THESS AL0N1KI- MACEDONIA

<2)
f
5th
EUROPEAN WIND
ENERGY ASSOCIATION
CONFERENCE AND EXHIBITION
10-14 OCTOBER 1994
THESSALONIKI - MACEDONIA - GREECE

CONFERENCE PROCEEDINGS
Poster Session
Volume HI
Edited by Dr. J.L. Tsipouridis

Organised by
the H E L L E N I C WIND E N E R G Y ASSOCIATION and
the E U R O P E A N WIND E N E R G Y ASSOCIATION
FIELD TESTS AND FINE-TUNING OF G A M M A 60 WIND TURBINE CONTROL SYSTEM
BY A REAL-TIME SIMULATOR
S.Avolio (*), S.Corsi (#), S.Golinelli (*), G.Moleti (*), F.Morabito (*), M.Pozzi (#)
(*) Alenia - Settore Sistemi Civili, (#) Enel - Centra Ricerca di Automatica, ITALY
SUMMARY
The paper describes a precise characterization on field
of the dynamic performances of the G A M M A 60 wind
turbine control system and a proposed fine-tuning
method of the regulation parameters by using an unique
real-time simulator named activator. The G A M M A 60
operating modes and control system features, the
operation and the architecture of the activator and some
of the field test results obtained are also presented.
INTRODUCTION
The design of a wind turbine control system is a very
important task, due to its significance both for the
quality of the operation performances and for the
attainment of the security requirements.
It is then essential, during the field tests in general and
mainly in the system commissioning activities, to check
deeply the correct operation of the control system and
to tune finely the regulation parameters, in order to
achieve the best dynamic responses and the highest
reliability levels in all the possible operating conditions.
Unfortunately such tests are often quite difficult, if not
unfeasible, due to the intrinsic and unknown variability
of the real wind, to the inconvenient accessibility of the
control apparatus or to the discontinous compliance of
the operating conditions with those required by a given
test, claiming in general long times and boring activities.
These can be drastically reduced, or anyway simplified
and rationalized, if advanced data acquisition tools,
supervision instruments and suitable real-time wind
simulators are directly available, well arranged and
fairly reliable.
For the G A M M A 60 project, the manufacturer Alenia,
starting from the codes used for the control system
design, developed a particular real-time simulator
named activator which, in conjunction with the
supervisory system of the machine, allowed
comprehensive factory tests of the regulators.
Subsequently this simulator was used, in collaboration
with Enel-Cra, during the commissioning field tests of
the control system, in order to achieve a detailed
dynamic characterization of the control loops
performances and a precise fine-tuning of some
regulation parameters.
237
The activator proved itself to be an excellent tool,
conceptually unique and practically effective, for a deep
testing of the regulation algorithms and a fine-tuning of
the control parameters, as well as for the overall
validation of the G A M M A 60 wind turbine control
system.
T H E G A M M A 60 W I N D T U R B I N E
The G A M M A 60 wind turbine is an advanced large size
generator (see Figure 7), commissioned by Enel to
Alenia-West and characterized by a two-bladed rotor
diameter 2Rg of 60 m, a rated electric power Pe of 1.5
MW, a maximum gearbox torque Cm of 380 KNm and a
nominal rotor speed cor of 44 rpm [Avolio et al (1) and
(2)].
The G A M M A 60 prototype was installed in the first
half of 1992 at Enel's Alta Nurra test site in Sardinia
and, after the end of the commisioning activity, has
been tested jointly by Enea, Enel and the manufacturers
[Attanasi et al (3)].
Technical features of G A M M A 60 can be broken down
into "basic" characteristics (upwind fixed-pitch rotor
and teetered hub), which were chosen among well-
proven solutions, and "advanced" characteristics
(variable speed and power regulation through yaw
control), which represent .the innovative aspect of
G A M M A 60 as compared with other large wind turbine
generators [Avolio et al (4)].
In order to understand the control system needs and
tests, it is useful to give a short description of the
G A M M A 60 operating modes [Avolio et al (5)] and a
brief overview about the control system design and
architecture [Arcidiacono et al (6)].
G A M M A 60 operating modes
According to the different ranges of wind velocity Vv
(at hub height), three different operating modes are
followed, each of them being obtained through the
intervention of the control system.
Operation with constant power coefficient Cp(kS$). This
operating mode occurs for wind velocity Vv ranging
between 5 m/s (cut-in) and 12.5 m/s.

Figure 1 - The GAMMA 60 wind turbine generator.
At these winds, the rotor has to be held at its
performance peak and the generator torque Ce is
adjusted relative to the aerodynamic torque Cm to
manoeuvre the rotor speed cor, in order to maintain a
constant tip speed ratio X=(&rRg/Vv corresponding to
the maximum value of the power coefficient Cp(k,B);
the nacelle is kept aligned with the wind (the yaw angle
9 is maintained null).
For a wind velocity Vv of J2.5 m/s, a rotor speed cor of
35.5 rpm and the maximum gearbox torque Cm of 380
KNm are reached.
Operation with constant electric torque Ce. This
operation mode occurs for wind velocity Vv ranging
between 12.5 m/'s and 13.5 m/s.
Once the gearbox torque limit is reached, additional
electric power Pe can still be put through the system in
the form of increased rotor speed cor; the nacelle is still
kept aligned with the wind (9 is set to zero).
For a wind velocity Vv of 75.5 m/s, the nominal rotor
speed cor of 44.0 rpm and the rated electric power Pe of
7.5 MWare reached.
Operation with constant electric power Pe. This
operation mode occurs for wind velocity Vv ranging
between 75.5 m/s and 27 m/s (cut-out).
Once the electric power limit is reached, an
electrohydraulic yaw system holds the rotor speed cor
approximatively constant at its nominal value, yawing
238
the rotor out of the wind to maintain a torque balance
with essentially constant generator torque Ce and
aerodynamic torque Cm; the combined action of the
yaw disalignement 9 and the restraining torque balance,
causes the rotor speed cor and the electric power Pe to
remain nearly constant.
For a wind velocity Vv of 27 m/s, a yaw nacelle
disalignement 9 of about 60 deg is reached.
G A M M A 60 control system design
The G A M M A 60 control system was first designed by
Hamilton Standard for validating the feasibility of the
variable speed yaw control operation.
Subsequently Alenia-West developed its simulation
code, named C O D E W (COntrol Dynamic Evaluation of
Windturbine), and studied the regulation loops
dynamics, following various perturbations and critical
events, thus attaining a stable and well arranged code,
the same used for the real-time activator software.
All the design was also reviewed by the Enel-Cra
researchers, who worked with a detailed model
developed by an advanced dynamic analysis and
simulation tool, called EASY5 (Engineering Analysis
SYstem from Boeing Computer System). Control
system dynamic performances were studied in depth in
order to validate the design choices of the regulation
loops structures, to test the achievement of the steady-
state and dynamic requirements, and identify all the
possible improvements to the algorithms and parameters
[Arcidiacono et al (7)].
G A M M A 60 control system architecture
The G A M M A 60 control system consists of two
regulation loops: one, acting through the generator
torque Ce control, for maximizing the power ratio
coefficient Cp(k,Q) and limiting the mechanical torque
Cm, and the other, acting through the yaw angle 9
control, for limiting the rotor speed cor and the electric
power Pe at high winds.
A general schematic for the variable speed wind turbine
control is shown in Figure 2 and each control loop is
now briefly described.
Generator speed control loop. The generator speed
control loop modulates the electrical torque Ce to
control the rotor speed cor in order to achieve, at any
wind velocity Vv, the maximization of the power ratio
coefficient Cp(k,Q) rather than the limitation of the
gearbox mechanical torque Cm.
Rotor speed control loop. The rotor speed control loop
is designed to hold the rotor into the wind (9 null) when
the system is operating at low winds Vv, below nominal
rotor speed cor and rated electric power Pe: at high
winds Vv, when the system is operating at rated electric
power Pe, the control modulates yaw heading 9 to
maintain nominal rotor speed cor.
 Generator speed control
INTEGRAL
REGUL.
Vi ion
Vnon + / INTEGRAL
REFERENCE -\ REGUL.
Rotor speed c o n t r o l loop
Figure 2 - General schematic of the GAMMA 60 wind turbine control system.
THE ACTIVATOR OPERATION
The intrinsic variability of the real wind doesn't allow,
in general, a precise validation of the field dynamic
performances of a wind turbine control system.
In particular, the fme-hining of the regulation
parameters, which may critically affect the overall
stability and the transient behaviour of the control
loops, can become very difficult, if not unfeasible, and
claims a boring repetition of dynamic tests.
An important preliminary activity, during die factory
tests of the control apparatus, consists in checking the
correct operation and good performance of each
subsystem and defining a reliable initial setting of the
control parameters.
As regards more precisely the field activities, the
following approaches can be used.
The conventional approach
The conventional approach for testing a wind turbine
control system, and in particular the regulation
algorithm performances, consists in varying the set-
points or some control parameters (gains and time-
constants), and repeating defined field tests with
different configurations.
This has obviously to be done on-line and in real-time,
with a perturbations amplitude so high, with respect to
IOOD
o
Vref +
Vgen
Vref
REFERENCE
Vrot
GEARBGX
=3
Pe Vger DRIVE
TRAIN
YAW ANGLE ELEC.HYDR. HYDRAULIC
REGUL ACTUATDR MOTOR
the natural fluctuations of the real wind (which must
also to be rather stationary during the repetition of all
the tests), but still sufficiently small, not to involve
heavily the non-linearities of the control loops (non-
linear aerodynamics, actuators saturations and dead-
bands). -
It has to be pointed out that tin's way to operate
changing the set-points assumes anyway fairly linear
characteristics of the control loops, in such a way the
fine-tuning carried out with different set-points can be
also considered valid for the rated set-points.
It is also important, and not always simple, to correlate
properly the dynamic evolution of the wind turbine
variables with the time instant of the parameter
perturbation (in some cases applicable only through an
inconvenient access to the control apparatus), and to
compare carefully the obtained results with the
corresponding ones, coming out from the factory tests
(such comparison often requires a deep knowledge of
the control operation and the expected performances).
The activator approach
An alternative approach is now described and
represents the basic idea of the activator operation (see
the general schematic in Figure 3), which is made
possible by the static converter used for the
interconnection of G A M M A 60 variable speed turbine
to Enel constant frequency network [Avolio et al (8)].
239
 Generator speed control loop
GENERATOR SPEED
RECTIFIER
REGULATOR
4 GEARBDX
-7^
Or
RCiTDR SPEED
REGULATOR
Rotor speed c o n t r o l loop
Vrot Vgen
Figure 3 - simulator (activator).
General schematic of the GAMMA 60 real-tim
Such a converter in fact allows to drive the wind turbine
actuating both the regulating electric torque Ce
provided by the control loop, and also a simulated
mechanical torque Cm evaluated by the real-time
activator on the base of assigned wind velocity and
direction values. In this way the wind turbine under test
can operate following small and large defined wind
perturbations, with the rated set-points of the control
loops and without any problem of on-line
synchronization and event relating.
More precisely, if the real wind conditions are
sufficiently negligible (small and steady actual wind
speeds), the activator can control the static converter in
such a way to reconstruct, as mainly regards the control
system, the effects of selected input variations of wind
velocity and direction (around higher simulated wind
speeds). That is obtained by driving the wind turbine
through a net electric torque Cn, which comes from the
balance of the regulating torque Ce and die mechanical
torque Cm computed in real-time from the aerodynamic
models. The electric power Pe is also simulated
according to the real generator speed cog and to the
torque reference Ce coming from the control system.
As can be seen in Figure 3, the activator does in real-
time the following calculations: the computation of the
relative wind direction 0, given by the difference
between the simulated wind direction 9v and the real
yaw nacelle position Qn; the computation of the
mechanical power Pm and torque Cm, transmitted to the
240
Yaw
Wgen DRIVE
TRAIN
ELEC.HYDR. HYDRAULIC
ACTUATOR MOTOR
f=l
Dirnav
rotor according to the simulated wind velocity Vv, the
real rotor speed cor, the relative wind direction 6 and the
aerodynamic power coefficient Cp(k,Q); the
computation of the electric power Pe, product of the
real generator speed cog and the electric torque
reference Ce coming from the regulator; the
computation of the net driving torque Cn, applied to the
rotor by the static converter and given by the difference
between Ce and Cm.
It has to be pointed out that the real wind, supposed
sufficiently small, steady and aligned to the nacelle
during the activator operation, represents actually a
disturbance on the wind turbine system, to be
considered additive as regards its contribution to the
mechanical torque Cm, parametric as concerns the
dynamic alteration of the rotor performances due to the
anomalous aerodynamic conditions. Nevertheless, a
reduction of the real wind torque contribution can be
achieved with relatively high rotor speeds, provided that
the security requirements for the unbalanced rotor
operation are assured.
THE ACTIVATOR ARCHITECTURE
The activator was developed by Alenia and operates on
a Vaxlab 3400 (Digital), that permits real-time
computing applications invoking time critical
operations synchronized to external events or processes.
The hardware is equipped with real-time
clock/counters, analog inputs and outputs, parallel
digital inputs and outputs, and is conceived to be
properly combined with the G A M M A 60 control and
data acquisition subsystems [Avolio et al (9)].
Vaxlab is based on the V M S operating system,
packaged witii the VSL software, including subroutines
for data acquisition and signal processing. The activator
language used is Fortran.
The real-time activator architecture conceived by Alenia
is shown in Figure 4. As can be seen, the activator
receives from the supervisory subsystem (Vax 3400),
through common areas via Ethernet, the following
inputs: the yaw nacelle direction Qn, for calculating the
relative wind direction 0; the generator speed cog, for
computing the electric power Pe; the rotor speed cor, for
evaluating the tip speed ratio X and the corresponding
power coefficient Cp(k,Q) and aerodynamic torque Cm.
The input coming from the regulator is the reference
torque signal Ce, going to the activator through A / D
board and used both for computing the electric power
Pe and the driving net torque Cn.
The following activator computed outputs are available
through D / A boards (with V/I converters): the wind
velocity Vv is sent to the data acquisition subsystem; the
wind direction relative to the nacelle 0 and the
generator electric power Pe are sent directly to the
control subsystem; the equivalent driving net torque Cn
is sent to pilot the static converter.
During an activator session, all these signals are
recorded in real-time and plotted on paper, and the most
important parameters are saved for each test in a
different configuration file. These complete data sets
can be easily reviewed, plotted and processed, using
customized graphics routines, developed by Alenia on
Vaxlab.
GAMHA 60 VWD TURBINE GENERATOR
ur
Nacelle
Supervisory
Data
Control
Rotor Generator
acquisition
subsystem subsystem
subsys ea
Ce Yav
actuator
D/A and V/I
Vv(sin) Pe(sim) 9<sia)
ug Ce
&
Cp=f(\,4)
GAMA 60 RAL-TIME SIMULATOR (ACTIVATOR)
Figure 4 - The real-time activator
conceived by Alenia.
F I E L D TESTS AND FINE-TUNING
OF G A M M A 60 C O N T R O L S Y S T E M
The G A M M A 60 wind turbine has been deeply tested
in field as concerns its mechanical and structural
requirements [Aliberti et al (10)] and also with regard to
its operation and control features. In particular the
control system has been validated both in real-wind
conditions and in ideal-wind conditions, using the
activator.
The G A M M A 60 field tests carried out by using the
activator can be broken down in two main categories,
winch regard respectively the steady-state
characterization of the wind turbine and the dynamic
performances of the control loops.
Steadv-state characterization
The significance of the activator field tests has been
first examined verifying the reliability of the real-time
simulator in reconstructing real wind conditions for the
wind turbine generator. That has allowed also to
calibrate the communication channels and to tune up
some activator configuration parameters taking into
account the mechanical and aerodynamic characteristics
of G A M M A 60.
The steady-state characteristics obtained by using the
activator, which was exciting the system with very slow
ramp perturbances of wind velocity Vv (from 7.5 m/s to
22.5 m/s with a gradient of 1 m/s/miri), are shown in
Figure 5 (rotor speed cor and yaw angle 0 vs. wind
velocity Vv curves) and Figure 6 (electric torque Ce and
electric power Pe vs. wind velocity Vv curves).
In these Figures both the theoretical and experimental
curves are represented, giving evidence of the excellent
correspondence obtained and the good reliability of the
activator operation.
Dynamic performances
Inverter
Rectifier The dynamic performance of the generator speed
control loop has been validated, comparing the
experimental data both with the design objectives and
with die tiieoretical linearized analysis results; the
D/A and V/I damping and the speed of the transient response are
very satisfactory in all conditions. In particular during
the performance peak operation the system is equivalent
to a first order low-pass filter with time constant of
about 8 s (see Figure 7). The torque limit operation
splits the turbine rotor and static converter dynamics,
giving each loop a different time constant, more
precisely about 15 s for the rotor speed and about 1.5 s
for the converter torque (see Figure 8).
The rotor speed control loop exhibits a good
performance, being reasonably similar to a third order
low-pass filter, with complex eigenvalues having
acceptable damping coefficient (about 0.3) and
architecture resonance frequency tuned to the designed lead-lag
compensation; the transients of power and speed
241
 0 5 10 15 20 25 30 0 5 10 IS 20 25 30
Wind velocity [m/s] Wind velocity [m/s]

G A M M A 60 Wind Turbine Gcneraior: steady-state characteristics

G A M M A 60 Wind Turbine Generator: stcady-sutc characteristics
1800, 1 ! , , , . ,

..J i
-
0 5 10 15 20 25 30
0 5 10 15 20 25 30
Wind velocity [m/s]
Wind velocity [m/sl

Figure 5 - Theoretical and experimental steady-state Figure 6 - Theoretical and experimental steady-state
curves (rotor speed cor and yaw angle 6 curves (electric torque Ce and electric
vs. wind velocity Vv). power Pe vs. wind velocity Vv).
G A M M A 60 Wind Turbine Generator, generator speed control dynamics
limitation have a typical duration of about 30 s, in 33.51 , 1 . , , 1

which the rated power and speed are satisfactorily

maintained (see Figure 9). The yaw control actuation
has been proven to be also adequate, giving well
damped response with an equivalent time constant of
about 5 s, the proper value used for the rotor speed
control design.
A regulators fine-tuning has been succesfully carried out
to adjust some particular compensations of the E H V
non-linearities in the yaw actuation system and to deal
with the best resolution the rotor speed reference curve
programmed in the generator speed control loop. 0 10 20 30 40 50 60
G A M M A 60 Wind Turbine Generator: generator speed coniro! dynamics
2801 1 , 1 . . 1

CONCLUSIONS
270

The activator field tests confirmed the validity of the

bl 260
G A M M A 60 control system design, the reliability of the
I
simulation models and the goodness of the study results,
first obtained by the manufacturers and after reviewed 2 250
by Enel-Cra.
The activator permitted, in a practically effective way, I 240

the detailed validation on field of the control system

dynamic performances as well as the fine-timing of 230

some regulation parameters. 0 10 20 30 40 50 60

Also confirmed was the validity of G A M M A 60 Time [s]

supervisory system which allowed, in conjunction with Figure 7 - Dynamic response following wind velocity
the activator, the security development of a large variety Vv perturbation (from JO m/s to 11 m/s) at
of static and dynamic tests. maximum Cp(k,Q) operation

242
 G A M M A 60 Wind Turbine Grnera:cr elecrri: po^er control dynamics
G A M M A 60 Wind Turbine Generator gearbox torque control dynamics
46, . 1 . '

43 -

0 10 20 30 40 50 60

Tune [s| Time [s]

G A M M A 60 Wind Turbine Generator gearbox torque control dynamics G A M M A 60 Wind Turbine Generator: electric p o e r control dynamics

0 .1 2 3 4 5 6 7 8 9 10 0 10 20 30 40 50 60

Time |s] Time [s]

Figure 8 - Dynamic response following wind velocity Figure 9 - Dynamic response following wind velocity
Vv perturbation (from 12 m/s to 13 m/s) at Vv perturbation (from 14 m/s to 15 m/s) at
maximum torque Cm operation. rated speed co and power Pe operation.

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design and theoretical and experimental
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Netherlands. 9. S.Avolio, G.Moleti, F.Morabito, 1993,
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Thessaloniki, Greece. C.Golia, I.Sebastianelli, 1993, "Design, analysis
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243