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*Department of Mechanical and Aeronautical Engineering, University of Pretoria, 0002 Pretoria, South
Africa
Abstract
The purpose of the research presented in this paper is to obtain a design that will minimise the cost
of a steel tower for a wind turbine. The wind turbine tower investigated, is constructed from a slightly
conical ring-stiffened welded steel shell. This 45 m high shell is modelled by three stacked cylindrical
shell segments, each 15 m in length and each having constant average diameter and thickness. The wind
load is calculated according to Eurocode 1 Part 2-4. Design constraints on shell buckling and local
buckling of flat ring-stiffeners are considered. The ring-stiffeners are necessary to prevent ovalisation. To
calculate the manufacturing costs, the processing cost to form the shells into near cylindrical shapes, as
well as the cost to assemble and weld the segments, are taken into account. The cost function to be
minimised includes material and manufacturing costs. The optimum shell thickness, number of stiffeners
and dimensions of the stiffeners are calculated using Rosenbrock’s direct search method for function
minimisation complemented by an additional discretisation to account for available profiles. The results
indicate that the minimum cost solution corresponds to the minimum number of ring stiffeners. The
procedure proposed can be treated as a baseline for determining least cost designs of slightly conical
2
Corresponding author: Dr. P E Uys, Tel. +27 12 4202254, Fax. +27 12 3625087, e-mail:
petro.uys@up.ac.za
towers that meet the structural requirements of slender structures predominantly loaded by bending due to
dynamic loads.
Keywords: ring-stiffened shells, shell buckling, wind load, structural optimisation, welded structures,
manufacturing costs
1. Introduction
Design optimisation implies a search for better or more cost effective designs,
which minimise an appropriate objective function and satisfy certain design constraints.
Up-to-date engineering requires structures that have suitable load carrying capacity and
optimisation methodology has previously been developed [1] in which safety and
have to be applied.
The above approach has successfully been applied to several structural models
(welded beams, layered sandwich beams, tubular trusses, frames, stiffened plates and
shells), and industrial problems (silos, bunkers, bridge decks, a punching press table, an
aluminium truck floor, a belt-conveyor bridge) [2]. This design optimisation procedure
is now applied to determine an optimal wind turbine tower structure which features the
aspect of the structure considered is the fact that it is subjected to varying wind loads
and excitation from the turbine. To address these issues the optimisation is performed
2
for a chosen average shell segment diameter and number of stiffeners. The shell
thickness and ring stiffener thickness are the design parameters to be determined for the
optimal solution.
Wind turbines are becoming an important alternative to standard energy provision, since
wind energy costs are becoming comparable to coal and nuclear on average kWh costs
today [3]. Also the fact that wind energy is renewable and has no direct pollution related
CO2-production. The global wind industry grew by 40% p.a. during the years 1997 to
2001. Denmark is one of the countries where several research projects on the
development of wind energy resources have been pursued. In 2001 Danish wind turbine
companies supplied turbines with a rated capacity of 3000 MW. Some 40 countries use
Danish wind turbines, mainly Spain, the USA, Germany and Italy [3].
The growth in the wind industry necessitated related investigations. Fatigue loads
on wind turbines were investigated by Riziotis and Voutsinas [4]. Lavassas, Nikolaidis
and Zervas [5] analysed a prototype 1 MW steel wind turbine tower. Bazeos [6]
performed wind pressure measurements on towers. Horváth and Tóth [8] reported on
activities in wind energy in Hungary and devised a new method in wind turbine tower
design using a combined Finite Element and Fluid Dynamics Modelling approach to
Many academics and others are, however, not convinced of the viability of wind
energy as an alternative energy source to fossil and nuclear fuel [8]. Small-scale users
make up a considerable percentage of the whole [3]. Also, renewable energy sources
are considered to be more expensive than standard energy at many locations. Horváth
3
and Tóth [8] state that at present energy in Hungary is provided at half the estimated EU
foreseen. Energy costs also impact largely on production and living costs. It is therefore
very important to minimise the construction cost of wind energy generation devices.
Cost depends heavily on the wind speed at turbine sites. Designing for wind speed
implies structural requirements. This again underlines the relevance of the constrained
There are also other slender tower designs to which the mathematical optimisation
approach can be applied, such as for example TV towers [10,11], airport towers [12]
and cellular antennas [13]. Although these towers are not subject to the dynamic forces
of a rotating turbine, aerodynamic forces due to wind agitation is present. Against this
background the cost optimisation of the slender steel turbine tower being investigated
1 [14] to determine wind loads. A description of the constraints to which the system
must comply in terms of Det Norske Veritas (DNV) design rules [15] is given in section
5. Section 6 states the optimisation problem in terms of the design variables, objective
function and constraints. This is followed by the results in section 7 and conclusions
2. Problem Statement
4
The most suitable load-carrying structure for a wind turbine, is a welded steel
shell tower, which can be constructed as a tower composed of stacked cylindrical and
The aim of the present study is to formulate a methodology to optimise the design
of a 45 m high slightly conical (3.3 m at the bottom and 2.1 m at the top) ring-stiffened
shell tower with linearly varying diameter and stepwise varying thickness, subject to
wind forces and moments typical of conditions prevailing in Greece. The shell is
modelled by three stacked cylindrical segments each 15 m in length and each having a
constant average diameter, and a thickness that has to be determined (See Figure 1b).
The 15 m shell segments consist of five shell elements, height 3 m, which are welded
3. Methodology
For the cost minimisation, the procedure already developed by Farkas and Jármai [2] to
Design constraints on shell buckling and on local buckling of flat ring-stiffeners are
formulated according to DNV [15] and API [16] design rules. The wind load acting on
the shell tower is calculated according to Eurocode 1 Part 2-4 (EC1) [14]. The wind
force and bending moment acting on the top of the 45 m high tower for a 1 MW wind
turbine in Greece, is given by Lavassas et al. [5]. The load due to the self-weight of the
5
To avoid shell ovalization a minimum number of 5 and a maximum number of 15
proposed by Farkas [19] is used, which expresses the effect of radial shell deformation
The cost function includes the material and manufacturing costs. The
cost of forming shell elements from a flat plate into near cylindrical shapes, the cost of
cutting the flat ring-stiffeners, as well as the cost of assembly and welding.
The design variables in the optimisation procedure are the average thickness of
the shell segments and the dimensions and number of ring-stiffeners. The minimisation
According to the Eurocode [14] the average wind force FW (see Figure 1b) can be
(1)
r0 2
where Aref is the effective area and qref vref , (2)
2
6
with the air density r0 1.25kg / m 1.25 Nm s and the extreme wind velocity for
3 -4 2
kr
l , kr = 0.17, ct = 1, (4)
c r ct
z
c r k T ln and z0 = 0.01. (5)
z0
The values of kT,, ct and z0 are obtained for sea or level area from Table 8.1 in reference
[14]. The calculated values of ce for three characteristic heights are given in Table 1
below.
The dynamic factor related to the turbine motion for a height h = 45 m and average
c f c f 0y l , (6)
From Figure 10.8.2 in [14] , cf0 can be obtained. In Figure 10.8.2 [14] cf0 is presented
D m (z )
Re , D = 3m (7)
7
vm cr vref 1.43x36 51.48 , the viscosity of air 15 x10 -6 m 2 / s and
Re 10.3 x10 6.
From Table 10.8.1 in [14] k = 0.05, for a steel surface, thus k/D = 0.05/3 = 1.67x10-2, so
For a slenderness ratio l/D = 45/3 = 15 and for the effective area j 1 , the value of y l
The uniformly distributed wind loads for the three shell segments indicated by pw1, pw2
pw qref ce cd c f D . (8)
For the three shell segments, the wind loads are as follows: pw1 = 6.334, pw2 = 6.883 and
pw3 = 6.864 kN/m. The factored bending moments due to wind load Fw, are given in
Figure 1 (c), with M w0 = 997 kNm, the safety factor being 1.5. The factored load Fw0 =
282kN and the nacelle (rotor) self-weight Gw = 950 kN. Optimisation is performed for
the three shell segments using an average diameter and bending moment acting in the
8
hr E
�0.375 , (9)
tr fy
where tr is the ring stiffener thickness to be determined. Using the upper limit to obtain
hr = 9tr, (10)
According to Det Norske Veritas [15], for the length of one shell segment L = 15 m,
the number of ring stiffeners in one shell segment n, R the radius and t the thickness of
the shell, M pertaining to the moment on the shell segment (see Figure 1(b)): The sum
of the axial a and bending b stresses should be less than the critical buckling stress,
i.e:
Gw M w fy
a b 2 cr , (11)
2 Rt R t 1 l4
where
fy a b
l2 , (12)
a b Ea Eb
2
2E t
Ea 1.5 - 50 Ca (13)
121 - 2 Lr
2
2E t
Ea 1.5 - 50 Ca (14)
121 - 2 Lr
C a 1 r a
2
(15)
C b 1 r b
2
(16)
9
-0.5
R
r a 0.51
150t
(17)
-0.5
R
r b 0.51
300t
(18)
0.702 Z , Z
L2r
1 - 2 (19)
Rt
L
and Lr . (20)
n 1
The factor of (1.5-50 ) in Equations 13 and 14 expresses the effect of initial radial
circumferential weld is
where ATt is the area of specific strains near the weld. According to previous results of
0.3355QT 0
AT t , (22)
c0 r
10
where c0 is the specific heat, r is the material density and 0 is the coefficient of
UI
QT 0 C A Aw , (23)
vw
with 0 the coefficient of thermal efficiency, U the arc voltage, I is the arc current, vw is
the speed of welding, CA is the specific energy flow (J/mm3) related to the welding
u max
0.01 0.02 ; (27a)
4 Rt
u max u max
0.01 for < 0.01 and 0.02 for 0.02. (27b)
4 Rt 4 Rt
11
From Equations (13) and (14) it can be deduced that Ea and Eb does not depend on
Lr, since Lr2 is in the denominator and from Equations (15) and (16), Ca and Cb has Lr2 in
the numerator. The fact that the buckling strength does not depend on the shell length,
was first derived by Timoshenko & Gere [18]. Note that this dependence of E on Lr is
very small according to the API design rules [16]. It has however been determined that
in the case of external pressure, the distance between ring-stiffeners does play an
�2 �
Ar hr tr �� 2 0.06 �Lr t , (28)
�Z �
hr
R0 R - y G , yG , (30)
2(1 w )
Le t
w (31)
hr tr
and Le min Lr , Le 0 1.5 Rt . (32)
12
2 The cost function
(1) Manufacture five shell elements with a length of 3 m without rings. Two axial butt
welds (GMAW-C) are needed for every shell element. The cost to form a shell element
into a slightly conical, near cylindrical shape, is included in the factor KF0 described
below. From data obtained from the Hungarian production company Jászberényi
Aprítógépgyár, Crushing Machine Factory, Jászberény, the time T for bending a plate
(33)
(4 mm < t < 40mm and 750 mm < R < 1750 mm). In this equation, which also includes
the time to form the plate and reduce the initial imperfections due to forming, t is the
plate thickness and D is the diameter. The cost for shell formation is thus given by KF0 =
K F 1 k F W krV1 kF[1.3×0.224×10-3t2(2×3000)], (34)
13
where W is a difficulty factor expressing the complexity of the assembly and k is the
welded
(2) Weld a complete unstiffened shell segment, combining the five elements by using
four circumferential butt welds. This implies welding costs [2, 22] of
(35)
(3) Cut n flat plate rings using acetylene gas. The cutting cost amounts to [2, 22]
K F 3 k F c Cc t r 0.25 Lc , (36)
where c , Cc and Lc are respectively the difficulty factor for cutting, the cutting
Lc 2 Rn 2 R - hr n
14
(4) Weld n rings into the shell segment with double-sided GMAW-C fillet welds. (2n
K F 4 k F W n 1 rV2 1.3 0.3394 10-3 aW2 4 Rn
(38)
The size of the weld for a ring of thickness tr is aW = 0.5tr, but aWmin = 3 mm.
� h �
hr tr n .
The volume of material for a shell V2 is given by V2 5V1 2 �R - r � (39)
� 2�
K M k M rV2 . (40)
hr
K P k P S P , S P 4 R 1500 5 2 2 R - hr (41)
2
K K M 5( K F 0 K F 1 ) K F 2 K F 3 K F 4 K P . (42)
15
The material cost factor is kM = 1 $/kg, the labour cost factor is kF = 1 $/min, and the
The optimisation can be carried out using any appropriate constrained optimisation
algorithm. Here it was performed using Rosenbrock’s search algorithm [1]. The masses
It should be noted that the cost difference for the variation in number of ring
stiffeners (n = 5 to 15) is not very large (1.5 to 3.6%). The cost difference is most
The calculation of the first eigenfrequency of the optimised tower structure is made
using Eurocode 1 Part 2-4 [23] and results in 0.53 Hz. Using a simple finite element
model with a top diameter of 2.1 m, a 3.3 m base diameter, a turbine mass of 30 t, and
average diameters pertaining to every shell segment, the first eigenfrequency obtained
for the optimised geometry of the structure is 0.6 Hz without stiffeners and 0.63 Hz
when five stiffeners per section are added. The corresponding second eigenfrequencies
are 4 Hz and 6 Hz. Figure 2 (a) and (b) show respectively the shape of the tower with
stiffeners at the first and second eigenfrequencies. With a rotor frequency of 0.37 Hz
given by Lavassas et al. [5] and quoted by the Nordex company for comparable turbines
Fatigue calculations for fillet welded joints of the shell on the bottom and on the
intermediate diaphragms, are performed using the wind spectrum data of Lavassas et al.
[5]. According to Eurocode 3 Part 1-9 [24] the fatigue stress range for toe failure and for
16
thickness. The calculated safety factor is, in all cases of the spectrum, larger than the
8. Conclusions
A procedure has been developed to calculate the least cost design of a slightly
conical steel wind turbine tower that meets the structural requirements of slender
structures, predominantly loaded by bending due to dynamic loads. For the cost
optimisation both production and material costs are addressed. It is apparent from the
optimised design that the minimum cost solution corresponds to the minimum number
of ring stiffeners. Since shell thickness does not depend on the number of ring-
stiffeners, the optimal shell thickness and stiffener thickness can be calculated for
The expressions obtained from Eurocode Part 2-1 [14] for wind force calculations,
and the buckling constraint equations on ring stiffeners and ring stiffened shells derived
previously by Farkas & Jármai [22], can be applied to determine the most cost effective
structures which are structurally safe for different wind speeds. The algorithm should
however be extended to verify compliance with fatigue requirements [23] for the
welded joints of the shell on the bottom and on the intermediate diaphragms. The first
Part 2-4 [23], should also be limited to a value distant enough from the rotor excitation
frequency.
Acknowledgements
17
The research work was supported by the Hungarian Scientific Research
Foundation grants OTKA T38058, T37941 and the Hungarian - South African
Education, R&D Deputy Undersecretary of State and the South African partner is the
18
References
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Besos DE. Static, seismic and stability analyses of a prototype wind turbine
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[18] Timoshenko SP, Gere JM. Theory of elastic stability 2nd ed, New York, Toronto,
[20] Farkas J, Jármai K, Snyman JA, Gondos Gy. Minimum cost design of ring-
stiffened welded steel cylindrical shells subject to external pressure. In: Lamas A,
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Simoes da Silva L, editors, Proc 3rd European Conf Steel Structures, Universidade
shells subject to axial compression and external pressure. In: Short papers 5th World
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as a welded ring-stiffened cylindrical shell. Welding in the World 2004, 48(1/2): 37-
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[24] Eurocode 3: Design of steel structures Part 1-1, General structural rules Part 1-9:
[25] Nordex. N60/1300 kW N62/1300 kW Long term experience all over the world (as
21
Figure captions
22
Table 1. Calculated values of ce for different heights z
z (m) cr Iv ce
45 1.43 0.119 3.747
30 1.36 0.125 3.468
15 1.24 0.137 3.012
23
Table 2. Masses and costs for five ring-stiffeners
Shell Part Mass (kg) Cost without KP ($) KP ($) Total ($)
Top 5398 12096 3220 15316
Middle 9472 19772 3802 23574
Bottom 15648 30941 4389 35330
TOTAL 30518 62809 11411 74220
24
Gw
11
12
13
14
15
25
26
27