Bridgewater 750kW Maintenance Manual.pdf

NORWIN A/S IM-NWB(A)-User-Manual-(01)-01 Page 1 of 18

AERONAUTICA

WINDPOWER /

NORWIN

Doc. : IM-NWB(A)-User-Manual-(01)-01

Date:

File name:

19 September 2012 IM-NWB(A)-User-Manual- (01)-01

Doc. name: Instruction manual

AERONAUTICA - NORWIN wind turbines

User manual for AW 54 - 750 kW

Document ref.:

- Application Manual from Mita-Teknik

- Operation System User’s Manual from Mita-Teknik

Introduction

This user manual deals with the AW 54 - 750 kW wind turbine.

The objective of the manual is to give general information about the turbine and how it works, including a description of the necessary safety precautions for individuals inside or near the turbine as well as the turbines maintenance requirements.

Relevant sections of the user manual refer to more detailed descriptions in other manuals.

This user manual is written for the turbine owner or his representatives.

Contact information

The turbine is manufactured and sold by:

Aeronautica Windpower, LLC 11 Resnik Road Plymouth, MA 02360 www.aeronauticawind.com info@aeronautica.com

Revision no.: 01 Made by : Poul Relund (NORWIN) Date: 19 September 2012 Approved by : Tim Stearns (Aeronautical Windpower) Date: 19 September 2012 Earlier revisions:

Rev. Date Made by Checked by

DocuSign Envelope ID: BC3D6851-3981-4DC9-94FD-45326A541FD7

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Table of Contents

1.0 Safety rules and regulations for entering the wind turbine

1.1 Risk

1.2 General safety precautions

1.3 Turbines located in public area

1.4 High wind speeds, thunderstorm or risk of ice shedding

1.5 Fire in the turbine

1.6 Turbine rotation overspeed, visible loose parts, high vibrations or unusual noise

1.7 Climbing in the tower and nacelle

1.8 Safety equipment

1.9 Safety signs

2.0 Safety strategy of the wind turbine

2.1 General

2.2 The wind turbine’s safety system

2.3 The emergency stop system

2.4 The braking system and braking types

2.5 Interaction between brake systems

2.6 Monitoring of the blade pitch angle

2.7 Blade bearing exercising

2.8 Self-test and start-up procedure of the safety system

3.0 Technical description

3.1 Introduction

3.2 ASR - Active Stall Regulation

3.3 Rotor

3.4 Blade pitching system

3.5 Main frame

3.6 Shaft, bearing and gearbox arrangement

3.7 Generator arrangement

3.8 Mechanical brake system

3.9 Yaw system

3.10 Nacelle and cooling

3.11 Tower

3.12 Control panels

3.13 Mechanical locking devices

3.14 Noise

3.15 Technical data

3.16 Main components

3.17 Weights of components

4.0 Maintenance

4.1 Performance

4.2 Scope

4.3 Maintenance schedule

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1.0 Safety rules and regulations for entering the wind turbine

1.1 Risk

Entering a wind turbine can be dangerous because of the presence of high voltage, the risk of falling from heights, falling objects, and close proximity to moving or rotating components.

Therefore, only authorized personnel must enter the wind turbine!

1.2 General safety precautions

Before entering the turbine, read this user manual carefully.

The electrical system contains shock risk for high voltage, do not open the control panel.

Only trained personnel, with approved safety gear are allowed to climb the turbine tower (see section 1.7). Do not climb in tower and nacelle in case of suspicion of a defect (e.g. if unusual noise is observed). Instead, contact the maintenance company immediately.

Unauthorized personnel must not adjust the turbine in any way or make any design changes.

When leaving the turbine, the tower door must always be locked to prevent unauthorized personnel from entering into the turbine.

1.3 Turbines located in public area

Additional safety precautions must be considered if the turbine is located in an area open to the public.

An area around the turbine of minimum 30 ft. (9 m) radius must be permanently fenced in and locked for unauthorized persons.

Furthermore, the turbine owner must prepare an emergency and evacuation plan, which includes a description of the precautions to be taken in case of:

1) High wind speeds, thunderstorm or risk of ice shedding.

2) Fire in the turbine.

3) Turbine rotation overspeed, visible loose parts, high vibrations or unusual noise.

1.4 High wind speeds, thunderstorm or risk of ice shedding

Do not go near the turbine if the average wind speed is above 36 mph (16 m/s).

Leave the turbine immediately if lightning is observed in the horizon. Do not re-enter the turbine for at least 30 minutes from the last lightning sighting, and until the storm is completely out of sight.

If the blades are iced up it involves a great danger to walk below or close to the rotor. If the turbine is restarted with iced up blades it must be ensured that no persons are near the turbine, since there is danger of falling ice floes. Based on local icing conditions, the turbine owner must evaluate the site specific risk related to ice shedding or ice throw from the blades and, if necessary, install an ice detection system that keeps the turbine stopped when icing conditions occur. The turbine owner must also implement the necessary precautions to ensure that no persons are within the risk area when falling ice may occur.

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1.5 Fire in the turbine

In the event of any kind of fire in or close to the turbine, contact the local fire department.

If it is safe to enter the turbine, use the EMERGENCY STOP button on the tower control panel to stop the turbine. Turn off the main switch on the tower control panel.

Disconnect the turbine from the grid by turning off the main switch at the transformer outside the turbine. If it is not possible to disconnect at the transformer, contact the utility company to have the power shut down.

If a fire breaks out in a non-operating turbine, it can be put out with either a carbon dioxide fire extinguisher or a powder extinguisher. When the main switch is turned off, the voltage level in the generator cannot exceed 25V, no matter how fast the rotor is running.

1.6 Turbine rotation overspeed, visible loose parts, high vibrations or unusual noise

If the turbine rotation overspeeds, no one must, under any circumstances, be near the turbine.

An area around the turbine (min. 825 ft. (250 m) radius) must be evacuated and secured.

In case of visible loose parts, high vibrations or unusual noise, stop the turbine and contact the maintenance company immediately.

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1.7 Climbing in the tower and nacelle

Two persons must be present in the turbine when climbing in tower and nacelle. Either one person stays in the bottom of the tower and the other one climbs the turbine, or alternatively both persons climb the turbine at the same time. Each person must be equipped with a radio or a cell phone to be able to get in contact with each other.

If both persons are climbing the turbine, only one person is allowed to climb in the tower at a time, i.e. the first person must enter the nacelle before the second person starts climbing from the bottom of the tower ladder.

Only trained and authorized personnel must climb the turbine.

Use approved and maintained personnel safety equipment, see section 1.8.

Secure the turbine by the following steps, before climbing the tower:

1) On the tower control panel front, press the

MANUAL STOP button to stop the turbine.

Do not use the emergency stop button!

2) Activate the SERVICE MODE SWITCH (turn it clockwise).

3) After the turbine has stopped, disconnect the turbine from the grid by turning off the main switch on the control panel.

4) Each person who shall climb the turbine must mount a padlock in the main switch safety lock and hold the key in his pocket. Note: This is to make sure that nobody reconnects the turbine to the grid while a person is in the nacelle.

When climbing the tower, connect the safety harness to the glider on the tower safety rail.

Glider and harness can only be disconnected when standing on a platform and after the hatch has been closed.

When climbing up and down the tower ladder, close the hatch in each tower platform after climbing through.

Skylights in the nacelle roof and the nacelle crane hatch must not be opened.

Restart and leave the turbine immediately if the average wind speed exceeds 36 mph (16 m/s).

After climbing the turbine:

1) Remove the padlock from the main switch safety lock and turn the main switch and connect the turbine to the grid.

2) Deactivate the SERVICE MODE SWITCH (turn it counterclockwise).

3) Use the control panel display to start the turbine (see Application Manual from Mita-

Teknik). Note: Password is required to enter the control system!

MANUAL

STOP

SERVICE

MODE

SWITCH

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1.8 Safety equipment

Helmet Head light

Harness (ResQ type Q55)

Gloves

Safety shoes

Safety line with hook

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1.9 Safety signs

The following safety signs are used in the turbine.

Safety sign Sign meaning

Leave the turbine here.

(sign is placed inside the tower door)

Fire extinguisher is placed at this point.

(fire extinguisher is placed in nacelle and tower bottom)

Danger due to high voltage. Work in this area must be performed by authorized personnel only.

(sign is placed on control panels)

Wear safety harness when climbing in the turbine.

(sign is placed at ladder in the tower bottom)

Wear helmet in the turbine.

Wear protective footwear in the turbine.

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Wear protective gloves in the turbine.

Danger due to high voltage - only authorized personnel are allowed to enter the turbine.

(sign is placed outside on the tower entrance door)

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2.0 Safety strategy of the wind turbine

2.1 General

The general strategy of operation and control of the wind turbine is to operate in sequences.

First and foremost the control system continuously monitors the turbine for errors and external conditions before allowing the turbine to operate. During operation, the turbine is controlled by various active functions like blade pitching, yawing and start/stop of pumps etc. Due to the high speed that the control system is working at, all sequences will be run through approx. 50 times per second.

For the safety of the people in close proximity, and for the turbine itself, the control system is of the utmost importance.

If an error is detected by the system, it will be ranked according to severity. For each error that may occur on the turbine, a braking sequence is chosen. Simultaneously, the system may choose to shut down other functions.

Typically; the more critical the error, the faster the braking of the turbine. Any quick braking and shutdown of the turbine to a more safe condition will lead to more wear and tear of the turbine’s components.

The highest ranking is an emergency stop shutdown (brake program 200)! This will lead to blade pitch out and the rotating parts being put to a hold to the greatest possible extent.

Other errors discovered by the control system are ranked according to severity. This will result in braking actions right from an actual emergency braking over a blade braking to a normal braking.

The second-lowest ranking will generate a warning, i.e. the turbine may continue to run with an error that in the short term is not vital for the turbine lifetime and safety. This minor error will appear on the display in the tower base control panel and in the monitor program. A warning may cause the control system to change the control parameters in order to ensure that the turbine is not overloaded. So when a warning appears, a service check may be planned, but without loosing production as the turbine is not stopped.

The lowest ranking is when the system is OK. At this stage, the control system will conduct self-examination check, start-up, connection to the grid, make ASR operations, perform yawing etc.

A full description of which errors will cause the turbine to stop, and in which way, is kept in the documentation from Mita-Teknik.

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2.2 The wind turbine’s safety system

The turbine’s safety system has ONE purpose only: To put the turbine into safe condition, in case of errors.

The safety strategy for the turbine is of course part of the operating strategy, but being vital for the turbine’s life span, the most important items will be emphasized in this section.

The safety system consists of three items:

A monitoring system An activation system A braking system

The monitoring system consists of sensors reporting to the activation system. The most essential sensors, like e.g. monitoring of rotation speed, are always cross-monitored so that errors in a single sensor cannot become critical.

The activation system is under normal circumstances the control system itself. However, to ensure that an internal electrical error in the control system does not damage the turbine, an external emergency back-up system monitors the most critical parameters.

Whatever the case, the external safety chain is the highest ranking system and will in case of error disconnect the generator and activate the brake system. The system will react to: too high rotor speed, vibration sensor and activation of the emergency stop buttons.

The braking system is designed to bring the turbine to a safe stop no matter whether being activated by the control system, the external system or by absolute power interruption of the turbine.

The braking system consists of the mechanical brake and the aerodynamic brake (blade pitching). The two systems are completely independent of each other and can bring the turbine to a stop independently. In case of a severe error, both systems will be activated.

2.3 The emergency stop system

The emergency stop safety chain monitors the following:

Speed – by means of a separate over speed modules.

Nacelle vibrations – by means of an on/off sensor placed at the front end in the nacelle.

Activation of emergency stop buttons - placed in top and bottom of the turbine.

If the safety chain is broken, the main power will be disconnected. This means that both brake systems must be designed to work even during power interruption – which they are. The purpose of having an emergency stop system is that all errors that may arise and damage the turbine unquestionably will be discovered, either by the over speed sensor or the vibration sensor. To ensure that the turbine can be stopped at any time by using manual emergency stop, the emergency stop buttons are connected to the emergency stop system.

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2.4 The braking system and braking types

The braking system consists of a mechanical disc brake and an aerodynamic brake, working by pitching the blades.

The disc for the mechanical brake is mounted on the high-speed shaft, while the brake caliper is mounted on the gearbox. The brake caliper is of the fail-safe type, activated by steel springs forcing the brake pads. Deactivation of the brake is done by means of a hydraulic pressure, provided by the turbine’s hydraulic system.

To fully assure that the brake will actually work when needed; the hydraulic valves activating the brake are doubled. Further, one of the valves is equipped with an attenuation function to reduce wear and tear on the gearbox during normal non-critical braking. Wearing is continuously monitored during operation, furthermore, the brake undergoes a functional check at start-up. If an improbable situation where the mechanical brake fails; the aerodynamic brake will be able to stop the turbine on its own, and visa versa.

The aerodynamic brake makes the blades pitch in negative direction. This way, first; the load is taken off the blade so a light braking effect is obtained and second; if the blade is fully feathered, it will have a substantial braking effect. The blades are rotated by a hydraulic cylinder placed in the hub. The cylinder pressure (power) comes from either the turbine’s hydraulic station or from back-up accumulators, also placed in the hub. The system will work even with one of the pressure sources out of function and even with an error as severe as a leak in a hydraulic hose. An error on either of the two systems will bring the turbine to a stop immediately. Trying to restart the turbine, it will not be possible to get through the error check procedure and, hence, the turbine cannot be restarted. However, should the aerodynamic brake fail, the mechanical brake can bring the turbine to a stop independently.

The turbine has six different brake programs:

A detailed description of the brake programs can be found in the application manual from Mita- Teknik.

As described earlier, a more severe error will cause a more powerful braking, which will wear the turbine components more than a less powerful braking.

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2.5 Interaction between brake systems

With the mechanical brake activated and the blades in safe position (-85), relatively heavy loads on the transmission system may develop during high wind speeds. To avoid this, the mechanical brake is normally deactivated when the pitch angle is between -75 and -85. This will allow the rotor to rotate slowly.

Deactivation of the mechanical brake is performed by a special hydraulic valve with very low power consumption, activated by an electric sensor when the blades are in an angle between -75 and -85. The valve will be powered by a UPS system (battery), which will keep the valve open for up to five days, even during a complete power outage. Upon restart of the turbine, the control system will perform a self-test. This way it is also avoided that the mechanical brake accidentally is put out of operation.

For safety reasons, the personnel working in the turbine will always be able to activate an emergency stop button, so that the mechanical brake is activated immediately, regardless of the blade position.

2.6 Monitoring of the blade pitch angle

When the turbine is operating, the control system will change the pitch angles regularly. At the same time, the angle will be monitored to check that it is actually changed as expected.

The control system continuously compares the actual pitch angle with the measured pitch angle, and in case of conflict an error will occur.

2.7 Blade bearing exercising

The blade bearings are a very important part of the blade pitching system. To ensure correct lubrication of the bearings and correct application of lubrication on the ball races, the blades are turned to -20 once a day. Since this operation will cause a powerful braking effect, the generator will always be disconnected during this operation, and the rotor will go to low speed and thereafter perform a normal cut in sequence.

2.8 Self-test and start-up procedure of the safety system

During start-up of the turbine, the control system will go through a detailed self-test to ensure that the turbine’s safety system works correctly.

A detailed description of the self-test can be found in the application manual from Mita-Teknik.

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3.0 Technical description

3.1 Introduction

The AW 54 - 750 kW wind turbine is designed by NORWIN A/S in Denmark. The turbine is ASR regulated with a rotor diameter of 54 m. The turbine uses AW26 blades from Global Blade Technology. The blades can be pitched to obtain optimal operational conditions at both low and high wind speeds. This system together with our intelligent control we call: ASR - Active Stall Regulation.

3.2 ASR - Active Stall Regulation

The ASR wind turbines utilize the best things from both the stall- and the pitch regulated wind turbines. The ASR turbine has the same regulation possibilities as the pitch regulated turbine, but by using the stall properties of the blades the large load and power fluctuations that are typical for a pitch regulated machine are avoided

3.3 Rotor

Each blade is mounted on a four-point ball bearing, - mounted on the hub. Each blade is connected to the pitch mechanism inside the hub so that all three blades act simultaneously when pitching. The pitch actuator is a hydraulic cylinder placed inside the hub. The hub is mounted to the forged flange of the main shaft with bolts.

3.4 Blade pitching system

The blade pitching mechanism is placed inside the hub. The actuator is a hydraulic cylinder, supplied with pressurized oil by either a hydraulic power package, placed in the nacelle for normal operation, or an accumulator system placed in the hub, for emergency operations. The position transducer is placed in the hub parallel to the cylinder.

The hydraulic hoses with oil from the power package to the hub, is transferred through a rotating union placed on the back of the gearbox. The necessary electrical control lines are transmitted through slip-rings also placed on the back of the gearbox. In an emergency situation, the primary supply of hydraulic pressure will come from hydraulic accumulators placed inside the hub. Placed here, the system is well protected against a fire in the nacelle, and the system will also work in case of a complete pressure drop in the power package. The power package, including a separate accumulator, will serve as a secondary safety system.

3.5 Main frame

The main frame is a relatively flat welded design, which provides access from the tower to the nacelle directly through a manhole in the frame.

3.6 Shaft, bearing and gearbox arrangement

The rotor, shaft and gearbox arrangement is designed to be highly flexible for movements in the yaw and tilt directions. The main shaft is connected to the main frame at the front with a roller bearing and a bearing housing. The main bearing absorbs the axial loads of the rotor. The rear bearing is integrated in the gearbox, which is connected on both sides to the main frame with a support including a rubber element. This way, the system is supported at three places, making the load run smoothly from the rotor and into the tower. A cooler with an external fan cools the gear oil.

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3.7 Generator arrangement

The generator is mounted to the main frame behind the gearbox, opposite to the main shaft, and connected to the gear via a flexible coupling. The standard generator is an asynchronous double-wound, induction generator. Casing IP54. The isolation is in accordance with classification F, utilization with classification B.

3.8 Mechanical brake system

The mechanical brake is a spring type disc brake mounted on the high-speed shaft of the gearbox. The brake is ‘fail safe’, i.e. activated by springs when the hydraulic pressure is removed and released by use of hydraulic pressure.

3.9 Yaw system

The yaw system is a combined yaw brake and active yawing system designed in a very flexible manner so that it is possible to add additional yaw brakes if the turbine is to be erected on a very rough site. The connection between the nacelle and the tower is through a four-point ball bearing. The yaw drives are electrically driven standard units consisting of an electrical motor with brake included, a helical and a planetary gear unit. The number of yaw drives is four.

Apart from the brakes in the yaw drives, a hydraulic actuated disc brake system with a number of positive brake calipers is used. This system has a separate warning system for leakage. The yaw drives are actuated through soft starters, to equalize the torque between the motors, and to prevent a high peak torque in the starting situation.

3.10 Nacelle and cooling

The nacelle cover is made of fiber glass with steel reinforcements, and mounted to the main frame with steel supports through rubber dampers. The nacelle cover will provide standing height so that turbine maintenance may take place in protected surroundings.

3.11 Tower

The tower is a closed, conical tube tower fabricated in steel with a door at the bottom of the tower, and internal ladder and platforms at the tower flanges to ease torque tightening of flange bolts.

3.12 Control panels

The main control panel is placed inside the tower at ground level. With the possibility of adjusting selected parameters, authorized personnel can change operational limits of the turbine directly on the panel display.

It is possible to connect a laptop to the nacelle control panel to make the same control display available in the nacelle for control of the turbine during maintenance.

A battery back-up system supplies the emergency light.

Safety surveillance will monitor possible errors in the turbine and, if necessary, bring the turbine to a standstill. Should the turbine come to a standstill due to some unacceptable conditions, it will automatically restart when proper conditions have been restored, e.g. after grid failure. When errors require service, the turbine will not be able to restart until the error has been corrected.

The turbine has a number of built-in back-up functions that allow the turbine to operate even

NORWIN A/S IM-NWB(A)-User-Manual-(01)-01 Page 15 of 18 when a secondary system has broken down. These back-up functions increase the availability and make it easier to schedule maintenance of the turbine. If a secondary system has broken down, then a message will appear in the control panel display.

3.13 Mechanical locking devices

The turbine is equipped with a yaw locking device and a rotor locking device for maintenance and repair purposes.

3.14 Noise

According to experience, the high-speed shaft of the gearbox and the rotor itself are the sources of most noise from wind turbines. The rotor is the main source for broad-spectrum noise, where the sound from the gear are pure tones. The gears used in the turbine are designed from state-of-the art knowledge about how to build low noise gears and, further, each gear is tested for noise and vibration before accepted and installed into the turbine. Ventilation air through the nacelle will go through noise dampened ducts, dampening the air borne noise.

3.15 Technical data

Nominal electrical power: 200/750 kW

Power regulation: Active Stall Regulation (ASR)

Rotor diameter: 54 m

Rotor speed: 25.5 rpm at full load

Rotor: 3 blades placed upwind of tower

Swept area: 2290 m2

Tilt angle: 4.0°

Coning angle: 3.0° forward

Blades make: AW 26 – Global Blade Technology

Tip speed: 72 m/s at full load

Pitch angle: ASR

Blade bearings: 4-point ball bearings

Air brake, normal: Pitch towards -85°, actuated by the ASR regulation system

Air brake, emergency Pitch towards -85° fail safe, activated by accumulators in hub

Nominal pitch speed: 7.5°/sec

Mechanical brake: A fail-safe type disc brake

Brake torque: 1.8 times of nominal torque

Nominal generator speed: 1200/1800 rpm (60 Hz)

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3.16 Main components

1. Rotor system

2. Main shaft

3. Mainframe

4. Nacelle cover

5. Tower / top unit

6. Gearbox / transmission

7. Generator

8. Pitch system

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3.17 Weights of components

Tower for 55 m HH turbine

- bottom section 47 metric ton

- top section 25 metric ton

Tower for 65 m HH turbine

- bottom section 34.8 metric ton

- lower intermediate section 26.5 metric ton

- upper intermediate section 18.5 metric ton

- top section 12.0 metric ton

Nacelle

- main bearing housing 370 kg

- main frame 5.0 metric ton

- main shaft 2.3 metric ton

- gearbox 5.5 metric ton

- generator 3.5 metric ton

- yaw motor 110 kg

- top unit 560 kg

- nacelle, complete 25 metric ton

Rotor

- casted hub 2.4 metric ton

- blade bearing 550 kg

- hub assembly 5.0 metric ton

- AW 26 blade 2.6 metric ton

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4.0 Maintenance

4.1 Performance

Maintenance must be performed by Aeronautica Windpower certified technicians.

Observe that the maintenance must be performed as specified to maintain the turbine warranty.

4.2 Scope

The scheduled maintenance is divided into three types:

- Start-up maintenance (3-month maintenance)

- Elementary maintenance (½-year maintenance)

- Comprehensive maintenance (1-year maintenance)

4.3 Maintenance schedule

The below timeline shows the type of scheduled maintenance to be performed at a given time.

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T ur bi ne er ec ti on ye ar ar s ye ar s

NORWIN A/S IM-NWB-Maintenance-Manual-(01)-03 Page 1 of 91

Doc. : IM-NWB-Maintenance-Manual-(01)-03

NORWIN A/S

Date:

File name:

31 August 2011 IM-NWB-Maintenance- Manual-(01)-03

Doc. name: Instruction manual

NORWIN wind turbines

Maintenance manual - 750kW

Document ref.:

- User manual from C.C. ELECTRONIC

- High-speed brake manual from SVENDBORG BRAKES

- Yaw brake manual from SVENDBORG BRAKES

Introduction:

This maintenance manual specifies mandatory requirements related to maintenance of the NORWIN 750 kW wind turbine.

The target group for this specification is people working with turbine maintenance.

This specification is a part of the complete requirement package from NORWIN where documents’ order of precedence is:

1. Contract or purchase order and its attachments

2. Drawings

3. This maintenance manual

4. Other Norwin manuals

Where NORWIN manuals, specifications or drawings refer to standards, the latest edition must be used. In case of conflict between manuals, specifications or drawings and a standard, the most stringent must apply.

This maintenance manual describes minimum requirements and working in accordance with this manual does in no way relieve the contractor of the full responsibility for the turbine maintenance.

Revision no.: 03 Made by : Poul Relund Date: 31 August 2011 Checked by : Peter Olesen Date: 31 August 2011 Earlier revisions:

Rev. Date Made by Checked by 01 26 October 2009 Poul Relund Frank Nejlund 02 10 February 2011 Poul Relund Peter Olesen

NORWIN A/S IM-NWB-Maintenance-Manual-(01)-03 Page 2 of 91

Table of Contents

1.0 General

1.1 Scope

1.2 Personnel qualifications

1.3 Spare parts

1.4 Equipment and tools

1.5 Practical issues related to maintenance

2.0 Safety

2.1 General safety

2.2 Precautions in case of fire

2.3 Personnel safety equipment

2.4 Safety signs

2.5 Yaw locking device

2.6 Rotor lock

3.0 Bolts

3.1 Tools

3.2 Checking of bolt tightening

3.3 Precautions in case of significantly loose or broken bolts

3.4 Lubrication

3.5 Torque table

4.0 Control unit

4.1 Reading of error statistic

4.2 Check of temperature and pressure

4.3 Check of signal from anemometers

4.4 External visual inspection of control unit

4.5 Check of bolts’ torque

4.6 Visual inspection of switches, thermal relay cables and contactors

4.7 Replacement of contactor for 3 kW hydraulic pump

4.8 Check of main cables and multi cables

4.9 Replacement of batteries in UPS

4.10 Replacement of battery in PLC

4.11 Check of ventilation system

4.12 Replacement of air filters

4.13 Cleaning control unit inside

5.0 Capacitor bank unit (if relevant)

5.1 Check of ventilation system

5.2 Cleaning capacitor bank unit inside

5.3 Test of capacitors

6.0 Foundation

6.1 General

6.2 Bolts’ torque

6.3 Visual inspection of foundation with embedded steel section

6.4 Visual inspection of foundation with anchor flange and long foundation bolts

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7.0 Tower

7.1 Tower entrance system

7.2 Check of grounding system

7.3 Safety equipment in tower

7.4 Inspection of welds

7.5 Bolts’ torque

7.6 Check of light

7.7 Main cables

7.8 Check of main cable bolts

7.9 Cleaning

8.0 Cabin

8.1 Check of bolts

8.2 Check of anti-vibration mountings

8.3 Visual inspection of cabin

8.4 Check of light

8.5 Cleaning

8.6 Check for corrosion

9.0 Yaw system

9.1 Bolts’ torque at top unit, yaw bearing and main frame

9.2 Greasing of yaw gearing

9.3 Lubrication of yaw bearing

9.4 Verification of clearance between yaw wheel cogs and yaw gearing

9.5 Yaw gear bolts’ torque

9.6 Check of yaw encoder and tacho

9.7 Cleaning of top unit

9.8 Check of yaw gears

9.9 Check of yaw brakes

9.10 Torque check of bolts holding brake calipers

9.11 Test and adjustment of yaw cylinder

10.0 Rotor system (excl. hub inside)

10.1 Manual lubrication of main bearing

10.2 Main bearing automatic lubrication

10.3 Torque check of bolts between main bearing housing and main frame

10.4 Inspection of casted hub

10.5 Torque check of bolts between main shaft and hub

10.6 Torque check of bolts between blade bearing and hub

10.7 Lubrication of blade bearings

10.8 Check of spinner

10.9 Blade inspection

10.10 Measuring of pitch-out speed

10.11 Check of oil level in rotor lock pump

10.12 Lubrication of tubes for rotor lock

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11.0 Hub inside

11.1 Entering the hub

11.2 Torque check of bolts between blade bearing and hub extender

11.3 Torque check of blade bolts

11.4 Check of glue in guide shaft bore

11.5 Torque check of guide shaft bolts

11.6 Replacement of automatic lubrication in hub

11.7 Lubrication of triangle

11.8 Check of link arm bearings and bolts

11.9 Check of connection arm bearings

11.10 Check of pitch cylinder bearing

11.11 Check of bearing at pitch transducer

11.12 Check of accumulator supports

11.13 Accumulator pressure check

11.14 Check of bolts at hydraulic block

11.15 Cleaning of hub inside

11.16 Leaving the hub

12.0 Main gear

12.1 Check for leakage

12.2 Check for noise

12.3 Gear oil sampling

12.4 Replacement of gear oil filter (HYDAC)

12.5 Replacement of gear oil filter (HYDRA GRENE)

12.6 Replacement of off-line filter (HYDAC)

12.7 Replacement of off-line filter (HYDRA GRENE)

12.8 Check of gear oil level

12.9 Check of gear oil pressure

12.10 Check of gear oil cooler fan

13.0 High-speed brake

13.1 Visual check

13.2 Check of brake pads

13.3 Torque check

13.4 Bleeding of brake

13.5 Function test

14.0 Coupling

14.1 Visual check of coupling

14.2 Check of generator alignment

14.3 Torque check

15.0 Generator

15.1 Generator automatic lubrication

15.2 Check of main cables

15.3 Torque check of main cable bolts

15.4 Generator bolts’ torque

15.5 Generator water pressure check

15.6 Check of generator water cooler fan

15.7 Replacement of generator coolant

15.8 Replacement of generator bearings

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16.0 Hydraulic

16.1 Depressurizing the hydraulic system

16.2 Check for leakage in the hydraulic system

16.3 Check of hydraulic union

16.4 Replacement of hydraulic oil pressure filter

16.5 Replacement of hydraulic oil return filter

16.6 Replacement of hydraulic station air filter

16.7 Replacement of dehumidifier

16.8 Replacement of hydraulic oil

16.9 Check of hydraulic oil level

16.10 Accumulator pressure check

17.0 Wind vane and anemometer

17.1 Check of anemometers

17.2 Check of wind vanes

18.0 Nacelle crane

18.1 Check of nacelle crane

19.0 Electrical in nacelle

19.1 Visual inspection of electrical top box

19.2 Check of electrical swivel system

19.3 Check of grounding system

20.0 Function and sensor test

20.1 Test of cable twist sensor

20.2 Test of vibration sensor

20.3 Test of emergency stop

Maintenance report (Attachment 1)

List of equipment and tools (attachment 2)

List of consumables (attachment 3)

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1.0 General

1.1 Scope

This maintenance manual describes mandatory requirements related to scheduled maintenance of the NORWIN 750 kW wind turbine.

The scheduled maintenance is divided into three types:

- Start-up maintenance (3-month maintenance)

- Elementary maintenance (½-year maintenance)

- Comprehensive maintenance (1-year maintenance)

The below timeline shows the type of scheduled maintenance to be performed at a given time.

The minimum scope of work required for each of the three types of maintenance is listed in the maintenance report (attachment 1). The maintenance report refers to the relevant sections in this manual where detailed description of the maintenance is given.

Instructions for repairs are not included in this manual.

1.2 Personnel qualifications

Turbine maintenance must be performed by skilled personnel with a technical background, who are trained for the maintenance job.

Legal requirement to education of personnel at present in force in the country where the turbine is located must be fulfilled.

All electricity work must be performed by authorized personnel.

Personnel must read and understand this manual before start of work.

1.3 Spare parts

A list of required consumables for scheduled maintenance can be found in attachment 3.

Additional spare parts may be required based on observations done during maintenance.

When spare parts are ordered, the nacelle serial number must always be fully stated.

Also all numbers and descriptions given on the defective part must be stated, e.g. make, voltage and building size.

S ta rt -u p m ai nt en m en ta ry m ai nt en pr eh en si ve m ai nt en m en ta ry m ai nt en pr eh en si ve m ai nt en m en ta ry m ai nt en pr eh en si ve m ai nt en ur bi ne er ec ti on ar ar s ye ar s

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1.4 Equipment and tools

A list of the minimum required equipment and tools is found in attachment 2. The company responsible for turbine maintenance must evaluate the need for additional equipment and tools based on local conditions and ensure that the necessary equipment and tools are available during turbine maintenance.

Handling and lifting equipment must be manufactured, approved, maintained and used in accordance with local safety regulations and NORWIN requirements.

Measuring equipment must be calibrated before use.

Test unit from C.C. Electronic must be used in order to be able to control the turbine from the nacelle.

User manual to be obtained from

C.C. ELECTRONIC

Test unit connection to top box

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1.5 Practical issues related to maintenance

The work is estimated to require the following working capacity:

- Start-up maintenance, two operators working for 16 hours (32 hours in total)

- Elementary maintenance, two operators working for 7 hours (14 hours in total)

- Comprehensive maintenance, two operators working for 10 hours (20 hours in total)

Before start of maintenance, read the report from the last maintenance. This report may include information about additional required work scope.

The wind turbine lubrication chart is placed inside the control unit in the bottom of the tower.

Tools, lubricants etc. can be hoisted in a bag to the nacelle by use of the nacelle crane.

After maintenance, remove all rubbish and check that there are no tools left in the turbine.

During maintenance, use the maintenance report (attachment 1) as checklist. Fill in the report to document that the maintenance has been performed.

The turbine must be stopped immediately if any major errors are found (e.g. cracks in the load bearing construction, damages on the main electrical system or safety related problems).

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2.0 Safety

2.1 General safety

The maintenance company is responsible for personnel having the necessary safety education to ensure safe work during maintenance.

Working with wind turbine maintenance is dangerous and may cause injury or death, if safety precautions are not observed.

Only skilled personnel is allowed to work with wind turbine maintenance. Unauthorized personnel is not permitted in or near the working area.

Use approved and maintained safety equipment only.

Personnel working in heights must be securely fastened by safety wire to prevent falls.

When climbing the tower, use safety harness connected to the glider on the tower safety rail.

It is not allowed to stay in areas with risk of falling objects.

Observe that handling of heavy components is dangerous.

Helmet, safety shoes and gloves are mandatory.

Use eye protection in areas with risk of eye injury.

Electrical danger must be observed and working with the electrical system requires special attention. Always make sure that the turbine is disconnected from the grid when working with the high voltage system.

Do not stay beneath the rotor if the blades or the nacelle are iced up.

Leave the turbine immediately if a thunderstorm is observed in the horizon. Do not re-enter the turbine until the thunderstorm is completely out of sight.

Do not go near the turbine if the average wind speed is above 16 m/s.

When leaving the turbine, the tower door must always be locked to prevent unauthorized personnel from entering into the turbine.

The label is used in this manual where special attention must be paid to safety.

2.2 Precautions in case of fire

In the event of any kind of fire in or close to the turbine, the main switch must be turned off. If it is not possible to get to the main switch, contact the electricity company to have the power shut down.

If a fire breaks out when the turbine rotation speed is out of control, no one must, under any circumstances, be near the turbine. An area around the turbine (min. 200 m radius) must be evacuated and fenced in.

If a fire breaks out in a non-operating turbine, it can be put out with either a carbon dioxide fire extinguisher or a powder extinguisher. When the main switch is turned off, the voltage level in the generator cannot exceed 25V no matter how fast the rotor is running.

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2.3 Personnel safety equipment

Helmet Head light

Harness (ResQ type Q55)

Gloves

Safety shoes

Safety line with hook

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2.4 Safety signs

The following safety signs are used in the turbine.

Safety sign Sign meaning

Leave the turbine here.

(sign is placed inside the tower door)

Fire extinguisher is placed at this point.

(fire extinguisher is placed in nacelle and tower bottom)

Danger - only authorized personnel is allowed to climb up in the turbine.

Wear safety harness when climbing in the turbine.

Wear helmet in the turbine.

Wear protective footwear in the turbine.

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Wear protective gloves in the turbine.

or

Danger due to high voltage. Work in this area must be performed by authorized personnel only.

(sign is placed on control unit, capacitor bank unit and generator junction box)

2.5 Yaw locking device

Always use the yaw locking device (locking yaw gearing to main frame) when working on parts of the rotating yaw system, or if the yaw brake system (brakes or yaw motors) is dismantled.

The yaw locking device is placed on the tower top platform.

IMPORTANT: - The locking device must be used only up to an average wind speed of 16 m/s.

- Do not activate the yaw motors after mounting the yaw locking device.

M16 bolts

M24 nuts

Installation instruction:

1) Install the two M24 rods.

2) Lift the locking device in place.

3) Push/screw the device into place making sure that the three rods and the teeth catch correctly.

Eventually, yaw the turbine slightly (without the two pairs of teeth touching one another).

4) Push/screw the locking device into place until it is firmly fixed to the bottom of the main frame.

5) In the control unit, switch off the contactors for the yaw motors.

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2.6 Rotor lock

Always use the rotor lock when working on parts of the rotating system, or when working in the hub.

IMPORTANT:

- The rotor must be brought to a complete stop before applying the locking device.

- The rotor lock must be used only up to an average wind speed of 16 m/s.

- Always yaw the turbine 90° out of the wind.

- Make sure that the mechanical brake is applied. If this is not possible, the pitch angle should be placed in either 0° or -85°.

How to activate the rotor lock:

1) Turn the rotor until the two axles are aligned with the holes in the locking plate.

2) Turn the arm on the pump and use the handle to pump the two axles into the locking plate.

Handle

Arm

Axle

Locking plate

After use, ensure that the arm is in the “deactivate” position and that the two axles are pressed completely back into the tubes

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3.0 Bolts

3.1 Tools

Torque wrenches must be calibrated before use and with the necessary intervals to ensure the correct torque.

3.2 Checking of bolt tightening

Check of bolts’ torque must not be carried out if the surrounding temperature is below -5°C (23°F).

Tightening of bolts must be done with a smooth, steady movement. Where possible, tightening must be performed on the nut and not on the bolt head.

Where the required torque is not specified in the relevant section of this manual, find the torque in the torque table in section 3.5 based on the bolt diameter and quality class.

If the bolt is tightened correctly, it will not move when affected by the specified torque.

At “100% check”, all bolts in a joint must be checked.

At “random check”, the torque is checked on 10% of the bolts in a joint, however, at least two bolts must be checked. For each loose bolt, two extra bolts must be checked until all bolts in the joint are checked. After checking, mark the checked bolts with the date when the check was performed.

3.3 Precautions in case of significantly loose or broken bolts

If significantly loose or broken bolts are discovered in the tower, blade or hub connections after the three-month inspection, the following procedure must be adhered to:

1. Replace the bolts and tighten to the correct torque.

2. Check the torque of the two neighboring bolts. If they are loose after tightening of the replaced bolt, the neighboring bolts must be replaced too and tightened.

3. Continue this way until the neighboring bolt is not loose after replacement of the defective bolts.

Defective bolts must be replaced by bolts of same dimension, quality and surface treatment.

Bolt heads and nuts must be marked with a marker pen line after being tightened to the specified torque. Subsequently, the bolts must be checked and marked with yet another marker pen line, i.e. fully tightened and checked bolts and nuts are marked with an “X”.

After tightening

After check

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3.4 Lubrication

All new bolts above M12 must be lubricated with MOLYKOTE G-Rapid Plus Paste (grease with molybdenum disulphide).

3.5 Torque table

h re ad s iz e

Q u al it y cl as s

T or q u e [N m

T or q u e [F oo t-p ou n d h re ad s iz e

Q u al it y cl as s

T or q u e [N m

T or q u e [F oo t-p ou n d

M4

8.8 3.1 2.3

M18

8.8 210 155

10.9 4.5 3.3 10.9 300 221

12.9 5.3 3.9 12.9 350 258

M5

8.8 6.1 4.5

M20

8.8 300 221

10.9 8.9 6.6 10.9 420 310

12.9 10.4 7.7 12.9 500 369

M6

8.8 10.4 7.7

M22

8.8 400 295

10.9 15.5 11.4 10.9 570 420

12.9 18 13.3 12.9 670 494

M7

8.8 17 12.5

M24

8.8 510 376

10.9 25 18.4 10.9 730 538

12.9 30 22 12.9 850 627

M8

8.8 25 18

M27

8.8 750 553

10.9 37 27 10.9 1070 789

12.9 43 32 12.9 1250 922

M10

8.8 51 38

M30

8.8 1000 738

10.9 75 55 10.9 1450 1069

12.9 87 64 12.9 1700 1254

M12

8.8 87 64

M33

8.8 1400 1033

10.9 130 96 10.9 1950 1438

12.9 150 111 12.9 2300 1696

M14

8.8 97 72

M36

8.8 1750 1291

10.9 145 107 10.9 2500 1844

12.9 165 122 12.9 3000 2213

M16

8.8 145 107

10.9 215 159

12.9 250 184

Note: Torques for M12 and smaller bolts are based on bolts without grease (taken directly from box).

Torques for M14 and larger bolts are based on bolts lubricated with grease containing molybdenum disulphide (MOLYKOTE G-Rapid Plus Paste).

Lubricate the bolt’s thread

Lubricate the bolt’s head on the inside

Lubricate the nut on the inside

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4.0 Control unit

4.1 Reading of error statistic

4.2 Check of temperature and pressure

Analyze error codes listed in the control unit display and perform corrective action if necessary.

General: Operate the control unit keyboard/display in accordance with the manual from C.C. Electronic

Check temperatures and pressure readings in the control unit display

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4.3 Check of signal from anemometers

4.4 External visual inspection of control unit

Check the control unit for damages.

4.5 Check of bolts’ torque

Check the bolts inside the control unit, see manual from C.C. Electronic.

Check that the wind speed from both anemometers is shown in the display

High voltage!

Only authorized personnel is allowed access inside the control unit.

Turn off the main switch before opening the control unit.

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4.6 Visual inspection of switches, thermal relay cables and contactors

4.7 Replacement of contactor for 3 kW hydraulic pump

4.8 Check of main cables and multi cables

Check the main cables and the multi cables in the bottom of the tower and inside the control unit.

Perform a general check inside the control unit

Replace the contactor “K11.30” for the 3 kW hydraulic pump

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4.9 Replacement of batteries in UPS

4.10 Replacement of battery in PLC

Replacement of batteries:

1) Remove the two clips

2) Lift and turn the UPS

3) Remove the lid

4) Change the batteries inside the UPS

5) Mount lid and remount the UPS

Clip

Lid

UPS

Important: Voltage must be on, on the control unit during replacement of battery (otherwise the software will be lost)

Replacement of battery:

1) Remove the cable from the display

2) Open the cover and change the battery

3) Close the cover and remount the cable

High voltage!

Turn off main switch before opening the control unit.

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4.11 Check of ventilation system

4.12 Replacement of air filters

Replace the four air filters (see above).

4.13 Cleaning control unit inside

If necessary, clean the control unit inside.

To remove dust, use vacuum cleaner. Important: Do not use compressed air!

Check the four air filters.

Replace dirty and damaged filters

Start the two fans and check function.

The upper fan is started by setting the thermostat B10.25 below ambient temperature.

The lower fan is started by setting the thermostat B10.30 below ambient temperature.

After check, set the thermostats B10.25 and

B10.30 to 40°C

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5.0 Capacitor bank unit (if relevant)

Note: The capacitor bank may be included in the control unit.

5.1 Check of ventilation system

Check the four filters in the door and the filter in the top of the unit. Clean filters if dirty.

Check function of the two fans in the door. Start the fans by setting the thermostat B2 below ambient temperature. After check, set the thermostat to 40°C.

5.2 Cleaning capacitor bank unit inside

Clean the capacitor bank unit inside, if necessary.

To remove dust, use vacuum cleaner.