Atch 4 Maintenance Task List REV01.xlsx

XLSX spreadsheet 720 KB Posted May 8, 2023

Attached to: Vestas Wind Turbine Generator (WTG) Maintenance AMD02
Solicitation number: FA461323R0006
Issued by: Department of the Air Force Global Strike Command

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Sheet1

Location:

PREVENTATIVE MAINTENANCE CHECKLIST

V47

GREEN = Complete no further action needed. Yellow = Action suggested. Red = Task not complete action needed.

Date:

Turbine 1

Task No.

Description

Task Description

Pretension force Torque

Auxillary Notes

Interval

Hours

Material

Tools

Date and Technician Team

3 mo.

6 mo.

9 mo.

yrly

Maintaining the Hub

lubricate 3 blade bearings : all grease nipples 3 to 5 strokes

All grease nipples on the blade bearings (10 nipples/bearing) must be lubricated with grease. While lubricating the bearings, turn the blades manual from feathered to working position and back. By turning the blades, a good distribution of the grease in the bearing can be achieved. Press In each nipple 3 to 5 strokes of grease.

Maintaining the Blades

Visual check blades

Inspect for crack, corrosion, lightning damage and other damage on blade surface, Inspect if the sealing between blade flange disc and blade shell is complete. Check the Inner surface for cracks, stress whitening, and flaking. Remove any debris from all rotor blades. Repair as needed In accordance with the "surface treatments" section of the O&M manual.

Visual check blade bearing

Inspect for cracks, obstructions, and debris. Inspect the condition of the seals.Inspect if the Inside ring has no abnormal play in relation to the outside ring of the blade bearing.

Check torque nuts M30 of blades/bearing (1200 Nm) and bearing/hub (1650 Nm) + visual blade inspection

Inspect hash marks of the blade root bolted connection to the blade bearinginside the hub. Re-torque if rreeded. Re-torque if needed. Inspect for crack, corrosion, lightning damage and other damage on blade surface, Inspect If the sealing between blade flange disc and blade shell is complete. Check the Inner surface for cracks, stress whitening, and flaking. Remove any debris from all rotor blades.

Check torque nuts M36 hub/main shaft (2594 Nm)

Inspect hash marks of the nuts which connect the hub with the main shaft of the gearbox.Re-torque if needed.

Check torque nuts M30 coupling plates / bearing(1650 Nm) + play

Inspect hash marks of the nuts which connect the coupling plates to the blade bearing.Re-torque if needed.

Check torque nuts M24 triangle / coupling plates (800 Nm)t

Inspect hash marks of the nuts which connect the coupling plates to the triangle.Re-torque if needed.

Visual check seals blade bearing

Inspect for wear, damage, and corrosion. Replace if necessary.

Conservation hub

Inspect for cracks,corrosion, stress fractures,leakage.Inspect the blade roots for damage or debris.

Maintaining the Gearbox

Visual check oil level

Inspect oil level in 30 minutes after standstill,oil level should

rocate in scale mark. Add if needed.

Mobil SHC XMP 320

Check abnormal sound and vibrations

Listen for abnormal sounds outside of the normal operation of the component.

Visual check on leakage

Inspect hoses to and from gearbox,including the cooling fan.

Inspect oil filter sea.Clean if needed.

Visual check of nuts (gearbox / silenct blocs / nacelle)

Inspect location of hash marks for the bolts by which the gearbox is mounted on the nacelle for signs of movement. Re- torque, if needed, per manufacturer's specifications.

Oil sample and filtration

The oil samples have to be taken at the oil drain plug of the gearbox with the tower in service mode and above 32° F

outside temperature.

Conservation gearbox

Check the corrosion protection and look for cracks in the gearbox. Inspect for leaks around coolant pipe and fittings. Repair as needed In accordance with the "surface treatments" section of the O&M manual.

Check torque nuts (M36) gearbox/silent blocs / nacelle

Inspect hash marks of the nuts by which the gearbox with silent blocs is mounted on the nacelle. Retighten if needed.

Maintaining the Generator

Visual check of nuts (generator / silent blocs/ nacelle) and check abnormal sound

Inspect location of hash marks for the bolts by which the generator is mounted on the nacelle for signs of movement. Re-torque, if needed, per manufacturer's specifications. Listen for abnormal sounds outside of the normal operation of the component.

Lubricate the generator

Lubricate generator bearings through the two grease nipples. Each grease nipple should receive 3-5 strokes.

Check torque generator cables in connection box 30 Nm

Inspect connection (hash marks) of all bolts in the generator box. Re-torque if needed.

Check torque bolts M30 generator / silent blocs= 88 Nm (4xM16) and bolts M24 silent blocs / nacelle = 46 Nm (16xM12)

Inspect hash marks of all bolts. Re-torque if needed.

Measuring Isolation resistance

Using an ohmmeter to ensure there is no short.

Maintaining the Main Shaft, Bearings and Housing

Lubricate the Main Shaft and housing

Lubricate generator bearings through the three grease nipples. Each grease nipple should receive 10 strokes.

Check torque nuts (M36) housing/nacelle= 2800Nm + splltted ring (M20) = 200 Nm

Inspect hash marks of all nuts which connect the Main Shaft with the nacelle. Re-torque if needed. Inspect hash marks of all nuts of the splitted ring. Re-torque if needed.

Maintaining the Disc Brake

1. Visual check on wear of brake shoes and replacing, If needed: Minimum Thickness: 19 mm 2. Visual check of the air gap: 1 mm air gap on each pad 3. Checking spring package

Total air gap 2mm equally distributed on either side (1 mm). Inspect for dirt, debris, or damage to brake springs. Clean if necessary.

Check on leakage

Inspect hydraulic lines (2) to and from the hydraulic brake block. Clean and if necessary. Retighten by hand any loose hydraulic brakes lines.

Check of run up of brake disk

With the brake off, Inspect if brake disk is running up against the brake pads. The brake disk may run up smoothly against the brake pads but it may not run hot. Visually Inspect for dirt, debris, or damage on the brake disk.

Check mounting plate brake M20: 427nm

Inspect hash marks of the bolts by which the brake plate Is mounted to the nacelle. Re-torque if needed.

Maintaining the Hydraulic Unit

Hydraulic Rotary Joint :Check on leakage+ abnormal noise

Check on leakage. If a leakage is observed, disassemble the rotary joint and replace seals. Check abnormal noise. If abnormal noise can be heard, the rotary joint has to be disassembled and the bearings have to be checked. Replace bearings, if necessary.

Oil sample

The oil sample has to be taken at the measuring-coupling of the hydraulic group.

Replacement of filters (lf needed)

Two filters must be replaced, if necessary (depends on oil analysis report): High pressure filter - insert; Air filter - Insert

Check hydraulic disk brake pressure: 0 bar [BRAKE ON); 210 bar (BRAKE OUT)

Connect a manometer on the measuring coupling on the disk brake control block.

Check nitrogen pressure 38.4L: 120 bar; 0.5L: 30 bar; 10L: 80 bar; 1L: 10 bar

Using a gauge, ensure proper level of nitrogen as per manufacturer's specifications.

Maintaining the Yaw Motor

Lubricate yaw pinion and yaw bearing gears

Yaw the turbine manually while lubricating the yaw bearing gears.

Lubricate yaw bearing (Inside 6 grease nipples) 4 to 5 strokes grease during yawing

The yaw bearing has to be greased through 6 grease nipples which are mounted on the bearing and which can be reached from inside the tower. Each nipple has to be lubricated with 4 to 5 strokes of grease. Yaw the turbine manually while lubricating.Only by yawing the turbine a good distribution of the grease in the bearing can be achieved.

Check torque nuts (M24) yaw motor / nacelle = 422 Nm

Inspect location of hash marks for signs of movement. Re-torque,if needed,per manufacturer's specifications.

Lubricate bearings yaw gearboxes

Yaw the turbine manually while lubricating the yaw bearing gears by using a greasing pump (each gearbox has 1 greasing nipple).

Visual check oil level yaw gearboxes

The oil level in the yaw gearboxes has to be between the minimum and maximum mark on the oil level gauge, mounted on each gearbox.

Check torque nuts (M24) yaw motors / nacelle =422m

Inspect hash marks of the nuts by which the two yaw motors are mounted onthe nacelle. Re-torque if needed.

Molntaining the Yaw Brake

Check torque nuts (M24) brake calipers (6) I nacelle= 640 Nm

Inspect hash marks of the nuts by which the six brake calipers are mounted on the nacelle. Re-torque If needed.

Maintaining the Yaw Mechanism

Check torque nuts M27 nacelle/yaw bearing = 1250 Nm

Inspect hash marks of all nuts by which the yaw bearing is fastened against the nacelle. Re-torque if needed.

Check torque nuts M27 yaw bearing/tower = 1250 Nm

Inspect hash marks of all nuts by which the bearing Is fastened against the tower. Re-torque if needed.

Maintaining the Electric

Check torque bolts K1/K1' K2/K2' + capacitors K3 K4/K4' + resistors

Located inside the power box, visually inspect hash marks by removing cover plate inside the generator box. Retighten if needed.

Check torque bolts generator box 86Nm

All the bolts in the generator cable connection box have to be checked. Check torque bolts resistors in the power box and capacitor box. All the bolts of the resistor In the powerbox and capacitor box have to be checked if they are fastened. Visually Inspect 4 hash marks. Retighten if needed.

Visual check resistors

Inspect for damage,wear,and corrosion.

Visual check cable twist

Inspect for twisting In cables that go to the nacelle. If cables are found to be twisted,manually yaw in opposite direction to rectify twisting.

Check emergency button function

Verify proper operation of emergency button. 3 buttons in nacelle. 1 button at base control.

Testing contactors K1/K1', K2/K2', K3 and K4/K4' with keyboard

With the turbine in run mode,and as power begins to be produced,ensure that the contactors pull in cleanly.

Testing contactors K1/K1', K2/K2', K3 and K4/K4' with keyboard and emergency button on

See previous point but now with the emergency button on. The contactors may not react. There are four emergency buttons. One at the base control,one at the top control,one at the main bearing,and one at the yaw ring. Do the test with both buttons. Ensure release of the contactors.

Check all bolt- and plug connections in power-, control-, resistor and capacitor box

Check all bolt- and plug connections in the power-,control-, and capacitor box. Retighten if needed.

Check contacts K1/K1', K2/K2' and K4/K4'

Dismount the front cover of the contactors and check if all contacts are In a good state. The contacts may not be burned in.

Check emergency brake system master / backup

The emergency brake system Is mouflted between the generator and the gearbox.Depress the emergency brake system when both the generator and the rotor are at low rotation speed.

Test vibration detector

The vibration detector is mounted below the gearbox. Activate the vibration detector by moving the needle of the detector manually.

Test automatic rewinding by cable twist

With the cables untwisted, manually yaw the turbine 3.8 full revolutions. When yaw stop (S104 deactive) is reached the turbine starts to automatically untwist the cables. The turbine has to be out of service mode, because automatic yawing is not active in this mode.

Maintaining the Pitch Mechanism

Check torque of bolts • pitch cylinder/hub= 800 Nm (m24) • guiding cover/hub= 306 Nm (M24)

Inspect hash marks for movement. If needed,retighten to manufacturer's specifications.

Check pitch speed

The blade should take 1 second to pitch 10 degrees.

Maintaining the Tower

Check torque of anchor bolts

Visual inspection-of anchor bolts.

Check torque of mid flange bolts

Visual inspection of mid-flange bolts.

Gear Case: Vibration Analysis

Vibration measurements are to be recorded on the main bearings, gearbox, and generator.

NOTE:work to be done by others.

Software

Inspect error log to determine recent error activity. Perform parameter tests of turbine primary. Address any unfavorable test results.

Monitoring

Inspect SCADA in the base of the tower to determine that the screen and all activities, lights, and text shown are operating properly.

Visual check foundation

Visually check the foundation for cracks in the concrete or base section. Check the joint between the concrete foundation and base section for cracks, damage and flaking. Check the corrosion protection on base section. Touch up damaged paint work, If needed. Repair as needed in accordance with the "surface treatments" section of the O&M manual.

Visual check conservation

Inspect hash marks of bolts. Listen for abnormal sounds in each deck. Inspect paint and bolts for damage. Repair as needed in accordance with the "surface treatments" section of the O&M manual.

Visual check tower ladder

Inspect the ladder and connection for cracks or other damage. Inspect ladder splices and bolts/nuts for wear.

Air filter inside the tower door

Change the air filter inside the tower door.

Maintining the Nacelle

Conservation of the Nacelle

Inspect for damage, wear, corrosion,and leakage, where applicable, of the FAA light, lightning protection components, wind vane, anemometer, radiator, roof access hatch, seams, walls, and roof. Repair as needed in accordance with the "surface treatments" section of the O&M manual.

Visual check polyester cover

Inspect for damage such as cracks and rust on metal mountings. Check that cover Is functioning.

Maintaining Safety

SAFETY SHUTDOWN test

All emergency stop buttons are in good working order, reset each one, and verify/clear error.

EMERGENCY SHUTDOWN test

Deactivate QB button in nacelle located on side of top controller and lower controller located on front face of cabinet.

Disc brake action TRIGGER POINT test

Initiate an emergency stop to verify brake action is accurate.

CLIMB ASSIST

Inspect operations, stability, reliability annually

Maintaining the Top and Ground Controllers

Fuse Section

Check fusing and breakers. Verify all are functional.

Processors & Display Panel

Verify processor Is functionaland all lights indicate proper status.

Control Panel

Verify cooling fans are operational

Display Panel

Check alarm screen and verify no alarms are active. Go through alarm history and note repeated alarms. Troubleshoot if problem alarms are found.

Maintaining the Fenway Windform Control System

Data Processing Computer in the electric room at the pier

Open the cabinet and check the air filter- replace as needed. Check that the computer is functioning properly, by scanning through the data screens. Reference the Fenway Windfarm Control System Users Manual to troubleshoot any problems. If any faults or failures are indicated, troubleshoot the system back to the VMP controller or related PLCS, sensors or other instrumentation to correct the fault.

Fenway Communication Link

Check with TPP control room staff to ensure that all data points are being translated to the DITP PICS system.

Computer Enclosure

Verify cooling fan is operational

Lubrication Locations

Lubrication

Lubrication of all major components is a critical element of the Work. The Contractor must review the mechanical and electrical O&M manuals and the lubrication points diagram and materials chart (included as Attachment E) to ensure they are using the recommended lubricant for each component that requires lubrication; and that all lubricants are being applied at the required intervals.

Greese gun

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File details come from the government source that posted it. Updated May 8, 2023.