Traceability of pitch angle position for small scale wind turbine to get

a maximum Energy Extraction

Ali Musyafa
(1)
, Farid .R.M.
(1)
I.M.Yulistya Negara
(2)
, Imam Robandi
(3)
(1,)
Department of Engineering Physics, Faculty Industrial Engineering , ITS Surabaya

(2,3,)
Jurusan Teknik Elektro FTI, ITS Surabaya
Kampus ITS Keputih, Sukolilo, Surabaya 60111
Telp : +6231-5947188 Fax : +6231-5923626
E-mail : musyafa@ep.its.ac.id

Abstract

Global crisis in financial, energy, together with climate and enviromental, has motivated word
community to seek for alternative energy resourses, known as the new and renewable energy source to
replace conventional widely used fossil energy. Wind energy, regarded as potential candidate of the
clean alternative source that may help to solve the crisis. The development of the worlds wind turbine
instalation in 2010 reached 30 %, with a total capacity of 160 GW. The comprise of USA=39 GW,
Germany and China = 26 GW, followed by Spain, India, Italy, etc. Indonesia as a tropical country with low
wind speeds (3-6 ms
-1
) is also participate in the development. In 2008 there are 1.2 MW wind turbine
instalations, and in 2011 a new plant is built in Bulukumba-South Sulawesi and Aceh, each with 0,5 MW
and 10 MW, respectively. However, the majority of the installed turbines technology come from other
countries, which are not fully suited with local conditions and the exist a great problem in dependency
of the spare parts from the producers. Therefore, it needs to develop our own local wind turbines
technology, with the key players from LAPAN,BPPT, state and private Universities in Indonesia.

This paper reports development and test of a prototype for wind turbine with blade diameter of 2
m, with three blades of airfoil NREL S83n. Crucial problem in implementation of small scale wind
turbine for low wind speed regimes ( i.e. 3-6 ms
-1
, like in most areas in Indonesia), is to determine the
position of pitch angle of turbine blade. The right position of blades pitch angle may produce maximum
mechanical power, wich means also maximum electrical energy. The proof of concept experiments were
done by considering pre-determined dimension, type and diameter of blade, as well a range of angular
velocity and power produced. The prototype of turbine was exposed to variation of wind speed flow,
and stepwise variation of bladess pitch angle was set through PC, with angular step of 5
0
for range of
angle 0-90 degrees. Optimal pitch angle 0f 15 5 degree was obtain, with a maximum value of Cp=0.54


Keyword : Pitch angle, wind turbine, mechanical energy, Electrical power.


1. INTRODUCTION

Global crisis in 2008, viz namely the financial crisis, energy crisis and climate-environmental crisis,
has motivated and encouraged the world community to seek alternative energy resources, such as new
and renewable energy to replace conventional energy. For now on, wind energy has a claim on new and
renewable energy, therefore wind energy can be proven to solve the three crises above. The world
wind turbine installation development in 2010 reached 30% with a total capacity of 196,63 GW. They
comprises of China = 44,73 GW, USA= 25,81 GW and Germany = 27,22 GW, followed by Spain, India,
Italy, etc. Indonesia as a tropical country with low wind speeds (3-6 m / s) is also not left behind. In 2008,
Indonesia has 1.4 MW wind turbine installations, and in 2011 a new plant is built in South Sulawesi and
Aceh Bulukumba consist of 0.5 MW and 10 MW respectively. However, the majority of the installed
wind turbines in Indonesia are from other countries, as a result there is a great dependency of the
components from other countries. Therefore, it is needed to develop local wind turbine either by
LAPAN, BPPT, colleges, or the general public [1-2-3].
Wind energy conversion systems (WECS) consists of wind turbines, generators, power
electronics, network systems and control systems. Small scale of WECS is wind turbines with
<10 kW capacity, this turbine is suitable for low-speed wind farms such as Indonesia. The
important part of SKEA is the wind turbine. In this part, the wind kinetic energy will be
transformed into mechanical energy and then converted into electrical energy. Fluctuation in
the wind kinetic energy value were often influenced by the wind speed changes and the type of
air. Wind turbine mechanical energy production value is parallel with the wind kinetic energy
input [4-5]. Maximum mechanical power production of wind turbines can be attained by
increasing the angle of wind turbine rotational speed. Wind turbine mechanical power production
depends on several variables of wind turbines, such as power coefficient (Cp), which depends on
the value of (, ). is the tip speed ratio (TSR) that cost = R / V), the value of R constant wind
turbines, mean while the fluctuation of V value depend on the condition of the wind field, is
the angular velocity of the wind turbine correlated to a blade angle position. Hence, the most
influence variable of mechanical power production of wind turbines is the blade angle position
other quantities which influence over mechanical power production is the type of blade and blade
number, but its value is constant after the system was designed [6].
The wind turbine performance can be monitored, if a prototype wind turbine is outfitted with
a computer-based electronic monitoring system. Here, major scales such as V, and are likely
to be monitored. To obtain these quantities, wind turbine is outfitted with a sensing rotary
encoder for sensing turbine rotational speed. Furthermore, this rotation data is processed by
processor, and then it is displayed and recorded in real time by the PC. The variations of blade
angle position changes can be set via PC, so the blade angle position changes can be done in
every single step 5
o
quickly and precisely [7]. From this experiments, all data related to head
position blade angle changes, wind speed and the speed will be processed to obtain the relation
between the wind power and the turbine mechanical power output. The maximum power
production values are obtained when the blade angle is in a particular position and then this value
is used as a reference for developing the turbine and the design of control systems. This study
focuses are to find and trace the position angle blade wind turbine that can produce maximum
mechanical power.
2. WIND TURBINE SYSTEM

A wind power production by a wind turbine can be expressed through a kinetics wind
energy equation using equation (1) and (2) [13].

( )
2
w r air
2
w
v x A
2
1
mv
2
1
U = = (1)

3 2
2
1
2
1
w r air w r air
v A
dt
dx
v A
dt
dU
P = = = (2)

Where U is a kinetic energy (Joule),
air
is air density (kg/m
2
), A
r
is a sweeping blade area (m
2
),
v
w
is a wind speed (m/s), and P is wind turbine power (watt). Kinetics energy is converted into
rotational energy or wind turbine power. When the wind passed through the blade, a wind
velocity profile can be illustrated using a contour tube as in Fig. 1. There are four points to be
considered as in Fig. 1. The velocity profile and its relation to the sweeping blade area are given
below:

1 3 2
3
2
v v v = = (3.a)
1 4
3
1
v v = (3.b)
1 3 2
2
3
A A A = = (3.c)
1 4
3A A = (3.d)

Equation (4) can be used to calculate the extraction of wind power. The power can be calculated
by comparing the wind power before and after the blade:

( ) |
.
|

\
|
= = =
3
1 1
3
4 4
3
1 1 4 1
9
8
2
1
2
1
v A v A v A P P P
air air
(4)

|
.
|

\
|
=
(

|
.
|

\
|
=
3
1 2
3
1 2
27
16
2
1
3
2
9
8
2
1
v A v A P
air air
(5)

A substitution eq. (5) into eq. (4), and substitution the value of A, it can be obtained a
constant of 16/27 = 0.59. This value is known as a Betz coefficient [14]. This coefficient shows a
maximum efficiency of wind turbine or it is called a power coefficient (Cp). It is known that
wind power production is also effected by the Cp. The bigger Cp can produce the bigger wind
power production. The expression of extracted wind power also can be written as in eq. (6).


3
2
1
w r p air
v A C P = (6)

Cp also can be determined in a simple way based on P
1
and P
4
as in eq. (7)

1
1 4
P
P P
Cp

= . (7)
Tip speed ratio is the ratio between the rotational speed of the blade tip to wind speed. Blade tip
speed is obtained by multiplying the rotor angular velocity (rad / s) with the radius of the rotor. This
value is then compared with the wind speed in zone 1. R is the radius of the rotor and the RPS is the
rotation per second.

V
RPS R
TSR
. . 2
= (8)
A design of wind turbine is shown in Fig. 2. It consists of three blades, a gear blade, motor
servo, a generator and others supporting components. The blade is designed based on an air foil
contour standard of NREL S833, S835 and S834. This blade type is chosen with a consideration
of its easiness of fabrication process. The blade has a length of 100 cm and a thickness of 18 %,
15 % and 21% t/C. It is made of fiber material. A gear box is fabricated based on a specification
of the motor servo. The gear box can achieve a movement resolution of 5
o
. The fabricated wind
turbine parameters are shown in Table 1.


Figure. 1. Velocity profile in the wind turbine area



Figure. 2. Prototype of wind turbine
Table 1. Specification of the developed wind turbine

SPESIFIKASI
Rotor Blade
Span = 85 cm
Blade = 3
Airfoil = non-uniform NREL S835 (root), S833 (primary), S834 (tip)
Tapered, no-twist.
Blade Shaft = Stainless Steel, 10 mm, l = 15 cm
Material = Fiberglass
Pitch Setting
Motor Servo = GWS Servo S125-1T/2BB/F 360 Deg
Driver = Mikrokontroler ATMega8535L
Angle rotasi = 360
o
Power Suplay Catu daya = 6 V
Torque = 6.60 kg/cmB
Gear box = Nylon, 1:1.25
Rotary Sensor
Rotary Encoder = Relative, 20 slate, 40 mm
PhotoInterrupter = Sharp GP1S53, 5 mm gap,
IR (Tx) Phototransistor (Rx)
Center Plate & Hub Cover
Center Plate t = 20 mm, 28 cm
Material = Poly Vinyl Chloride (PVC) Grey
Hub Cover Material = Fiberglass
Rotor Shaft
Stainless Steel, 15 mm, t = 2 mm, l = 55 cm
Shaft holder = bearing NTN 6203LU
Rotary Connector
Carbon Brush Holder = Bosch dan Black Dekker
Carbon Brush = Makita

The fabricated wind turbine is equipped with a monitoring software based on Visual Basic 6 and a
serial port interface for data communication. This software is used to control and to show the position
of the pitch angle of the wind turbine blade. The measurement data can be presented in real time to
indicate all of the necessary information. Monitoring system is also equipped with recording data
system based on Microsoft Office-Excel integrated with the Visual Basic. Therefore, all of measurement
process for the wind turbine can be accessed in real time and online. In this paper, wind speed data for
experiment taken for a period of 100 seconds, in a steady state for the variation of wind speed 3-8 m/s.
It indicates that the most of wind speed is in the range of 3-6 m/s. Therefore, it is necessary to design a
wind turbine with an operational wind speed within this range.



3. RESULTS AND DISCUSSION
Wind turbine prototype testing is done by test of each component block and divice; which includes
hardware testing; rotating connector, rotary encoder sensors, signal conditioners, transmitters and
displays. Testing is also done on the system software. When test results have met the criteria state, then
performed the integration of hardware and software systems. WECS Testing is done by performing
experiments in the laboratory of ITS, which suport by wind power generating system (blower) that wind
speed can be set varied in the range of 3-8 m/s. At the initial stage of experiments carried out setting
changes blade pitch angle position () through the software starts the smallest angle followed by the
blowing of the wind speed varied start low then increase to the highest speed. Monitoring and recording
system to read wind turbine angular velocity indicated by the PC screen. The experimental results are
used to calculate the amount of power coefficient (Cp).
Relationship varied position blade angle and wind speed varied to produce wind turbine rotational
speed is varied as well, as a whole shown in Table 2. Testing of wind turbine systems are also made to
find relationships wind speed, angular position, rotational speed, and coefficien of power and Tip
speed ratio (TSR). The result of calculation and the correlation shown in Figure [3-7]. Fig.3. show wind
speed data varied 0-8 (m/s) during the period of one year imposed on a wind turbine to see the
performance of wind turbines. From the test data obtained subsequently calculated the value of tip
speed ratio. values obtained from the relationship pitch angle position and rotational speed are then
used to calculate the tip speed ratio (TSR). and Cp values, obtained at a position angle between the
(10-20)
0
. Relationships of Cp, and from the calculation for the whole range shown in Fig. 6.
In the view of this experiment, there is correlation of all process variable including wind speed,
blade angle position, rotational speed, tip speed ratio, power production, and wind turbines coefficient.
The correlation of those variables can be seen in Fig. [3-7]. After V, , , , Cp, is found, then the input
and output mechanical power can be calculated. The two amount of those powers are shown in Fig.6. In
the line with that, the optimum wind turbine power coefficient and optimum RPM are also shown in
Fig.7-8.

0 50 100 150 200 250 300 350
1
2
3
4
5
6
7
8
9
10
Time (daily rate)
W
i n
d

S
p
e
e
d

(
m
/
s
)

Figure. 3. Wind speed versus Time

.
Figure. 4. Rotational speed versus pitch angle wind turbine for differen wind speed

Fig. 5. TSR versus Pitch angle and Wind speed

TSR achieved when the maximum wind speed 7.5 m / s, pitch angle position of 50-70 degrees. As
for the position of the pitch angle of 75 to 90 degrees, the TSR value is 0. Position that is able to produce
pitch angle of rotation is 50-70 degrees. The next 7 Cp equation is written as follows;

(9)

From equation 9, the power coefficient of wind speed at each point and a certain pitch angle can be
known. The coefficient of relationship power, wind speed and pitch angle. From these data can be
searched against the value of the maximum power coefficient of wind speed at the position of each
pitch angle. Table 3 shows the value of the maximum power coefficient of wind speed and optimum
pitch angle. From tebel known that wind turbines have a power coefficient which is good enough
considering the horizontal axis wind turbines typically have a maximum power coefficient between 0,35
- 0,40.




Fig. 6. Power coefficient versus Tip Speed Ratio for differen wind speed
Table 2. Maximum Cp in Pitch Angle
Angle (o) Maximum Cp Wind speed
5 0.523 4.8
10 0.545 7.5
15 0.545 7.5
20 0.510 7.5
25 0.398 4.1
30 0.473 7.5
35 0.435 7.5
40 0.394 7.5
45 0.435 7.5
50 0.435 7.5
55 0.352 7.5
60 0.262 7.5
65 0.308 7.5
70 0.214 7.5

Pitch Angle, the optimal pitch angle position of wind turbine is the position where the wind
turbine can produces maximum power at a certain wind speed. To obtain the optimum pitch
angle is done by two approaches. The first approach is through the relationship between power
coefficient with wind speed and pitch angle. While the second approach through the relationship
between wind speed and RPM with the pitch angle. With the first approach is known that the
pitch angle that produces a high power coefficient, is on the entire range of wind speeds at an
angle of 10, 15, and 20 degrees. In other parts for wind speed 3 m / s, wind turbines with pitch
angle positions 10, 15, and 20 have a lower coefficient of power, but> 0.3. In the second
approach RPM relationship with wind speed and pitch angle, 50-30 degrees is approached in a
position, then approximated by polynomial regression of order 3. optimum pitch angle values
obtained on the wind speed range (2.8-7.5) m / s.


Fig. 7. The optimal regime characteristics

Figure. 8. Rotational speed versus pitch angle wind turbine for differen wind speed
Table 3. Maximum Pitch Angle for difference wind speed
Wind speed (m/s) Optimal pitch angle
2.8 10.35
3.8 10.37
4.1 13.10
4.8 10.15
6.5 13.16
7.0 16.19
7.5 10.87

4. CONCLUSION
Prototipe turbin angin yang dirancang mampu menghasilkan nilai-nilai koefisien daya maksimum
berada pada rentang posisi sudut pitch 10-20 derajat, ( ketika kecepatan angin 7.5 m/s dan posisi sudut
blade 10 dan 15 derajat, nilai Cp= 0,545 ), sedang ( ketika kecepatan angin 7.5 m/s dan pada sudut 20
derajat nilai Cp =0,510 ), Fig.7.
The position of pitch angle that produces the maximum RPM for wind speeds from 2.8 to 7.5 m / s
are :
The position of blade angle 10.35 with wind speed 2.8 m / s generate RPM = 39.6
The position of blade angle 10.37 with wind speed 3.8 m / s generate RPM = 54.3
The position of blade angle 13.10 with wind speed 4.1 m / s generate RPM = 64.4
The position of blade angle 10.15 with wind speed 4.8 m / s generate RPM = 69.0
The position of blade angle 13.16 with wind speed 6.5 m / s generate RPM = 112.
The position of blade angle 16.19 with wind speed 7.0 m / s generate RPM = 99.0
The position of blade angle 10.87 with wind speed 7.5 m / s generate RPM = 168.1

The results of the design pitch angle regulator capable of regulating blade angle range 0 to 90
degrees with intervals of 5 0.39 degrees.
Nomenclature
A rotor swept area [m
2
]
Cp power coefficient [pu]
R maximum rotor radius (m)
P
aero
aerodynamic power [W]
T
rot
torsional rotation at the turbines rotor [N.m]
T
a
aerodynamic torque[N.m]
T
g
torque generator [N.m]
T
aux
torque auxiliary [N.m]
J
g
generator inertia [kg/m
2
]
J
t
rotor inertia [kg/m
2
]
arodynamic damping coefficient
[N.m.s/rad]
c
T
torsion coefficien (-)
v wind speed (m/s)

t
rational speed (rad/s)
T
o
optimum torsion (N.m)
v
o
optimum wind speed (m/s)
C
op
optimum power coefficient(-)
B
t
friction coefficien of turbine
Greek symbols

rot
angular speed of rotor
efficiency (-)
tip speed ratio [pu.]

o
optimal tip speed ratio [pu.]
air density (kg/m
3
)
pitch angle blade (
o
)
u Hellman coefficient (-)

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