multimegawatt windturbine hybrid tower
TRANSCRIPT
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Multimegawatt
windturbine hybrid tower
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Table of contents
• Tower structure
– Functions
– Loads and design combinations
– Design process
• ECO100 T90 meters
• Hybrid tower development
• Prototype validation and instrumentation
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Tower Str.: Functions • Main
– To maintain the nacelle and the rotor at the specified height
– To transfer properly turbine loads to the ground
– To ensure the dynamic stability of the turbine
• Secondary
– To facilitate access to the turbine
– To protect internal equipment
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Loads • Aero elastic models:
Bladed® software from
Garrad Hassan
• In accordance with IEC
61400
• More than 30 ten-minute
events
• Operating life : 20 years
• Event repetition according
to statistic wind distribution
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Design combination loads
• Energy generation
• Energy generation + faults incidences
• Start process
• Normal stop
• Emergency stop
• Standing still
• Idling and fault conditions
• Transport, packing, maintenance and
repairing
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Design process
Loads
Turbine
Geometry
Material
Tower Design
Extreme Analysis
Fatigue Analysis
Dynamic Analysis
Tower Validation
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ECO100 – T90 meters • Type IEC – IIA
• Nominal power: 3 000 kW
• Bearing height: 90 meters
• Nominal rotor diameter: 100 m
• Nominal wind speed: 12 m/s
• Turbine speed range: 1000 – 1800 rpm
• Control: variable speed with pitch control
• 20-year life
• Hybrid tower 90 meters:
– Steel tubular structure : 80 meters
– Poured concrete structure: 10 meters
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ECO100 – T90 meters
ECO100 – T90 m prototype . March 2008. La Collada (Tarragona, Spain)
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ECO100 – T90 meters
90 m
10
m
Steel tubular structure 80m
Poured concrete structured 10m
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ECO100 – T90 meters
• Prototype installed since March 2008
• Over 2900 operation hours
• Overall energy: 2 149 221 kWh
• Maximum wind measure: 56 m/s (CII Vgust_50y = 60m/s)
• Design approval
• Certified Power function
• Certified Energy Quality
• France: 5+1 new ECO100 – T90 meters in process
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Hybrid tower development
• Design and validation (FEA)
– Tower structure
– Foundation
– Steel-concrete connection system
• Connection system tests
– Static rupture tests
– Fatigue tests
• Prototype manufacturing
• Prototype instrumentation
• Dynamic measures, both of the tower and the connection system
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Design and validation
• FEM model:
• Tower and foundation: – Solid95 3-D 20-Node Structural Solid
• Door frame: – Shell93 8-Node Structural Shell
• Ground interface: – Contac52 3-D Point-to-Point Contact
~221000 Elements
~659000 Nodes
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Design and validation
• Boundary
conditions:
– Restrictions
– Loads
• Ground
interface
model:
• Ballast
module
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Design and validation
• Rotational stiffness + Stress distribution on ground
– Maximum load operation
Vertical movements UY Contact52: Contact Status
NO GAP
Contact52: Contact Penetration
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Design and validation • Rotational stiffness + Stress distribution on ground
– Extreme loads
Vertical movements UY Contact52: Contact Status
GAP
Contact52: Contact Penetration
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Design and validation Dynamic analysis – Tower frequencies (global model)
2nd frequency : side to side.
Global model IKERLAN
1st frequency : side to side.
Global model IKERLAN
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Design and validation Vacuum thrust
Simplified model for the connection zone Compression stresses distribution
Equivalent Pressure to an Extreme load
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Design and validation • Thermal gradient effect on the connection
area
Connection joint model
Temperature implementation
Stress distribution both in steel and in concrete
Temperatures Distribution.
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Design and validation
• Load concentration over the upper stretch
Upper stretch model – Nacelle Joint
Non uniform loads application over the orientation crown
Stress distribution on the upper stretch of the steel tower
Stress concentration location
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Connection system Steel Sector embedded in concrete
Patent Protected
JOINING DEVICE FOR HYBRID WIND TURBINE TOWERS.
In-situ concrete tower
Tower foundation
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Connection system
• Loads transmissions through
Perfobond ‘shear connectors’
• Innovative concept for the steel-
concrete connection (patent
protected)
• Perfobond system tested in civil
applications
• Load transmission guaranteed using
strut-and-tie model
• High performance and uniform load
distribution
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Connection system tests
• Rupture and fatigue tests
• Carried out by the University of
Santander
Simulation tests – Stress distribution in Perfobond System
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Connection system tests
Rupture tests • Connection’s Ultimate Rupture Resistance
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Connection system tests
Fatigue tests • 2 million cycles + load increasing until rupture
Test piece 1 – Fatigue test Test piece 2 – Fatigue test
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Prototype Instrumentation
Instrumentation using strain gauges • Concrete + Reinforcement + Perfobonds
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Prototype Instrumentation
Instrumentation using strain gauges
Strain gauges: concrete and reinforcement
Strain gauges in perfobond
Interior instrumentation / tower’s outside view
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Prototype validation
• Dynamic measurements in the tower
– Good correlation between model and
prototype
Maximum oscillating
frequency
Emergency Stop at
70 seconds
Maximum oscillation
in the tower
Real Oscillation
Simulation
oscillation (in blue)
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Prototype validation
• Dynamic measures on the connection zone
– Start + Production + Emergency stop
– Full power and limited power
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Prototype validation
• Dynamic measures on the connection zone
– Start + Production + Emergency stop
– Full power and limited power
• Maximum and minimum stresses measured values
lower than the previously estimated ones
• Strain compatibility between concrete, reinforcement
and Perfobonds