INDUSTRIAL INSPECTION TRAINING

1
SBU-Quality Services

Inspection of
WTG Assembly & Testing
By
B.V.L. Prasad

2
 Terms

ƒ Flatness,parallelism,gap checks after bolting,runout,faceout,surface

finish(Ra,Rz),surface profile –
undulations,ovality,taper,cicularity,cylindricity,aerodyanamic lift,Torque,clamp
force,synthetic mineral grease,fits & tol. Clearance fit Interference fit.,line dori center
line marking,planetary gearbox in most areas.
ƒ The big news in Hannover came from Enercon, which presented a new generation
rotor blade, with a measured aerodynamic efficiency of 56% (Cp = 0.56). This is,
according to industry experts, six percentage points above the current state of the
art (Cp = 0.495-0.50), and a figure that challenges the Betz limit, where Cp max =
0.593. (In a series of wind tunnel experiments during the 1920s, German scientist
Albert Betz found that a maximum of 59.3% of the wind's energy could be captured.)

3
 Drive train types

Advancements in drive trains

Level 4 – Maglev, Superconductor WTG

Level 3 – Gearless (Enercon, Vensys, NewGen)

Level 2 – Multibrid (Vestas,BARD,GE,Clipper),

Hydrodynamic drives(Dewind),Hydraulic drives (Statoil),
RLE hydrodynamic drives,Artemis hydrodynamic

Level 1-traditional design-3point suspension

(Suzlon,Gamesa,Siemens etc)

4
Gearless WTG

5
Super compact drive

6
Schematic

7
Without main rotor shaft

8
3 POINT SUSPENSION TYPE wtg

9
10
11
12
13
14
15
16
17
18
19
Lube oil + radiator for gearbox

20
WTG shopfloor

21
22
Bearing induction heating

23
Main bearing – spherical roller

24
25
 Inspection of Wind Mill Components

Girder System (2.0 MW)

26
Yaw base tilting mechanism - Clipper

27
28
Polyamide

29
Thyssen slew rings (SKF,IMO are others)

30
Soft zone not present in Thyssen

31
32
33
Shrink disc

34
 Combined assembly – shaft + g.b on yaw base

ƒ Problem – stud fouling

35
Combined assembly – shaft + g.b on yaw base at site

36
Generator assembly - 1

37
Generator assembly - 2

38
Generator assembly - 3

39
SKF laser alignment check

40
Brake disc + hspacer

41
H-Spacer + composite damper

42
Winch + cheaqured plate assembly + Generator assembly complete

43
Complete Nacelle with hub

44
Complete Nacelle with hub

45
Testing – load test current/voltage readings

46
Transformer inside nacelle,Slip rings

47
Supervisory control and data acquisition

48
Nacelle cover

49
Nacelle cover

50
51
52
53
54
 Pitch drive assembly

ƒ Mounting
ƒ Backlash check

55
56
Control Panel unit - MLS

57
MLS Pitch panel+ABB power panel+ good wiring routing

58
Rajasthan wtg panels with AC

59
MLS – battery bank

60
Mita plc platform

61
Bachmann(GL certified) CANBUS Platform

62
63
ƒ Pitching types:-stall ,active pitching,morphing blades
development.

64
Wind vane + annemometers

65
Testing of Hub

66
67
Testing of Hub

68
Pitch drive yaw drive load test

69
 Advancements in
towers

Advanced
GE Wind + WASATCH
Weserwind GmbH Force Technology Concrete & steel
NREL+ With
SWAY Floating CORUS patented Offshore WindSea floating Dismantled
MIT Active
foundations tower Wind turbine Offshore wind turbine Sections.Northstar
Floating wind Magneto-rheological
towers tower towers USA.
turbines damper
Hybrid towers

70
Assembly line tools,robotics,cobotics

71
Advanced bolting mechanisms

72
73
74
75
Bolts studs with clamp sensing mechanisms – Rotabolt
Suzlon,Intellifast

76
Bolt coating check

77
Greasing guns with sensors

78
 Hydraulic hoses ,
ƒ o ring type ,ferrule type,pipe rating ,construction details ,make,visual checks,ferrule
assembly,tube cutting,

79
Lube room

80
81
Lube cart + disposible funnels

82
Advanced storing - stackers

83
Shuttle lift

84
Kone anti sway cranes

85
Kone Suzlon

86
Surveyor Safety

87
By Rahul Bhatt photo check sheet – www.qualityinwind.nl

88
Advanced material handiling

89
Nacelle with damper - esm

90
Advanced Insp. Methods-photogrammetry , laser insp. Spyglass
thermal imaging + Adaptronics

91