WIND TURBINE MAKING, TESTING AND SIMULATION

Project report submitted in partial fulfillment of the requirement

for the degree of

BACHELOR OF TECHNOLOGY
In
Department of Mechanical Engineering
By

Ritwik Bhattacharyya
(University Roll Number- 12600712078
&
Registration Number- 121260110601 of 2012-13)

Abhishek Biswas
(University Roll Number- 12600712078
&
Registration Number- 121260110789 of 2012-13)

Souvik Jana
((University Roll Number- 12600712090
&
Registration Number- 121260110613 of 2012-13)

Under the guidance of

Prof. Sukanta Kumar Saha

Associate Professor
Department of Mechanical Engineering
Heritage Institute of Technology

ACKNOWLEDGEMENTS
This project would not have been possible without the invaluable support and guidance
from our mentor, Prof. Sukanta Kumar Saha, to whom we extend our heartfelt gratitude.
Besides, we would like to thank Prof. Siddhartha Ray, Dean of our esteemed institute and
Prof. Sukanta Sarkar, head of our Department for providing motivation and incredible moral
support. We would also like to take this opportunity to thank our workshop technicians Anupam
Sir and Sudipto Sir for standing by our side and helping us with the machine tools.
Finally, we would like to thank all the team members for providing the cohesive teamwork
needed to complete this project.

Abhishek Biswas
Souvik Jana
Ritwik Bhattacharyya

TO WHOM IT MAY CONCERN

This is to certify that Shri Abhishek Biswas, Shri Souvik Jana, Shri Ritwik Bhattacharyya has
done their B. Tech. final year project work (ME-781) on MAKING, TESTING AND ANALYSIS
OF WIND TURBINES under my supervision. They have meticulously carried out all the work
and recorded the findings carefully. The results presented in this work are solely the results of their
theoretical / experimental findings and to the best of my knowledge it has not been published
anywhere else.

Mr. Sukanta Saha

Associate Professor
Department of Mechanical Engineering

This project report titled MAKING, TESTING AND ANALYSIS OF WIND TURBINES by
Shri Abhishek Biswas, Shri Souvik Jana, Shri Ritwik Bhattacharyya,Students

of 4 th year

Mechanical Engineering has been accepted and evaluated by the undersigned in partial fulfillment
of the requirement for the degree of B.Tech. in Department of Mechanical Engineering.

Name and designation

--------------------------------------------------------------------------------------------------

ABSTRACT

Introduction
Wind turbine is a device that extracts energy from the flowing wind. It converts
kinetic energy of wind into electrical energy via mechanical energy and also. Shapes of the
wind turbine blades are varied according to their applications. Historical they were more
frequently used as a mechanical device to turn machinery. There is a tremendous amount of
free energy in the wind which is available for energy conversion. The use of wind machines
to harness the energy in the wind is not a new concept and can be dated back as far back as
Chinese in 2000 B.C. These early machines were used for pumping water for irrigation
purposes and later developed as windmills for grinding grain. It has only really been in the
last century that intensive research and development have gone into the use of wind energy
for electricity generation.

Though the wind turbines have demonstrated their viability in the quest for clean,
renewable and sustainable energy resources, the primary cost i.e. capital cost is the
prominent risk for their installation. There is no fuel cost and lower maintenance cost of
wind turbine than conventional power plants. Further their indirect carbon emission
through their material fabrication is paid back within nine months of operation for off shore
turbines. However, intensive site investigation including the mean, average wind speed, wind
direction and climate intermittency of the flow is needed.

Wind turbine, in general, consists of the rotor blades, a drive train connected to gear
box, an electric generator, a mounted tower which supports these components in addition to
a yaw mechanism, electric cable and inter connections as well as control equipment. Airfoil
shape of the rotors blade creates imbalanced pressure gradients between the pressure sides
and suction sides as they passes by the rotor sweep area. This causes a net aerodynamics
forces and makes the constrained blade rotate around the rotor hub.

1.1

Types of wind energy conversion devices

Wind energy conversion devices can be broadly categorized into two types according
to their axis alignment.

1.1.1 Horizontal axis wind turbines

Horizontal-axis wind turbines (HAWT) have the main rotor shaft and electrical
generator at the top of a tower, and must be pointed towards the wind. All grid-connected
commercial wind turbines today are built with a propeller-type rotor on a horizontal axis
(i.e. a horizontal main shaft). 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. Most horizontal axis turbines built today are two- or threebladed, although some have fewer or more blades.
HAWT type of wind turbine fulfills the requirement of compactness and design need
compatible with present scenario. Based on the acquired knowledge and information,
investigations have been started on horizontal-axis wind turbines in early eighties, but only
limited number of work have been done in this field. Reported literature [8] shows that basic
geometrical parameters mainly, angle of attack, chord length, twist angle, radius of
curvature influence the blade characteristic. Wind turbines of different parts are shown in
Fig. 1.2(a).
Further horizontal-axis wind turbines can be divided into five sub group:

1.1.1.1

Upwind wind turbine

Upwind wind turbine is type of wind turbine in which the rotor faces the wind. This
is the most common type of small turbines operating in the U.S. Its reduced tower shading. The
air will start to bend around the tower before it passes it so there is some loss of power from the
interference, just not the degree as in the downwind turbine.

The drawback of the system is that rotors are not flexible and placed at some distance
from the tower. In addition an upwind machine needs a yaw mechanism to keep the rotor
facing the wind.

1.1.1.2

Downwind wind turbine

A horizontal-axis wind turbine the rotor is in the downstream of the tower. Downwind
wind turbine has an advantage of that it can be operated without help of yaw mechanism. In
case of downwind wind turbines rotors may be constructed flexible. It is help to maintain the
proper dynamics of machine. Downwind wind turbine is also lighter in weight than upwind
wind turbine.

The flexible blade advantage can also be a disadvantage as the flexing may fatigue the
blades. Tower shadow is problem with a downwind machine since the rotor blade actually passed
behind the tower. This can cause turbulence and increased fatigue on the unit.

1.1.1.3

Dutch-type grain-grinding windmills

Man has used Dutch windmills for long time. In fact, the grain-grinding windmills
those were widely used in Europe since the middle ages of Dutch. The blades, generally four,
were inclined at an angle to the plane of rotation. The wind being deflected by the blades
exerted a force in the direction of rotation. The blades were made of sails or wooden slats.

The Dutch windmill becomes obsolete with the advent of cheaper fossil fuel and also
because of requirement of high-skilled labours. However, with the depletion of fossil fuels
there has been a renewed urge to exploit renewable energy resources. It was found that
certain modification in the earlier design of windmills makes them very useful for pumping
water.

1.1.1.4

Multi blade water-pumping windmills

Modern water-pumping windmills have a large number of blades generally wooden

or metallic slats-driving a reciprocating pump. As the mill has to be placed directly over the
well, the criterion for site selection concerns water availability and not windiness. Therefore,
the mill must be able to operate at slow winds. The large number of blades gives a high
torque, required for driving a centrifugal pump, even at low winds. Hence sometimes these
are called fan-mills.

As these windmills are to be installed in remote places, mostly as single units,

reliability, sturdiness and low cost are the prime criteria, not efficiency. The blades are made
of flat steel plates, working on the thrust of wind. These are hinged to a metal ring to ensure
structural strength and the low speed of rotation adds to the reliability.

1.1.1.5

High-speed propeller- type wind machines

The horizontal-axis wind turbines that are used today for electrical power generation
do not operate on thrust force. They depend mainly on the aerodynamic forces that develop
when wind flows around blades of airfoil design. Windmills working on thrust force are
inherently less efficient.

1.2

Wind power scenarios in India

The Indian wind energy sector has an installed capacity of 11807.00 MW (as on March 31,

2010). In terms of wind power installed capacity, India is ranked 5 th in the World. Today India is a
major player in the global wind energy market.
The potential is far from exhausted. Indian Wind Energy Association has estimated that
with the current level of technology, the on-shore potential for utilization of wind energy for
electricity generation is of the order of 65,000 MW. The unexploited resource availability has the
potential to sustain the growth of wind energy sector in India in the years to come.

1.2.1 Wind power density in India

Wind in India are influenced by the strong south-west summer monsoon, which starts in
May-June, when cool, humid air moves towards the land and the weaker north-east winter
monsoon, which starts in October, when cool, dry sir moves towards the ocean. During the period
march to August, the winds are uniformly strong over the whole Indian Peninsula, except the
eastern peninsular coast. Wind speeds during the period November to march are relatively weak,
though higher winds are available during a part of the period on the Tamil Nadu coastline. The
wind pattern at different parts in India is shown in Fig. 1.1.
A notable feature of the Indian programmed has been the interest among private
investors/developers in setting up of commercial wind power projects. The gross potential is
48,561 MW and a total of about 11,807.00 MW of commercial projects have been established until
March 31, 2010. The break-up of projects implemented in prominent wind potential states(as on
March 31, 2010) is as given below

Fig. 1.1 Wind power density in India

Table 1.1 State-wise Wind Power Installed Capacity in India

Gross Potential (MW) Total Capacity (MW)
till 31.03.2010
Andhra Pradesh
8968
136
Gujarat
10,645
1864
Karnataka
11,531
1473
Kerala
1171
28
Madhya Pradesh
1019
229
Maharashtra
4584
2078
Orissa
255
Rajasthan
4858
1088
Tamil Nadu
5530
4907
Others
4
Total
48,561
11807
(All India)
State

The Ministry of New and Renewable Energy (MNRE) estimates that there is a potential of
around 90 GW for power generation from different renewable energy sources in the country,
including 48.5 GW of wind power, 14.3 GW of small hydro power and 26.4 GW of biomass.

The current figures are based on measurements from only nine states, and which were
taken at low hub heights, in line with old technology. A more recent wind atlas published by the
Center for Wind Technology (CWET) in April 2010 estimated the resource potential at 49,130
MW. This was based on an assumed land availability of 2% and 9 MW of installable wind power
capacity per square kilometer.
However, wind power in India is concentrated in a few regions, especially the southern
state of Tamil Nadu, which maintains its position as the state with the largest wind power
installation. It had 4.6 GW installed on 31 March 2010, representing close to 40% of Indias total
wind capacity. This is beginning to change as other states, including Maharashtra, Gujarat,
Rajasthan, Karnataka, West Bengal, Madhya Pradesh and Andhra Pradesh start to catch up, partly
driven by new policy measures. In December 2009, MNRE announced a national generation-based
incentive (GBI) scheme for grid connected wind power projects, for the cumulative capacity of
4,000 MW to be commissioned by March 2012.

Wind turbine manufacturers operating in India include Indian company Suzlon, which is
now a global leader. 17 companies now manufacture wind turbines in India and another eight are
in the process of entering the Indian wind power market, through either joint venture under
licensed production, as subsidiaries of foreign companies or as Indian companies with their own
technology. Wind turbines and turbine blades have been exported from India to the USA, Europe,
Australia, China and Brazil.

1.2.2 The Global Wind Energy Outlook scenarios for India

Under the International Energy Agency (IEA) reference scenario, Indias wind power
market would shrink considerably from the current annual additions of around 1,300 MW to only
600 MW per year by 2030. The result would be a total installed capacity of 24 GW by 2020 and
30.5 GW by 2030. Wind power would then produce close to 60 TWh every year by 2020 and 75
TWh by 2030, and save 35 million tons of CO2 in 2020 and 45 million tons in 2030.
Investments in wind power in India would also drop from the current levels of 1.7 billion per
year to only 730 million by 2030. Under the GWEO scenarios, they expect that by the end of
2010, between 12,600 MW and 12,800 MW will be installed in India. Under the Moderate
scenario, the total installed capacity would reach almost 25 GW by 2015, and this would go on to
grow to 46 GW by 2020 and 108 GW by 2030. By 2030 wind power would be generating almost
400,000 GWh per year and be avoiding the emission of 373 million tons of CO2 each year.

1.3

Wind power scenarios in world

Wind could meet 12% of global power demand by 2020, and up to 22% by 2030,

according to a study published today by the Global Wind Energy Council and Greenpeace
International. The GWEO 2010 finds that wind power could play a key role in satisfying the
worlds increasing power demand, while at the same time achieving major greenhouse gas
emissions reductions.

The 1,000 GW of wind power capacity projected to be installed by 2020 would save as
much as 1.5 billion tons of CO2 every year. These reductions would represent 50-75% of the
cumulative emissions reductions that industrialized countries committed to in their 2020
Copenhagen pledges. By 2030, a total of 34 billion tons of CO2; would be saved by 2,300 GW
of wind power capacity.
In terms of total installed wind power capacity, 830 GW would be reached in 2020 and
close to 1,800 GW by 2030 (more than three times as much). The Advanced scenario paints a
picture in which wind power would become a central player in global power generation. By 2020,
the worlds combined installed wind fleet would produce 2,600 TWh of clean power, which would
account for 11.5%-12.3% of global electricity supply. This would rise to 5,400 TWh by 2030 and a
share of 18.8%-21.8% a fifth of the worlds power needs could thus be satisfied by wind power
alone.

Table 3.2 Wind power worldwide June 2010

Position

1
2
3
4
5
6
7
8
9
10
11
Total

1.4

Country

USA
China
Germany
Spain
India
Italy
France
United Kingdom
Portugal
Denmark
Rest of the world
Total

Total capacity

Added capacity

Total capacity

June 2010

June 2010

End 2009

[MW]
36,300
33,800
26,400
19,500
12,100
5,300
5,000
4,600
3,800
3,700
24,500
175,000

[MW]
1,200
7,800
660
400
1,200
450
500
500
230
190
2,870
16,000

[MW]
35,159
26,010
25,777
19,149
10,925
4,850
4,521
4,092
3,535
3,497
21,698
159,698

Investment
The cost developments in the GWEO scenarios are based on the assumption of a gradually

decreasing capital cost per kilowatt of installed capacity, due to increased deployment, which

accelerates technological progress and increases economies of scale in manufacturing, which in

turn results in lower equipment costs. Since this progress will be faster the more units are
produced, the cost of wind turbines is projected to decrease most quickly in the Advanced and
least quickly in the Reference scenario. Capital costs per kilowatt of installed capacity are taken as
an average of 1,350 per kW in 2009. In the Reference scenario, these costs fall gradually to
1,240 per kW by 2020 and 1,216 by 2030. In the Advanced scenario, costs will fall more rapidly
to reach 1,093 per kW in 2030. In the Advanced scenario the annual value of global investment
rises rapidly from 57.5 billion in 2010 to 109.1 billion by 2015, and peaks at 202 billion in
2030.

1.5

Wind turbine performance parameters

The performance of wind turbine depends on some parameters, such as tip speed ratio (),

power coefficient (Cp), vortex loss (Cpscmitz), profile loss (profile), tip loss (uc), aerodynamic
efficiency of the blade.

1.5.1 Tip speed ratio

The ratio of circumstantial speed in meter per second of the blade element and wind
velocity is known as tip speed ratio. The tip speed ratio can be given by:

Where

Vc r

Vc
Vr

rn
30

Vr = wind velocity.
Equation (1.1) can be written as,

(1.1)

(1.2)

rn
30Vr

(1.3)

1.5.2 Power coefficient (Cp)

Higher value of power coefficient means better performance of the wind turbine. The
power coefficient is governed by many interrelating and dynamics parameters like output power of
turbine (PP), input power (Pr), wind velocity (Vr), radius of rotor (R), cross-sectional area of rotor
(A) and density of air (air) etc.
The power coefficient for wind turbine can be given by:

Cp

PP
Pr

(1.4)

The power generated in Watt by kinetic energy of the air flow passing through a circle with
radius R before the turbine surface can be stated as,

Pr

1
R 2 Vr 3
2

(1.5)

So, the equation (1.4) can be written as,

Cp

PP
1
R 2 Vr 3
2

(1.6)

Theoretically the maximum power co-efficient is 0.5926 which is called the Betz limit and
productivity obtained in practice can be 45% at the maximum.

1.5.3

Different losses in wind turbine

Conversion of the entire theoretical power of blades into gainful power, which refers to mil
power, is not possible. During conversion, some losses may occur. These losses are described in
the following articles.

1.5.3.a

Vortex loss (Cpscmitz)

According to the Betz theory the wind does not change before and after the wind turbine
plate. However the air mass encounting the blade changes its direction. The vortex loss can be
calculated from the graph of vortex loss (C pscmitz) vs. tip speed ratio () given by the N. S. Centin et
al. [8] if the same profile is used throughout the blade.

1.5.3.b

Profile loss (profile)

Profile loss depends upon some interrelating parameters like tip speed ratio (), slide
number (), lift co-efficient (Ck), drag co-efficient (CD).
The profile loss for wind turbine can be given by:

profile 1

(1.7)

Slide number can be expressed as the ratio of lift co-efficient (Ck) and drag co-efficient
(CD).

So equation (1.7) can be written as,

Ck
CD

(1.8)

profile 1

1.5.3.c

CD
Ck

(1.9)

Tip loss (uc)

In the end of a blade, there takes place on airflow from the lower side the of the profile to
the upper side coupling with the airflow coming to the blade, this airflow generates a gradually
widening. Also end loss depends on some parameters like number of blade (B), tip speed ratio ().
The end loss (uc) can be given by,

uc 1

1.5.3.d

1.84
B

(1.10)

Blade number loss

In the with more than four blade, the air movement through blades gets complicated and its
theoretical analysis can be not easily be made. Therefore, the theory of Glauert-Shmitz applies to
the wind turbines with four or less wind turbine blade. Having considered all the losses mentioned,
the power co-efficient is given equation (1.6) becomes,

Cp Cpscmitz profile uc
1.5.4

(1.12)

Aerodynamics efficiency (a) of blade

The aerodynamics efficiency of blade elements is defined as the ratio of useful power

extracted from the wind to the power supplied by the wind.

1.6

Motivation of the present study

Majority of the experimental investigations were taken with help of sophisticated

instruments like vane anemometer, whereas the experimentations carried out in the
developing countries like India employ pitot static tube with inclined tube manometer for the
measurement.

An attempt was made to study the effect of airflow through different horizontal axis
wind turbine of difference blade length (0.3808 m and 0.228 m).
In the present investigation velocity of air flow was measured with help of pitot static
tube. The Pitot tube was putting into flow field and fixing near the wind turbines hub cone.
The main purpose of the study is to investigate the wind turbine performance and airfoil
characteristics change with the variation of length of wind turbine blades. The other
geometrical parameters of such horizontal axis wind turbine are kept constant (=3,
Lt
0.64 ).
Lr

Literature review
Wind energy is a growing renewable energy because of its several advantages, such as ease
of development, environmental friendliness, the existence of several feasible sites to establish
wind farms and cost effectiveness. Therefore, the design of wind power plants has been receiving
much more attention than ever before. The horizontal-axis wind turbine (HAWT) is the most
frequently used type found in operation. Whilst being geometrically simple, its operating regime is
aerodynamically complex and in some cases, particularly unsteady. The design of a wind turbine
structure involves many considerations such as strength, stability, cost and vibration. Most
literature on wind turbine control have focused on maximizing power for wind speed in the range
between the 5 m/s and 25 m/s. Reduction of vibration is a good measure for a successful design of
blade structure. Literatures reviews for the present study consist of two parts, experimental works
and numerical works and are described below.

2.1

Experimental works
Vardar and Eker [1] studied the rotor planning principles for horizontal axis wind turbines

to increase the wind turbine efficiency. Optimization processes is the main criterion for increase
the wind turbine efficiency. Obtaining maximum energy production from a wind turbine depends
on various factors such as height of wind turbine, wind turbine blades sweep area, aerodynamics
structure, air density, wind speed etc.
They investigated that the most important ones of these factors are the height of wind
turbine and aerodynamics structure of wind turbine blades. They also concluded that the height of
wind turbine is important because wind speed is proportional to the height of earth surface.
Aerodynamic structure of the wind turbine is important because it can transform maximum 59% of
the kinetic energy that wind has to useful energy.
They also conducted an experiment on the electric energy performances of the wind
turbine rotors. They carried out the experiment with help of 270 sets of rotor of different forms of

some NACA profile. They concluded that by the use of NACA 4412 profile yielding gave highest
performance at twisting angle of 0 and blade angle of 5. They also reported that by the use of
NACA 4415 profile yielding gave highest electrical energy at twisting angle of 0 and blade angle
of 8 and two blades.
In order to extract the maximum possible power, it is important that the blade of small
wind turbines starts rotating at the lowest possible wind speed. The starting performance of a three
bladed, 2m diameter horizontal axis wind turbine was investigated by Wright and Wood [2] in test
field and compared with calculations employing a quasi-steady blades element analysis. They also
suggested that most of the starting torque is generated near the hub, whereas most power
producing torque comes from tip region according the blade tip element calculation.
Research on wind turbine rotor models using National Advisory Committee for
Aeronautics (NACA) profile has been reported by the Vardar and Alibas [3]. They conducted the
experiment on NACA profile made from balsa wood density of 0.075 g/cm 3. According to their
result, rotor model of NACA 4412 profile had highest rotation rate of 3077 rpm with 0 grade
twisting angle, 5 grade blade angle with 2 blades and rotor model of NACA 4415 had maximum
power co-efficient of 0.425 with 0 grade twisting angle, 18 grade blade angle and with 4 blades.
Kishinami et al. [4] reported theoretical and experimental investigations on aerodynamics
characteristic of horizontal axis wind turbine. Their result had shown that at the wind speed of 4.5
m/s, the possible Cp values varying between 0.23 and 0.41.

Ozdener [5] used NACA 4415

profile as a wind turbine blade profile and reported the rotation rates up to 2722 rpm power rates
up to 0.275 at wind speed levels ranging between 5.04 m/s and 10.5 m/s. Malawi and Badr [6]
reported the highest power co-efficient of 0.49 for NACA 23012 profile.
Kurtulmus et al. [7] investigated the angle of attack for various blades profile like NACA
0012, NACA 4412, NACA 4415 and NACA 23012 and also co-relations between lift and drag
forces rate. In order to calculate the lift and drag force, minimum power coefficient, Snack 2.0
computer programmer has been used by them. From experimental result they concluded that the

most convenient angle of attack was in the range of 3 and 9 for the above NACA profile and
highest drag rates for Re = 20000.
Cetin et al. [8] established the importance of optimum tip speed ratio for wind turbine
blade design characteristics. They investigated that tip speed ratio depends upon the profile type
used and number of blades. According to their result, assessment of tip speed ratio is main key
factor to wind turbine blade design. To determine the optimum tip speed ratio and power factor,
different blade profile such as NACA 4415, LS-1, Clark Y, Goyyining-398, C-80, M-6, Raf-15,
NACA 2212 etc. have been tasted till date. The optimum tip speed ratio of LS-1 is 10, NACA is 8
and Clark Y is 5 and 3.5. Most of the results are comparable with the experimental results of
different researchers already discussed.
According to the theory of maximum power factor of 0.5926(called Betz limit) where as in
practice it could be 45% at the maximum condition according to the above researchers.
Theoretical productivity is more than real productivity due to the some losses. The losses are
profile loss, end loss, whirlpool loss, and blade number loss.
Kazumasa et al. [9] studied the design and performance of 3 kW wind turbine generator
with thin airfoil blades and a tip speed ratio of 3. The designed wind turbine had been controlled
via two method, fist was the method of variable pitch angle and second was the regulating the field
current of generator. For both cases wind turbine was experimented in real wind condition. They
proposed a specific blade design theory of seven arcs thin airfoil, which means that airfoil, was
compressed with seven circular arcs.
In order to analyze the characteristic of thin airfoils XFOIL [10] analysis program, blade
element and momentum theory (BEM) had been used. According to their result, the automatically
controlled wind turbine had an average generator output of 1105 W and a power coefficient of
0.14 under a mean wind speed of 10 m/s. From analysis they concluded that theoretical and
experimental analyses were conducted to present the thin airfoil blade characteristic and
performance.

A blade pitch measurement system [BPMS] has been developed by the Whale [11]. To
measure the change in blade pitch produced on a small wind turbine by a blade pitching protecting
mechanism, BPMS was developed. In order to protect the wind turbine against very high winds or
sudden removal of load a common protection method, blade feathering has used. His investigation
has proved to be a simple and cost-effective means of logging blades pitching on small wind
turbine. He reported that BPMS was successful in recording the behaviors of the blade feathering
mechanism in field trials with a 20 kW and 30 kW wind turbine. Mahmmud et al. [12] reported an
optical slip ring telemetry system designed to transfer pitching moment and teeter data from the
rotary frame of reference of a 16 kW turbine.
Hirahara et al. [13] investigated the basic performance of a very small wind turbine (D =
500 mm) designed for multi purposes by considering the energy output (PO), turbine rotating speed
(n), power coefficient (Cp) and torque (T) etc. as governing geometrical parameters. From their
experimental resulted power output was 0.4 W in maximum and 0.36 W in the rated condition.
Also the tip speed ratio was 2.7 at optimum condition. Their result agreed reasonably with
experimental result at slow wind speed on the basis of flow visualization and particle image
velocimetry (PIV). Measurement around the wind turbine, they have shown that actual flow
passed through the blades was about 20% slower than the ideal flow. The airflow around the
turbine was measured by using particle image velocimetry. They also concluded that experimental
wind turbine i.e. F500 shown a good efficiency in the range of 8~U c~12 m/s. tip vortex shed
from the blades tip was also visualized clearly.
Camblog et al. [14] operated wind turbine at variable speed instead of fixed speed. Variable
speed operation increases the aerodynamics efficiency and reduces the drive train torque and
generated power fluctuations. A 180 kW wind turbine whose simulation model has been validated
with field data is emulated on an 18 kW test bench. They investigated that test bench trials are a
very useful step between numerical simulation and trials on the real system because they allow
analyzing some phenomena that may not appear in simulations without endangering the real
system.

The trials on the test bench show that the non-conventional controller leads to a higher
aerodynamic efficiency and that this is offset by higher mechanical torque and electric power
fluctuations. They also concluded that direct speed controller (DSC) has more flexibility than
classic indirect speed controller (ISC), that this flexibility can be used to increase the energetic
efficiency of the VSWT and that this controller can be implemented on a real system.
Goeij et al. [15] implemented a bending-torsion coupling arrangement in a wind turbine
rotor blade to provided passive pitch-control. They concluded that if this bending-torsion coupling
is used to reduce the maximum loads on a blade, the required twist change and hence coupling is
lower and principle may still be applicable.
Henriques et al. [16] presented the design methodology of a new wind turbine airfoil that
achieves in urban environmental by increasing the maximum lift. For this purpose they proposed
an inverse method to obtain to new turbine blade section with constant pressure-load along the
chord, at the design inlet angle. In comparison with conventional blade section design, the new
airfoil has maximum lift, reduced leading edge suction peak and controlled soft stall behavior due
to a reduction of the adverse pressure gradient on the suction side.
They developed a wind turbine system that consists of diffuser shroud with a broad ring
flange at the exit periphery and wind turbine was placed inside it. The flanged diffuser shroud
plays a role a device for collecting and accelerating the approaching wind.
Renewable energy generation in urban environment has been receiving an increased
attention over recent years due to the proximity with the point of use. Building integrated wind
turbines are an interesting option in the respect.
Muller et al. [17] analyzed oldest form of wind energy converter, the sistan type wind mill
and discussed about the modern adaptation of drag force type energy converter for building
integrations. They also concluded that the design improvements can lead to increase of theoretical
efficiency of a drag force type rotor about to 48% (conservative) and 61% (optimistic). Their
initial experiments with a scale model had shown that efficiency higher than 40% can be achieved.

Sicot et al. [18] have evaluated experimentally rotation and turbulence effects on wind
turbine blade aerodynamics, focusing particularly on stall mechanism. They proposed a method to
determine the position of separation point on the rotating blade, based on chord wise pressure
gradient in separated area. The result showed an influence on free steam turbulence level on the
separation point and also the lift augmentation for a rotating blade.
Alireza et al. [19] presented a method for decoupled design of bend twist adaptive blades
(BTAB) in which the aerodynamics and structural designs take place separately. According to the
above researchers, the main advantage of this method was the significant reduction time by
replacing a finite element analysis (FEA) based coupled aero structure (CAS) simulation in the
aerodynamics objective evaluation by a non-FEA based CAS simulation. Maheri et al. [20]
conducted an experiment on a coupled on simplified version of the above method.
Karam and Negm [21] proposed an optimization model for the design of typical blade
structure of horizontal axis wind turbines. They used floquets transition matrix theory to calculate
the aero elastic stability boundaries and steady state response.
They proposed a good design philosophy for reducing vibration i.e. separate the natural
frequencies of structure from the harmonics of rotor speed. Pritchard and Adelman [22] formulated
a mathematical optimization model by considering minimization of the induced shearing forces at
rotor hub as a measure of vibration reduction.

2.2

Numerical works
Literature survey on blade tip geometric modifications reveals that most of investigations

are done to improve the aerodynamic performance of turbine rotors and possibly making them less
sensitive to wind gusts by using their structural response to variable loadings. Different blade tip
modifications, sweep, dihedral and winglet, have been considered and analyzed independently
with an optimization code by the Chattot [23] based on the Goldstein vortex model [24]. He

reported that from the aerodynamic point of view, the power capture can be enhanced with these
more complex geometries.
Chalothorn and Tawit [25] studied optimum angle of attack for untwisted blades of wind
turbine. They also reported that numerical simulation of horizontal axis wind turbine was carried
out to determine the optimum angle of attack that produced the highest power output.
Computational fluid dynamics (CFD) was used as a simulating software. They concluded that
optimum angle of attack were near the maximum lift point. They have showed that rotating frame
of reference was used during the numerical simulation, but the blades and grids were fixed in
respect to rotating reference. Steady state, incompressible flow was assumed in their study. They
also used sequential algorithm, semi-implicit method for pressure linked equation, standard k -
and in viscid model were used as basic turbulence model.
Andrew et al. [26] introduced an intelligent wind turbine control system based on models
integrating the following three approaches such as data mining, model predictive control and
evolutionary computation etc. To enhance the control strategy of the intelligent system, a multiobjective model is proposed by them.
According to their investigation an intelligent wind turbine controls system increasing the
competitiveness of wind energy. Their result showed that for turbulent wind, the intelligent control
system smoothed the output power, generator torque and rotor speed. They concluded that the
wind power is maximized predominately when the speed is below its rated value and the blade
pitch angle is fixed.
Wind turbine control system mainly focused on maximizing power for wind speed in range
between the cut in and cut out wind speed. The wind turbine power output was a linear function of
the wind speed assumed by the Nanayakkara et al. [27]. Denoising techniques could be applied to
enhance the data quality.
Wanga et al. [28] developed a small wind turbine with scoop to collect more incoming
flow or a diffuser to minimize the effects of wakes after rotor blades. Due to the increase of

awareness of renewable energy sources, many researchers Turan et al. [29] and Carroll [30]
conducted experiment on micro and small wind turbine, mainly in urban site.
To predict the aerodynamic forces on the blades of a horizontal axis wind turbine (HAWT),
different design module such as blade element momentum (BEM) method, lifting line method
(LLM), lifting surfaces method (LSM), Nbody/particle simulation methods, asymptotic
expansion method (Euler special), NavierStokes equations etc. have been tested till date. Most of
the results are comparable with the experimental results of different researchers already discussed.
Among them, BEM method seems the simplest and the most commonly used one to
calculate the aerodynamic forces on wind turbine blades. The blades were designed by a
FORTRAN code based on the BEM theory, by which the chord and blade angle distribution along
the radius were obtained.

Lanzafame and Messina [31] investigated the performance of a horizontal axis wind
turbine continuously operating at its maximum power coefficient was evaluated by a calculation
code based on BEM theory. They introduced a mathematical model based on BEM theory, which
enables the design of rotor blades by fluid dynamics, and the evaluation of wind turbine
performance (in design and off-design conditions). Using this model, they can predict the wind
turbine aerodynamics design at wider range. The BEM theory is based on the Glauert propeller
theory according to the Glauert.
In order to get the accurate result BEM has been modified in recent year. The lift (C L) and
drag (CD) coefficients for a given airfoil were evaluated from wind tunnel measurements.
In order to control the power curve of a wind turbine, a mathematical model for the fluid
dynamics design, based on Glauert propeller theory [32], has been implemented by the
Lanzafame, Messina [33]. The mathematical model is known as the Blade Element Momentum
(BEM) Theory. They also generated two different mathematical codes (both based on BEM

Theory) one to design the wind turbine at the design wind speed, and the other to evaluate the offdesign rotor performances.
The generated numerical code was a mono-dimensional, does not require large calculation
resources (as the three-dimensional CFD Codes), works with a very short calculation times and
gives reliable results. They reported that before investigation of control power curve in micro wind
turbine, some basic parameters and constrains were considered, such as design parameters, the
wind velocity, the number of rotor blades, the aerodynamic airfoil (constant along the entire blade)
and the rotational velocity etc. They concluded that in spite of high power coefficients, the power
in the central range of wind velocities dropped markedly, prohibiting power regulation by partial
or controlled stall of the rotors.
Yurdusev et al. [34] had reported an extensive high quality analysis process artificial
neutral network for estimating of tip speed ratio and power factor.
They investigated that optimal tip speed ratio was a key issue while designing turbine
blades. Their result showed that the optimal design of Tip Speed Ratio (TSR) will directly affect
the power generated and consequently the effectiveness of the investment made. Related literature
suggests that TSR be taken between 7 and 8 and in practice generally taken as 7 for a 3-blade
network-connected wind turbine.
Fuglsang and Madsen [35] represented a recently developed numerical multi- disciplinary
optimization method for design of horizontal axis wind turbines. The studied the optimum airfoil
characteristic behavior of the wind turbine and reported that the airfoil sections had a relatively
high maximum lift at the entire span including the tip region. This design was based on numerical
optimization and several calculated models such as aerodynamic calculation, structure calculation,
time domain aero elastic calculation, extreme loads calculation and estimation of aerodynamic
noise etc. From this analysis they concluded that total manufacturing cost of the wind turbine
could be estimated from the design load. To reduce the computing time of analysis a semi
empirical sensitivity analysis was developed by them to limit the number of evaluation of the full
load life time spectrum.

Anina and Masson [36] proposed an extended k- model for the turbulent flow through the
horizontal axis wind turbines. Their model predicted the near wake region based on the turbine
performance. The complete set of equations such as continuity equation, two momentum equations
for transport of velocity, the energy equation and the transport equation for k- model were
expressed in polar co-ordinate system. These equations are solved by employing simulation
software of FLUENT [37] in the two dimensional mode with no swirl. FLUENT was a controlvolume based technique for converting the governing equation into algebraic equation that can be
solved numerically. SIMPLER [38] algorithm with second order upwind scheme has been adopted
for all dependent properties. The result shows that extended model has better performance than the
standard k- model with model constants proposed by Cespo et al. [39] for wind turbine operating
with thrust co-efficient from 0.67 to 0.82.
Wang et al. [40] investigated the possibility of improving wind energy capture, under low
wind speed condition in a buildup area. They reported that scoop boosts the air flow speed by a
factor of 1.5 times equivalent to an increase in power output of 2.2 times with the same swept
CFD model.
Hu and Cheng [41] proposed a bucket shaped duct wind turbine which produced sucking
effect according to Bernoullis principle to increase the wind speed inside the duct and enhance the
efficiency of wind turbine.
Moreover, the geometry of the duct was optimized by combination of an improved
complex algorithm, an object oriented optimizing program interface. According to their analysis
the optimal shape of the interior of the duct appeared to be an unconventional nozzle, which
extended the range wind turbine speed by 60% and also increased the power extraction efficiency
by 80%.
Grant [42] et al. described a closed circuit type wind tunnel study of the wake dynamics of
an operational horizontal axis wind turbine. They used laser sheet visualization (LSV) technique to
measure the trajectories of the trailing vorticity under various condition of turbine yaw and blade
azimuth. They compared their experimental results with the prediction of a prescribed wake

model. The investigation was made on full size Marlec turbine in a wind tunnel. The wind had an
overall diameter of 0.9 m and a hub diameter of 0.24 m. in both cases they ensured that the main
thrust producing section of turbine rotor operated above the critical Reynolds number. They also
investigated the turbine wake structure and its sensitivity of operational conditions. Their work has
highlighted man key features of wind turbine wakes and has provided valuable code validation
information.

Making Procedure
3.1.

Construction of hub

Rotor Hub Assembly

Rotor Hub attachment

Fig 3.1-Rotor hub nose and housing with the sleeve inside

The rotor hub has three parts: Casing, nose and attachment. The casing holds the attachment
and the nose. For construction of the hub PVC pipe is used for the casing and wood is used for the
nose. For the nose initially a wooden block was taken and turning operation on it was done on a
lathe. The cylinder went through turning in steps, of diameters 110mm and 88mm respectively.
The front end of the cylinder with 110mm diameter was then taper turned to give the following
geometry and shape. Finally, sandpaper was use to give the required surface finish. The casing was
made by turning and sawing off a long PVC pipe of 10 mm thickness until the required length of
150 mm is obtained. For the rotor hub attachment a wooden block was turned into a cylinder and
ultimately sawed off to get the desired length of 150 mm. Then drilling is done through it to
produce a hole of 19.05 mm. To produce the cut on one side of the cylinder where the blades will
be mounted, internal turning and boring is done to get the desired dimensions of 50 mm diameter

and 48 mm depth. Finally a metal sleeve was placed in the cut which was previously constructed
from a GI pipe by turning.

3.2.

Construction of rotor shaft

Fig. No. 3.2 Rotor Shaft with bearing mounting attachment

For the rotor shaft a cylinder made of mild steel of diameter 25 mm is chosen. On one end of
the shaft a thread was made of length 100 mm and nominal diameter 19.05 mm. This shaft was to
be fitted to the attachment by a nut. Two bearing mountings were bought and attached to the shaft
at appropriate positions for the bearing assembly.

3.3

Construction of bearing assembly

Fig. No. 3.3 Bearing Assembly showing bearing

As it is a small wind turbine and pitch control of the blades is very costly and cumbersome,
provisions need to be made in the wind turbine such that it can yaw freely facing the direction of
wind. So the hub and the blades need to be supported on a sturdy platform and properly lubricated
bearings are required for its free movement. The bearings are chosen as ball bearings because of
their low friction and vast use. The internal diameter of the bearings is 35mm each.
For the support plate Aluminium is chosen because its rust free and easily machinable.
Two Aluminium plates each with 3mm thickness is cut into dimensions of 27mm*15mm. Then a
wooden slab was cut into the same dimensions and each face was rubbed with sandpaper to
facilitate adhesion. Same process was repeated with the two plates and Araldite was used to attach
the wooden slab between them. Finally filing was done on each faces of the finished slab for
proper finish.

3.4.

Construction of Blades
For cutting the blade from the pipe section the following design shown below was agreed

upon. The blade was decided to have a tapering section with the wider section as the root and the
thinner section as the tip. As the blade was cut from a single PVC pipe of thickness 5mm, it has
uniform thickness. The arc length at the root is 150 mm and at the tip it is 40 mm. The blade
length is currently decided upon as 197.5cm. A length of 17.5 cm at the root is allotted to hub
mounting.

Fig 3.4 showing a cut blade from a 31

cm diameter pvc pipe. The thickness
at root is greater than the tip

Simulation Work

Rxperimentak Work

Conclusion

Future Scope

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