The quest for reduced levelized cost of energy has driven significant growth in wind turbine size; however, larger rotors face significant technical and logistical challenges. The largest published rotor design is 25 MW, and here we consider an even larger 50 MW design with blade length over 250 m. This paper shows that a 50 MW design is indeed possible from a detailed engineering perspective and presents a series of aero-structural blade designs, and critical assessment of technology pathways and challenges for extreme-scale rotors. The 50 MW rotor design begins with Monte Carlo simulations focused on optimizing carbon spar cap and root design. A baseline design resulted in a 250-m blade with mass of 502 tonnes. Subsequently, an aero-structural design and optimization were performed to reduce the blade mass/cost with more than 25% mass reduction and 30% cost reduction by determining optimal blade chord and airfoil thickness for best aero-structural performance.

Extreme-size wind turbines face logistical challenges due to their sheer size. A solution, segmentation, is examined for an extreme-scale 50 MW wind turbine with 250 m blades using a systematic approach. Segmentation poses challenges regarding minimizing joint mass, transferring loads between segments and logistics. We investigate the feasibility of segmenting a 250 m blade by developing design methods and analyzing the impact of segmentation on the blade mass and blade frequencies. This investigation considers various variables such as joint types (bolted and bonded), adhesive materials, joint locations, number of joints and taper ratios (ply dropping). Segmentation increases blade mass by 4.1%–62% with bolted joints and by 0.4%–3.6% with bonded joints for taper ratios up to 1:10. Cases with large mass growth significantly reduce blade frequencies potentially challenging the control design. We show that segmentation of an extreme-scale blade is possible but mass reduction is necessary to improve its feasibility.

Offshore floating wind foundations supporting a large wind turbine require a large yard facility or significant facility upgrades for their fabrication. To overcome the cost increase associated with facility upgrades, an innovative lightweight modular floating foundation is developed. The foundation comprises multiple modules to enable their assembly on water, offering many benefits and expanding fabrication options for a reduction in the overall cost of the platform. In this paper, the foundation modules and their assembly are briefly described, and an analysis of the platform’s dynamic responses is presented. The modular foundation includes a modular and lightweight tension leg platform (TLP) called “MarsVAWT” which supports a Darrieus 10 MW vertical axis wind turbine (VAWT). The platform is moored with highly pretensioned wire rope tendons. The responses of the platform are analyzed in the time domain in a semi-coupled manner under the turbine operating and parked conditions for an offshore site in the US Northeast. The tower base shear forces and bending moments increase considerably with the combination of wind and waves, compared to those with wind only. The tendon tensions on the weatherside in the operating condition at high wind speeds are comparable to the values of the 50-year extreme (parked). The tendon tension increases are highly correlated to the platform pitch, as well as the horizontal and vertical velocities and vertical acceleration at the tendon porch. The modular platform performances and tendon designs are confirmed to comply with industry standards and practices.