Annexure 1 0202070101 - FEA Results Rev. 02 Dated 23-02-18

Confidentiality: 0 / CONFIDENTIAL INFORMATION
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MODELLING AND CALCULATION Date: 23/02/2018 Pg.1of63
REPORT
Approval
process: Windcare
Documentation Type: Title:
Prepared:
Deliverable: DERRICK STRUCTURE STRENGTH Verified:
ANALYSIS
Approved:
SCOPE
This report focuses on Wind Care Derrick Structure strength analysis, according to the requirements imposed
by the references exposed in this document, in order to certify its safety.
KEYWORDS
Derrick Structure,Wind Care, Ultimate Analysis
RECORD OF CHANGES
Rev. Date Author Description

GERARDO ROJAS/
00 22/01/2018 Initial Version
ALTEN
GERARDO ROJAS/
01 05/02/2018 VON-Mises of Individual component detail added
ALTEN
GERARDO ROJAS/
02 23/02/2018 VON-Mises of Pin detail added
ALTEN
ICA-TEC-001-R06 (en)Edition 1
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MODELLING AND CALCULATION REPORT
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Title: DERRICK STRUCTURE STRENGTH ANALYSIS
REFERENCES
Standards and guidelines
[1] International Standard IEC 61400-1 Third edition 2005-08 Wind turbines. Part 1: Design requirements.
[2] Germanischer Lloyd. Rules and Guidelines. IV Industrial Services. Guideline for the Certification of
Wind Turbines. Edition 2010.
[3] DIBt Regulations. Edition March, 2004.
[4] Leitfaden für eine Betriebsfestigkeitsrechnung (Guideline for Fatigue Analysis), H. Gedehus, H. Zenner,
4th edition, publisher verlag staisen 1999.
[5] VDI 2230 Part 1, Systematic calculation of high duty bolted joints – Joints with one cylindrical bolt,
issued: 2003-02.
[6] ISO-898-1. Mechanical properties of fasteners made of carbon steel and alloy steel. Part 1: Bolts, studs
and screws with specified property classes. Coarse thread and fine thread.
[7] ISO-3506-1:2009 Mechanical properties of corrosion-resistant stainless steel fasternes - Part 1: Bolts,
screws and studs.
[8] EN 10025-2. Hot Rolled Products of Structural Steels – Part 2: Technical Delivery Conditions for Non-
Alloy Structural Steels.
[9] EN 1993-1-8 2005. Eurocode 3: Design of steel structures - Part 1-8: Design of joints.
[10] EN 1993-1-9 2005. Eurocode 3: Design of steel structures - Part 1-9: Fatigue.
Books
[11] HYPERMESH 14.0 User’s Guide. ALTAIR Engineering.

[12] ABAQUS 6.13 Standard User’s Manual. SIMULIA.
[13] ABAQUS 6.13 Keywords manual. SIMULIA.
[14] ABAQUS Theory Manual, Version 6.13. SIMULIA.
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UNITS & SYMBOLS
Units (SI)
 l Length (m)
 m Mass (kg)
 ρ Density (kg/m3)
 F Force (N)
 M Moment (Nm)
 σ Stress (Pa)
 a Acceleration (m/sec2)
Symbols
 Rm Tensile strength (Pa) or (MPa)

 Rp0.2 = ReH Minimum yield strength (Pa) or (MPa)
 E Young’s modulus (Pa) or (MPa)
 ν Poisson’s ratio
  Friction coefficient
 e Minimum percentage elongation after fracture (%)
 γM Partial material safety factor
 γf Load safety coefficient
 D Fatigue Damage (D = 1/Nf)
 Nf Fatigue life ratio
Abbreviations
 M.S. Margin of Safety

 FEM Finite Element Method
 FEA Finite Element Analysis
The rest of the symbols, abbreviations and units are explained in the corresponding chapters.
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INDEX
SCOPE.............................................................................................................................................. 1
KEYWORDS ..................................................................................................................................... 1
RECORD OF CHANGES ..................................................................................................................... 1
REFERENCES ................................................................................................................................... 2
UNITS & SYMBOLS .......................................................................................................................... 3
INDEX .............................................................................................................................................. 4
1 INTRODUCTION ..................................................................................................................... 6
2 MARGIN OF SAFETY SUMMARY .............................................................................................. 6
2.1 ULTIMATE STRENGTH .................................................................................................................. 6
3 MATERIAL PROPERTIES ......................................................................................................... 7
3.1 METALLIC COMPONENT ............................................................................................................... 7
3.1.1 Ultimate Analysis Properties ....................................................................................................... 7
4 ALLOWABLES & PARTIAL SAFETY FACTORS .......................................................................... 9
4.1 MATERIALS ................................................................................................................................. 9
4.1.1 Ultimate Strength Analysis ......................................................................................................... 9
4.2 LOADS ........................................................................................................................................ 9
4.2.1 Ultimate Strength Analysis ......................................................................................................... 9
4.3 SUMMARY OF SAFETY FACTORS ................................................................................................... 9
5 MODEL DESCRIPTION .......................................................................................................... 10
5.1 GENERAL DESCRIPTION ............................................................................................................. 10
5.2 REFERENCE SYSTEMS ................................................................................................................ 11
5.3 COMPONENTS ........................................................................................................................... 12
5.3.1 Nacelle Framework Beam ........................................................................................................ 12
5.3.2 Lateral Connection .................................................................................................................. 13
5.3.3 Flange .................................................................................................................................... 14
5.3.4 Pulley Beam ............................................................................................................................ 15
5.3.5 Top Support ........................................................................................................................... 16
5.3.6 Stay Structure ......................................................................................................................... 16
5.3.7 Frame Beam ........................................................................................................................... 20
5.3.8 Bolted joints ........................................................................................................................... 22
5.3.9 Welded joints .......................................................................................................................... 25
5.4 INTERFACES .............................................................................................................................. 26
6 BOUNDARY CONDITIONS..................................................................................................... 28
6.1 GENERAL DESCRIPTION ............................................................................................................. 28
6.2 IMPLEMENTATION IN THE MODEL .............................................................................................. 29
7 APPLIED LOADING ............................................................................................................... 30
7.1 General description .................................................................................................................... 30
7.1.1 Pre-tension forces ................................................................................................................... 30
7.1.2 Lift Loads ............................................................................................................................... 30
7.1.3 Ultimate Load Cases Summary ................................................................................................. 30
7.2 IMPLEMENTATION IN THE MODEL .............................................................................................. 30
7.2.1 Pre-tension forces ................................................................................................................... 30
7.2.2 Lift Loads ............................................................................................................................... 31
8 CALCULATION ...................................................................................................................... 31
8.1 ULTIMATE STRENGTH ANALYSIS ................................................................................................ 31
8.1.1 Introduction............................................................................................................................ 31
8.1.2 Bolted joints ........................................................................................................................... 31
8.1.2.1 Modelled bolted joints .......................................................................................................... 31
8.1.2.2 Non modelled bolted joints ................................................................................................... 33
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8.1.3 Welded joints .......................................................................................................................... 36

8.1.3.1 Summation of nodal forces at weld section ............................................................................ 36
8.1.3.2 Forces and moments at each fillet ......................................................................................... 37
8.1.3.3 Stresses at each fillet ........................................................................................................... 38
8.1.3.4 Weld resistance accomplishment ........................................................................................... 38
8.1.4 Load cases definition ............................................................................................................... 39
9 RESULTS ............................................................................................................................... 40
9.1.1 Ultimate Strength Linear Material Analysis ................................................................................ 40
9.1.1.1 Pulley Weight Load Case ...................................................................................................... 40
9.1.2 Margin of Safety calculation ..................................................................................................... 49
9.1.3 Bolted joints results summary .................................................................................................. 50
9.1.4 Welded joints results summary ................................................................................................ 52
10 CONCLUSIONS ...................................................................................................................... 57
APPENDIX A: LIST OF COMPUTER FILES ...................................................................................... 58
APPENDIX B: LIST OF WELDS ....................................................................................................... 59
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1 INTRODUCTION
2 MARGIN OF SAFETY SUMMARY
2.1 ULTIMATE STRENGTH
Page Load Case Failure criteria MS
50 WC_Structure_Extreme Total Strain Neuber Valid

50 WC_Structure_Extreme Material Yielding 0.41
50 WC_Structure_Extreme Material Yielding 0.32
Table 2-1. Summary steel supports structures results. Lift Loads.
Page Bolted Joint Load Case MS

51 M20: PRELOADED 94 KN WC_Structure_Extreme 0.385
51 M20: PRELOADED 60 KN WC_Structure_Extreme 1.492
51 NON-MODELLED BOLTS WC_Structure_Extreme 0.131
Table 2-2. Bolted joints summary of results.
Page Load case Weld Id MS

56 WC_Structure_Extreme WELD_331 0.03
Table 2-3. Welded joints summary of results.
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3 MATERIAL PROPERTIES
The Derrick structure is basically composed of steel profiles and supports.
3.1 METALLIC COMPONENT
3.1.1 Ultimate Analysis Properties

The mechanical and strength properties of the studiedmetallic components are those exposed inTable 3-1,
and are obtained from Ref. [6] and Ref. [8].
Material S355 Class 8.8 Bolts
Reference EN-10025-2 ISO-898-1

Thickness range
t≤16 d≤16 d>16
(mm) / quality
Rm = Ftu (MPa) 510 800 830
ReH = Fty (MPa) 355 640 660
e (%) 22 12
E (MPa) 210000 210000
ν 0.3 0.3
ρ (*103 Kg/m3) 7.85 7.85
Table 3-1. Metallic material mechanical properties.

Rlim is the maximum allowable value of the stress.
Rlim = 0.2/m
Where m(γM=1.1) is the material safety factor.
If the calculated stress is near the elastic limit, there is a deviation between the real behaviour of the
material and the linear elastic behaviour, so the real stress is different than the FE calculated one.The
material non-linear strain will be determined using Ramberg-Osgood approximation using minored values
(γM=1.1).
1
 n
   
   0.002   
E  Fty 
  
 M 
Where:
 = total strain (elastic + plastic strain)
 = stress
Fty = yield stress.
n = Ramberg-Osgood coefficient
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In order to calculate the value of hardening coefficient n, Ramberg-Osgood curve is imposed to pass through
the ultimate strength point minored with the material partial safety factor.
The steel material curve is calculated according toTable 3-1.
The ultimate strength point is:
 = 20 %
 = 470/1.1= 427.3 MPa
This way, the value obtained for n is 0.061
Thus, Ramberg-Osgood equation to calculate real non-linear strain is:
1
    0.061
  0.002 
210 E 9  323E 6 
According to Neuber criteria, the transformation from the linear curve to the Ramberg-Osgood curve must
follow the equation:
    const.
The value of the constant depends on the value of the stress, so each point of the linear curve has a
different value. Using non-linear techniques it is possible to solve the set of equations (shown graphically in
the figure below).
600
Ramberg-Osgood
Neuber
500
Linear-Elastic
400
300
200
100
0
0 0.002 0.004 0.006 0.008 0.01
Figure 3-1. Neuber correction.
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4 ALLOWABLES & PARTIAL SAFETY FACTORS
The safety factors have been applied according to Germanischer Lloyd regulations (Ref. [2]) and IEC 61400-1
regulations (Ref. [1]).
4.1 MATERIALS
4.1.1 Ultimate Strength Analysis
The partial material safety factor M used as a basis for metallic componentsand welds is M = m · n=
1.1 (with m= 1.10 and n= 1 for non-fail safe structures of component class 2) according to the specified in
IEC 61400-1, 3rd Edition Ref.[1].
For bolted connections subjected to tension and shear, the partial safety factor will be M2 = 1.25 for bolt
resistance and M3 = 1.25 for slip resistance, according to Eurocode (Ref. [9]).
4.2 LOADS
4.2.1 Ultimate Strength Analysis
The safety factor for lift loads is 1.5. (Ref. [2])
4.3 SUMMARY OF SAFETY FACTORS
Every safety factor used in the analysis is shown in the following table:
ULTIMATE STRENGTH ANALYSIS
General Non-post Laminate Modulus Global

Ageing cured Temperature
Factor method Product. Scattering Factor
Allowables Metallic 1.10 - - - - - 1.10

Material
Loads Live Loads 1.50 - - - - - 1.50
Table 4-1. Partial safety factors.
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5 MODEL DESCRIPTION
A finite element model has been used in order to analyse the structural behaviour of the Derrick structure.
Altair HYPERMESH v14.0 (Ref. [11]) software is used as pre-processor and static analysis solver. Altair
HYPERVIEWv14.0 is used as post-processor for all performed analyses.
5.1 GENERAL DESCRIPTION
The model includes many beam profiles made up by steel sections. The beam profiles have been joined
between them by means of bolts modelled as single beam elements, also welded joints have been used to
the assembly. Contacts between the components have been modelled in order to prevent partial
penetrations. The bolted joints of the support structure have beenmodelled in a more detailed way. The
Figure 5-1 shows a general view of the model.
Figure 5-1. FEM model general view.
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5.2 REFERENCE SYSTEMS
The model coordinate systems are defined according to the rules stated on Ref. [2].Model definition is set in
the Basic or Global Coordinate System, which can be seen inFigure 5-2. The origin and the axes directions
are defined as described in Table 5-1.
Name Global coordinate system

Type Cartesian
Mobile / fixed Fixed
Origin Placed on the Structure bottom
X+ Horizontal in machine backwards direction
Y+ Vertically upwards
Horizontally sideways, so that X, Y, Z rotate
Z+
clockwise
Table 5-1. Global coordinate system definition.
Figure 5-2. Basic or global coordinate system.
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5.3 COMPONENTS
The components that constitute the Derrick Structure of Wind Care have been modelled with first order shell
elements (ABAQUS S4 and S3).Also, every subcomponent have been defined as steel S355.
5.3.1 Nacelle Framework Beam

The nacelle framework beam is the main structure at this design. As can be seen in Figure 5-3, the structure
is composed by beams with different sections. In Figure 5-4, a detailed view of the assembly between beams
by preloaded bolts is shown.
Figure 5-3. Nacelle framework beam structure.
Figure 5-4. Deitaled view of Nacelle framework structure assembly.
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5.3.2 Lateral Connection

To connect the upper nacelle from one side to the other side, it is used the following beams structures called
Front Beam, Middle Beam and End Beam that can be seen in following figures. Every component in this
structures are welded to fix the beams.
Figure 5-5. Front beam structure.
Figure 5-6. Middle beam 1 structure.
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Figure 5-7. Middle beam 2 structure.
Figure 5-8. End beam structure.
5.3.3 Flange
This components connects the lateral connection structure and the nacelle framework beam by M20
preloaded bolts. Also, Flange structure include a structure called Lateral Plates to improve performance.
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Figure 5-9. Flange structure.

5.3.4 Pulley Beam
To support the pulley, it is used the called Pulley Beam that is composed by two parts, the front and back
structure.
Figure 5-10. Front pulley beam structure.
Figure 5-11. Back pulley beam structure.

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5.3.5 Top Support

Top support is the structure used to connect each frame at Lateral connection support and is made by M20
preloaded bolts. Also, this component is fixed by welded with its own flanges.
Figure 5-12. Top support structure.
Rear zone of top support structure has been modelled with solid elements (Figure 5-13) because it works
under compression pressure and shell elements are going to show peaks values that means non-realistic
stress values.
Figure 5-13. Top support structure solid submodel.
5.3.6 Stay Structure

To connect the Derrick structure to other structure, it is used the stay structure. This structure is composed
by two parts, Stay plate and Stay support. Also each part, is composed by other components like is shown in
the following figures. Front Stay Plate Structure has been modelled with solid elements because it works
under compression pressure.
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Figure 5-14. Front stay plate structure.
Figure 5-15. Middle 1 stay plate structure.
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Figure 5-16. Middle 2 stay plate structure.
Figure 5-17. Lateral 1 stay plate structure.
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Figure 5-18. Lateral 2 stay plate structure.
Figure 5-19. Stay post structure. Top and bottom section.
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Lateral 1 Stay Plate

Lateral 2 Stay Plate
Front Stay Plate

Middle 2 Stay
Plate Middle 1 Stay
Plate
Figure 5-20. General view of Stay Structure.

5.3.7 Frame Beam
Frame beam structure is modelled to connect lateral connection and stay structure to other external
structure. Is composed by different parts called as Front frame beam, Middle frame beam and End frame
beam that are connected by M20 preloaded bolts to all the structure and can be shown in following figures.
Figure 5-21. Front frame beam.
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Figure 5-22. Middle frame beam.
Figure 5-23. End frame beam.
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Middle Frame
Beam
Front Frame Beam
End Frame Beam
Figure 5-24. General view of Frame Beam Structure.
5.3.8 Bolted joints

The bolted joints of the Derrick Structure have been modeled in two different ways, depending on whether
they are modelled or not. The modelled bolted joints are those joining the steel components among them,
while the non modelled joints are those joining the external structure among them and with the steel
components. The different bolted joints and their modelizations are presented below.
The bolted joints of the Derrick Structure have been modeled with ABAQUS B31 beam elements. Their
section is circular and with a radius corresponding to the strength section of the bolt (A s from Ref.[5]). The
washers that contact with the steel plates have been modeled with ABAQUS C3D8 solid elements. The bolts
are joined to the solid mesh of the washers by means of CONN3D2 ABAQUS elements with BEAM properties.
These connectors are located at one extreme of the bolts, modelling the behavior of the hexagonal head in
the upper side; and at the threaded end of the screw or the nut, depending on the joint, thus connecting the
joining parts.
The total lengths of the bolts have been calculated according to the requirements in Ref.[5] when obtaining
the bolt axial resilience (chapter 5.1.1.1 of Ref.[5]), as shown inFigure 5-25.
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Figure 5-25. Division of a bolt into individual cylindrical solids and deformation regions outside the bolt from Ref.[5].
The meshed length of bolts is:
l FEM  l SK  l K  lGM (8.1)

The equivalent extension length of the head for hexagon head bolts is:
l SK  0.5  d
(8.2)
The extension length of the engaged thread part (lGM) is composed of two regions (one with the minor
diameter of the engaged bolt thread lG and the one of the tapped thread region or nut region l M). According
to VDI:
lGM  lG  l M  0.5  d  0.33  d

for tapped thread joints (8.3)
lGM  lG  l M  0.5  d  0.4  d for bolted joints (8.4)
In theFigure 5-26 the beam elements of a bolt are shown. As it can be seen there, the connection between
the bolts and the solid mesh is made up by connectors rigid beam type.
Figure 5-26. Front Support Structure to steel ring bolted joint.
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The preloaded bolted joints and their properties are listed in Table 5-2.
Joining parts Metric Class AS (mm2) rS (mm)
Assembled Structure* M20 8.8 245 8.83
Table 5-2. Preloaded bolted joints.

*Since the external connection has not been included in the model bolted joints between the metallic components and the external
structure have been modelled as constraints and results have been obtained from their reactions and using a load factor of 0.2.
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5.3.9 Welded joints

The welded joints of the Derrick Structure have been modelled intwo different ways, depending on whether
they are connected or not.
- Connected welded joints
The connected welded jointshave been modelled by means of tied contacts (ABAQUS feature) using the
nodes placed in the web edges as slave nodes and the elements of the plate as the master surfaces of the
contact.
Slave nodes
Master elements
Figure 5-27. Connected welded joints.
- Non-connected welded joints

The non-connected welded joints are modelled as rigid elements (ABAQUS KINEMATIC COUPLING), directly
from a node of one joining part to the opposite node of the other part. The Figure 5-28 shows the joint
between non connected components.
Figure 5-28. Non-connected welded joints.
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5.4 INTERFACES
A summary of the interfaces is shown in following figures and in Table 5-3 is shown comments about
interfaces.
Tied
Contact Pair
Figure 5-29Interfaces in FEM Model.
Figure 5-30Detailed view of interface in FEM Model.

As well is shown inFigure 5-30, interface between flanges and lateral connections are tied and the others are
defined as contact pair due to they are assembled by bolts.
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Interface Type Comments
Between components Contact pair Friction µ=0.15.
Washers Tied -
Welds Tied -
Table 5-3. Summary of interfaces.
Also, 3D model must be connected with 2D model by abaqus SHELL TO SOLID contact as ref. [14]
recommends. As in Figure 5-31 is shown, the interface between solid and shell elements has been defined
due to the structure works under compression pression.
Figure 5-31Detailed view of Shell to Solid (red) interface in FEM Model.
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6 BOUNDARY CONDITIONS
The Derrick structure assembly is attached to other structure by means of 32 bolts, all of them at the stay
structure. Nodes corresponding to the bolts locations have been fixed. The position of the bolted areas is
shown in theFigure 6-1.
Figure 6-1. Boundary Condition location.
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6.2 IMPLEMENTATION IN THE MODEL
The boundary condition definition has been done using kinematic couplings between the nodes located at the
hole and another node at the center of it that is restrained as is shown inFigure 6-2.
Figure 6-2. Boundary Condition (encastre) implementation in the model.
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7 APPLIED LOADING
The Derrick structure finite element model has been analyzed under the applied loading derived from Section
6.4. of Ref.[2]. The following load actions are to be taken into consideration.
7.1.1 Pre-tension forces
According to VDI Eurocode (Ref. [9]), the pretension load to be used in design calculations is shown in the
table below.
Metric M20 M20 M20
Class 8.8 8.8 8.8
As (mm2) 245 245 245
Pre-tension load (N) 94000 60000 137200*

Table 7-1. Pre–tension loads.
*The pretension load applied is the corresponding to the 70% yield strength.
7.1.2 Lift Loads

For consider pulley weight, a load of 7250 kg has been considered:
Pulley weight Fp = 106.575KN
Partial safety factor for live loads is F = 1.5, included in Fp.
7.1.3 Ultimate Load Cases Summary

As requested in Section 6.4 of Ref.[2], only the lift load must be considered.
Thus the following load case have been taken into consideration for the analysis of the structure:
Load
Case
Name Gravity Lift Load F Wind F Total
1 Pulley Weight No 106.575 KN 1.5 No 1.5
Table 7-2. Load Casedescription.
Figure in the following section represent the lift load case considered.
7.2 IMPLEMENTATION IN THE MODEL
7.2.1 Pre-tension forces

The preloaded bolt elements are pre-stressed by means of an ABAQUS Card *PRE-TENSION SECTION (See
Ref [12] for more information). The preloads applied are those previously exposed in Table 7-1.
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7.2.2 Lift Loads

Lift load has been applied from beam element connected to front pulley beam structures.
In the following picture, the node where the corresponding Lift Loads is applied is presented.
106.575 KN
Figure 7-1. Load Case.Pulley weight load: 106.575KN.
8 CALCULATION
8.1 ULTIMATE STRENGTH ANALYSIS
8.1.1 Introduction
In this section the strength and stability analysis methods of the components of the Derrick structure are
explained.
The Derrick structure has been analyzed against the corresponding yield limit for stress minored with the
partial material safety factor Mdescribed in 4.1.1. Regarding to the bolts, the calculation will be explained in
detail in the next points.
The finite element model has been calculated using ABAQUS v6.13-1.
8.1.2 Bolted joints

8.1.2.1 Modelled bolted joints
The stress will be evaluated in two section of the bolt:
- Head side (HD): in the section under the head (see Figure 8.1).
- Thread side (TH): in the first threaded section (see Figure 8.1).
If no results are available in these points, they shall be calculated by interpolation.
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tapped thread region

l =0.5d; l =0.33d
G M
head region
l =l +l =0.83d
GM G M nut region l =0.5d (hexagon bolts)
SK
l =0.5d; l =0.4d
G M
l =0.4d (socket head
SK
l =l +l =0.9d
GM G M
cap screws)
GM
GM
SK
l
l
TH TH HD
TAPPED THREAD
BOLTED JOINTS
JOINTS
Figure 8.1. Different bolt ends according to VDI 2230 Ref. [5].
Next is explained how the stress in bolts is obtained. The axial stress due to the axial force is:
Fx
 axial 
As (11.1)
The maximum axial stress due to the bending moment is:
M bend ·ymax
 Bend 
I (11.2)
In the expressions above As is the section. As the section of the bolt is circular:
 ·Rs 4
I
A   ·Rs , y max  Rs
2
4 and (11.3)
where I is the inertial moment and Rs is the minimum radius of the bolt thread.
The bending moment is calculated as:
M bend  M y  M z
2 2
(11.4)
This bolts stress calculation is developed in an excel spreadsheets taking into account the section forces and
moments of the bolts, extracted from the Abaqus calculations. The section forces are defined as follows, as it
is shown in Figure 8-2:
 SF1: Axial section force (N)
 SF2: Shear section force in direction 1(N)
 SF3: Shear section force in direction 2 (N)
 SM1: Bending moment along direction 1 (Nm)
 SM2: Bending moment along direction 2 (Nm)
 SM3: Torsional moment (Nm)
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X
SF1 SM3
SM1
SF2
Y
Z
SF3
SM2
Figure 8-2. Bolt section forces and moments definition.
Then, Fx = SF1, My= SM1 and Mz=SM2.
According to VDI 2230 (Ref. [5]), the yielding point of the bolt has not to be exceeded. The torsional stress is
only partially considered (using a reduction coefficient k  = 0.5).
 red , B   Z2  3k  2  R p 0.2 min (8.5)
For the tension stress, the maximum loaded fiber of the bolt is used. It tension is calculated with the FEA
obtained axial force Fax and bolt section bending moment Mbend:
 Z   axial   Bend (8.6)
In the case of the torsional stress due to tightening method, it is calculated with:
MG
 (8.7)
WP
where the thread torque MG follows the expression below:

d2  P 
M G  FMzul   1.155 G min  (8.8)
2    d2 
In that expression the used FMzul is the bolt pretension, d2 is the pitch diameter of the bolt thread, P is the
thread pitch and G min is the friction coefficient in the thread (here 0.10 has been used). From the
expression (11.7) the inertial polar moment is calculated as:

WP  d 03 (8.9)
16
where d0 is the diameter of the relevant smallest cross section of the bolt (here d 0 = ds is used).
8.1.2.2 Non modelled bolted joints

Non modelled and preloaded bolted connections (Preload force = 137.2 KN) are subjected to combined shear
and tension, so they have been analyzed using the following criteria based on Table 3.2 of Ref. [9]:
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Ft , Ed  Ft , Rd
Fv , Ed  Fv , Rd
Fv , Ed  Fb , Rd , Steel
Fv , Ed  Fb , Rd ,Composite
Fv , Ed Ft , Ed
 1
Fv , Rd 1.4·Ft , Rd
Where:
Ft,Ed is the design tensile force per bolt for the ultimate limit state;
Fv,Ed is the design shear force per bolt for the ultimate limit state;
Ft,Rd is the design tension strength per bolt;
Fv,Rd is the design shear strength per bolt;
FB,Rd,Steel is the design strength of the steel profile per bolt.
FB,Rd,Composite is the design strength of the composite laminate per bolt.
The acting loads are obtained from the Derrick Structure FE Model and from each load case. The allowable
loads for each bolt depend on its material properties, metric and configuration. Next, the expressions used
for calculating the allowable values are presented:
 Tension resistance, Ft,Rd:
k 2 · f u ,b ·As
Ft ,Rd 
M2
 The shear strength of the bolt, Fv,Rd :
 v· fu ,b·A
Fv , Rd 
M2
 The bearing strength of the steel profile, Fb,Rd Steel:
t ·D· f u ,S 355
Fb,Rd ,Steel  1.5· s
M2
Where:
 K2 takes a value of 0.9 according to Table 3.4 of Ref.[9].
 As is the stress cross section area of the bolt (seeTable 5-2)
 fub is the ultimate tensile strength of the bolt.
 M2 is the partial safety factor; see section 4.1.1 of the current document.
  v , takes a value of 1.0 for bolts in normal holes and 0.63 for long slotted holes according to Table
3.4 of Ref. [9].
 ts are the thickness of the steel flange.
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 D is the diameter of the hole on the steel profile or solid laminate (conservatively the bolt diameter is
assumed).
 fu,S355 is the ultimate tensile strength of the steel that has been used in the model.
In order to carry out the strength analysis, the tension and shear forces are extracted directly from the
boundary nodes in the FE model.
Abaqus section force SF1 represents the axial force in a beam element while SF2 and SF3 the shear forces in
two orthogonal directions in the cross section plane. Hence, Ft,Ed and Fv,Ed are calculated in this way:
Ft ,Ed  SF1
Fv ,Ed  SF 23  SF 2 2  SF 32
Where,
 SF1 is the section force in the beam direction (axial);
 SF2 is the section force in local 1 direction (section plane);
 SF3 is the section force in local 2 direction (section plane);
 SF23 is the resultant shear force (section plane).
The margin of safety for each ultimate limit state is calculates as show below:
Ft ,Ed
MSt  1
Ft ,Rd
Fs ,Ed
MS s  1
Fv ,Rd
Fb ,Ed
MSb  1
Fb ,Rd
F Ft ,Ed 
MS c  1   v ,Ed  

 Fv ,Rd 1.4·Ft ,Rd 
Where,
MSt is the margin of safety for tension resistance,
MSs is the margin of safety for slip resistance,
MSb is the margin of safety for bearing resistance,
MSc is the margin of safety for combined tension and shear.
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8.1.3 Welded joints

Welded joints have been modelled by means of tied contacts using the nodes placed in the web edges as
slave nodes and the elements of the plate as the master surfaces of the contact using the ABAQUS Card
*CONTACT PAIR, TIED see Ref.[12].
From the ABAQUS analysis, total forces and total moments about to the origin due to the contact pressure
and frictional stress of all welded joints tied contacts are obtained. Stresses at each fillet of the welds are
studied to validate the welded joints. The procedure to get the stresses from the section forces of one
welded joint is summarized below:
 Summation of weld forces at weld section

 Forces and moments at each fillet
 Stresses at each fillet
 Weld resistance accomplishment
8.1.3.1 Summation of nodal forces at weld section
From the Abaqus analysis, total forces and total moments about to the origin due to the contact pressure and
frictional stress for each welded joint are obtained.
First, forces and moments at each node must be translated to the origin of the welded joint with the
expressions:
RG  RO
M G  M O  GO  RO
Where R are the forces, M the moments, the subscript G refers to the origin of the weld and the subscript O
refers to the node origin.
The summation of these forces and moments considering only the contribution of the elements from one of
the parts connected is what is called section forces or free body cut, and represents what the welded joint
must stand. Then, the aim of the weld analysis is to check if the welded joint can either stand these forces or
not.
After that, it is important to change the coordinate system: from the global one to the welded joint local
coordinate system. The reason of the coordinate system change is that this way, all weld joints have the
same orientation at their local coordinate system and then, the force distribution calculation is less
complicated. In Figure 8-3, axes x and y correspond to the weld local coordinate system and the point G is
the origin of the weld.
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Y Y
A B
X G X
G
Figure 8-3Welded joint local coordinate system.
8.1.3.2 Forces and moments at each fillet
Weld sections described in section 5.3.9 are composed of many fillets, as the example given in Figure 8-4.
Then, it is necessary to find the forces and moments at each fillet in order to analyze their stress level.
According to Ref. [9], it must be defined a distribution of forces and moments which complies with the
following conditions:
 Static equilibrium must be accomplished at weld section.

 Every fillet must stand its stresses due to the force distribution.
 Stress distribution must be realistic.
Figure 8-4Fillets at weld joint.
For the Spinner weld fillets, distribution hypotheses fulfilling these considerations have been made.
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8.1.3.3 Stresses at each fillet
From the forces at each weld, it is possible to calculate its stress level. According to Ref. [9], only one normal
stress and two shear stresses are considered in the verification of the design resistance of the model, as it is
shown in Figure 8-5.
Figure 8-5Stresses on the throat section of a fillet weld.

Where:
┴ is the normal stress perpendicular to the throat
|| is the normal stress parallel to the axis of the weld
┴ is the shear stress (in the plane of the throat) perpendicular to the axis of the weld
|| is the shear stress (in the plane of the throat) parallel to the axis of the weld
These stresses shown in Figure 8-5 are expressed at the weld throat coordinate system, which is not the
same as neither the weld joint local coordinate system nor the global system defined.
8.1.3.4 Weld resistance accomplishment
According to Ref. [9], the design resistance of one fillet will be sufficient if the following expressions are both
satisfied:
fu
W  M 2
MoSWELD1: Equivalent stress: 1  0
  3( 2   ll2 )
2

0.9 f u
M2
MoSWELD2: Normal stress: 1  0

Where fu is the ultimate tensile strength of the weakest part joined, w is a correlation factor (0.9 for S355
steel according to Table 4.1 of Ref. [9]) and M2 is the material safety factor (described in section 4.1.2).
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8.1.4 Load cases definition

For the assessment of the ultimate strength, a total of four non-linear static analyses have been carried out.
According to the description given inTable 7-2, the following sequence of steps is defined:
 Step 1: The bolts pre-tension forces from Table 7-1are applied.

 Step 2: Starting from Step 1, the corresponding Lift loadis applied.
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9 RESULTS
In the next figures, the ultimate strength analysis results with linear material definition are shown.
Firstly, for steel structures, Von Mises stress maps will be presented. Finally, summary tables with bolts and
welds results will be shown.
9.1.1 Ultimate Strength Linear Material Analysis
9.1.1.1 Pulley Weight Load Case
Figure 9-1Displacements: Derrick Structure, Pulley Weight case (scale x10). General view 1.
Non-real stress peak

values due to tied 227.90 MPa
interface edges
511.40 MPa
Figure 9-2Von Mises stress: Derrick Structure, Pulley Weight case. General view 1.
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Figure 9-3Von Mises stress: Front Beam Structure, Pulley Weight case. Detailed view.
Figure 9-4Von Mises stress: Middle Beam1 Structure, Pulley Weight case. Detailed view.
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Figure 9-5Von Mises stress: Middle Beam2 Structure, Pulley Weight case. Detailed view.
Figure 9-6Von Mises stress: End Beam Structure, Pulley Weight case. Detailed view.
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Figure 9-7Von Mises stress: Top Support Structure, Pulley Weight case. Detailed view.
Figure 9-8Von Mises stress: Front Pulley Beam Structure, Pulley Weight case. Detailed view.
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Figure 9-9Von Mises stress: Back Pulley Beam Structure, Pulley Weight case. Detailed view.
Figure 9-10Von Mises stress: Front Frame Beam Structure, Pulley Weight case. Detailed view.
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Figure 9-11Von Mises stress: Middle Frame Beam Structure, Pulley Weight case. Detailed view.
Figure 9-12Von Mises stress: End Frame Beam Structure, Pulley Weight case. Detailed view.
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Figure 9-13Von Mises stress: Stay Post Structure, Pulley Weight case. Detailed view.
Figure 9-14Von Mises stress: Nacelle Beam Structure, Pulley Weight case. Detailed view.
In Figure 9-2, Figure 9-13 and Figure 9-14 there are points where the stress is higher than the yield limit.
The higher stress zone has been analysed through an elastic-plastic material analysis using the minored
Ramberg-Osgood curve for the material.
To clarify the image with stress 511.40 MPa (Figure 9-2) it has been made a submodel to show the
compression effect.The submodel has been attached between the 2D model and 3D model with a shell to
solid contact.
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Figure 9-15Von Mises stress: Derrick Structure, Pulley Weight case. Submodel 1.
In the same way, to clarify Figure 9-7 non-real stress peaks values it has been made another submodel to
show the compression effect.
Figure 9-16Von Mises stress: Derrick Structure, Pulley Weight case. Submodel 2.
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244.30 MPa
Non-real stress peak

values due to contact
interface edges
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Figure 9-19: Von Mises stress: Pin, Pulley Weight case. Detailed view.
9.1.2 Margin of Safety calculation

The previous figures show the maximum Von Mises linear stress for each component. All peak values have
been considered except those due to singularities produced by the bolt preload application method, and rigid
interfaces definitions.
The Margin of Safety obtained for ultimate strength is calculated comparing the linear stress with the
allowable stress, in the case of the steel components.
 allowable, yield Fty  M
M .S .  1  1 (9.1)
 VonMises,max  VonMises,max
The Derrick structure results for all studied load cases, for composite and steel components, are shown in the
next table:
VM Stress Allowable Total Strain Margin of

Load Case Figure
(MPa) (MPa) Neuber(%) Safety
511.40 355/1.1 0.38 Valid Figure 9-2

227.90 355/1.1 - 0.41 Figure 9-2
150.80 355/1.1 - 1.14 Figure 9-3
152.90 355/1.1 - 1.11 Figure 9-4
77.70 355/1.1 - >2 Figure 9-5
Lift Load 98.80 355/1.1 - >2 Figure 9-6
180.90 355/1.1 - 0.78 Figure 9-8
32.90 355/1.1 - >2 Figure 9-9
10.10 355/1.1 - >2 Figure 9-10
9.50 355/1.1 - >2 Figure 9-11
3.50 355/1.1 - >2 Figure 9-12
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VM Stress Allowable Total Strain Margin of

Load Case Figure
(MPa) (MPa) Neuber(%) Safety
332.90 355/1.1 0.18 Valid Figure 9-13

171.70 355/1.1 - 0.88 Figure 9-14
232.90 355/1.1 - 0.39 Figure 9-14
493.80 355/1.1 0.36 Valid Figure 9-14
488.60 355/1.1 0.35 Valid Figure 9-14
511.40 355/1.1 0.38 Valid Figure 9-14
511.90 355/1.1 0.38 Valid Figure 9-14
473.70 355/1.1 0.33 Valid Figure 9-14
492.90 355/1.1 0.36 Valid Figure 9-14
232.50 355/1.1 - 0.39 Figure 9-14
161.60 355/1.1 - 1.00 Figure 9-14
244.30 355/1.1 - 0.32 Figure 9-17
13.1 355/1.1 - >2 Figure 9-19
14.4 355/1.1 - >2 Figure 9-19
14.0 355/1.1 - >2 Figure 9-19
196.2 355/1.1 - 0.64 Figure 9-19
4.2 355/1.1 - >2 Figure 9-19
14.4 355/1.1 - >2 Figure 9-19
4.3 355/1.1 - >2 Figure 9-19
4.9 355/1.1 - >2 Figure 9-19
2.3 355/1.1 - >2 Figure 9-19
1.8 355/1.1 - >2 Figure 9-19
Table 9-1.Derrick Structure MS summary table.
As can be observed in the previous table, the maximum stress appears in the Nacelle Framework with a
value of 511.90 MPa, which is over the maximum material allowable stress. However, it has been
demonstrated that deformation values are under 0.38%, which is much lower than the failure strain value
(1%). In addition to this, the value has been obtained through an elastic-plastic calculation using the
minored Ramberg-Osgood curve for the material, being this a conservative procedure, as seen in
section3.1.1. In conclusion, the Derrick Structure complies with the ultimate strength safety requirements.
9.1.3 Bolted joints results summary
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In the following tables, envelope results of the margins of safety for every bolted joint is presented.
σ total
Preloaded bolted joint MS
(MPa)
M20: PRELOADED 94 KN 474.53 0.385

M20: PRELOADED 60 KN 263.44 1.492
NON-MODELLED BOLTS 164.25 0.131
Table 9-2.Derrick Structure bolted joints MS summary table.
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9.1.4 Welded joints results summary

The following table shows the summary of the minimum margins of safety for every welded joint.
Weld MoS Weld MoS Weld MoS Weld MoS

WELD_1 >2 WELD_2 >2 WELD_3 >2 WELD_4 >2
WELD_5 0.28 WELD_6 1.47 WELD_7 1.48 WELD_8 0.28
WELD_13 1.41 WELD_14 >2 WELD_15 >2 WELD_16 1.42
WELD_17 >2 WELD_18 >2 WELD_19 0.95 WELD_20 0.93
WELD_33 1.42 WELD_34 1.41 WELD_35 >2 WELD_36 >2
WELD_37 >2 WELD_38 >2 WELD_39 >2 WELD_40 0.80
WELD_45 >2 WELD_46 0.86 WELD_47 >2 WELD_48 >2
WELD_81 1.26 WELD_82 >2 WELD_83 >2 WELD_84 >2
WELD_89 >2 WELD_90 >2 WELD_91 0.83 WELD_92 >2
WELD_101 1.50 WELD_102 1.13 WELD_103 1.01 WELD_104 >2
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WELD_145 >2 WELD_146 1.33 WELD_147 1.31 WELD_148 1.33
WELD_189 1.83 WELD_190 1.15 WELD_191 >2 WELD_192 0.72
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WELD_329 >2 WELD_330 1.54 WELD_331 0.03 WELD_332 0.24
WELD_412 1.44 WELD_413 >2 WELD_414 1.41 WELD_415 1.02
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WELD_524 >2 WELD_525 1.52 WELD_526 0.65 WELD_527 >2
WELD_568 >2 WELD_569 0.86 WELD_570 0.80 WELD_571 >2
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WELD_656 >2 WELD_657 >2 WELD_658 >2 ESPECIAL >2
S_WELD_1 >2 S_WELD_2 >2 S_WELD_3 0.40 S_WELD_4 >2
S_WELD_5 0.41 S_WELD_6 >2 S_WELD_7 >2 S_WELD_8 >2
S_WELD_9 >2 S_WELD_10 >2 S_WELD_11 >2 S_WELD_12 >2
Table 9-3. Derrick Structure welded joints MS summary table.
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10 CONCLUSIONS
The stresses for the Derrick structure are lower than the allowable limit of 323MPa. In addition, all checks
made to the bolted and welded joints have positive margins of safety.
Therefore, it can be concluded that the Derrick structurecomplies with the requirements for ultimate
strength analysis according to the established requirements.
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APPENDIX A: LIST OF COMPUTER FILES
File Date Content

MODEL.zip 26/04/2017 ABAQUS Auxiliary input files
WC_Structure_Preload.inp 26/04/2017 ABAQUS input file for bolt preload load case
WC_Structure _Extreme.inp 26/04/2017 ABAQUS input file for pulley weight load case
WC_Structure_Preload.dat 26/04/2017 ABAQUS data file for bolt preload load case
WC_Structure _Extreme.dat 26/04/2017 ABAQUS data file for pulley weight load case
Table A.1. List of computer files.
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APPENDIX B: LIST OF WELDS
DOC DOC DOC DOC

FEM NAME FEM NAME FEM NAME FEM NAME
NAME NAME NAME NAME
WELD_1 R_SOLD1 WELD_2 R_SOLD2 WELD_3 R_SOLD3 WELD_4 R_SOLD4
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NAME NAME NAME NAME
WELD_217 R_SOLD254 WELD_218 R_SOLD255 WELD_219 S9 WELD_220 S10
WELD_221 S23 WELD_222 S24 WELD_223 S25 WELD_224 S26
WELD_281 S84 WELD_282 S86 WELD_283 R_WELD1 WELD_284 R_WELD2
WELD_285 R_WELD3 WELD_286 R_WELD4 WELD_287 R_WELD5 WELD_288 R_WELD6
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DOC DOC DOC DOC

NAME NAME NAME NAME
WELD_305 R_WELD23 WELD_306 R_WELD24 WELD_307 W_1 WELD_308 W_2
WELD_309 W_3 WELD_310 W_4 WELD_311 W_5 WELD_312 W_6
WELD_460 WELD_1 WELD_461 WELD_2 WELD_462 WELD_3 WELD_463 WELD_4
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DOC DOC DOC DOC

NAME NAME NAME NAME
WELD_600 SOLD_1 WELD_601 SOLD_2 WELD_602 SOLD_3 WELD_603 SOLD_4
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DOC DOC DOC DOC

NAME NAME NAME NAME
WELD_656 S43 WELD_657 S85 WELD_658 WELD_50 ESPECIAL ESPECIAL
SOLID_WELD_ SOLID_WELD_ SOLID_WELD SOLID_WELD
S_WELD_1 S_WELD_2 S_WELD_3 S_WELD_4
1 2 _3 _4

5 6 _7 _8
9 10 _11 _12
Table B.1. List of welds in FEM Model.
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Derrick Structure,Wind Care, Ultimate Analysis

Rev. Date Author Description

Title: DERRICK STRUCTURE STRENGTH ANALYSIS

Standards and guidelines

[11] HYPERMESH 14.0 User’s Guide. ALTAIR Engineering.

Title: DERRICK STRUCTURE STRENGTH ANALYSIS

UNITS & SYMBOLS

 Rm Tensile strength (Pa) or (MPa)

 M.S. Margin of Safety

Title: DERRICK STRUCTURE STRENGTH ANALYSIS

Title: DERRICK STRUCTURE STRENGTH ANALYSIS

8.1.3 Welded joints .......................................................................................................................... 36

Title: DERRICK STRUCTURE STRENGTH ANALYSIS

2 MARGIN OF SAFETY SUMMARY

2.1 ULTIMATE STRENGTH

Page Load Case Failure criteria MS

50 WC_Structure_Extreme Total Strain Neuber Valid

Table 2-1. Summary steel supports structures results. Lift Loads.

Page Bolted Joint Load Case MS

Table 2-2. Bolted joints summary of results.

Page Load case Weld Id MS

Table 2-3. Welded joints summary of results.

Title: DERRICK STRUCTURE STRENGTH ANALYSIS

The Derrick structure is basically composed of steel profiles and supports.

3.1 METALLIC COMPONENT

3.1.1 Ultimate Analysis Properties

Material S355 Class 8.8 Bolts

Reference EN-10025-2 ISO-898-1

ReH = Fty (MPa) 355 640 660

E (MPa) 210000 210000

ρ (*103 Kg/m3) 7.85 7.85

Table 3-1. Metallic material mechanical properties.

Title: DERRICK STRUCTURE STRENGTH ANALYSIS

Figure 3-1. Neuber correction.

Title: DERRICK STRUCTURE STRENGTH ANALYSIS

4 ALLOWABLES & PARTIAL SAFETY FACTORS

4.1.1 Ultimate Strength Analysis

The safety factor for lift loads is 1.5. (Ref. [2])

4.3 SUMMARY OF SAFETY FACTORS

ULTIMATE STRENGTH ANALYSIS

General Non-post Laminate Modulus Global

Allowables Metallic 1.10 - - - - - 1.10

Loads Live Loads 1.50 - - - - - 1.50

Table 4-1. Partial safety factors.

Title: DERRICK STRUCTURE STRENGTH ANALYSIS

5.1 GENERAL DESCRIPTION

Figure 5-1. FEM model general view.

Title: DERRICK STRUCTURE STRENGTH ANALYSIS

5.2 REFERENCE SYSTEMS

Name Global coordinate system

Table 5-1. Global coordinate system definition.

Figure 5-2. Basic or global coordinate system.

Title: DERRICK STRUCTURE STRENGTH ANALYSIS

5.3.1 Nacelle Framework Beam

Figure 5-3. Nacelle framework beam structure.

Figure 5-4. Deitaled view of Nacelle framework structure assembly.

Title: DERRICK STRUCTURE STRENGTH ANALYSIS

5.3.2 Lateral Connection

Figure 5-5. Front beam structure.

Figure 5-6. Middle beam 1 structure.

Title: DERRICK STRUCTURE STRENGTH ANALYSIS

Figure 5-7. Middle beam 2 structure.

Figure 5-8. End beam structure.