2. Control design:
    2.1 Basic set up: Cp tracking (power vs wind), pitch mapping and RPM limits.
    2.2 Grid support functions and setpoint tracking strategy (active power, ramp rates, reactive power, voltage control).

  3. Stability & frequency mapping:
    3.1 Perform Campbell diagram analysis to ensure structural frequencies (tower 1st/2nd fore-aft) do not coincide with rotor 1p or 3p passing frequencies.
    3.2 Assess aero-elastic damping.

  4. Define design load cases (DLC), based on IEC and run simulations.

  5. Load post processing and load feedback to components:
    5.1 ULS and FLS.
    5.2 Feed loads to blade, hub, main-shaft, tower, yaw, pitch.

  6. Initial design load envelope: Establish design load limit (e.g. max tip deflection, tower/blade root bending, main shaft torque).

4. Integrated component design

Based on the load inputs each component is developed further.

  1. Blade: structural sizing (spar caps, shear webs), full-scale blade test.
  2. Tower: global buckling, local shell buckling, door openings, weld class, fatigue hotspots, transportation and erection constraints.
  3. Drivetrain (hub, main shaft, main bearing): Bearing selection, shaft sizing for combined loads.
  4. Generator: finalize gearbox ratios (if used), electromagnetic sizing, thermal design.
  5. Converter and electrical: (need help!).

5. Load iteration & optimization

  1. Full load simulations with the updated components.
  2. Previous steps repeat.
  3. Optimization & load alleviations: if loads are below the envelope, reduce material; if over, apply control-based load redistribution.
  4. Design freeze: final design load envelope; component design is frozen.

6. Type certification (not project specific)

  1. Design basis evaluation -> Approved design basis document
  2. Load calculation verification -> Load calculation review report
  3. Structural design review -> Component design assessment report
  4. Rotor blade testing -> Blade test certification
  5. Control & Protection System Review -> Control system safety compliance report
  6. Manufacturing Quality System Audit -> Manufacturing conformity statement
  7. Prototype Testing -> Prototype validation report.