Quality Management of Precast Concrete Segments for Wind Turbine Towers
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Transcript of Quality Management of Precast Concrete Segments for Wind Turbine Towers
Quality Management of Precast Concrete Tower Segments for Wind Turbine Towers
CONCRETE GROWTHconcrete materials engineers
Santie Gouws Quality Manager – Precast Concrete Tower Segments for Acciona Windpower;MD - Concrete Growth
CONCRETE GROWTHconcrete materials engineers
Wind Energy (I)
Rotor
Hub
Tower
> 80 m
Rotor
Blades
Nacelle
Enclosing
African
Elephant
CONCRETE GROWTHconcrete materials engineers
Wind Energy (II)
Development of Turbine Capacity and
Tower Height
Hybrid
towers
CONCRETE GROWTHconcrete materials engineers
Wind Energy (III)
Tubular steel towers
Concrete towersTower technology options
• SA economic development depends on
• Electricity supply
• Job creation
• IRP 2010 to 2030
• 55 000 MW to be installed in next 20 years
• Up to 9 200 MW wind energy through REIPPP
• 2,5 to 3MW turbines - > 3000 tower structures
• Tower structure ~ 15 % of capital cost of wind farm
• Round 3 Local content requirements:
→ increased to threshold of 40%, target of 65%
• Concrete towers, relatively new technology internationally,
but obvious contender for local contentCONCRETE GROWTHconcrete materials engineers
Wind Energy in South Africa (I)
CONCRETE GROWTHconcrete materials engineers
Wind Energy in South Africa (II)
Development of Turbine Capacity and
Tower Height
CONCRETE GROWTHconcrete materials engineers
Wind Energy in South Africa (III)
Cost of Energy vs Hub Height
CSIR,
Greene &
E-Science
Associates
CONCRETE GROWTHconcrete materials engineers
Wind Energy in South Africa (IV)
Job creation – impact of 50MW wind farm
446
525
525
346
368
368
250
266
266
836
1 380
1 746
691
1 080
1 441
679
902
1 267
1 052
1 350
1 630
796
997
1 272
669
784
1 063
- 1 000 2 000 3 000 4 000
120m Imported steel tower
120m Concrete tower
100m Imported steel tower
100m Concrete tower
80m Imported steel tower
80m Concrete tower
Number of Full Time Equivalent jobs
Direct impactIndirect impact
Induced impact
CSIR, Greene &
Urban-Econ
Development
Economists CONCRETE GROWTHconcrete materials engineers
CONCRETE GROWTHconcrete materials engineers
Acciona Windpower (I)
International Footprint
Canada 45 MW
USA 704 MW
Mexico 555 MW
France 39 MW
Spain 1,607 MW
UK 32 MW Poland 120 MW
Greece 6 MW
Italy 68 MW
South Korea 68 MW
Australia 239 MW
Chile 60 MW
China 249 MW
CONCRETE GROWTHconcrete materials engineers
Acciona Windpower (II)
South Africa
Canada 120 MW
USA 6 MW
Mexico 258 MW
Spain 99 MW
Poland 33 MW
Brasil 330 MW
Chile 45 MW South Africa 148 MW
AW 3000 Orders and Commitments (2013)
CONCRETE GROWTHconcrete materials engineers
Acciona Windpower (III)
Current 3.0 MW WTG dimensions
• Blades:
• Length: 48m-61.5m
• Weight: 10t-12t
• Nacelle + Hub:
• Length: 17.6m
• Weight: 140t
• Tower
• Length: 87.5m-95.5m (Steel); 100m-120m (Concrete)
• Weight: 290t (95.5m Steel); 1180t (120m Concrete)
Acciona Windpower (VI)
CONCRETE GROWTHconcrete materials engineers
AWP Wind Farm in Spain
DESIGNED FOR RE-PRODUCTIONSTRONG QUALITY CONTROL SYSTEM
GOUDA WIND FARM
• 46 x 3 MW WTG’s
• 100 m high concrete tower support
structures
• Assembled from 5 by 20m cylindrical
pre-assembled units
• Final assembly onto in situ foundation
and post-tensioned
• 17 individual segments/tower
Reproduction of AWP towers as
done elsewhere in the worldCONCRETE GROWTHconcrete materials engineers
Acciona Windpower (VII)
GOUDA WIND FARM
• Individual concrete segments manufactured by
Concrete Units in Cape Town for the 1st time,
transported to Gouda
• 782 segments cast from 5 re-usable moulds
• Each segment weighs
60 tonnes
• 9 months of
precasting
Strong AWP Quality
Control SystemCONCRETE GROWTHconcrete materials engineers
Acciona Windpower (IIX)
• Semi-circular, tapered concrete element
• Building-blocks of concrete towers
CONCRETE GROWTHconcrete materials engineers
Keystones - building blocks (I)
20m
• Keystones at Concrete Units Factory in CT
CONCRETE GROWTHconcrete materials engineers
Keystones – building blocks (II)
• Top & Bottom of Keystones, horizontal joints
CONCRETE GROWTHconcrete materials engineers
Keystones – building blocks (III)
CONCRETE GROWTHconcrete materials engineers
Keystones - building blocks (IV)• Vertical joints of keystones
• Keystones being
pre-assembled
at Gouda
CONCRETE GROWTHconcrete materials engineers
Keystones – building blocks (V)
• Level 1
immediately
installed
onto foundation
• Levels 2 to 4
pre-assembled onto
trestles
• Vertical joints
grouted before
final assembly
CONCRETE GROWTHconcrete materials engineers
Keystones – building blocks (VI)
• Levels 1, 2 & 3 – 4 keystones each
• Level 4 – 3 keystones
• Level 5 – 2 keystones
CONCRETE GROWTHconcrete materials engineers
Keystones – building blocks (VII)
• Concrete Batching• Batching plant & ready-mixed concrete trucks
• Mould Set-up• 5 moulds for 782 keystones, re-used daily
• Keystones are cast horizontally
• Mould has bottom section and lid
• Reinforcement and Fixtures• 1 reinforcement design for keystones of each level
• Fixtures differ per keystone per level, depending on
position in tower
• Concrete Casting• Self-compacting concrete pumped into moulds
• Curing and Demoulding• Thermal curing up to required strength
• Demould 1 day after casting
• Final Finishing• On temporary support structure - horizontallyCONCRETE GROWTH
concrete materials engineers
Keystone Manufacture (I)
Mould Bottom with Cover Blocks
CONCRETE GROWTHconcrete materials engineers
Keystone Manufacture (III)
TO ENSURE ‘QUALITY’:
WHICH ASPECTS DO WE WANT TO
CONTROL AND WHY?
• Structural Design Requirements
• Production Requirements
• Functional Requirements for Tower
Assembly and use in Tower
CONCRETE GROWTHconcrete materials engineers
Aspects to Control (I)
Structural Design
CONCRETE GROWTHconcrete materials engineers
Aspects to Control (II)
DIMENSIONS
INPUT REQUIRED OUTPUT
MOULD DIMENSIONS GEOMETRY of KEYSTONES
MOULD DESIGN TOWER GEOMETRY
CONCRETE MATERIAL PROPERTIES
INPUT REQUIRED OUTPUT
RAW MATERIALS COMPRESSIVE STRENGTH
PROPORTIONS of RAW MATERIALS
COMPACTION
TIME of MIXING
TEMPERATURE
Structural Design
CONCRETE GROWTHconcrete materials engineers
Aspects to Control (III)
REINFORCEMENT & POST TENSIONING
INPUT REQUIRED OUTPUT
RAW MATERIALS LOAD BEARING CAPACITY
SHAPE AND SIZE - KEYSTONES during PRODUCTION PROCESSES
POSITION - FINAL TOWER
COVER TO REINFORCEMENT
INPUT REQUIRED OUTPUT
COVER DEPTH DURABILITY
LIMITS ON CRACKS
Structural Design
CONCRETE GROWTHconcrete materials engineers
Aspects to Control (IV)
JOINTS BETWEEN KEYSTONES
INPUT REQUIRED OUTPUT
GEOMETRY OF VERTICAL JOINTS
VERTICAL STRUCTURAL CONNECTION
VERTICAL JOINT REBAR
GEOMETRY OF TOP & BOTTOM OF KEYSTONE
HORIZONTAL STRUCTURAL CONNECTION
REBAR POSITION
REBAR LENGTH
REBAR STRAIGHTNESS
DUCT DIMENSIONS & LENGTH
Functional Requirements
CONCRETE GROWTHconcrete materials engineers
Aspects to Control (V)
PRE-ASSEMBLY FIXTURES
INPUT REQUIRED OUTPUT
ANCHOR BOLT CONNECTION INSERTS PROPERTIES AND POSITIONS
KEYSTONE POSITIONING during PRE-ASSEMBLY
DUCT DIMENSIONS KEYSTONE POSITION AND LEVEL IN TOWER for TOWER GEOMETRY
BOLT CONNECTION INSERTS PROPERTIES AND POSITIONS
WORKING PLATFORMS
PRE-ASSEMBLY
CONCRETE GROWTHconcrete materials engineers
Levelling tool
Prop support
fixture
Vertical joint
Aspects to Control (VI)
Platform
Functional Requirements
CONCRETE GROWTHconcrete materials engineers
Aspects to Control (VII)
LIFTING MECHANISMS
INPUT REQUIRED OUTPUT
TPA POSITION & PROPERTIES LIFT HORIZONTALLY
LIFTING LOOP DIMENSIONS & POSITIONING
LIFT VERTICALLY
FIXTURES FOR OPERATION OF TOWER
INPUT REQUIRED OUTPUT
BOLT CONNECTION INSERTS PROPERTIES & POSITIONS
ELECTRICAL CABLING
MECHANICAL LIFT
Functional Requirements
• TPA’s for lifting in horizontal position
CONCRETE GROWTHconcrete materials engineers
Aspects to Control (IIX)
Functional Requirements
• Lifting loops
• Ducts
CONCRETE GROWTHconcrete materials engineers
Aspects to Control (IX)
Manufacturing Requirements
CONCRETE GROWTHconcrete materials engineers
Aspects to Control (X)
MOULDS
INPUT REQUIRED OUTPUT
FLOWABILITY OF CONCRETE MOULD DESIGN FOR HORIZONTAL CASTING
DEMOULDING STRENGTH MOULD TURN-AROUND TIME
THERMAL CURING
SUPPORTS AFTER DEMOULDING
INPUT REQUIRED OUTPUT
DEMOULDING STRENGTH BE ABLE TO BE SUPPORTED ON TWO POINTS ONLY AFTER DEMOULDING
CONCRETE GROWTHconcrete materials engineers
Quality System Overview (I)• Engineering Specification & Design
• Functional Design and Structural Design by AWP Engineering
• Based on International Structural Design Code – Eurocode
• Captured in Engineering Drawings and Project Specifications
• Comparison with SANS and Adaption of Specification where Relevant
• Instructions• Documents describing how each action shall be performed in order to meet
the Engineering Design and Specifications
• Inspection Sheets• Documents filled in throughout each step of the process documenting the
procedures followed
• Quality Teams• Contractor – Responsible for Manufacturing according to the quality
specifications; and for documenting their procedures according to the
Quality System
• AWP Quality Team – Inspection of actual processes and checking of
documentation to ensure processes were correctly followed; coordination
with AWP Engineering team where specifications not clear or where
deviations are required for practical, local reasons
CONCRETE GROWTHconcrete materials engineers
Quality System Overview (II)• Traceability
• From Raw Material to Keystone throughout all Processes
• Tolerances• +/-
• There are no ABSOLUTES
• In line with Engineering Design & Functional Requirements
• Practically Achievable at Related Cost
• Frequency of Measurement• Initial Production
• Serial Production
• Differs per material type depending on inherent variability & application
Entire process is broken down into individual steps and each is
checked and documented against fixed, repetitive, easy-to-
check criteria
engineering specifications/drawings
CONCRETE GROWTHconcrete materials engineers
Quality System Overview (III)
engineering support
INSTRUCTIONS
INSPECTION
SHEETS
QUALITY
TEAM
CONCRETE GROWTHconcrete materials engineers
Quality System Overview (IV)SPECIFY MEASURE
&
RECORD
DESIGN
CORRECT
CANNOT
CORRECT
ok
production
deviation
specification
deviation
not ok
Inspection Sheets - Concrete
• FLOW TEST FOR
SE SELF-COMPACTING
C CONCRETE
R RECORDED ON SHEET
CONCRETE GROWTHconcrete materials engineers
Quality System
Inspection Sheets - Concrete
• Cube specimens
CONCRETE GROWTHconcrete materials engineers
Quality System
Inspection Sheets - Concrete
• Strength testing
CONCRETE GROWTHconcrete materials engineers
Quality System
Measure already cast-in ducts to
determine extent of problem
CONCRETE GROWTHconcrete materials engineers
Case Study – Ducts too small (IV)
CONCRETE GROWTHconcrete materials engineers
Case Study – Ducts too small (VI)Update Specification & Inspection Sheets
CONCRETE GROWTHconcrete materials engineers
Case Study – Too much water (IV)Confirmed by Concrete Test Result