Inspection of wind turbine bolted connections using the Ultrasonic Phased Array system

Mills, Brandon and Javadi, Yashar and Abad, Farhad and Lotfian, Saeid and MacLeod, Charles and Mehmanparast, Ali and Pierce, Gareth and Gachagan, Anthony (2024) Inspection of wind turbine bolted connections using the Ultrasonic Phased Array system. Heliyon. ISSN 2405-8440 (https://doi.org/10.1016/j.heliyon.2024.e34579)

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Abstract

This study explores the inspection of bolted connections in wind turbines, specifically focusing on the application of Phased Array Ultrasonic Testing (PAUT). The research comprises four sections: acoustoelastic constant calibration, high tension investigation on bolts, blind tests on larger bolts, and FEA verification. Existing inspection methods, utilizing strain gauges or single-element transducers, have limitations in comprehensiveness and cost-effectiveness. While promising calibration outcomes were observed, high-stress tests revealed unexpected nonlinear behaviour. Blind tests demonstrated differences in Time of Flight, but calculated stress remained inflated. FEA verification aligned with measurements up to preloads of 200kN, diverging thereafter. In conclusion, PAUT emerges as a promising tool for bolt inspection, offering multiple imaging modes for simultaneous stress monitoring and defect detection. The study advocates for PAUT as a robust method to enhance wind turbine safety, longevity, and future in-situ testing.

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