Influences of manufacturing processes

on offshore support structures

Project:
j
RAVE - GIGAWIND alpha
p ventus
Prof. Dr. P. Schaumann, ForWind - Leibniz University Hannover
Dr. H. Huhn, Fraunhofer IWES

Gefrdert auf Grund eines Beschlusses

des Deutschen Bundestages

Projekttrger

Koordination

Holistic design concept for OEWC

support structures on the base of
measurements at the offshore test
field alpha
alpha ventus
ventus
P j t consortium:
Project
ti

I d t i l partners:
Industrial
t

Associated project in:

Funded by:

GIGAWINDav
TP 2
The working
g packages
p
g
TP 1 - Load modelling for wind and waves and its
TP 3
TP 1
correlation effects
TP 8
TP 2 - Influence of manufacturing aspects on fatigue
resistance
TP 7
TP 3 - Corrosion protection for offshore steel
TP 6
TP 4
structures
TP 4 - Reliable load monitoring at global and local
TP 5
parts of the structure
TP 5 - Development
D
l
t off new scour protection
t ti
systems
t
and local scour monitoring,
TP 6 - Modelling of the load-carrying behaviour for driven offshore
piles
TP 7 - Automated Validation of general structural models
TP 8 - Holistic design
g concept
p for OWEC support
pp
structures

Outline

BIFab

Objectives
Laser measurements
Total station + ultrasonic
ltrasonic
Parameter studies
S f
Surface
modelling
d lli
Summary

Doti

Objectives
j

Jakubowski (2003)

Objectives
j
Ninian Central North Sea Oil Platform Niall
Cotton

Serial production
cn-online.de

Piece production

Laser measurements (1)

Measurement system: laser scanner

Object: jacket R4

Manufacturing of a frame

Laser measurements (2)

Best fit analysis
Best-fit
Approximation of point cloud by ideal cylinders
Average diameter
Deviation from average diameter (out-of-roundness)
Identification
Id tifi ti off cylinder
li d axes
Angular misalignment
Misalignment of axes

Out-of-roundness of a tube

Point cloud (green) and best-fit

cy de
cylinder

Laser measurements (3)

Angular misalignment

Actual:
111,44

Actual:
68,48

Check of production accuracy

Discrepancy in magnitude of
measurement spreads
X1S_NEU
Set: 111,55
Actual
:
111,45
, 5

Set: 68,45

X-node 1, welded,
Check measurement
Actual:
111,50

Actual:
68,50

X1S

X1H

X-node 1, tack welded

Actual
:
68,41

X-node 1, welded

Total station + ultrasonic (1)

10 tubes:
Measuring
g devices:
Total station,
calliper ultrasonic thickness gage,
measuring tape
Parameters:
Circumference U (diameter D)
Wall thickness t
Out-of-roundness O

Burntisland Fabrications

Agreement with common

codes / regulations (DIN
EN 10219-2, GL Wind IV-2

Total station + ultrasonic (2)

Measurement: Jacket

Relative
Hu
h [-][-]
Relative
frufigkeit
requency

Evaluation of measurements:
Determination of centerline
from surface points
Statistical evaluation of inaccuracies:
Expected value =0 known
for , eund L
Use of absolute values and
classification
-Test
Test for normal distribution
not successful
More data needed, in order to
determine statistically assured
distribution

weld

Klassenhufigkeit
Histogram
|e| - |e(n=43)
| - (n=43)
0,5
Messw erte
Measurement
0,4

Half-Normal
Distrib.
halbseitige Normalvert.

0,3
0,2
0,1
0
4,33

8,66

12,99 17,32 21,64 25,97 30,30 34,63

Class limit (upper)[m[mm]

Klassenobergrenze
m]

Parameter studies (1)

Influence of out of plane eccentricities on ULS
Calculation on 3D framework
Imperfection: translation of single nodes
In detail: out-of-plane translation of X-node

3,3%
3 3% under
d max. iimperfection
f ti acc. to
t EC

[N/m
mm]

Meridional stress at x-node

Maximum
allowed
ll
d
imperfection acc.
to Eurocode: 6 cm

80
60
40
20
0
-20
-40
-60
60
0,0

0,1
0,2
0,3
0,4
Imperfection [m]

0,5

Parameter studies (2)

Lokal impact on fatigue stress
Brace 55

Brace 66

Influence of angular misalignments

FE solids model
Eccentric load application
Increase
I
off internal
i t
l forces
f
Shifting of stress concentrations
00
0.0

0
0.1
1

0
0.2
2

0
0.3
3

Imperfection [m]

Small influences on SCF

0
0.0
0

0
0.1
1

0
0.2
2

0
0.3
3

Imperfection [m]

Parameter studies (3)

Planar K
K-Joint
Joint
Investigation of 3 elementary load cases as givens by the
empirical equations of EFTHYMIOU for calculating the SCF
Variation of e and g for exemplary geometry (D/d=800/400 mm)
dA

dB
tA

(SCF/SCF(e=0))

tB
+21,0%

S b A
Strebe
brace
b

S brace
Strebe
b B

+11,7
%

-0,5%

T
L

Gurt
chord

2e/(D-d)
2e/(D
d)
e
+

N2=N1(1/2)

=g/D

Parameter studies (4)

Investigations on DK
DK-Joints
Joints Global Model
Model AV 4:
Sea state
JONSWAP-spectrum:
H s= 3 m
Tp= 8 s
2 directions:
0 und 90
0
90 (rel.
(rel Jacket)
10 min, seed identical
ANSYS/ASAS

3 Configurations:
0: undeformed
1: e
= 100 mm
2: L
= 100 mm

Parameter studies (5)

top

Accumulated Damage Weld See state 0

0-Direction
Direction
DHotSpot

Chord:
m=5
(
(norm.)
)

-1

inwards

inwards

-1

+14%

-1

+84%
0: undeformed
1: e=100mm

2:L=100mm

-1

Surface modelling (1)

Cleaning of point cloud

Software Cyclone, Leica Geosystems

Measurement point based meshing with triangular elements

Surface modelling (2)

Alternative meshing algorithm

Impressing of real surface on ideal structure

Loading of point cloud
Calculation of new radii
T
Translation
l ti off nodes
d

cut A

cut A

Surface modelling (3)

Structural analysis

Summaryy

Applicability of different measuring techniques

Geometric deviations in tolerance limits
Optional reduction of substitute design imperfections
Development of numerical tools for evaluation and
reverse engineering
i
i
(->
( FEM)

Thank
a You
ou very
e y much
uc for
o your
you
attention!