Influence of geometric imperfections and increasing turbine sizes on validity load transfer functions in bolted ring-flange connections

Abstract

The global focus on climate change and the transition away from fossil fuels has highlighted the importance of renewable energy sources. Offshore wind turbines are being optimized and are therefore growing in size and power.

This research focuses on bolted ring-flange connections, a connection type that plays a crucial role in the design of offshore wind turbines, as they transfer the external force between parts of a turbine. The objective of this thesis is to analyze how the increasing dimensions from current to future offshore wind turbines and geometric imperfections impact the reliability of analytical approaches for load transfer functions (LTFs) for these connections. Two components of this objective are considered: examining the influence of different dimensions of ring-flange connections and analyzing the impact of various gaps between flanges on LTFs for 'current generation' and 'next generation' turbines. Analytical calculations are compared to results obtained with finite element analyses, which are assumed to represent an actual connection.

Based on the research findings, the following conclusions are made. Firstly, the widely used tri-linear approach by Schmidt/Neuper [18] for obtaining the LTF in bolted ring-flange connections is found to be unreliable for current and future turbine sizes. This method highly underestimates the forces in the bolts when initial gaps are present between the flanges. Calculations performed with this approach could lead to an overestimation of the turbine's lifetime compared to reality by multiple years, possibly causing more maintenance or early failure. Alternative approaches, such as a very new and not yet approved polynomial approach, show reliable results, providing accurate estimations of bolt forces for large connection diameters. Additionally, currently verified tolerances for gaps between flanges (1 mm over 30° and 2 mm over entire circumference) are outdated, and larger gap heights or smaller gap lengths are expected in practice, especially for future turbines. These gaps lead to a larger bolt force in practice, decreasing the fatigue resistance and lifetime of the structure. Even though very small gaps are expected to occur often, lower bolt forces are obtained compared to larger gaps, both with an expected height to length ratio of 𝑢𝑔𝑎𝑝/𝑙𝑔𝑎𝑝= 0.53 ∗ 10^−3. In analytical design calculations, it therefore is recommended to consider larger sized gaps with a gap length of approximately 1600 mm with its expected gap height.