Visual and Grease Maintenance Instruction E-48 / E-53 & WW48 / WW53 WEC

VISUAL AND GREASE MAINTENANCE INSTRUCTION

Visual and Grease Maintenance

E-48/E-53 & WW48/WW53 WEC
Prepared By/Date : - Mitesh Prajapati / 30-Sept-2013
Checked By /Date : - Amit Patel / 21-Oct-2013
Approved By/Date : - Zonal Heads and WWO Head / 01-Dec-2013
Document Name :- s-ind-me-08-eng-eng-13-001 Rev000
Released Date :- 01-Dec-2013
Revision Date / No : - 01-Dec-2013/ Rev 000

WIND WORLD (INDIA) LTD;

Unit-II, Survey No 33,
Silver Industrial Estate,
Daman Patalia Road,
Bhimpore. Daman (U. T.)
India. Pin - 396 210.

Tel : +91 260 2221220, 2220628

Fax : +91 260 2220068

s-ind-me-08-eng-eng-13-001 Rev 000 Page 1 of 9

Visual and Grease Maintenance Instruction E-48 / E-53 & WW48 / WW53 WEC

Description of Maintenance Intervals

Visual Maintenance (V): -

During the visual maintenance carry out all
maintenance points described in this document and
cross them off on the maintenance checking report.

Visual + Grease Maintenance (V+G): -

During the visual + grease maintenance carry out all
maintenance points described in this document and
cross them off on the maintenance checking report.

Electrical Maintenance (E): -

Electrical maintenance is to be executed yearly once
as per the maintenance instruction.

Mechanical Maintenance (M): -

Mechanical maintenance is to be executed yearly
once as per maintenance instruction.

Note:- Interval between “Mechanical” and “Visual + Grease” maintenance shall be six month incase of
any scheduling sequence.

In addition every four / six years: -

Some maintenance points are to be executed in every four / six year maintenance cycle, which are
mentioned in this document as “every 4/6-year Mechanical maintenance”.

Additional Notes: -
All pending points of previous maintenances, applicable retrofitting, modifications and all
necessary repair work has to be carried out during this maintenance activity according to the
specified technical instructions.

Maintenance Checking Report: -

Mark the maintenance activities as follows on the checking report:-

Completed maintenance activities in totality X

Incomplete maintenance activities, points which are not completely OK or Pending O
Optional features listed against maintenance point “according to equipment” −

All requested data have to be mentioned in the “Others and Remark column” of maintenance checking
report. All remaining works and related observations to be recorded in the maintenance checking
report / remaining work plan.

Complete maintenance checking report, measurement sheet, service report & all attachments has to
be file in “Life Time File” immediately after completion of maintenance. Record the maintenance
execution details in service maintenance logbook and SAP system as well.

Technical Instructions / Information Documents: -

Follow all concerned technical instructions released after the issue date of this document. Execute the
upgrade, retrofit works during this maintenance according to specified technical instructions, and fill up
separate service report if activity is completed. Record the same in SAP system.
List down all pending modification, retrofitting and pending activities in the maintenance checking
report if it is not completed due to any specific reason.

Procedure: -
One service technician should perform the visual maintenance in the tower base and complete all
necessary documents. The second service technician has to carry out visual checks on the tower and in
the nacelle.
Supplementary operations (e.g. technical instructions) are separately listed in the maintenance
instructions. Although visual maintenance does not generally require the use of tools, it may be
necessary to take along equipment to remove protective grids or similar. Abseiling equipment should
only be used if both service technicians climb up to the nacelle.

s-ind-me-08-eng-eng-13-001 Rev 000 Page 2 of 9

Visual and Grease Maintenance Instruction E-48 / E-53 & WW48 / WW53 WEC

Document References: -

This symbol indicates that the additional technical document for individual maintenance points
needs to refer; which is mentioned in this document at necessary places. It is absolutely necessary to
follow these documents during maintenance for complete activity as stated in that particular technical
instruction!

Maintenance Points According to Equipment (Optional Feature): -

If any optional feature has been used in the turbine; then execute these applicable checking points as
stated in this maintenance instruction.

In order to optimise maintenance work; cooperation from the maintenance team is required.
Contact to the central TSS team / TSI / ASL / Site TSS team incase of any difficulty in understanding
the individual maintenance checking points, suggestion, improvements and critical points.

Safety Instructions: -

Strictly follow WWIL and national safety guidelines while executing the maintenance work. Any unsafe
act may result in material damage or personal injury. In order to avoid this, take note and comply with
all safety instructions mentioned in this document and released by SHE department. Depending on the
degree of risk, safety instructions are marked with the following symbols:

Warning Potential injury/damage as a result of non-

Symbol Meaning
Text compliance

DANGER Imminent danger Severe or mortal injury

Potentially dangerous
WARNING Serious personal injury or material damage
situation

CAUTION Danger Risk of slight or minor injury/risk of material damage

User tips and other

IMPORTANT Situation that is neither dangerous nor harmful
useful information

IMPORTANT!!!
• Take note and comply with the latest safety instructions for work in and around the wind
energy converters (WEC).
• Get issued the “Work Permit” and follow all instructions very precisely.
• Each member shall be wearing/using proper Personnel Protection Equipments (PPE).
• All team members shall be having complete knowledge about the work, the inherent work
hazards, etc. based on the concerned activity protocols / guidelines.

DANGER!!!
• Electric current passing through the human body may cause severe injuries and fatal
accident.
• Follow “Five Safety Rules” instruction and the applicable national safety regulations. Only
skilled (WWIL trained / HV line licensed) electricians may access power cabinets as well
as medium-voltage & low-voltage areas.
• Risk of fatal accidents if rotor is not locked. Work on the rotary parts and rotor brake is to
be carried out only; if the manual rotor lock has been set properly.

s-ind-me-08-eng-eng-13-001 Rev 000 Page 3 of 9

Visual and Grease Maintenance Instruction E-48 / E-53 & WW48 / WW53 WEC

WARNING!!!
• Broken machine parts may cause severe injuries, damages and fatal accident.
• Do not ascend WEC in case of wind speed >23m/sec. / thunderstorm / winch operation /
faulty ladder / not keeping healthy PPEs and safety devices incomplete.
• Maintenance work in the nacelle area may only be carried out at wind speeds up to 16m/s
over a 10-minute mean.
• Follow safety rules & use PSE while rotor & yaw movements during the test run. A turning
rotor may cause severe injuries and fatal accident.
• During the test-run in the nacelle secure yourself by a shock-absorbing lanyard to a
designated attachment point behind the main carrier.
• During the mechanical over speed switch test, no person shall remain in the nacelle or in
the top of the tower.

Complete WEC
1 • Check that the turbine is running in normal mode at the start of the maintenance.
• Listen for any abnormal noises (e.g. blade, bearing, yawing, humming sound, loose
components & so on…).
• Check stored previous status & warning messages data in the I/O board CC to know the
turbine behaviour for necessary corrective action during preventive maintenance.
• Check temperature data, feeding data, generator data, converter data, general data,
sensor data and pitch data for any abnormal behaviour / unbalance data abnormal values.
• Check that control cabinet documents are complete and in order:- Current status list,
Maintenance logbook.
Before starting the maintenance inform to the WWCC and operator /
owner about the preventive maintenance.
Complete WEC Visual Check:
¾ Note down operating hours and kwh readings, carry-out the following switching operations at
CC operating panel to stop the turbine: -
• Switch “Maintenance” to “ON” mode
• Switch “Start/Stop” to “Stop” mode
• After rpm reach at zero, switch “Manual/Automatic” to “Manual” mode
• Switch OFF the control cabinet’s “Main switch”

Visually inspect whether there are any deficiency like :

• Corrosion in components and hardware
• Mechanical damage (e.g. cracks, deformation, flaking, cable insulation damage, cable
routine and edge protection etc…)
• Leaks (of oil, water, grease)
• Missing of components or parts
• Presence of Soil / foreign objects
• Tower internal and Control cabinet lighting
If deviation found then write down in checking report.
Bolt Connection Checking of Entire WEC
2 Check every bolt and screw connection (M16 and above) visually and by knocking test.
• If any bolts do not have the required torque, check all bolt joints and determine the cause
• Check for any blackish powder observed at bolt connection.

Record the knocking test result into the maintenance checking report (Ex. Number of hardware
loose / Degree of rotation / Hardware make and batch no. etc…)

In the event of deformed or broken bolts/screws, proceed as follows:

• Check the entire bolt/screw connection, determine the cause and record in checking report.
• If any hardware/bolt/screw observed loose, slipped or damage replace complete
hardware assembly with new one.

Important: Use calibrated torque wrench only. (Mention the torque wrench serial no., calibration
certificate no. & Due date under remark column).

s-ind-me-08-eng-eng-13-001 Rev 000 Page 4 of 9

Visual and Grease Maintenance Instruction E-48 / E-53 & WW48 / WW53 WEC

Tower Base
3 Carry out visual checking of entire tower base from inside and outside.

• Tower Bottom Accessories, Safety Equipments and Warning Signs

• Tower entrance area and basement
• Foundation and grouting
• Electrical cabinets and accessories
• Basic Settings and Turbine Data Sticker
• Tower fan, station fans, Power cabinet fan and ventilation hose
• PE and earthing system of WEC
• WEC transformer and Machine external electrical area

Tower (Steel and Concrete)

Warning!!!

Falls from a height may cause severe injuries and even death!
Note down the position of a deficiency which cannot be rectified immediately. For this purpose,
count up the ladder section and its rung from the bottom. Contact service Dispatch to rectify
the damage as quickly as possible.
In the event of major defects which may endanger personnel safety, block off the safety ladder
and affix a warning sign. Inform the wind turbine operator/owner!
4 Carry out visual checking of entire tower and assembly parts.

• Check precast concrete tower as per instruction “s-me-02-eng-04-012”

• Steel Tower and Steel Section on Concrete Tower
• Safety ladder
• Platform and tower assembly parts
• Cables and cable connection, Polyamide Clamps, Cable Guide and Fastening
• Check vibration ball functioning as per instruction “s_ind-me-01-eng-eng-07-002”

Machine House

DANGER!!!
Idling rotor is very danger; if it is not locked! Obey Work Permit!!!
A turning rotor may cause severe injuries and even death.
Only work on or in the rotor head and on the rotor brake with rotor lock set.
Only access the rotor head with rotor lock set. While locking the rotor, take care that the
stopper bolt is install and rotor lock pin does not damage the rotor area and lock pin.
The rotor brake does not work if power supply fails! Keep safe distance from rotating parts!
5 Carry out visual checking of entire machine house.

• Rotor lock assembly and hydraulic unit

• Rope Winch (Material Lifting)
• Safety Equipments and Warning Signs
• Electrical cabinets and basic settings
• Check the filter cabinet fuses
• GRP Casing, Hatches
• Nacelle platform and Add on Parts
• Cabling / Lights / sockets / earth leakage circuit breaker
• Nacelle Cooling Fans and Ventilation System
• PE sliding contact and nacelle earthing system
• Main carrier, Axle pin
• Yaw control system and assembly parts
• Wind Measuring Device / Anemometer and Wind Vane / Aviation system
• Check the generator and main carrier smoke detector. Open smoke detector sensor, clean
it properly and reconnect in its housing.

s-ind-me-08-eng-eng-13-001 Rev 000 Page 5 of 9

Visual and Grease Maintenance Instruction E-48 / E-53 & WW48 / WW53 WEC

Generator
6 Switch off the main switch on the nacelle control cabinet.

Visually check generator healthiness thoroughly as stated in the generator checking instruction.
In the case of deficiencies observe complete the generator inspection report “s_ind-me-03-eng-
eng-11-001” and cross off on the maintenance checking report.

• Check for any foreign material, salt deposition, dirt and dust deposition in the generator.
Use vacuum cleaner, dry brush and cleaning materials for cleaning generator thoroughly.
• Check for any burning, blackish, brownish, smoke marks, corrosion, damage, paintwork,
coating, insulation sheet, conductor damages, crack, welding seams, spread conductor
bunching, loose connection in pole shoe mounting hardware, insulation, paint peel off,
oil/grease slippage on winding, rainwater penetration, overhung and pole shoes marking.
• Check the air gap for: Scratches, foreign objects etc…

In the case of defects or damage, complete the generator air gap measurement report and
cross off on the checking report.
Over Voltage Arrestor
7 • Check generator over voltage arrestors for correct ratings (460V) and mounting; ensure
that earthing cable is connected in-between surge arrestor and body. Visually check surge
arrestor and replace if its observe faulty (blackish, brownish, burn…).
• Check CC, PC, NCC and RSD box Overvoltage surge arrestors and replace defective /
faulty, if any.
Rotor Head
8 Carry out visual checking of entire rotor head.

• Rotor Mounted Boxes hardware, cover locking clamps and Cable Routing
• Rotor Hub and Blade Adaptor
• Spinner Support, spinner Casings, Cables
• V Rings and Bearing Seal Rings
• Pitch Gear Box and Pitch Bearing
• Spinner Fasteners, Sensors, Lamps, Hub Area and Add-on-parts
• Central lubrication system

Check the axle pin jacking hole through SRB for any grease leakage.
Note: - If leakages observed then inform immediately to the Central TSS team with photograph.

9 Slip Ring Unit:

CAUTION!!!
Possible respiratory tract irritation caused by coal dust flying around.
When working on the carbon part of the slip ring unit, Wear appropriate respiratory
protection, nose mask according to the latest safety instructions!
Before checking the slip ring unit, carry out the following switching operations on the NCC.
• Switch OFF the main switch of NCC, press the emergency stop button, disconnect SRB’s
connectors from NCC (J02 and J03) and excitation controller (J03). Switch ON the NCC
main switch for lamps.
• Check “Label” makes slip ring units as stated in the maintenance instructions “s-me-08-
ger-eng-06-001” (according to operating time – Annual, 5-Year, 10-Year maintenance).
• Use ethylic alcohol 95%, dry brush for cleaning and ensure that whether there is still a
light oil film on the SRB rings. Replace SRB PCB if its brushes observe melt, worn-out.
NOTE: - Do not open “MAINTENANCE FREE” SRB for checking and cleaning purpose!

• Check and remove if grub screw is available in front bearing jacking hole in axle pin. Align
the jacking holes of SRB flange with axle pin holes as per Instruction.

s-ind-me-08-eng-eng-13-001 Rev 000 Page 6 of 9

Visual and Grease Maintenance Instruction E-48 / E-53 & WW48 / WW53 WEC

10 Lightning Protection System: -

WARNING!
Checking of lightning protection system during thunderstorm, cloudy weather and
raining atmosphere is dangerous.
Pitching out the rotor blade may cause serious injury!
Pay attention that totally or partially pitch-in a blade may be unexpectedly pitch-out
at any time via emergency standby capacitor mode (e.g. power failure).
¾ While checking the lightning protection system of concerned rotor blade, lock the rotor so
that concerned blade A (B, C) comes at 12 O’clock.
¾ Check the lightning protection system for burn marks and damage, clean if observe smoke.
• Lightning rods for sharp tip, Discharge colour gray for corrosion and paint damages.
• Lightning protection ring for correct installation and if observe uneven; adjust it.
¾ Check the settings of the lightning protection system as follows.
• Use the “Blade A (B, C)” buttons on the NCC to manually pitch-in & pitch-out the blade.
• The distance between the blade and the lightning rod should be as close as possible; but
not less than 1mm at the narrowest point and 10mm max. in complete periphery.
• Ensure that the lightning rods do not touch the blade’s lightning protection ring.
• The lightning rod tip points to the discharge ring centre on the blade.
• Set the distance between the lightning rod and the stator ring (12 O’clock position)
between 10mm to 15mm maximum.
• The lightning rod has to point to the discharge colour (grey).
• Insulate the spinner spoke with a rubber insulation mat; if the distance between
lightning rod – rotor blade and the discharge rod – stator has observe less than 40mm!
¾ Rotate and check the rotor.
• Ensure that the lightning rods do not touches to the stator ring.
• Ensure that the total spark air gap (Discharge ring & Stator) may not exceed 25mm.
11 Static Discharge Box: -
CAUTION !!!
Ensure that there is no voltage. Use separate cable to short both ends and discharge
the voltage across static discharge box terminals.

IMPORTANT!!!
In order to check the resistance, disconnect the discharge box and discharge if the
rotor blade is statically charged.
If all discharge boxes function correctly, do not install 1mm² discharge cable!
¾ Check the resistance value of the static discharge box and record in remarks.
• Disconnect one of the connecting cables on the discharge box to check the resistance.
• Nominal value should be 50kΩ ±5kΩ.
• Check that 5-8 turn coil of discharge cable present.
¾ Reconnect the connecting cable on the discharge box for temporary purpose, If the
discharge box is observe defective; replace defective discharge box on topmost priority.
• Replace the discharge box by a static discharge cable with a cross section of 1mm² and
note down under “Others / Remarks” in the checking report that “Discharge box of blade
“A/B/C” defective, static discharge cable installed”. This is only temporary purpose, till
the defective discharge box replace.
Rotor Blade
12 Carry out visual checking of the rotor blades and assembly parts.
• Check the rotor blades for damage with binocular
• Check that the sealing brushes are correctly and securely positioned
• Check the rotor blades for paint damage, spoiler crack, V-profile, tip damage, surface
crack, sealing brushes, drainage sleeve, blade skirt, top coating, leading edge, trailing
edge, fungus, abnormal sound from blade and any other abnormalities...
Check rotor blade hardware connection visually and by knocking test.
• If any bolts do not have the required torque, check all bolt joints and determine the cause
• Check for any wear debris, blackish powder, impression of bulging and hair line crack at
T-bolt position.
In case of hardware / Nut observed loose, slipped or damage replace it with new.
• In case of deficiencies complete the rotor blades inspection report “s-ind-r-03-eng-13-001
Rev000” and cross off on the checking report.

s-ind-me-08-eng-eng-13-001 Rev 000 Page 7 of 9

Visual and Grease Maintenance Instruction E-48 / E-53 & WW48 / WW53 WEC

During Grease Maintenance:

Additionally carry out the following steps during grease maintenance.
Only use oil and grease approved by wind world (India) ltd!
Machine House
13 Yaw Gear System:

• Grease the yaw control teeth with Mobil gear OGL 461.

14 Yaw Bearing (Ball bearing slewing rim):

• Check the brass elbow for grease chock-up. Replace the permanent lubricators
(4 x SHC 460) for the ball bearing slewing rim.
Note: Confirm the actuation of lubricating tin after breaking the actuator cap and mention the
installation date on the lubricators after installation
Rotor Head
15 Centralize Lubrication System (According to Equipment):
Check the working of entire lubrication system as per instruction and fill the checking report
“s_ind-m-03-eng-eng-07-001 Rev001”.
• Check main line, secondary line, distributor, support plates, grease leakages, assembly
parts, grease tank, sealing, bosh clamps, connector, damages, pressure switch, valve
mounting and any other abnormalities

Carry the repair/stabilization work as per instruction (s_ind-me-01-eng-eng11-001 Rev000)

• Fill the grease reservoir up to the maximum mark
• Carry out a CLS test run from the pitch control box Blade-B in the “special functions”
menu under “lubrication system: t=xxx sec Start” using the acknowledge button.

Note down the cut-out pressure time and filled grease quantity in CLS tank under
“Others/Remarks” column in the maintenance checking report.
16 Hub Bearing / Blade Flange Bearing (according to equipment):

• Replace the permanent lubricators for the Front and rear bearing (3 x SHC 460 each).
• Replace the permanent lubricators for the all blade flange bearings (3 x SHC 460 each).
• Replace the permanent lubricators for additional lubrication (1 x SHC 460 each).

Note: - Mention the installation date on the lubricators after installation.

After Maintenance
17 Listen and Observe WEC for Normal Operation.

• Clear away all tools, tackles, instruments and remaining materials

• Remount all safety guard nets, close tarpaulin cover and switch off spinner lamps
• Remove rotor lock and turn the nacelle in auto mode for face turbine in the wind direction.
Check turbine any abnormal sound in idle mode
• Use the quick start button on the nacelle control cabinet to initiate a quick start and listen
to the wind turbine in normal mode
• Press the quick start button again to stop the wind turbine

• Switch off the nacelle lamps and lock NCC door

• Close all platform hatches while descending the tower

s-ind-me-08-eng-eng-13-001 Rev 000 Page 8 of 9

Visual and Grease Maintenance Instruction E-48 / E-53 & WW48 / WW53 WEC

18 Start the Wind Turbine:

Reset the WEC control system!

• Switch off the main switch on the control cabinet and switch on again after a few seconds.

Start the wind turbine from the control panel on the control cabinet:
• Set the manual/automatic switch to “Automatic”
• Set the start/stop switch to "Start". (Status message: 0:1 Turbine starting)
• Wait until the WEC automatically restarts normal operation after about three minutes
• Listen for abnormal noises
• Status message: 0:0 Turbine in operation
• Set the maintenance switch to “Off”

Lock all cabinets. Lock the wind turbine on leaving.

19 Documentation Work / Maintenance Logbook / LTF: -
• Record the maintenance operations in the maintenance logbook and fill up service report,
all concerned checking reports.
• Send report for authority checks, SAP data entry and Life Time File (LTF) records.

s-ind-me-08-eng-eng-13-001 Rev 000 Page 9 of 9