Recovery Act: Large Wind Turbine Drivetrain Testing Facility

This Funding Opportunity Announcement is for the design and construction of a large dynamometer facility for testing 5 to 15 MW rated drivetrains, with supporting systems, and the operation and maintenance of these facilities for the benefit of wind stakeholders nationwide. The proposed facility can be new construction or involve the design and modification of an existing building suitable for electrical, mechanical, and other physical needs associated with a dynamometer test stand. Overhead cranes, access doors, and other facility infrastructure suitable for accommodating associated components and equipment will be required. It is envisioned that the facility will include sufficient office space for permanent staff and visiting users as well as conference rooms, lunch room, restrooms, computer stations, etc. Applicants will be required to submit detailed multi-phase plans including concept designs, preliminary designs, engineering procurement and construction contract management, and operation and maintenance. DOE envisions awarding a single $45 Million financial assistance grant award on a competitive basis. This $45 million program is to assist in the design and construction of an accredited dynamometer testing facility capable of performing Highly Accelerated Life Testing (HALT) of 5 to 15MW rated wind turbine drive trains and generators, including all required supporting systems. As HALT is assumed to require at least a 30% overload in the rated torque of the test article, the dynamometer facility will require a minimum capacity of 20MW to support testing of a 15MW rated drivetrain. The facility should incorporate features to accommodate large direct drive generators in addition to generator/gearbox drivetrain configurations. In addition, the capability to simultaneously impart dynamic and/or steady off-axis loads (bending, radial and axial loads) to the low speed shaft of the test article will be required. It is anticipated that the facility will incorporate multiple test bays, permitting simultaneous, independent testing of two 7.5MW rated drivetrains. It is expected that the test bay dynamometers would be coupled to obtain a single test capability of up to 15MW rated drivetrains. The facility should incorporate the necessary electrical infrastructure to permit interconnection of the test article at all common system operating voltages. The facility should also be capable of testing generator system response to grid anomalies and for grid code compliance. Independent accreditation of the facility to conduct certification testing in accordance with applicable wind turbine design standards will be required.