1. Introduction
Floating offshore wind turbines (FOWTs) have been studied extensively from the 2000s due to the increasing need to shift to renewable sources of energy and the significant potential for development of offshore wind in deep-water sites with large prevailing wind velocities. Along with this, there has also been a shift from academic interest to industrial and commercial projects. FOWTs are complex systems with extensive interaction between aerodynamic loads on the rotor nacelle assembly (RNA), structural deformation of the rotor blades and supporting tower, hydrodynamic loads on the floater hull coupled with a mooring system and power cables, and the control modeling of the turbine (see
Figure 1). To design and dimension these systems, it is thus important to model critical physical aspects as accurately as possible. Turbine capacities are quickly increasing from 5 to 8 MW (Hywind Scotland and Hywind Tampen) towards designs with 15 MW (already being tested) and even 20 MW. Such large structures, with rotor diameters in the order of 200 m or larger, pose challenges for the numerical modelling. Matha and Schlipf [
1] discussed exhaustively such challenges along with the pros and cons of potential flow (PF) vs. Computational Fluid Dynamics (CFD) methods. Otter et al. [
2] provided a comprehensive review of experimental and numerical modelling of FOWTs, where tools were classified as “low”, “mid”, and “high” fidelity. As in all numerical modelling involving approximations, there is an inherent trade-off between accuracy and efficiency. PF methods (classified as “mid-fidelity” methods by Otter et al. [
2]), which assume in-viscid and irrotational flow and an incompressible fluid, are generally used to calculate hydrodynamic loads on structures, combined with simplified models for possible rotational and viscous flow effects. These provide efficient numerical solutions that represent loads and motions with good accuracy for large-volume structures, and are therefore widely used in marine/ocean engineering. CFD methods, on the other hand, inherently account for viscous and other nonlinear effects and are classified as “high-fidelity” methods by Otter et al. [
2]. However, they are much less efficient than PF methods, thus requiring significant computational resources.
There are several codes, both commercial and open-source, that have been used to numerically model FOWT systems. FAST [
3] is a widely used open-source software developed by the National Renewable Energy Laboratory (NREL) that is composed of several individual modules, which are coupled in a time domain aero-hydro-elastic-servo solver. Recently, FAST was renamed to OpenFAST. Orcaflex [
4] is a commercial software for general modelling of floating dynamic systems, which during recent years has been given the possibility to perform aero-hydro-elastic-servo simulations for FOWTs, including extensive validation against OpenFAST results. Both OpenFAST and Orcaflex use hydrodynamic coefficients from well-documented frequency-domain Boundary Element Method (BEM) solvers such as Wamit as input to represent wave loads. Structural loading/deformations of the turbine tower and rotor blades are described using the Finite Element Method (FEM) combined with the Blade Element Momentum Theory (BEMT) to resolve aerodynamic loads. The FEM is also used to describe the behaviour of mooring lines. The respective solvers for the various system components are coupled in time domain. Several studies examining the capabilities of the two codes are available in the literature, and a few relevant works are described in the following.
Dagher et al. [
5] presented an extensive study for three floating platforms supporting the NREL 5 MW turbine at a 1:50 scale and compared experiments with FAST simulations, showing good agreement for wind-only cases but with some discrepancies when waves were included. Stewart et al. [
6] presented a comparison of a calibrated FAST model against experimental data for a tension leg platform (TLP) FOWT, with good agreement in the wave-excitation frequency range. Wang et al. [
7] found good agreement between numerical (OpenFAST) and experimental results during investigation for a 5 MW OC3 spar-type FOWT at a scale of 1:50. The reasons for the differences in the results of the FOWT under wind, wave, and current conditions were discussed. Kim and Shin [
8] performed validation of a numerical FAST model against experiments for a 1:40 scale 750 kW FOWT for various load cases. They found good agreement between the numerical model and experiments for surge and heave motions, but larger differences for pitch motion. Ahn and Shin [
9] compared results from FAST and an in-house code with experimental results for a 10 MW FOWT model at scale 1:90 with good agreement. Thomsen et al. [
10] studied the “TetraSpar” floater concept and investigated the use of new modelling approaches in Orcaflex and OpenFAST for the numerical representation of the floater hull. For this specific concept, modelling the hull as either rigid or flexible gave considerable differences. Vittori et al. [
11] performed experiments for a 1:49 scale model of a 10 MW FOWT system and compared with OpenFAST numerical results. They noted that the pitch natural frequency shifts with wind loading on the FOWT system. This effect could not be captured in the simulations, since the numerical model does not update the hydrostatic restoring when the hull is tilted. In addition to the ones referenced here, there are several other studies with similar experimental and numerical analysis showing reasonable or good agreement. Among the reasons for observed differences between experimental and numerical results, the inherent limitation of potential flow theory has been suggested. PF solvers generally represent hydrodynamic (and hydrostatic) loads based on a linear solution, and viscous loads are at best represented in an approximate manner. Several researchers have tried to improve the simulation accuracy by using CFD solvers in different ways. However, CFD simulations for FOWTs present their own set of challenges ranging from complex setup to high-resource computational requirements. In addition, the CFD setup and associated assumptions (including turbulence modelling, neglecting structural blade deformation, etc.) imply that these simulations should not by default be perceived as superior to PF solvers. However, with proper setup and experience-based modelling choices in both aerodynamic and hydrodynamic modelling, accurate “high-fidelity” CFD simulations can be achieved. In addition, CFD captures flow phenomena such as turbine wakes in a way that PF methods cannot.
Traditionally, CFD methods have been used in the floating wind industry to better understand the hydrodynamics of floater hulls for FOWTs or to simulate the aerodynamics for the rotor. For CFD modelling of (fixed) land-based wind turbines, a variety of literature exists and a few important references are mentioned in the following with particular focus on the use of the open-source code OpenFOAM (OF). Sanderse et al. [
12] reviewed state-of-the-art CFD simulations of wind-turbine wake aerodynamics, and discussed techniques for modelling the rotor and the wake including turbulence models. Tossas and leonardi [
13] discussed the implementation of the actuator line model (ALM) and actuator disk model (ADM) using OF. Stergiannis et al. [
14] studied the differences in modelling a rotor wake using CFD through the ADM model and a full rotor model. They found that the wake behind the turbine using the two approaches can be quite different and, therefore, the choice of model representing the best compromise between accuracy and efficiency should be made based on the parameters of interest. For example, for estimation of loads on the rotor, ADM is more efficient without sacrificing accuracy, whereas to analyse wake features a full rotor model is needed.
Numerous authors have studied the hydrodynamic loads of floater hulls using CFD excluding the turbine and associated aerodynamics, but considering the structural mass/inertia of the tower, turbine blades and RNA. Among them, Beyer et al. [
15] analysed surge free-decay tests using the Navier–Stokes (NS) equations for the OC3 spar model in turbulent flow conditions. Benitz et al. [
16,
17] performed turbulent-flow CFD simulations to calculate hydrodynamic loads on the OC4 semi-submersible floater hull in current and waves, highlighting the presence of shadow effects behind the columns of the semi-submersible hull. Rivera-Arreba et al. [
18] performed laminar-flow CFD simulations for heave and pitch free-decay of the OC5 semi-submersible. In addition they performed simulations in regular waves, and found differences between CFD and PF results for large-steepness wave cases. Nematbakhsh [
19,
20] performed laminar-flow CFD simulations for a tension-leg platform (TLP), where they conducted free-decay tests in surge and heave, and computed the regular-wave response using the level-set (LS) method to model the free-surface deformations. Li and Bachynski [
21] compared nonlinear diffraction wave loads on the OC6 floater with CFD and a PF hybrid model (the latter including Morison elements to approximate viscous loads), discussing the advantages of using CFD for estimation of higher-order loads. They also discussed the effect of a mean pitch angle (tilted hull geometry) on diffraction loads. Li and Bachynski [
22] proposed a method for correcting quadratic transfer function (QTFs) for wave-drift loads obtained from PF using CFD data, and demonstrated that the modified QTFs improved the agreement with experimental data. In addition, Galera-Calero et al. [
23] performed numerical simulations for a semi-submersible FOWT platform using the commercial CFD code Star-CCM+, showing reasonable agreement between numerical results and experimental results obtained in the LIR/NOTF wave basin by Saitec Offshore Technologies.
Recently, with a general increase in CFD capability and availability of computational power, CFD studies on coupled aero-hydrodynamics of FOWTs have been performed. In this framework, Xu et al. [
24] provided an exhaustive review on CFD simulations for FOWTs. The authors discussed the advantages of using CFD for fully coupled simulations, including detailed resolution of wake flow-field features. Among the drawbacks and shortcomings mentioned are high computational requirements, the lack of studies capturing blade deformation for large turbines (aero-hydro-elastic studies), and the lack of studies with realistic modelling of turbine inflow conditions. Liu [
25] and Liu et al. [
26] performed fully coupled aero-hydrodynamic simulations of FOWTs using OF, comparing results against industrial/engineering codes (e.g., OpenFAST) with reasonable agreement. In addition, these works discussed the advantages of using CFD, including high-detail representation of the wake field behind the turbine. Such representation of the wake field makes it possible to analyse the inflow for downstream turbines more realistically, and can thus serve as a tool to optimize the layout/area of floating wind farms. Zhou et al. [
27] expanded on the work of previous authors comparing CFD simulations with OpenFAST results, stating that nonlinearity of wave loads in steep waves causes differences between CFD and other methods. Cheng et al. [
28], Huang and Wan [
29], analysed the fully coupled aero-hydrodynamic model for a FOWT with an in-house OpenFOAM-based solver called naoe-FOAM-SJTU for the hydrodynamics combined with an Unsteady Actuator Line Model (UALM) for the aerodynamics. The authors concluded that the UALM model resolves the flow with reasonable accuracy when compared to BEMT models, but less accurate (albeit more efficient) when compared to full rotor modelling. Tran and Kim [
30] performed coupled aero-hydrodynamic simulations for a floating turbine focusing on the surge motion, concluding that the power production of the turbine is influenced by the platform surge motion. Tran and Kim [
31] performed aero-hydrodynamic coupled CFD simulations also including mooring line dynamics for the DeepCwind floating platform and the NREL 5-MW turbine. A prescribed motion was enforced to the platforms, and comparisons with experiments and FAST showed good agreement. Tran and Kim [
32] extended their previous work incorporating fluid–structure interaction for the rotor blades allowing platform motions in six degrees of freedom (DOF), and showed good agreement with FAST. Liu et al. [
33] extended their CFD work for the NREL 5 MW turbine, coupling the CFD solver with a code to solve the structural deformations of the rotor blades and forcing the turbine to move sinusoidally in surge. Differences between the CFD solver and FAST were observed, and between CFD simulations with rigid and deforming blades, respectively. Arabgolarcheh et al. [
34] performed CFD simulations for a 5 MW FOWT using the ALM method, concluding that, as expected, the ALM modelling provides efficiency compared to full rotor models. Zhang and Kim [
35] also compared BEMT and CFD codes, and showed that for a fixed turbine, the results for the two approaches were relatively similar. However, for a floating system, there were differences in the thrust from the two solvers. The wake behind the FOWT system was also discussed in detail.
Although a few are mentioned above, a relatively limited number of studies have been published where the aero-hydrodynamic coupling for FOWTs using CFD and PF solvers is compared. Even fewer studies have considered the aero-hydrodynamic-structural coupling for FOWTs. The aim of the present research is to extend the work of aforementioned researchers to a larger turbine and associated floater hull, since most of the published studies use a 5 MW turbine in their analyses. With the global trend in the floating wind industry to deploy larger turbines of 10 MW and beyond, larger aerodynamic and hydrodynamic nonlinear loading effects appear. As a starting point, the open-source IEA 15 MW turbine (defined in Gaertner et al. [
36]) along with the associated open-source Volturn US-S floater hull (defined in Alle et al. [
37]) is selected. Due to computational limitations and to validate the solvers used, the scaled version of the IEA 15 MW turbine defined in Kimball et al. [
38] and Mendoza et al. [
39] is studied, for which Mendoza et al. [
39] has provided experimental results for a “performance-matched” model turbine in varying wind, rotor speed and blade pitch conditions. The main aim of the performed work is to further explore the utility of PF (using Orcaflex) versus CFD (using OpenFOAM) methods for solving FOWT systems, as a contribution to continue building knowledge for the floating wind community. To assess the solver accuracy, we compare fixed-turbine thrust results obtained with the PF and CFD solvers against the aforementioned experiments from Mendoza et al. [
39] for a load case. Hydrodynamic aspects related to the floater hull (excluding the RNA and tower) are examined using both PF and CFD. Challenges related to accurate modelling of large turbines and subsequently larger floating substructures in CFD are highlighted.
The present study is an extension of the work presented in Siddiqui et al. [
40]. A fully aero-hydrodynamic coupled FOWT model (including floater hull and turbine) is implemented in OF, where the floater is allowed to move freely in pitch while disregarding rotor blade deformations. The same setup is modelled in the PF solver to allow for a proper comparison of the turbine thrust between the two solvers. The differences in the wake-flow features between the fixed and floating turbines are studied using the CFD solver. Furthermore, the wake field obtained with the CFD solver is compared with a simplified model described in de Vaal and Muskulus [
41]. Finally, a qualitative cost-benefit analysis is presented comparing the usefulness and utility of CFD methods relative to industry-standard PF methods for the analysis of FOWTs. The paper is structured as follows:
Section 2 provides a brief description of the properties of the IEA turbine and Volturn US-S floater including the properties for the scaled turbine and the scaling method. The simulation scenarios with related parameters are provided in
Section 3. The theoretical background for the PF and CFD solvers is described in
Section 4, including the associated boundary conditions, numerical setup, mesh generation, and simulation parameters. Methods for data analysis to obtain hydrodynamic and aerodynamic quantities of interest are described in
Section 5. Results and discussion are provided in
Section 6, before the conclusions and suggestions for future work are given in
Section 7.
7. Conclusions
The aim of the present work was to investigate the usefulness of CFD in the analysis of FOWTs by comparing CFD results from OpenFOAM with PF results from Orcaflex. The former properly accounts for nonlinear hydrodynamics including viscous-flow effects, whereas the latter uses hydrodynamic coefficients from a frequency domain analysis based on perturbation theory combined with empirical formulations for viscous-flow effects. A 15 MW open-source turbine with an associated floater, mirroring the industry trend of going towards larger turbines, are used as basis for the study together with relevant environmental parameters. To avoid excessive computational demands, scaled versions of the turbine and floater were modelled in the CFD setup. However, a full-scale floater was modelled for pure hydrodynamic cases. Details for the boundary conditions, mesh generation, and solver setup are thoroughly explained. The following observations are highlighted from the comparison between CFD and PF:
Hydrodynamic coefficients estimated with PF and CFD generally agree well. However, some nonlinear behaviour not captured in the PF results are indicated by the CFD method. For diffraction scenarios, the CFD results indicate instances of moderate nonlinearity related to increasing wave steepness and mean floater pitch, and for the mean wave-drift forces, the CFD results indicate some nonlinearity related to increasing wave height (documented in Siddiqui et al. [
40]);
Added mass coefficients from forced oscillation CFD simulations are in fair agreement with PF results. The damping forces due to forced oscillations in the CFD simulations are on the other hand significantly larger than the PF radiation damping. This is attributed to rotational and viscous-flow effects. For a direct comparison between CFD and PF radiation damping, CFD simulations should ideally have been performed without viscosity. Nevertheless, the results indicate that viscous damping must be added in PF, preferably calibrated against CFD or experiments, to yield physically sound behaviour. This is here exemplified through a comparison of free-decay CFD and PF simulations;
In uniform current, the drag force obtained with the CFD solver shows a directional dependence that cannot be reproduced by using Morison elements in the PF solver. This is due to viscous directional dependent interaction effects between the columns that may be important to account for to reliably estimate hydrodynamic loads due to current and/or waves, or resistance during towing. In this regard, the use of CFD may help to capture flow physics not revealed by PF at a reasonable computational cost (as a moderate simulation time is needed to estimate loads in uniform compared to unsteady inflow). Such information may, e.g., be used to enhance the accuracy of a PF model by introducing different Morison drag coefficients depending on the flow direction.
The aerodynamic thrust forces obtained from the PF and CFD solvers are in good agreement for the fixed turbine case with differences less than 6%. However, for the floating turbine a significant difference (around 33%) is observed for reasons that should be examined in a future work.
To quantify the experiences made in the present work,
Table 17 presents a cost-benefit analysis for the simulations performed considering four parameters: CPU time, setup complexity, potential advantages, and software license cost. The parameters are classified as “low”, “medium”, and “high” with points assigned from 1 to 3 to each depending on the parameter. For example, a “high” potential advantage corresponds to 3 points, whereas a “high” license cost corresponds to 1 point.
The cost-benefit analysis in
Table 17 indicates that, in general, available industrial PF tools provide as good (if not better) results as the CFD solver while incurring significantly lower computational costs. When looking specifically towards analysis of hydrodynamic properties, on the other hand, the CFD solver has equal or better rating than the PF solver. This is, e.g., due to a more accurate representation of viscous damping. Although the computational cost of CFD for pure hydrodynamic studies is significantly larger than for PF, it is still considered reasonable.
The computational cost of performing coupled aero-hydrodynamic simulations with CFD is too high to justify the use of CFD for general analysis of floater motions, turbine thrust, etc. In addition, implementation of the controller and flexible blades in the CFD solver is needed, whereas state-of-the-art PF methods already have such capabilities built in. CFD does however present the opportunity to investigate the detailed flow patterns in downstream aerodynamic wakes, which can have utility in the overall design of a wind farm.
The main conclusion from the work is therefore that, considering the present state-of-the-art, available industrial PF tools are preferable for coupled aero-hydrodynamic simulations of FOWTs. CFD may however be a useful tool to improve the accuracy of hydrodynamic coefficients in PF models through calibration, and may in some cases be considered as an alternative to performing hydrodynamic model tests.