Innovative Interface Solution Using Post-Tensioned Cables

PO.ID
184
to Connect the Tower and the Foundation in Wind Turbines
lvaro Hernando / ngel Daz / Enrique Martnez / Jos Ramn Carril
MS Enertech / MS Enertech / MS Enertech / Burgos University

Abstract Assessment Example

Existing connection solutions between wind turbine tower and foundation Cable interface calculated and designed for a real 2.5 MW wind turbine
(embedded steel tube and bolt cage) present handle and assembly
difficulties, tolerances issues, are an expensive part of the foundation budget,
and are linked to most of the foundation pathologies.

This poster presents a connection between tower and foundation using pre-
stressing cables as an alternative system that solves most of those issues,
offering at the same time important savings.

This solution is patented by MS Enertech according to WO 2013/156632.

Case example 2.5 MW WTG
Interface Bill of Materials

An Innovative Solution to anchor the Element Quantity

Grout (m3) 0,503
tower to the foundation: Cable! Strands Y1860 (kg) 1244

2x0,62 cables anchorages (ud) 176

2x0,62 anchor head (ud) 176
Product Description
Capot (ud) 176

Anchoring cage formed by POSTENSIONED CABLES

Un-bounded pre-stressing system based on commercial elements
Steel cable yield limit: 1.860 MPa / Tensile limit: 1.670 Mpa
Cost reduction up to 50% that can lead
Cable formed by 2 to 7 strands of 0,6 inside a duct into important Savings on the foundation
Certified fatigue behavior
Known load transfer pre-stressing and long term loses Conclusions

It is presented a very interesting solution that may contribute to the

improvement of the wind power industry
This alternative solution provides important savings to improve the cost
efficiency of the wind power sector
Its flexibility and low tolerance sensitiveness helps to assembling and
Lower top cable details
positioning operations, contributing to a more flexible construction of the
foundation
The reduction of the uncertainties associated to fatigue and pre-stress
loses helps to minimize future foundation pathologies
Solution feasible to be applied either for onshore and offshore wind
power, when a concrete structure and a steel tube (i.e. tower) must be
connected
Furthermore, the solution has important improvement possibilities by
means of adapting the current lower tower flange to the minimum number
Upper top cable details
Cable Cage with upper template
of cables, as well as applying non linearity on FE models and considering
plastification

Advantages

Reduced uncertainties in regards to fatigue and pre-stress loses

Important material reduction due to:
Steel area reduction because of the higher yield strength View through tower and T flange View through foundation main body

No need of lower flange

No need structural upper flange, just a template in some cases
Low sensitiveness to positioning tolerance due to flexible characteristic
Assembly versatility:
Fully embedded: Lower top cable passive; upper top cable active
References
1. Jos Ramn Carril Gonzlez, lvaro Hernando Aragn, Enrique Martnez Camarero, Conexin entre una torre de un
aerogenerador y su cimentacin y procedimiento de ejecucin de dicha conexin, conexin entre una torre de un aerogenerador
y su cimentacin. PCT WO2013/156632 (2012)
2. AlHamaydeh, Mohammad,Hussain, Saif,. Optimized frequency-based foundation design for wind turbine towers utilizing soil
structure interaction, Journal of the Franklin Institute Journal of the Franklin Institute. 348 (2011) 1470-1487.

Accessible: both lower and upper tops cable may be active 3. C Horgan . Using energy payback time to optimise onshore and offshore wind turbine foundations, RENE Renewable Energy. 53
(2013) 287-298.

EWEA 2014, Barcelona, Spain: Europes Premier Wind Energy Event