Integrating Ideas from Related Industries into ... -...
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Integrating Ideas from Related Industries into Small Wind Towers Güneş Demirbaş, P.E., M.Sc., M.ASCE President Proprietary and Confidential: The information contained in this document is the sole property of G-Tower, PLLC. Any reproduction in part or as whole without the written permission of G-Tower, PLLC is prohibited.
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Integrating Ideas from Related Industries into Small Wind Towers
Güneş Demirbaş, P.E., M.Sc., M.ASCE President
Proprietary and Confidential: The information contained in this document is the sole property of G-Tower, PLLC. Any reproduction in part or as whole without the written permission of G-Tower, PLLC is prohibited.
Brief introduction about G-Tower Related industries to small wind Integrating ideas from these industries into small wind * Finish * Fasteners, connection members * Quality control process * Manufacturing * Foundation systems * Tower accessories * Monopole vs. lattice * Special topics Conclusion
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Assisting our customers in providing secure, reliable and affordable electric energy.
G-Tower provides tower engineering, inspection, procurement and
project management services to the wind energy and electric transmission line industries.
G-Tower focuses only tower portion of wind energy and utility
projects.
G-TOWER, PLLC
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Tower Engineering Services: • Steel monopole design • Steel lattice tower design • Drafting & detailing • Design of tower accessories • Finite element analysis • Engineering review • Providing P.E. stamp • Lattice vs. pole comparison • Foundation design • Technical advisory • Technical management
Other Tower Services: • Tower supply • Fabrication inspection • Site inspection • Project management • Procurement services • After sales services • Business development • Marketing & strategy • Business plans & investors
SERVICES
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PROJECTS 2013
Wind Energy R&D
Small Wind
ElectricTransmission Line
20%
28% 52%
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What are these related industries? Electric transmission line towers Wireless structures Large wind turbine towers Lighting high mast Traffic gantry structures Proprietary and Confidential: The information contained in this document is the sole property of G-Tower,
PLLC. Any reproduction in part or as whole without the written permission of G-Tower, PLLC is prohibited.
What are the design manuals for such structures? Electric transmission line: ASCE 74 & ASCE 7-05 for structural loading ASCE 72 & ASCE 48-05 for pole design ASCE 10-97 for lattice tower design Utility scale wind: IEC WT 01 IEC 61400-1 IEC 61400-2 Wireless: TIA EIA-222-G for structural loading & design Highway structures: AASHTO 2009 for structural loading & design Lighting: CP3-TR7 & EN40 & AASHTO 2009 Small Wind: IEC 61400-2 TIA EIA-222-G-DS1
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Hot dipped galvanizing per ASTM A 123. Plenty of galvanizers in the U.S. Largest kettle dimension is 55’ x 12’ x 10.5’ in the U.S.
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Proprietary and Confidential: The information contained in this document is the sole property of G-Tower, PLLC. Any reproduction in part or as whole without the written permission of G-Tower, PLLC is prohibited.
Weathering steel is used in electric transmission line poles. Why not in small wind poles? Eliminates galvanizing period, shorten lead times in larger projects. ASTM A871 Grade 65 Aesthetics
Painting in lighting poles: only external surface paint Base coat: Hot dipped galvanize per ASTM A123 Finish coat: Urethane polyester powder or Base coat: Hot dipped galvanize per ASTM A123 Tie coat: Polyamide epoxy Finish coat: Aliphatic acrylic polyurethane Painting in utility scale wind towers: both internal and external surface paint Too large diameter to galvanize Diameter / wall thickness ratio is > 160 Out of galvanizing limitations Minimum of SSPC-SP-6 commercial sandblast Shall meet the minimum requirements of ISO 12944 Corrosivity category C3 requirements
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Electric transmission line towers face vibration like small wind towers. Lattice towers have hundreds of members and thousands of bolts to be connected.
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Spring washers and palnuts are used on each bolt in electric transmission line lattice towers. Bolts per ASTM A394 Type 1 Nuts shall be hexagonal & shall conform to ASTM A563 Grade DH Hot dipped galvanize per ASTM A153 Spring washers per ANSI B27.1 Palnuts 5/8” and ¾” diameter
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We have bolted connections in pole structures, too: • Anchor bolts: foundation connection components • Flange bolts: connections between shafts (if not slip-joint connection) Recommended pretension torque values shall be presented to installers All bolt holes shall be aligned to permit insertion of the bolts without damaging the threads. Bolts shall be placed in all holes with washers positioned and nuts threaded to complete the assembly. The snug-tightened condition is the tightest that is attained with a few impacts of an impact wrench or the full effort of a worker using an ordinary spud wrench to bring the connected plies into firm contact . Usage of torque wrench and torque meter is mandatory.
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Quality control process is very important! Manufacturing inspections, third party inspections of wind towers are commonly performed in the utility scale wind industry. Inspection-1: Production inspection; after manufacturing, before coating Inspection-2: Final inspection; prior to shipment
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What needs to be inspected? Material Check: mill certificates, mechanical and chemical test reports,
charpy requirements. Process Check: WPS, UT & MT reports, welder certifications, galvanize
thickness, toe crack check, presentation of quality manual and quality plan. Dimensional Check: Conformity to the drawings. Assembly Check: Assembly of ladders, platforms, gin-pole connections, any
other connections. Quantity check: Conformity to the bill of materials prior to shipment of tower
to the job site. The purpose of inspections is to understand and solve potential problems in the tower plant prior to shipment. The goal is to eliminate potential problems in the job sites during installations and during the life performance of towers.
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Charpy requirement: Performance of steel in cold climates • 15 ft-Ibs at -20F per ASTM A673 (commonly considered) • Frequency at each heat • Guaranteed by steel supplier Charpy requirement shall be discussed with customer according to the climate conditions in the project site.
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Welding in Pole Structures: • Weld material and acceptance criteria as specified in AWS D1.1. • Longitudinal seam weld is 60% minimum penetration. • All circumferential welds is 100% penetration (100% UT). • Longitudinal seam weld at slip-joint zone is 100% penetration (100% UT). • Presentation of WPS (welding procedure specification). • Presentation of PQR (procedure qualification record). • Presentation of welder certification stamp log. • Presentation of AWS D1.1 welding certificate. • Presentation of quality manual and plan. • Toe crack check (visual inspection after galvanize).
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Forged ring is used in utility scale wind towers to eliminate scrap cost. In the quest to become more cost competitive, the wind turbine generator OEMs are developing larger turbines to harness even more wind. This means taller towers, larger blades, and bigger drive trains. These needs translate into being able to supply larger rings and meet ever-more demanding chemical and mechanical specifications. Forged rings started to be used in high voltage transmission line poles.
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Flange facer portable machines: Flange flatness tolerance is very important in wind towers because of fatigue on bolts. Recommended flatness tolerance is between 0.1” and 1/16” depending on tower dimensions.
Proprietary and Confidential: The information contained in this document is the sole property of G-Tower, PLLC. Any reproduction in part or as whole without the written permission of G-Tower, PLLC is prohibited.
Proprietary and Confidential: The information contained in this document is the sole property of G-Tower, PLLC. Any reproduction in part or as whole without the written permission of G-Tower, PLLC is prohibited.
Proprietary and Confidential: The information contained in this document is the sole property of G-Tower, PLLC. Any reproduction in part or as whole without the written permission of G-Tower, PLLC is prohibited.
Proprietary and Confidential: The information contained in this document is the sole property of G-Tower, PLLC. Any reproduction in part or as whole without the written permission of G-Tower, PLLC is prohibited.
Proprietary and Confidential: The information contained in this document is the sole property of G-Tower, PLLC. Any reproduction in part or as whole without the written permission of G-Tower, PLLC is prohibited.
External Climbing: Step bolts Aluminum ladder McGregor ladder
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Internal Climbing: • Aluminum/steel ladder • Internal platforms • Lighting • Anchor points • Grounding • Cable routes
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Potential structure options are analyzed by preliminary engineering in order to determine the most cost effective structure in electric transmission line projects. Lattice tower or tubular pole? Self-supporting or guyed?
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In-place cost comparison shall be prepared In-place cost comparison shall include tower, installation and foundation cost estimates. Actual in-place cost of approx. 80 miles of 500 kV transmission line “OVERALL ACTUALS”
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PM/Planning/ Design
1%
Preliminary Engineering
1%
Environment 1%
Survey 2%
Land 2%
Materials 42%
State Use Tax 1%
Construction Support
0% Construction 39%
Award Fee 4%
F&I Program
Costs 7%
80 miles of 500 kV Single Circuit Line with Steel Mono Poles
Total = $92,057,398
PM/Planning/ Design
1%
Preliminary Engineering
1%
Environment 1%
Survey 3%
Land 2%
Materials 31%
State Use Tax 1%
Construction
Support 0%
Construction 48%
Award Fee 4%
F&I Program Costs 8%
80 miles of 500 kV Single Circuit Line with Lattice Towers Total = $84,006,627
Actual in-place cost of approx. 80 miles of 500 kV transmission line. “MATERIALS”
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Poles and Anchor Bolts
64%
Conductor 19%
OHGW 1%
Insulators 4% State Use
Tax 3%
Hardware and Other
Misc 9%
80 miles of 500 kV Single Circuit Line with Steel Mono Poles
Total = $39,520,784 Tower Steel
47%
Conductor 28%
OHGW 2%
Insulators 6%
State Use Tax 4%
Hardware and Other Misc
13%
80 miles of 500 kV Single Circuit Line With Lattice Towers Total = $27,412,507
Actual in-place cost of approx. 80 miles of 500 kV transmission line. “CONSTRUCTION”
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Pole Erection and Assy
9%
Foundations
26% Conductor 21%
OHGW 2%
Access Roads
8% Retirement 5%
Construction Support
4%
Contract Environmental/Cultur
al Mitigation
2%
Contract Constructio
n Manageme
nt 1%
F&I Costs 15%
Other 7%
80 miles of 500 kV Single Circuit Line with Steel Mono Poles
Total = $44,616,868
6,86
Tower Steel 25%
Foundations
15% Conductor 19%
OHGW 2%
Access Roads
7% Retirement 5%
Constructio
n 4%
Contract Environmental/Cultural Mitigation
2%
Contract Constructio
n Manageme
nt 1%
F&I Costs 13%
Other 7%
80 miles of 500 kV Single Circuit Line with Lattice Towers Total = $48,674,374
Which one better? Lattice and pole both have advantages and disadvantages However, usually lattice is more cost effective in high voltage lines (>345 kV) Pole is more cost effective in medium and low voltage lines (<345 kV) Less expensive See-through structure High stiffness Low freight cost No welding Low maintenance cost Low installation cost Bird friendly Aesthetics Less land occupation Less design risk at joints
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Vortex shedding: Estimating the wind-induced response of structures is a main topic in the area of the wind engineering research over the last 40 years. Analyses are usually carried out through theoretical formulations, numerical algorithms, wind tunnel tests, full scale experiments and code provisions.
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Dampers are used in electric transmission line towers, lighting poles and utility scale wind towers to eliminate vibration
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500kV TL Project
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Construction workers spot-welded helical strakes on each tower leg, which successfully mitigated wind-caused harmonics vibrations.
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Tilt-up function is a need in the small wind industry for the remote areas. • Hydraulic tilt-up • Gin-pole • Guyed tilt-up
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THANK YOU!
G-Tower, PLLC www.g-tower.com
(205) 616 4905 Houston, TX
G-Tower’s mission is:
To be a reliable partner in order to enhance and add value to the projects of its customers
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