Structural monitoring of an onshore wind turbine foundation using strain sensors

Abstract

To date, the vast majority of onshore wind turbines are cast integrally with the foundations through embedded rings. Local damage around the bottom flange of the embedded ring was observed in a large number of existing foundations. Wind turbine foundations lack structural redundancy. The tower-foundation interface is the weak point and the deterioration of the interface will reduce the foundation’s effectiveness. This study is focused on structural health monitoring of a 1.5-MW onshore wind turbine foundation with embedded ring, on the basis of strain signals acquired continuously from the turbine foundation. A strain sensor monitoring system was installed in field to monitor the concrete status by measuring strain patterns and subsequently alerting any abnormal state of concrete in long term. It was integrated with a dynamic strain acquisition system to develop a real time relationship between the behaviour of local concrete deformation and the characteristics of loads exerted on the foundation. The performance of the foundation was simulated through numerical calculations. The results obtained from the sensors, numerical model and environmental operating data showed that the wind speed and direction dominated the loads exerted on foundation and local concrete deformation inside the foundation. The concrete deformation varied around the circumference of the embedded ring resulting from changes of wind direction and rotor position. The overall distribution pattern correlated roughly with peaks and troughs of calculated forces as well as the mean wind speed. Moreover, cracks were detected to occur in both sides of the bottom flange of the embedded ring and those cracks outside the flange were observed to fluctuate correlated to the change of wind speed. The field test demonstrates that the long-term monitoring of the local concrete deformation is necessary to ensure the safety of the foundation.