Corrosion fatigue analysis of NREL’s 15-MW offshore wind turbine with time-varying stress concentration factors

Abstract

Over the last twenty years, significant development in wind turbine technologies has led to a dramatic increase in the scale of wind turbines with many now beginning to be installed in offshore locations. Consequently, modern multi-megawatt offshore wind turbines are exposed to increased cyclic loading in addition to an increased risk of corrosion attack. The combination of these two factors may result in wind turbine support structures becoming increasingly vulnerable to fatigue corrosion. The objective of this work is to investigate the impact of material thinning in fatigue-prone areas with respect to fatigue loading and ultimately to examine the potential repercussions on the lifespan of wind turbine support structures. To achieve this, a composite model is constructed coupling results from a multi-body structural dynamic model with time-varying Stress Concentration Factors (SCF) obtained from a finite element model (FEM) of NREL’s 15-MW monopile-based offshore wind turbine. The nonlinear aeroelastic multi-body dynamic model of the wind turbine is used to generate stress time histories for a set of environmental conditions based on the operational conditions of the wind turbine. The finite element model of the wind turbine is then used to identify fatigue-vulnerable regions in the wind turbine support structure and calculate SCFs for these specific areas. The integration of SCFs into the fatigue calculations reduced the lifespan of the turbine tower by a factor of 4, demonstrating the importance of precisely modelling such local stress concentrations for effective fatigue analysis. A novelty of this work arises in the ability of the finite element model to update the SCFs of the fatigue-prone areas over time as corrosion-induced wastage alters the substructure’s geometry, thereby inducing a global redistribution of stresses. A fatigue analysis is carried out availing of the SCFs which vary annually in addition to the stress-time histories produced by the multi-body dynamic model. The results illustrate that the phenomenon of corrosion thinning induced an 8.9% reduction in the fatigue life of the wind turbine tower, thus emphasising the significant importance of proactive maintenance strategies to mitigate the impact of corrosion.