Development of an inflight centrifuge screw pile installation & loading system Therar A.H. Albaghdadi, Michael J. Brown & Jonathan A.
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1 Development of an inflight centrifuge screw pile installation & loading system Therar A.H. Albaghdadi, Michael J. Brown & Jonathan A. Knappett Division of Civil Engineering,, UK
2 Screw piles for offshore wind energy foundations Aims and objectives A novel approach, using screw piles (scale up geometry) for offshore wind turbine foundations. Numerical modelling FEA 2D & 3D Physical modelling - Develop 2D servo actuator. - Installation of screw piles models in flight. - Axial loading tests in centrifuge (compression & tension). Installation of onshore screw pile (photo courtesy of Iron Brothers Ltd.)
3 Screw piles for offshore wind energy foundations Upscaling onshore screw piles for offshore use Benefits over driven piles Low noise and vibration Relatively high capacity as soil-soil shear mobilized (low flange spacing) Geometry optimisation Uncertainties over upscaling Predicting torque requirements for infrastructure investment Optimising lateral performance - numerical modelling (Al-Baghdadi et al 2015)
4 Screw piles for offshore wind energy foundations Previous studies at the 1g lab test (compression) Optimization of flanges spacing ratio (S/Df) Screw pile performance under cyclic axial and lateral loading Numerical Modelling (FEA- 2D Plaxis) S/Df and Df/Dp ratios optimization Reducing D f /D p Reduce in the capacity with reducing Df/Dp S/D f =2
5 Screw piles for offshore wind energy foundations Numerical modelling of screw piles Numerical Modelling (FEA- 3D Plaxis) Enhance the lateral capacity Near surface flange effect (up to 22% increase) V-H combined loading Problems with 1g and numerical modelling (FEA) 1g lab test: scaling problems (low soil stress) FEA: screw pile wished in place (installation cannot be modelled) Approaching seabed surface
6 Centrifuge modelling of screw piles Centrifuge modelling of screw piles with single installation and loading operation In flight installation Predicting realistic installation force and torque Previous studies showed that1g installation can reduce the capacity up to 50% Centrifuge tests results of straight shafted piles installed in dense sand (Ko et al., 1984)
7 2-D servo-motor actuator system 2D actuator system for centrifuge modelling (Vertical and rotational servo actuator system) System specification Weight 131 kg Height 0.8m Max. stroke 300 mm Max. vertical speed 1.67 mm/s 8 7 Max. torque 306N.m 9 Max. capacity ±10 kn
8 Centrifuge modelling of screw pile Control system Servo control system Servo motor controller (crio-9024) AKD servo motor drivers (AKD Drivers) 2 Servo motors (AKM54H & AKM53H) NI Labview software 2013 NI-RIO 13.0 and NI soft motion module Data acquisition system (DAQ) Fylde micro analog 2 modular instrument (FE-MM8) Up to 8 transducers (2.5V - 10V) Wide rage of single amplifier (1-5000) Centrifuge cabin
9 2-D servo-motor actuator system Problems with centrifuge modelling with single installation and loading operation Cable problem: Centrifuge test at 10 g level Novatech F310-Z axial force and torque transducer (±20kN & 30Nm) Worked during 1-g test trials Problem at high g level (cable trapped due to increase cable self weight)
10 Problems with centrifuge modelling with single installation and loading operation Centrifuge test at 20, 40 & 50 g level 2-D servo-motor actuator system The cable was pre-coiled Using convoluted cable sleeving to guide the cable) Developing a new system using a slip-ring (for future centrifuge tests) Screw pile model
11 Centrifuge testing of screw piles Problems with centrifuge modelling with single installation and loading operation Screw pile model damage problem: Screw pile damaged after penetration of 280 mm in dense sand (Dr 85%) at 22g Dp= (3-6)mm ; Df= (10-20)mm ; tf = 0.75 mm Flanges no. = 3 ; S/Df=3 (Tsuha et al., 2013) Screw pile damaged after penetration of 200 mm in dense sand (Dr 73%) at 50g. Dp=10 mm ; Df= 25 mm ; tf = 1.4 mm Flanges no. = 7 ; S/Df=1
12 Centrifuge testing of screw piles Problems with centrifuge modelling with single installation and loading operation Installation force and torque of screw pile with penetration of 200 mm in dense sand (Dr 73%) at 50g. Dp=10 mm Df= 25 mm Embedment depth = 200 mm Total length = 400 mm Bottom flange damage (assumed)
13 Centrifuge testing of screw piles Flanges welded carefully with the shaft D p The shaft is one solid part Increase extension shaft diameter 1. Increasing the g level up to 50g 2. The centrifuge stabilised at 50 g 3. Installation of the screw pile to 200mm 4. Installation ends 5. Start of compression test 6. End of compression test 7. Start of tension test
14 Centrifuge testing of screw piles Centrifuge testing of screw piles in dense sand (I D =73%) Empirical factor Qu K. T Hoyt & Clemence (1989) Field tests of screw piles under compression load (Sakr, 2010) K c varied ( ) m -1 with decrease shaft and flange diameter from D p = 0.508m and D f =1.016m to D p = 0.324m and D f = 0.762m respectively. Screw pile capacities at prototype scale g level Shaft dia., D f (m) Flange dia., D f (m) Spacing ratio, S/D f Capacity in compression, Q c (kn) Installation Torque, T (kn.m) Empirical factor, K c m
15 Centrifuge testing of screw piles Effect of flange diameter to screw pile shaft diameter (at 50 g level) Single flange at the bottom Normalized flange diameter (D f /D p )
16 Centrifuge testing of screw piles Effect of flanges spacing ratio (S/Df) FE 2D Plaxis Centrifuge tests (Dr = 73%) Flange spacing optimization (S/Df) 2.0 Reducing D f /D p S/D f =2 S/D f =2.5
17 Development of an inflight centrifuge screw pile installation & loading system Conclusions: - Develop a new servo control system at the. - Carry out centrifuge tests on screw pile models at high g level (50 g) in one single operation. - High capacity can be applied (±10 kn & 30 N.m). - The empirical factor (Kc) was increased with decreasing the shaft and flange diameter of the screw pile. - The optimum flange spacing ratio (S/D f ) was found to be about 2.0 (compression).
18 Thank you for your attention!
19 References Al-Baghdadi TA, Brown M, Knappett J & Ishikura R (2015) Modelling of laterally loaded screw piles with large helical plates in sand. 3rd Int. Symp. on Frontiers in Offshore Geotechnics June 2015, Oslo, Norway Knappett J, Brown M, Brennan AJ & Hamilton L (2014) Optimising the compressive behaviour of screw piles in sand for marine renewable energy applications. Int. Conf. On Piling & Deep Foundations, Stockholm, Sweden, 21st-23rd May Ko, H. Y., Atkinson, R. H., Goble, G. G., & Ealy, C. D. (1984). Cenrifugal modelling of pile foundations. Analysis and Design of Pile Foundations (ed. J.R. Meyer), ASCE. Tsuha CH, Thorel L & Rault G (2013) A review of centrifuge model tests of helical foundations.1 st International Geotechnical Symposium on Helical Foundations. Boston, 8-10 August 2013.
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