report turbine inspection wtg 15976, waardtocht 4...wind turbine inspection waardtocht 4 wtg 15976...
TRANSCRIPT
11-11-2015
Report Turbine inspection
WTG 15976, Waardtocht 4
Report No. V662015046
Wind turbine inspection Waardtocht 4 WTG 15976
Date: 11-11-2015 Page 2 of 20
Contents
1 Purpose ................................................................................................................................... 3
2 Abbreviations ........................................................................................................................... 3
3 General information ................................................................................................................. 4
4 Wind turbine main components ............................................................................................... 4
5 Documents ............................................................................................................................... 5
6 Logbook: Overview of recent maintenance .............................................................................. 6
7 Logbook: Transformer ............................................................................................................. 6
8 Logbook: Notable events ......................................................................................................... 6
9 Tower and towerbase .............................................................................................................. 7
10 Yaw system .......................................................................................................................... 8
11 Cabinets nacelle ................................................................................................................... 9
12 Nacelle ............................................................................................................................... 10
13 Gearbox and main shaft ..................................................................................................... 12
14 Generator and coupling ...................................................................................................... 14
15 Hydraulic system nacelle .................................................................................................... 15
16 Rotor .................................................................................................................................. 16
17 Conclusion .......................................................................................................................... 20
Wind turbine inspection Waardtocht 4 WTG 15976
Date: 11-11-2015 Page 3 of 20
1 Purpose
On behalf of Vattenfall an inspection has been executed on the wind turbine. The purpose of the inspection is to
determine the technical state of the wind turbine.
2 Abbreviations
ok okay
nok not okay
na not applicable
nav not available
nc not checked
info for information purpose
Items marked with “ok” and “info” show no visual irregularities. All issues which are not acceptable are marked
with “nok”. Items which are “nok” will be classified in three different classes.
Class Clarification Description in report
Priority Low An irregularity, which is not a safety issue, and is relatively easy to solve.
Low
Priority High An irregularity, which is not a safety issue, and is more serious and is more time and/or money consuming to solve.
High
Safety Issue Issues which concern the safety of the people working in the turbine.
Safe
Wind turbine inspection Waardtocht 4 WTG 15976
Date: 11-11-2015 Page 4 of 20
3 General information
Wind turbine name: Waardtocht 4
Wind turbine type: V66 – 1750KW – 690V/50HZ – R7035
Wind turbine S/N: 15976
Location: Middenmeer
Hub height: 78
Total production [kWh]: 20439703 (according to display)
Total hours: 45201 (according to display)
Nominal power [kW]: 1750
Year of installation: 2003
Date of inspection: 02-11-2015
Inspectors: P. den Braber
D. Lagerweij B. van de Braak J. Langenbach
4 Wind turbine main components
Component Type Year Serial number
Nacelle V66 – 1750KW – 690V/50HZ – R7035 2002 769402-46-02-66307
Gearbox Winergy PEAB 4395 2006 4809519 – 0020 - 4
Revision gearbox - - -
Gearbox oil Castrol Alphasyn PG 320 2007 -
Generator ABB AMK 500L 4A BATYH 2005 4581390
Blade 1 Vestas 32B - 35247
Blade 2 Vestas 32B - 20527
Blade 3 Vestas 32B - 20533
Wind turbine inspection Waardtocht 4 WTG 15976
Date: 11-11-2015 Page 5 of 20
5 Documents
Component Remark
1 Operator manual Operating manual is available at the turbine.
Machine directive 2006/45/EC, 1.7.4.2 states as part of the Contents of
instructions:
“(e) the drawings, diagrams, descriptions and explanations necessary for the
use, maintenance and repair of the machinery and for checking its correct
functioning;”
ok
2 Wiring diagram Wiring diagrams are not available at the turbine.
Machine directive 2006/45/EC, 1.7.4.2 states as part of the Contents of
instructions:
“(e) the drawings, diagrams, descriptions and explanations necessary for the
use, maintenance and repair of the machinery and for checking its correct
functioning;”
nok
3 Hydraulic diagram Hydraulic diagrams are not available at the turbine.
Machine directive 2006/45/EC, 1.7.4.2 states as part of the Contents of
instructions:
“(e) the drawings, diagrams, descriptions and explanations necessary for the
use, maintenance and repair of the machinery and for checking its correct
functioning;”
nok
4 Maintenance manual Maintenance manual is not available at the turbine.
Machine directive 2006/45/EC, 1.7.4.2 states as part of the Contents of
instructions:
“(e) the drawings, diagrams, descriptions and explanations necessary for the
use, maintenance and repair of the machinery and for checking its correct
functioning;”
nok
5 Logbook Logbook is available at the turbine. ok
Wind turbine inspection Waardtocht 4 WTG 15976
Date: 11-11-2015 Page 6 of 20
6 Logbook: Overview of recent maintenance
Year Type of maintenance Date of execution Maintenance schedule
Commissioning 02-2003 2003
… … … …
9 E- 36 month service 16-02-2012 2012
9½ B - 6 month service 31-08-2012
10 G - 60 month service 11-04-2013 2013
10½ B - 6 month service 30-08-2013
11 M – 11 year service 13-03-2014 2014
11½ B - 6 month service 20-08-2014
12 N – 48 month service no service record 2015
12½ B - 6 month service 19-08-2015
7 Logbook: Transformer
Date Event
… …
25-03-2013 Transformer inspection
24-02-2014 Transformer inspection
25-02-2015 Transformer inspection
8 Logbook: Notable events
Date Event
29-01-2007 Gearbox exchange
11-01-2007 Gear oil exchanged Castrol Alphasyn PG 320
13-05-2014 Replaced DE and N-DE bearing generator
30-04-2015 Plain and sliding bearings replaced (blade A, B and C)
Wind turbine inspection Waardtocht 4 WTG 15976
Date: 11-11-2015 Page 7 of 20
9 Tower and towerbase
Item Remark
1 Outside ok
2 Inside Bolt of the support of the tower cables is missing (arrow).
nok
Low
3 Towerbase HV-switch overview
Info
4 Towerbase cabinet overview
Info
5 Miscellaneous The cover of the light in the tower is not mounted.
nok
Safe
Wind turbine inspection Waardtocht 4 WTG 15976
Date: 11-11-2015 Page 8 of 20
10 Yaw system
Item Remark
1 Yaw bearing overview
Info
2 Yaw ring teeth
Yaw ring shows no irregularities.
ok
3 Yaw pinions Yaw pinions show no irregularities.
ok
4 Yaw gears Yaw gear at the front at the right is leaking (arrow).
nok
Low
Wind turbine inspection Waardtocht 4 WTG 15976
Date: 11-11-2015 Page 9 of 20
11 Cabinets nacelle
Item Remark
1 Controller The controller is not modified/reinforced.
nok
High
2 Connection boxes ok
3 Cooling system Minor leakage at the coupling of the cooling system.
Radiator housing of the cooling of the convertor is corroded.
nok
Low
Wind turbine inspection Waardtocht 4 WTG 15976
Date: 11-11-2015 Page 10 of 20
12 Nacelle
Item Remark
1 Nacelle overview
Info
2 Frame Turbine is equipped with a welded frame.
Info
3 Nacelle housing Parts of the insulation are missing or damaged.
nok
Low
4 Weather station
Info
Wind turbine inspection Waardtocht 4 WTG 15976
Date: 11-11-2015 Page 11 of 20
5 Miscellaneous Insulation in the cooling duct on the roof is blocking the air flow.
nok
Low
6 Miscellaneous Minor corrosion visible at the bracket at the left at the front of the nacelle.
Cover of the light is broken.
nok
Low
Wind turbine inspection Waardtocht 4 WTG 15976
Date: 11-11-2015 Page 12 of 20
13 Gearbox and main shaft
Item Remark
1 Main shaft bearings
Grease of the front bearing is dark and magnetic.
nok
High
2 Radiators
ok
3 Manifold Oil present at the manifold and there is also oil visible on the plate under the manifold.
nok
High
4 CCJ-unit CCJ-filter is leaking and the connection box is mounted with cable ties.
nok
Low
Wind turbine inspection Waardtocht 4 WTG 15976
Date: 11-11-2015 Page 13 of 20
5 Gear oil system ok
6 Hoses and pipes Leakage at the pipes of the mechanical oil pump. An absorbing rag is already placed by the maintenance team.
nok
High
7 Torque-arms Torque-arm system has been modified.
Info
8 Paint / Corrosion ok
9 Brake-system overview
Info
10 General leakage
Due to leakage of the gearbox, the frame is covered with oil.
nok
High
Wind turbine inspection Waardtocht 4 WTG 15976
Date: 11-11-2015 Page 14 of 20
11 Miscellaneous Hydraulic coupling is covered with oil. The plug of the low pressure reservoir also not tightened correctly.
nok
Low
14 Generator and coupling
Item Remark
1 Coupling The composite parts of the coupling are in an acceptable condition.
ok
2 Paint / Corrosion ok
3 Slip ring The slip ring shows no visual irregularities. It is remarkable that the earth pin is
equipped with only one brush.
Info
Wind turbine inspection Waardtocht 4 WTG 15976
Date: 11-11-2015 Page 15 of 20
4 Miscellaneous Cables of the automatic grease unit of the generator are not mounted correctly.
nok
Low
15 Hydraulic system nacelle
Item Remark
1 Overview
Info
2 Hoses ok
3 Leakage Leakage present near the rotation unit. It is also possible that the oil is from
leakage in the hub.
nok
Low
4 Corrosion ok
Wind turbine inspection Waardtocht 4 WTG 15976
Date: 11-11-2015 Page 16 of 20
16 Rotor
Item Remark
1 Overview
Info
2 Paint / Corrosion Some corrosion present at the entrance of the hub and minor damage at the paint in the hub.
nok
Low
3 Connection spinner
Connection has not been reinforced. No cracks detected in the tubes (See 16.2).
ok
4 Hub cabinet
overview
Info
Wind turbine inspection Waardtocht 4 WTG 15976
Date: 11-11-2015 Page 17 of 20
5 Connections cylinder to the
blade
The clearance of the link bearings of pitch cylinders A, B and C are 0,04 [mm], 0,07 [mm] and 0,09 [mm]. This is acceptable according to the Vestas Manual.
ok
6 Connections cylinder to the
hub
The clearance of the slide bearings of pitch cylinders A, B and C are 0,40 [mm], 0,43 [mm] and 0,47 [mm]. This is acceptable according to the Vestas Manual.
ok
7 Hydraulics inside
the hub
ok
Wind turbine inspection Waardtocht 4 WTG 15976
Date: 11-11-2015 Page 18 of 20
8 Hydraulics outside the hub
ok
9 Blade bearings Minor pollution with grease from the blade bearings.
nok
Low
10 Blade covers One cover is starting to open.
nok
Low
11 Blades overview Green pollution visible on the surface of the blades.
Protective tape at the leading edge of the blades is damaged (arrows).
nok
High
Wind turbine inspection Waardtocht 4 WTG 15976
Date: 11-11-2015 Page 19 of 20
12 Miscellaneous A bolt is missing in the plate of blade A.
Protective sleeve of the piston of blade B is damaged.
Lightning cable of blade C is damaged.
nok
Low
Wind turbine inspection Waardtocht 4 WTG 15976
Date: 11-11-2015 Page 20 of 20
17 Conclusion
The logbook shows that the turbine and the transformer have been maintained on a regular basis, according to
the maintenance schedule of Vestas.
The gearbox has been exchanged in 2007. There are no indications that the generator has been replaced and
the bearings of the generator are replaced in 2014.
The link and sliding bearings of the pitch cylinders have been replaced in 2015.
The protective tape on the leading edge of the blades is damaged at all three blades.
The overall condition of the turbine is quite acceptable for a twelve year old turbine. There are however several
issues (marked as nok in this report) present and it is recommended to solve these, in order to improve the
condition of the turbine.
D. Lagerweij
11-11-2015
TeSuCon B.V.
Mercuriusweg 8 3771NC Barneveld +31610032858 [email protected] www.tesucon.nl
16-11-2015
Report Gearbox inspection
WTG 15976, Waardtocht 4
Report no. V662015086
Gearbox inspection Waardtocht 4 WTG 15976
Date: 16-11-2015 Page 2 of 14
Contents
1. Purpose ............................................................................................................. 3
2. General Information .......................................................................................... 3
3. Reporting setup ................................................................................................. 4
4. Inspection results ............................................................................................. 5
5. Summary ......................................................................................................... 14
6. Conclusion ....................................................................................................... 14
Gearbox inspection Waardtocht 4 WTG 15976
Date: 16-11-2015 Page 3 of 14
1. Purpose
On behalf of Vattenfall an inspection has been executed on the wind turbine gearbox. The
purpose of the inspection is to determine the technical state of the gearbox. The visual
inspection of the gearbox has been executed with a GE Everest XLG3 Videoscoop.
2. General Information
Turbine Information
Wind turbine name: Waardtocht 4
Wind turbine type: V66 – 1750KW – 690V/50HZ – R7035
Wind turbine serial no: 15976
Location: Middenmeer
Hub height: 78
Total production [kWh]: 20439703
Total hours: 45201
Nominal power [kW]: 1750
Year of installation: 2003
Date of inspection: 02-11-2015
Inspectors:
P. den Braber
D. Lagerweij
B. van de Braak
J. Langenbach
Gearbox Information
Gearbox type: Winergy PEAB 4395 i = 78,659
Gearbox serial number: 4809519 – 0020 - 4
Production year gearbox: 2006
Revision: -
Revision number: -
Oil type: Castrol Alphasyn PG 320
Date of last oil change: Gearbox exchange date
Gearbox has been exchanged on 29-01-2007
Gearbox inspection Waardtocht 4 WTG 15976
Date: 16-11-2015 Page 4 of 14
3. Reporting setup
The next drawing shows a cross-section of a planetary gearbox with two linear stages with
corresponding bearing positions. The drawing should be used as a reference for the bearing
position only.
Gearbox inspection Waardtocht 4 WTG 15976
Date: 16-11-2015 Page 5 of 14
4. Inspection results
Picture 1
Picture 1 shows bearing position no. 1, the bearing of the planet carrier at rotor side. Line of
damage is visible on the inner ring.
Picture 2
Picture 2 shows the bearing of the first planet wheel. No irregularities.
Gearbox inspection Waardtocht 4 WTG 15976
Date: 16-11-2015 Page 6 of 14
Picture 3
Picture 3 shows the bearing of the second planet wheel. No irregularities.
Picture 4
Picture 4 shows the bearing of the third planet wheel. No irregularities.
Gearbox inspection Waardtocht 4 WTG 15976
Date: 16-11-2015 Page 7 of 14
Picture 5
Picture 5 shows bearing position no. 5, the bearing of the planet carrier at generator side. The
bearing shows no irregularities.
Picture 6
Picture 6 shows bearing position no. 6, the bearing of the low speed shaft at rotor side. The
bearing shows no irregularities.
Gearbox inspection Waardtocht 4 WTG 15976
Date: 16-11-2015 Page 8 of 14
Picture 7
Picture 7 shows bearing position no. 7, the bearing of the low speed shaft at generator side.
Damage is visible on the inner ring.
Picture 8
Picture 8 shows bearing position no. 9, the bearing of the intermediate shaft at generator side.
The bearing shows no irregularities.
Gearbox inspection Waardtocht 4 WTG 15976
Date: 16-11-2015 Page 9 of 14
Picture 9
Picture 9 shows bearing position no. 11, the bearing of the high speed shaft at generator side.
The bearing shows no irregularities.
Picture 10
Picture 10 shows the active flank of the ring gear. No irregularities.
Gearbox inspection Waardtocht 4 WTG 15976
Date: 16-11-2015 Page 10 of 14
Picture 11
Picture 11 shows one of the planet wheels. None of the planet wheels show irregularities.
Picture 12
Picture 12 shows the active flanks of the sun pinion. No irregularities.
Gearbox inspection Waardtocht 4 WTG 15976
Date: 16-11-2015 Page 11 of 14
Picture 13
Picture 13 shows the active flanks of the wheel of the low speed shaft in the linear stage. No
irregularities.
Picture 14
Picture 14 shows the active flanks of the pinion of the intermediate shaft in the linear stage.
No irregularities.
Gearbox inspection Waardtocht 4 WTG 15976
Date: 16-11-2015 Page 12 of 14
Picture 15
Picture 15 shows the active flanks of the wheel of the intermediate shaft in the linear stage. No
irregularities.
Picture 16
Picture 16 shows the active flanks of the pinion of the high speed shaft in the linear stage. No
irregularities.
Gearbox inspection Waardtocht 4 WTG 15976
Date: 16-11-2015 Page 13 of 14
Picture 17
Picture 17 shows the oil level of the gearbox.
Picture 18
Picture 18 shows the place for the magnet of the gearbox. The magnet is missing in this
gearbox.
Gearbox inspection Waardtocht 4 WTG 15976
Date: 16-11-2015 Page 14 of 14
5. Summary
The bearing of the planet carrier at rotor side shows a line of damage on the inner ring.
The bearing of the low speed shaft at generator side shows damage on the inner ring.
The magnet in this gearbox is missing.
6. Conclusion
The condition of the gearbox is good enough to keep the gearbox in operation. The
irregularities at bearing position 1 and 7 are remarkable and it is recommended to keep
monitoring these bearings closely in the future. It is not possible to replace the bearings
without dismounting the complete gearbox.
It is also recommended to mount the original magnet in the gearbox.
Dennis Lagerweij
Barneveld, 16-11-2015
TeSuCon B.V.
Mercuriusweg 8
3771NC Barneveld
The Netherlands
Tel +31610032858
Email [email protected]
Web www.tesucon.nl