GE Renewable Energy
– Original –
Technical Documentation
Wind Turbine Generator Systems
3MW Platform - 50/60 Hz
Installation Manual
Applicable for Wind Turbine Generators from 2.5 MW to 3.8 MW
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© 2017 General Electric Company. All rights reserved.
GE Renewable Energy
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https://renewables.gepower.com
All technical data is subject to change in line with ongoing technical development!
Copyright and patent rights
This document is to be treated confidentially. It may only be made accessible to authorized persons. It may
only be made available to third parties with the expressed written consent of General Electric Company.
All documents are copyrighted within the meaning of the Copyright Act. The transmission and reproduction of
the documents, also in extracts, as well as the exploitation and communication of the contents are not allowed
without express written consent. Contraventions are liable to prosecution and compensation for damage. We
reserve all rights for the exercise of commercial patent rights.
2017 General Electric Company. All rights reserved.
GE and
are trademarks and service marks of General Electric Company.
Other company or product names mentioned in this document may be trademarks or registered trademarks of
their respective companies.
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Installation_Manual_3MW-DFIG-xxHz_EN_r02.docx
GE Renewable Energy
– Original –
Installation Manual
Table of Contents
1
2
3
4
5
6
7
8
Introduction ..................................................................................................................................................................................................... 7
1.1
Prerequisites for the Installation.................................................................................................................................................. 9
1.2
Confidentiality .................................................................................................................................................................................... 10
1.3
Installer's Responsibilities ............................................................................................................................................................ 11
Tooling requirements! .............................................................................................................................................................................. 13
1.4
GE Energy Responsibility .............................................................................................................................................................. 14
1.5
Acronyms and Definitions............................................................................................................................................................ 14
Reference Documentation .................................................................................................................................................................... 15
2.1
Technical Reference Documents ............................................................................................................................................. 15
2.2
Work Instructions ............................................................................................................................................................................. 16
2.3
Checklists ............................................................................................................................................................................................. 17
2.4
Drawings – Turbine Components............................................................................................................................................. 19
2.5
Drawings - Tooling .......................................................................................................................................................................... 20
Tools, Parts Shipped as Loose Kits ..................................................................................................................................................... 21
3.1
Tools ....................................................................................................................................................................................................... 21
3.2
Parts Shipped as Loose Kits ........................................................................................................................................................ 21
Safety ............................................................................................................................................................................................................... 22
4.1
Operations Involving the Use of a Crane.............................................................................................................................. 32
4.2
Qualification and Orientation of the Installation Personnel ........................................................................................ 32
4.3
Safety Equipment............................................................................................................................................................................. 33
4.4
Personal Protective Equipment (PPE)...................................................................................................................................... 33
4.4.1 Safety Harness ............................................................................................................................................................................. 34
4.4.2 Protective Equipment for Measurements on Live Components .......................................................................... 35
Preparatory Work....................................................................................................................................................................................... 37
Foundation .................................................................................................................................................................................................... 38
6.1
Tower Base Ring ............................................................................................................................................................................... 38
6.1.1 Drawings ......................................................................................................................................................................................... 38
6.2
Identifying the Tower Base Ring ............................................................................................................................................... 39
Tower Base Ring (75 m and 85 m)...................................................................................................................................................... 39
Tower Base Ring (98.3 m) ....................................................................................................................................................................... 39
Tower Base Ring (110 m and 120 m) ................................................................................................................................................ 40
Tower Base Ring (131 m) ........................................................................................................................................................................ 40
6.2.1 Preparing the Foundation Anchor Bolts and Installing the Tower Base Ring ............................................... 41
6.2.2 Preparing the Tower Base Ring ............................................................................................................................................ 41
6.2.3 Verifying the Foundation is Level ........................................................................................................................................ 41
6.2.4 Installing the Tower Base Ring ............................................................................................................................................. 42
6.3
Preparing the Foundation ............................................................................................................................................................ 44
Pre-assembled Power Module (PPM) ................................................................................................................................................ 46
7.1
Safety Information for Installation of the PPM .................................................................................................................. 47
7.2
Overview of the Hooking Points ................................................................................................................................................ 49
7.3
Overview of the Installation Sequence .................................................................................................................................. 50
7.4
Assembling the PPM ....................................................................................................................................................................... 53
7.5
Installing the Fit Up Aid Tool (Transformer Alignment Brackets)............................................................................... 56
Tower................................................................................................................................................................................................................ 82
8.1
First Tower Section .......................................................................................................................................................................... 83
8.1.1 Inspecting the Tower Section................................................................................................................................................ 85
8.1.2 Preparing the Tower Section ................................................................................................................................................. 86
8.1.3 Example Attachment and Usage of the Lifting Gear ................................................................................................. 88
8.1.3.1 Plate Lifting Gear.................................................................................................................................................................... 88
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8.1.3.1.1
Attachment of Plate Lifting Gear ............................................................................................................................... 88
8.1.3.1.2
Lifting the Tower Section from the Low-loading Trailer................................................................................. 90
8.1.3.2 HTS ACTEK WKA System ..................................................................................................................................................... 94
8.1.3.2.1
Attachment of HTS ACTEK WKA System ................................................................................................................ 94
8.1.3.2.2
Lifting the Tower Section from the Low-loading Trailer................................................................................. 96
8.1.4 Assembling the First Tower Section ................................................................................................................................ 100
8.1.4.1 Installing the Guide Rail System................................................................................................................................... 101
8.1.4.1.1
Assembling the Rail Assembly ................................................................................................................................. 104
8.1.4.1.2
Installing the Controller Level Guide Rail System ........................................................................................... 106
8.1.4.1.3
Installing the Transformer Level Rail Assembly .............................................................................................. 110
8.1.4.2 Installing the Base Section over the PPM ................................................................................................................ 115
8.2
Installing the Entrance Stairway ............................................................................................................................................ 125
8.3
Adjusting the Entrance Door ................................................................................................................................................... 129
8.4
Completing the PPM Assembly ............................................................................................................................................... 130
9 Assembling the Following Tower Sections .................................................................................................................................. 140
9.1.1 Inspecting the Tower Section ............................................................................................................................................. 143
9.1.2 Preparing the Tower Section .............................................................................................................................................. 144
9.1.3 Attachment and Usage of the Lifting Gear ................................................................................................................. 146
9.1.4 Installing the Tower Section ................................................................................................................................................ 147
9.2
Corrosion Protection .................................................................................................................................................................... 155
9.3
Checking/Adjusting the Railing Doors................................................................................................................................. 155
10
Nacelle ..................................................................................................................................................................................................... 156
10.1 Inspecting the Nacelle ................................................................................................................................................................ 162
10.2 Preparing the Nacelle.................................................................................................................................................................. 162
10.3 Lifting the Nacelle ......................................................................................................................................................................... 175
10.3.1 Lifting Gear for the Nacelle ............................................................................................................................................ 175
10.3.2 Attachment of the Lifting Gear..................................................................................................................................... 175
10.4 Assembling the Nacelle .............................................................................................................................................................. 183
11
Hub ............................................................................................................................................................................................................ 188
Typical Hub Configurations ..................................................................................................................................................................... 188
11.1 Inspecting the Hub ....................................................................................................................................................................... 189
11.2 Lifting the Hub ................................................................................................................................................................................ 190
11.2.1 Attaching the Lifting Gear ............................................................................................................................................... 192
12
Rotor Blades.......................................................................................................................................................................................... 196
12.1 Inspecting the Rotor Blades ..................................................................................................................................................... 196
12.2 Offloading the Rotor Blades ..................................................................................................................................................... 197
12.3 Preparing the Blades ................................................................................................................................................................... 205
12.4 Blade Handling ............................................................................................................................................................................... 209
12.4.1 Example: Double Crane Lift ............................................................................................................................................ 213
12.4.2 Example: Single Crane Lift .............................................................................................................................................. 214
13
Rotor ......................................................................................................................................................................................................... 217
13.1 Preparing the Rotor ...................................................................................................................................................................... 217
13.1.1 GE Pitch Control System (MSS Hub Pitch System) ............................................................................................... 219
13.1.2 GE Pitch Control System (For Turbines with PTB Hub Pitch System) .......................................................... 227
13.2 Attachment of the Blades ......................................................................................................................................................... 236
13.3 Assembling the Rotor .................................................................................................................................................................. 238
13.4 Assembling the Nose Cone and Final Rotor Assembly Work................................................................................... 248
13.5 Final Rotor Assembly Work ...................................................................................................................................................... 252
13.6 Lifting the Rotor.............................................................................................................................................................................. 256
13.6.1 Example Lifting Gear - Lifting Tool for 100 m and 103 m Rotor Diameter.............................................. 256
Typical Hub Configurations ................................................................................................................................................................ 256
13.6.2 Attaching the Rotor Lifting Gear .................................................................................................................................. 259
13.7 Installing the Rotor (Hub with Blades) ................................................................................................................................. 260
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Blades with serrations: ......................................................................................................................................................................... 263
Blades with serrations: ......................................................................................................................................................................... 269
14
Checks ..................................................................................................................................................................................................... 283
15
Cables ...................................................................................................................................................................................................... 287
15.1 Slip Ring Wires ................................................................................................................................................................................ 288
15.2 Lowering the Power, Control & Communication Cables ............................................................................................ 297
15.3 Lowering the Generator, Rotor, Stator & Ground Cables .......................................................................................... 313
15.3.1 Arranging the Cables at the Transition between the Cable Saddle and the Tower Cable Tray ... 327
Plastic Cable Ties ..................................................................................................................................................................................... 328
15.3.1.1
Arranging the Cables at the Transition between the Cable Saddle and the Tower Cable Tray
“OLD” TPH Structure for 98.3mHH .................................................................................................................................................. 329
15.3.1.2
Arranging the Cables at the Transition between the Cable Saddle and the Tower Cable Tray
“NEW” BoM Structure for 110mHH ................................................................................................................................................. 330
15.4 Installing the Cable for the Cable Untwisting Switch .................................................................................................. 331
15.5 Splicing the Stator, Generator and Ground Cables ...................................................................................................... 332
General Overview of the Cable Arrangement at Each Level Prior to Installation .................................................... 333
Overview of the Final Cable Arrangement at Each Level .................................................................................................... 334
16
Signs and Labeling to be Attached to the Wind Turbine Generator System by the Operator/Owner ..... 344
17
Installation of the Ladder and Fall Protection System ..................................................................................................... 344
18
Connections .......................................................................................................................................................................................... 345
18.1 Electrical Connections at PPM ................................................................................................................................................ 346
18.1.1 PAS00 Grounds: ................................................................................................................................................................... 346
18.2 Electrical Connections and Testing Requirements ....................................................................................................... 353
Field Tests ................................................................................................................................................................................................... 353
18.3 Medium Voltage Cables between the Grid and MVSG (Grid and Next Turbine).............................................. 356
18.4 Connection of the HV Cables between MVSG and the Transformer.................................................................... 360
18.5 690 V Transformer to Converter CAE Cabinet................................................................................................................. 368
18.6 6kV Cables between the Transformer and SSC Cabinet ............................................................................................ 372
18.6.1 6kV Cables between the Transformer and SSC Cabinet Schneider Configuration............................. 373
18.6.2 6kV Cables between the Transformer and SSC Cabinet LimitAmp Configuration .............................. 377
Opening De Energized SSC cabinet during installation ........................................................................................................ 378
18.7 690 V Converter CAE Cabinet to AUX Transformer ...................................................................................................... 389
18.8 400 V LVDP to AUX Transformer ............................................................................................................................................ 392
18.9 Control/Communication between MCC/SSC and the Converter CCC Cabinet ............................................... 395
18.10 Control/Communication AUX Cables between MCC/SSC and the Transformer Junction Box.
TransformerLevel ......................................................................................................................................................................................... 399
18.10.1
PT – 100 Cable and Tower Door Exhaust Fan .................................................................................................. 403
18.11 Connect the 400 V Auxiliary Cables (Top Box) to LVDP ............................................................................................... 404
18.12 Connect the Power Cables (690 V) from the Generator to Converter Cabinet................................................ 406
18.13 Connecting the 6 kV Generator Stator Cables to the Stator Switch Cabinet SSC ......................................... 411
18.13.1
Connecting the 6 kV Generator Stator Cables to the Stator Switch Cabinet SSC LimitAmp
Cabinet
................................................................................................................................................................................................ 419
18.13.1.1 Routing and Terminating Cables to the Bus Bars .......................................................................................... 421
18.13.2
Critical to Quality Testing and Inspections ........................................................................................................ 423
Generator .................................................................................................................................................................................................... 423
Converter – 400 V.................................................................................................................................................................................... 423
Converter – 690 V.................................................................................................................................................................................... 423
Generator to (SSC) – 6 kV ..................................................................................................................................................................... 424
Transformer to (SSC) – 6 kV ................................................................................................................................................................ 424
Prior to Closing Cabinet Panels or Completion of Work. ...................................................................................................... 424
18.14 Installing the Floodlighting ....................................................................................................................................................... 425
19
Ground Resistance Test .................................................................................................................................................................. 425
20
Verify the Gearbox and Generator Alignment ..................................................................................................................... 426
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21
Remaining Work ................................................................................................................................................................................. 427
21.1 Mechanical Completion ............................................................................................................................................................. 427
22
Transport Fixtures .............................................................................................................................................................................. 428
22.1 Downtower Equipment (PPM) .................................................................................................................................................. 428
22.2 Tower .................................................................................................................................................................................................. 428
22.3 Nacelle ................................................................................................................................................................................................ 428
22.4 Hub ....................................................................................................................................................................................................... 428
22.5 Nose Cone......................................................................................................................................................................................... 428
22.6 Blades ................................................................................................................................................................................................. 428
22.7 Special Tool Return ....................................................................................................................................................................... 428
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GE Renewable Energy
– Original –
Installation Manual
1 Introduction
This Installation Manual describes the basic procedures for the assembly of
3MW Platform Wind Turbine Generator Systems
with 100 m, 103 m, 120 m, 130 m and 137 m rotor
hub heights from 70 m to 131 m
and a rated power of 2.5-3.8 MW.
These instructions apply to the steel tubular tower, nacelle, and rotor blades. The installation requirements and
instructions must be followed precisely in order to avoid damage and to guarantee a problem-free and exact
installation. It is the owner’s/installer’s responsibility to meet all safety, local and general regulations that apply
for the specific site, task or project during installation.
It will enable the constructor to safely erect a Wind Turbine Generator System (WTGS) in accordance with the
specifications of the manufacturer.
The following components are considered in this document:
Tower base ring
Pre-assembled Power Module (PPM)
Rotor Assembly and Installation Considerations
120 m diameter and smaller can be installed as a completely assembled rotor.
Rotors with a 2900 hub must be installed utilizing Single Blade Method SBI.
SBI method requires the following electrical and mechanical preparations before beginning rotor assembly.
Parties responsible for performing this work will review and understand the procedures before beginning the
work.
The following is a list of activities that will be covered under separate reference documentation. Contact GE
representative for a copy of the latest revisions.
Install the unbalanced rotor turning gear before the nacelle leaves the ground.
Receive and assemble SBI tool and partial disassembly is required to relocate to next pad.
All power and communication cables must be lowered and secured to PPM but not terminated
Identify power source to the top box to enable the Yaw and Gearbox oil pump systems.
Connect appropriate size and Voltage portable generator to the temporary wiring to the top box.
Follow the Temporary Yaw procedure to correctly orient machine head to perform SBI.
Energize gearbox oil pump for a minimum of 5 min. to before activating turning gear, leave oil
pump running while the turning gear is engaged.
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Install the Hub (2900 Hubs have double row bolt pattern on the main-shaft connection).
Using turning gear orient the hub to the first position to install the blades and apply Rotor
Lock/LOTO.
Connect SBI tool and taglines to the blades and install onto the hub.
Verify all blade to pitch bearing torqueing is complete.
De-energize and remove all SBI related temporary equipment (Mechanical and Electrical).
Hybrid Tower
The Hybrid Tower consists of a concrete section with steel tube tower sections on top.
This manual does not cover Hybrid Tower Installation. Refer to the Hybrid Tower Installation Manual.
DTO (Design to Order)
Refers to non-standard equipment in the scope supply that is not part of the standard design, and so is not
addressed in this installation manual. DTO equipment may be required to meet local codes and standards or
customer specific requirements. In cases where this equipment must be installed in the field, work instructions
will be made available by GE via project specific addendum to the installation manual. Contact GE Project
representative.
This Installation Manual is designed to provide the owner/installer with information on how to install the Wind
Turbine Generator (WTGS) in a safe manner in accordance with the manufacturers’ specifications, and is
subject to revision by GE Energy. The installation instructions include important warnings, cautions, and notes
about installing the wind turbine. These instructions do not cover components not provided by GE Energy.
The wind turbine generators are built in accordance with technical standards and the established safety rules.
Nevertheless, dangerous risks can arise for individuals, equipment can be impaired, and materials damaged, if
the converter and other devices are operated:
By personnel who are not trained and properly instructed and/or
Outside of guidelines prescribed by the company.
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1.1 Prerequisites for the Installation
Road/Crane/Rigging
Installer is required to design and procure all rigging and lifting devices, provide equipment offloading/staging
plan, provide a project specific lift plan(s). Ensure rigging and lifting design is safe and does not damage GE `s
equipment/subcomponents when it is attached to the lifting points or any part of the General Electric
equipment. The sail area and drag coefficient of the rotor must be incorporated through the lift plan. Static
loads and dynamic loads must be verified by the crane operator
The work zone must be clearly identified and personnel not involved in crane lift operations must leave the
crane work zone (danger zone) before lift operations starts.
Figure 1: WTGS Crane Work Zone (Danger Zone)
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An extensive analysis to determine the prerequisites for the installation (e.g. weather conditions, land
requirement or sufficient curing of the foundation) has to be carried out before the turbine is erected.
The roads and pads must meet the requirements of the Typical Road, Crane Pad & Turbine assembly area
specification. Offloading staging activities plan must include site survey and knowing the general
characteristics of the roads and condition of the soil for equipment safe/unrestricted travel, offload, staging
and Installation.
Staging plan must include Safety and Equipment damage preventive measures including but not limited to
resetting equipment to prevent damage due to poor cribbing/matting configuration, soft ground due to
potential freeze thaw cycles, rain, melting ice or flood zone, potential damage due to extreme weather
conditions such as high winds. Proper cribbing/matting and tie off arrangement shall be factored in, and must
be sufficient and properly rated to support weight of the components.
GE Energy will provide typical weights, dimensions and center of gravity for lifting GE-provided components
only.
Refer to the Transportation Description, weights and dimensions (see section 2) for exact descriptions and the
dimensions of all the turbine components which are to be mounted, and the data required for the assembly,
such as weights, fixing points, etc. Modifying the GE equipment lifting points is strictly prohibited.
1.2 Confidentiality
This document is to be treated confidentially. It may only be made accessible to authorized persons. It may
only be made available to third parties with the expressed written consent of GE Company. All documents are
copyrighted within the meaning of the Copyright Act. The transmission and reproduction of the documents,
also in extracts, as well as the exploitation and communication of the contents are not allowed without
express written consent. Contraventions are liable to prosecution and compensation for damage.
We reserve all rights for the exercise of commercial patent rights.
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1.3 Installer's Responsibilities
The role of the constructor is defined depending on the contract conditions:
Installation in GE's scope
The Installer is a General Electric employee or a GE subcontractor.
Installation in customer scope
The installer is a non-General Electric employee. GE's representative is the single point of contact
for the installer and responsible for the technical advisory at the installation site.
For both cases this installation manual defines the installer’s responsibilities. The Installer must ensure that the
erecting engineers are familiar with this Installation Manual. The Installer is responsible for the safety of the
personnel and must inform the personnel about the existing legal requirements and accident prevention
regulations and ensure that they are complied with. Furthermore, the country-specific safety and
environmental regulations must be complied with. The installation personnel may not alter the control and
protective system of the WTGS, add or omit anything without the written authorization of GE Energy. The
installation teams must have been trained and oriented in the correct installation of a WTGS. The training
records have to be made available on GE request.
Personnel performing Electrical Work are required to request training for operating, assembling and testing of
the SSC and MVSG cabinet 30 days before performing this work.
General Tool Calibration and Testing
NOTE
Tool calibration
The Installer has to ensure that the tools used are calibrated and that the
respective calibration/inspection data sheets are available to GE Energy on
request.
All measuring and test equipment must have a certificate of calibration and
visibly labeled. A third party verification of calibration certificate is also
required on any new or used tooling that measures pressure, force or
resistance, e.g. dial indicators, torque wrenches electrical, mechanical and
hydraulic, laser alignment tools, multimeters, electrical validation testing
equipment and electrical crimping tooling.
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NOTE
Daily Tool Log!
CRITICAL TO QUALITY!
Failure to perform inspections prior to each shift can allow damaged or substandard tooling to be utilized by employees. The Installer assumes responsibility
for any re-work associated with damaged or sub-standard tooling found to be
the root cause of improper installation per GE specifications. A verification of all
3rd party calibrations certificates is required and a copy will be kept in the site job
books on any new or used tooling that measures pressure, force, distance or
resistance.
A log of daily checks performed shall be documented and may be mandated
by the regional Installation Manager. The original logs shall be available to GE
upon request and the originals will be added to the site job books if deemed
necessary.
NOTE
Over torque using impact wrenches!
Over torque leads to bolt failure.
CRITICAL TO QUALITY!
When using impact wrenches do not exceed the torque values that are
specified for the bolt being tightened. Final torque must be applied using a
calibrated torque wrench!
NOTE
CRITICAL TO QUALITY!
Submit an RFI to GE for a list of the latest approved torque tooling for level 1
component connections e.g., Tower flanges, Rotor assembly and installation.
The following is the minimum daily check information that must be recorded in the installer provided form:
3rd party date of tool being tested
Date check performed
Operator performing check
Tool ID (serial #)
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Check value, 3 tests recorded with AvgEquipment used to check (MFG./Model/Serial Number) torque wrenches electrical, mechanical
and hydraulic, Pressure gauges, crimp heads, force gauges for hydraulic crimping.
Hydraulic tooling must be tested as an entire functional unit.
Tooling requirements!
1. Certificate of calibration from the manufacturer
2. Send new tool to third party for calibration verification.
If tool requires re-calibration,
3. Send in to get calibrated and issue new certificate of calibration.
4. Send to 3rd party for new verification certificate.
As long as the tool remains in calibration only the verification certificate has to be renewed each year. All
measuring and test equipment must have Identification traceable to a certificate of calibration.
All tool calibration verification services shall be subcontracted.
Examples of calibration requirements are, but not limited to:
Pressure gauges
Torque wrenches - electrical, mechanical and hydraulic
Norbar or equivalent test equipment
Skidmore or equivalent test equipment
Electric screw driver
Multimeters
Laser alignment equipment
Electrical validation equipment
Micrometer and digital and/or dial calipers
Consult with GE site representative for any tool used that is not listed as to if 3rd party calibration is required.
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1.4 GE Energy Responsibility
GE Energy’s responsibilities are to provide the owner/installer with comprehensive documentation to install a
wind turbine generator. General Electric provides all turbine components, ship loose kits, special tooling, and
technical advisors where applicable.
GE Energy reserves the right to withdraw its employees from unsafe site/work areas.
The installation manual is important for the safe installation of the turbine. The site constructor must ensure
the installation crews are familiar and comply with these instructions. Furthermore, adherence to local, state,
and country regulations regarding safety, environmental protection, electrical codes and related fields is
required.
Construction personnel are not allowed to change, add or modify the control and protection system of the
turbine without written authorization of a designated GE Energy representative, prior to change or
modification. Construction crews must be trained and instructed in the proper installation of the turbine.
1.5 Acronyms and Definitions
Acronym
Definition
CICL
Cable Installation Check List
DFIG
Directly Fed Induction Generator
DTO
Design to Order (Refers to non-standard equipment orders that is required to meet
local standards/regulations that is not part of the original design
ICL
Installation Check List
IIP
Installation Inspection Procedure
LVDP
Low Voltage Distribution Panel
MCC
Main Controller Cabinet in PPM, communicates with top box
Nm
Newtonmeter
PPM
Pre-assembled Power Module
SSC
Stator Switch Cabinet
UPS
Uninterruptible Power Supply
WTGS
Wind Turbine Generator System
LVDP
Low Voltage Distribution Panel
Table 1: Acronyms and Definitions
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2 Reference Documentation
2.1 Technical Reference Documents
Content
Document Name
Basic Information
Operating_Manual_3MW-xxHz_Basic
Technical Data
Technical_Description_3MW-xxHz_DFIG
Safety Manual
Operating_Manual_3MW_xxHz_Safety
Operating Manual
Operating_Manual_3MW_xxHz_Operating
Transport Manual
Transport_Documents_3MW-DFIG-xxHz
Manual for the Handterminal
Operating_Manual_Generic_xxHz_mContrUnit_exo
rPalm
Maintenance Manual
Operating_Manual_3MW-xxHz_Maintenance
Idling Manual
Idling_Manual_3MW-DFIG-xxHz
Road & Crane Pad Specification
Site_Roads_Crane_Spec_3MW-DFIG120_130_137-xxHz_EMEA
Site_Roads_Crane_Spec_3MW-DFIG-100_103xxHz_RoadCrane_EMEA
Specification Handling and Lifting (Drag Coefficient Sail Area)
Component_SailArea_DragCoef_Generic-xxHz
Wind Speed Limitations for Assembly and Maintenance
Contact Engineering for the latest Wind Speed
Limitations.
Customer Information for the Anchor Bolt System
General_Description_3MW50Hz_foundation_anchorAdapt
Weights and Dimensions
Weights_and_Dimensions_3MW_xxHz
Requirements for the Tower to Foundation Interface
Refer to contract technical foundation documents.
WebHMI-Remote Application
Operating_Manual_Generic_xxHz_ControllerHMI_
MarkVle
Storage Manual
Storage_Manual_3MW-DFIG-xxHz
Table 2: Technical reference documents
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2.2 Work Instructions
Work Instruction
Document Name
Technical Specification Wind Turbines Tower Internals
Bolting and Torqueing
103W2364
Bolt Torque Specification
Bolt_Torque_Specification_3MW_xxHz
Generator Installation
Engineering to provide
Flex Coupler Installation
2.X_Machine Head_Exchange of the coupling for Gen 0
Turbines
Gearbox Alignment
2.x_WDI_gearbox_alignment
Generator Alignment
2.x_WDI_generator_aligning
Gearbox Installed on the Ground
2.x_xxHz_WDI_gearbox_Install
Connection of Power Cables
GEWE.all_WDI_cable_crimping
Insulation Integrity Test
104W2311
Lightning Arrester Resistance, CE Measurement (optional)
2.5-100_xxHz_WDI_allComp_TestEN60204 (if applicable)
Transformer Operating and Test Manual
Vendor specific
Switchgear Operating and Test Manual
Vendor specific
Stator Synch Switch Operating and Test Manual
Vendor specific
WDI Single Blade Installation
Request latest version from GE engineering.
Table 3: Work instructions
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2.3 Checklists
The Installer is responsible for the daily maintenance of the following turbine specific documents (request the
latest version from GE's representative).
All completed pre-condition checklists section 5 IIP must be submitted to GE prior to Installation Inspection.
Checklist
Document
Installation Check List
Installation_Checklists_3MW-DFIG-xxHz_ICL
Torque Report
Installation_Checklists_3MW-DFIG-xxHz_BoltTorque
Generator Alignment Report
Contact Engineering for the latest generator alignment form.
Gearbox Alignment Report
Contact Engineering for the latest gearbox alignment form.
Cable Installation Checklist
Installation_Checklists_3MW-DFIG-xxHz_CICL
Grid Checklist
Installation_Checklists_3MW-DFIG-xxHz_Grid
Energization Process Flow Chart
3.x Equipment only Energization Process Flow Chart
Haca Safety Rail Inspection Protocol
HACA rail check list (if applicable)
or alternatively depending on the configuration of the WTGS
Tuf-Tug Fall Arrest System Inspection Protocol
Tuf-Tug Cable Safe Climb System inspection checklist
Installation Inspection Protocol
Installation_Checklists_3MW-DFIG-xxHz_IIP
Receiving Inspection Forms
Receiving_Inspection_Checklists_3MW-DFIG-xxHz_XXX
all receiving forms
Table 4: Checklists
NOTE
If equipment will be delivered to a lay down area for long-term storage refer
to Technical Guidelines for Storage of Wind Turbine Generator Systems.
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NOTE
Receiving Inspections:
GE provides a copy of the Receiving Checklists on EX works projects only.
If the GE receiving inspector is not on site, GE provides a copy of the
Receiving Checklists to the customer to perform the equipment receiving
inspection. Contact the GE representative for the latest revisions. The
customer will provide to GE the copies of the completed inspection checklist
prior to start of the installation activities.
NOTE
If equipment for two different projects is shipped to the same long term storage
area, the customer is responsible for maintaining equipment assignment for the
project it was intended for to insure the correct configuration is delivered to the
correct location.
If the customer decides to relocate any major component after the component
has been delivered to a pad, ensure the new pad location is communicated to
the GE site representative for configuration management purposes.
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2.4 Drawings – Turbine Components
Drawing numbers for project may change depending on configuration. GE project team to provide all
applicable documents.
Drawing no.
Content
Comment
117W6882
3-level PPM assembly, corresponding BoM
PPM assembly
117W6871
Transformer platform (section 1)
PPM assembly
117W6997
Controller platform (section 2)
PPM assembly
117W6892
Converter platform (section 3)
PPM assembly
117W6917
Assembly drawing ladder DTE
PPM assembly
114W8755
Assembly drawing converter
PPM assembly
105T5350
Fan and Plenum Assembly Instructions
PPM assembly
117W5906
Assembly ventilator
PPM assembly
Engineering to provide
Tower section lift and handling
Per hub height and tower design
114W5453
Left side panel assembly 2.5-2.75 (PMG + BTP
Nacelle)
Generator installation
114W5454
Right side panel assembly 2.5-2.75 (PMG + BTP
Nacelle)
Generator installation
117W6136
Machine head lift drawing
103W3327
Hub lift drawing
115W5268
Assembly hub steps/casting assembly
Hub assembly
114W4337
2.5 hub assembly mechanical parts outside pages
Hub assembly
103W2754
Blade support and lift drawing
Per blade design
Engineering to provide
Rotor lift drawing
Per rotor diameter and blade design
108W6416
Aviation lights, weather station mechanical
assembly
If applicable
Engineering to provide
Turbine electrical schematics and wiring diagram
Project specific
Table 5: Drawings – Turbine components
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2.5 Drawings - Tooling
Drawing no.
Content
Comment
Engineering to provide
Fit up aid tool drawing for turbines with 85 m and
98.3 m HH
as applicable
114W8776
Brace right alignment tool DTE
PPM Assembly
114W8775
Brace left alignment tool DTE assembly
PPM Assembly
GE-PPM-D6025-00
PPM rail system configuration detail
PPM Assembly
GE - PPM - DT7988-01
Upper rail
PPM Assembly
GE - PPM - DT7988-02
Lower rail
PPM Assembly
GE - PPM - DT7988-03
Tube bracket and joiner
PPM Assembly
GE - PPM - DT7988-04
Primary support short
PPM Assembly
GE - PPM - DT7988-15
Primary support medium
PPM Assembly
GE - PPM - DT7988-06
Primary support long
PPM Assembly
GE - PPM - DT7988-07
Pivot link arm
PPM Assembly
GE - PPM - DT7988-08
Latch arm
PPM Assembly
GE - PPM - DT7988-09
Latch arm assembly
PPM Assembly
GE - PPM - DT7988-10
PPM V5 main assembly
PPM Assembly
Table 6: Drawings – Turbine components
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3 Tools, Parts Shipped as Loose Kits
3.1 Tools
NOTE
For current tool list contact GE representative. Installer is responsible for all
tools and consumables.
3.2 Parts Shipped as Loose Kits
There are three categories of loose kits.
1.
Tower paint
2.
Bulk items shipped for all units such as fragile products or small parts and items shipped as a kit
for each turbine such as hoist or nacelle bolts are included in the erection accessories and PPM
accessories which are delivered in a container.
3.
Items shipped as a kit inside major components such as nuts and washers for rotor assembly, hub
nuts and washers or lifting lugs for PPM (Pre-assembled Power Module).
4.
Parts shipped late from General Electric or a vendor (MSD) to close shortage issues.
NOTE
Tower bolts are shipped in tower kits. Do not mix tower bolts; always maintain kit
integrity (1 kit to 1 tower). Bolt information is recorded in ICL. All bolts nuts &
washers used for any particular tower flange assembly must be from the same
manufacturer. If kit number is missing contact GE for further instructions.
NOTE
Consult with GE representative for a sample-packaging list for all parts
shipped loose kits parts as they may vary by pole and contractor may be
required to stage these parts at the site inside components prior to
installation.
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NOTE
Bulk shipments / Ship loose kit acceptance (Future PSL)
Each package contains a packing slip attached to either the outside or inside of
the container. The installer is responsible for verifying all bulk shipments / ship
loose kits are received in full as they arrive on-site. Complete quality form WFFOFPSL-007 “Ship Loose Kit Acceptance Form” and provide it to the GE Energy
representative within two working days. The installer will be responsible for
supplying shortage items at their expense if not noted on form or the form is not
provided to the GE Energy representative within two days of ship loose kits
arriving on-site.
The installer is responsible for maintaining custody and security of the PSL/MSD
and all major components.
NOTE
The collection system to GE WTG interconnects hardware and foundation
grounding hardware is supplied by the buyer.
4 Safety
Parties (companies and individuals) performing this work are responsible for reviewing the scope of work and
determining all training, safety measures, guidelines, and work practices that are necessary and for adhering
to and enforcing them.
Untied long hair, loose clothing (e.g. flapping coats, tops with wide sleeves or trousers with wide trouser legs)
as well as scarves, ribbons, headscarves or jewelleryent for Measurements on Live Components may not be
worn during the installation work! There is a fundamental danger of injury through being caught, pulled in or
picked up by rotating components! Clothing must be adapted to the respective work and the weather
conditions.
DANGER
Head injury risk!
Since there is a high risk of head injury, hard hats must be worn on the work
site at all times. Workers may trip or fall, or may bang their heads while
working in confined spaces. Due to wind conditions and other risk factors,
workers may encounter falling, flying or swinging objects.
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DANGER
Risk of falling objects!
Never remain in front or underneath the tower opening.
Whilst the tower is being erected any object or material that remained in the
tower or inadequately secured cable can fall out of the tower.
The process requires lifting and lowering equipment inside the tower and working
with, and staging, tools and materials on all tower platform levels. There are
many gap openings around the platforms and possible open personnel and tool
hatches Personnel will be working with small parts and tools which can fall
through the holes or open hatches.
Always ensure all equipment and tools are secured in closed tool bags.
All tools will be secured and tether rope will be utilized as required
Cover all hole openings that create a risk of falling objects as required.
All tower internal tool/materials hoisting operations must be performed by
properly trained personnel using the properly rated hoisting equipment,
rated certified lifting bags, hooks with safety latch.
Before use, take a moment to inspect all hoisting equipment and bag(s) to
ensure there is no damage, cuts/tears, or signs of excessive rubbing/wear.
Lifting equipment will be carefully coordinated. Two-way communication
must be available via radio.
All non-essential personnel must clear the area before hoisting operations
begin. Never remain in front or underneath the tower opening.
DANGER
Uneven/Slippery surfaces!
Uneven surfaces are present due to the shape of the WTG equipment.
Slippery surfaces may be present during wet or icy conditions.
Use caution when walking into any WTG surface that is not designed as
permanent walkaway.
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DANGER
Foot injury risk!
Steel or composite safety boots must be worn to reduce the risk of injury to
feet, in particular from striking against and jamming between objects, from
encountering falling or rolling objects, and from treading on or against
pointed and sharp objects.
DANGER
Crushing hazard!
During installation always ensure that hands, feet, and body are not between
any potential pinch points.
DANGER
Hand crush, cuts and burns risk!
Hands are exposed to mechanical dangers (cutting, grazing, pinching, and
crushing), and to danger from heat and cold (from touching hot objects and
convective heat). When protective gloves are prescribed or recommended,
they must be worn. Use caution when working around exposed rotating
components while the rotor is turning.
DANGER
Eye or facial injury risk!
Eye protection must be used during all work activities, along with using a fullface shield if there is imminent risk of eye or facial injury (when grinding work
is being performed).
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CAUTION
Wear hearing protection!
Proper hearing protection must be worn when working with any electrical or
hydraulic impact tooling!
Always assess the next task at hand. If 85 decibels will be exceeded, hearing
protection must be worn.
Observe requirements for hearing protection per your company's policies.
CAUTION
Know what you are lifting!
When the weight exceeds the limit for a single person, or if the load is awkward /
difficult to maneuver due to shape or size.
Request the help of a second person,
Transfer the load into smaller containers or use the crane or a fork lift.
Reference assembly drawings for weights.
DANGER
Falling hazard - Climbing tower ladder!
Prior to installing the top section verify the fall arrest system (Top Double TBracket and Head assembly is installed according to vendor installation
instructions.
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DANGER
Falling hazard!
When crew persons must climb the tower prior to installation of the
permanent safety cable system, personnel must be connected to a
temporary fall restraint system to allow ascent to top of tower section.
If an employee is working at a height that exposes them to a potential fall,
fall arrest equipment must be used, and 100 % tie-off at all times.
When climbing the tower, double lanyards (Y construction) are to be
equipped along with the safety harness and ladder safety device (e.g.,
Ladsafe/Tuf Tug).
The safety harness and the entire safety equipment must be checked before
use. Damaged equipment must never be used.
WARNING
Climbing tower ladder!
Tower ladder sections (aluminum) surpass the fixed ladder codes of OSHA and
ANSI and are suitable for a 330-pound load (150 kg). When multiple persons are
climbing different sections of the ladder separated by ladder supports to the
tower shell, the ladder will support three climbers at one time. This only applies to
towers provided by GE Energy.
DANGER
Climbing tower ladder!
When climbing tower using the cable fall arrest system one person per tower
section and a maximum of two people climbing the tower is allowed.
Never free climb the tower ladder. Always use the ladder safety system. The
ladder safety system is only rated for one climber per tower section,
maximum of two people climbing the tower in different tower sections at any
given time i.e., (While ascending or descending a ladder section, the ladder
section to be climbed must be cleared of any climbers. If multiple climbers
are ascending or descending, the tower hatches must be closed before the
next climber begins to climb the cleared ladder section.
If multiple climbers are climbing to the same section, climber to close the
hatch and stand away from the ladder.
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DANGER
Risk from lifting heavy loads!
Prior to lifting all heavy loads, a pre-lift meeting with all parties involved is
required (crane operator, rigger, supervisor, signalman, area safety, tag line
holders and any other personnel involved).
All lifting must be done in strict accordance with the installers lifting plan and
applicable job safety analyses must be reviewed prior to commencing work.
DANGER
Risk from overhead suspended load!
Never work under a suspended load. Make sure all people, vehicles,
equipment and materials are clear of the crane tail and load swing.
DANGER
Risk of equipment damage and personnel safety!
Aligning the WTG equipment bolt hole joints may be challenging due to possible
high winds and site conditions.
The process requires qualified and/or trained personnel as required:
In the use of equipment/crane signals,
Skills in the use of standard iron worker tools to aid in bolt hole joint
alignment!
Qualified to operate the GE brake and rotor lock system
Understand the proper operation of taglines are required to aid aligning the
bolt holes which allows the WTG to be installed safely.
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CAUTION
Blade handling!
When handling blades on shipping fixture(s):
Specific blade manufacturer’s handling instructions must be reviewed with
the crews and understood prior to commencing work.
Only use lifting points that are designated by blade manufacturer for lifting.
DO NOT use tie down points that are not designed for LIFTING.
Only use lifting points that are rated with enough capacity to lift the entire
weight of the blade(s).
If unsure, always consult with GE technical advisors and or GE engineering prior
to handling individual blades and/or blades in shipping fixtures for proper lifting
point identification according to the engineering design.
CAUTION
Blade and rotor damage prior to installation!
Each site should assess the need for additional blade and assembled-rotor tiedown arrangement. Locations and instances which demonstrate high groundlevel winds warrant additional consideration which may include: Additional
standard tie-downs and anchor points, further assessment of cribbing and
dunnage and the potential for cribbing and dunnage to sink into the ground.
WARNING
If the tower is completely assembled, including the rotor and access to the rotor
is required, park the rotor in a Y-position, such that one blade is pointed down, in
line with the tower.
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DANGER
Hydraulic disc brake and brake disc rotor lock use!
The installer must personally ensure all personnel assigned to work activities
inside the WTG are properly trained on the use of the hydraulic disk brake and
disk rotor lock, to ensure the hydraulic disc brake and brake disc rotor lock are
100 % engaged and locked out before attempting to:
Pre-tighten and torque the main shaft to hub hardware after rotor is fully
engaged onto the main shaft during rotor installation.
Disconnect the crane and remove the crane out of the working area after
rotor is installed.
Perform any work outside and/or inside of the hub after the rotor has been
installed.
Perform any work inside and/or outside the nacelle near exposed rotating
components after the rotor has been installed.
All GE employees must ensure the hydraulic disk brake and disk rotor lock is
100 % locked out before exiting the nacelle.
ATTENTION
Check components!
All components must be checked for visible damage, deformation and cracks
prior to assembly!
The components must be stored and mounted in such a way that any
damage that could adversely affect the standing stability or load-bearing
capacity and could thus cause potential accidents is avoided. Please contact
the GE site representative if damage is found prior to installing the
component.
DANGER
Risk of damage to equipment!
Tag lines must remain attached when installing components to stabilize the
load where environmental conditions (winds) may cause components to
make contact when hoisting.
Using Tandem picks on the nacelle during offloading and staging without the
use of a properly sized spreader bar will result in damage to the fiberglass
rigging hatch openings. This will result in installation delays, as nacelles with
fiberglass damage will not be allowed to be installed until corrected.
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DANGER
Risk of damage to the wind turbine generator system!
The rotor lock and the high-speed shaft brake must always be released
before leaving the turbine. Make sure that the machine is idling.
DANGER
Rotor lock not to be used to stop rotation!
Never use the rotor lock to stop drive train rotation. The hydraulic hand brake
must be used to stop the rotation.
No hub entry on wind speeds > 14 m/s, 12 m/s with 120 meter rotors.
DANGER
Electrical hazard!
Refer to the latest revision Energization Process Flow Chart and Verify GE
and Customer LOTO procedures are complementary.
Follow site specific LOTO policy if LOTO needs to removed or re-applied.
Ensure all pre- energization/de-energization checks per this document are
adhered to.
Follow electrical PPE requirements in the Electrical Service Bulletin (Element
HS 13. 2C) for any electrical work on the WTG (See the EHS Outage Plan or
the Construction EHS Plan).
DANGER
Electrical hazard!
Verify appropriate energy isolation procedures are followed based on local
standards and/or GE `s requirements.
Use caution during the inspection!
Medium voltage or high voltage may be present in the WTGS. The collection
system terminates at the second level medium voltage switchgear. Verify
that the installer LOTO plan and GE LOTO plan are complementary to ensure
the equipment is de-energized.
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DANGER
Electrical hazard!
If WTG has a PMG Generator, the rotor must be locked before performing phase
check and electrical validation testing and before terminating the generator
cables.
Verify appropriate energy isolation procedures are followed based on local
standards and/or GE requirements. I.e. local standards, customer LOTO plan
and GE LOTO plan must be complementary to ensure the equipment is deenergized.
WARNING
Tower rescue equipment (Abseiling device!)
An abseiling device must be available in the event of an emergency; the system
depends on the turbine configuration. Check the integrity of the seal of the
equipment bag on each visit to the nacelle.
The abseiling device is pre-assembled and is ready for use immediately after it
has been removed from the equipment bag.
Perform an additional visual inspection of the abseiling device immediately
before use. Care for and maintain the abseiling device as per manufacturer’s
recommendations.
ATTENTION
Environmental Risk!
Follow all applicable local regulations for use, containment and disposal of all
chemical substances.
NOTE
Emergency evacuation routes:
Where the main access road to any particular pad is blocked due to limited
space, the Buyer & Installer is responsible to plan for an alternative emergency
vehicle route and or site specific emergency evacuation plan in case there is an
emergency.
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4.1 Operations Involving the Use of a Crane
WARNING
Mind the maximum allowable wind speed!
For technical data to calculate the maximum allowable wind speed for crane
activities especially on parts and systems with a high sail area with respect
to system weight refer to the document “Specification handling and Lifting (Drag Coefficient Sail Area)”.
All operations involving the use of a crane may only be carried out based on the respective crane limitations,
site/weather specific circumstances and field personal experience. The final decision if work may be executed
rests with the crane operator and installer representative based on the lift plan.
4.2 Qualification and Orientation of the Installation Personnel
Only trained and oriented personnel may be deployed during the installation. Only trained People are allowed
to install the (optional) service lift. The spheres of responsibility of the personnel for the operation of tools must
be clearly defined! A responsible person who monitors safety during the installation and prevents any work
which compromises safety from being carried out must be appointed.
The installation personnel must be informed about and oriented in the current legal and accident prevention
regulations. Furthermore, the installation personnel must be oriented in the available safety devices on and in
the Wind Turbine Generator System and the safety devices of the installation equipment.
It must be ensured that the installation personnel have completely understood the instructions and that all the
instructions are complied with. Only thus will all concerned carry out work with safety in mind and with an
awareness of the dangers.
In addition to the Installation Manual and the binding regulations for accident prevention in the country of use
and applicable at the location, the technical regulations for safety and working in accordance with good
professional practice must also be complied with.
NOTE
Comply with the accident prevention regulations!
The country-specific accident prevention regulations must always be
complied with.
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4.3 Safety Equipment
The safety equipment serves to reduce risks and dangers. It must be guaranteed that every erecting engineer
uses his personal protective equipment (PPE), in order to prevent accidents or serious injuries.
4.4 Personal Protective Equipment (PPE)
Everybody must wear Personal Protective Equipment (PPE) when working on or in the WTGS to protect
themselves from injury in accordance with the GE Climbing Rules:
The PPE includes:
Full body fall protection harness w/ front, back and side D-rings.
Traveling safety hook
Double lanyards Y construction with shock absorbers
Suspension trauma strap
Hard hat equipped with chin strap
Steel-toe (or composite toe) safety boots (sturdy lugged soled footwear, capable of supporting
ankle)
Lanyard keepers are required for double lanyards with a single shock ABSORBER pack
Safety glasses
Gloves appropriate for climbing
Hearing protection (if required)
Rescue/escape system (Europe: black bag) with the rope length greater than tower height.
Breathing apparatus (if required)
Thermal clothing (if required)
The PPE must be approved and furnished with marks of conformity; which certify that it is suitable for the work,
the protection and also for the climatic conditions of the site. The extent and the equipment of the personal
protective equipment may vary in some countries.
NOTE
Check the protective equipment!
Check the completeness, the condition and the function of your personal
protective equipment in good time before entering the WTGS. If a piece of
the equipment is missing, it must be replaced before starting work.
The safety harness and the entire safety equipment must be checked before use. Damaged equipment must
never be used.
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The PPE must be inspected and tested by a technically competent person after any fall, or at least at the intervals
recommended by the manufacturer.
NOTE
Follow the instructions!
Follow the manufacturer's instructions for all component parts of the
personal protective equipment!
4.4.1 Safety Harness
The safety harness is used for your safety during the ascent and descent of the tower (safety harness and
traveling safety hook) and when carrying out work in areas where there is a danger of falling (safety harness
and safety rope).
WARNING
Check the safety harness!
Check the safety harness and the safety equipment, before you use it.
Damaged components must not be used and must be exchanged
immediately.
Care and handling of the safety harness and the complete safety equipment:
Never expose to acids/caustic chemicals. If this is unavoidable, rinse with water immediately
afterwards.
Protect from sharp edges and sharp-edged objects.
For clean and care, refer to manufacturer recommendations.
Store in a well-aired place out of direct sunlight.
Additionally, follow all of the manufacturers handling and care instructions.
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4.4.2 Protective Equipment for Measurements on Live Components
DANGER
CRITICAL TO SAFETY:
Ask and answer this question every day!
“Are you planning to work on (or near) electrical equipment or cables, etc.?”.
If you answered “Yes”!
You are required to work with your Site EHS and Site Leadership to establish a
Risk Assessment and train/ issue/communicate the Site Specific LOTO plan to
all affected team members BEFORE executing ANY work.
Examples including but not limited to Installation and Post Installation of:
Electrical equipment or any other testing that requires energizing or deenergizing e.g., IR/VLF/Hi-Pot Testing
Temporary Energizing/Lighting
Commissioning /Pre-Commissioning/Portable Generators
Permanent or Temporary Grid/PMT
Load Bank
DANGER
Life-threatening hazard! Danger! Electricity!
Contact can cause extremely serious injuries and even death.
DANGER
Electrical hazard!
Refer to the latest revision Energization Process Flow Chart and Verify GE and
Customer LOTO procedures are complementary.
Follow site specific LOTO policy if LOTO needs to removed or re-applied.
Ensure all pre- energization/de-energization checks per site-specific LOTO
are adhered to prior to beginning any work.
Follow electrical PPE requirements in the Electrical Service Bulletin (Element
HS 13. 2C) for any electrical work on the WTG (See the EHS Outage Plan or
the Construction EHS Plan).
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Special PPE is required for measurements or work on live components. This provides protection against
electricity flowing through the body, e.g. as a result of touching live components in operation. Furthermore, it
provides protection against accidental arcs caused by insulation breakdowns e.g. as a result of switching
operations under load.
Please refer to the GE Electrical Service Bulletin to check specific requirements for the different risk categories.
NOTE
The following PPE requirements listed in Table 7 below are an addition to the
requirements outlined by the Wind Turbine Climbing Rules.
Danger class
2
Required Electrical PPE
Note: Underwear must be of cotton or other natural fiber.
Cal/cm
(Joule/cm2)
Uniform: Long sleeves and long pants required (minimum of untreated
natural fiber non-melting clothing. 4.5 oz/yd²: 153 g/m2 weight) such as
100 % cotton or at least NFPA Category 1 or EN Class 1
0
Up to 1.2
(Up to 5)
Other PPE:
Safety glasses
Ear canal inserted hearing protection (starting 1Q10)
1000 V or higher gloves and leather shells
Uniform: Arc resistant (AR) shirt and AR pants or overalls (4 cal/cm²); at least
NFPA Category 1 or EN Class 1
1
Other PPE:
Safety glasses
Arc-rated face shield (starting 1Q10)
Hard hat (class E) (all new hard hats and required 1Q10)
All leather upper heavy duty work shoes – EH rated (all new shoes
and required by 1Q10)
1000V or higher gloves and leather shells
Ear canal inserted hearing protection (starting 1Q10)
1.2 to 4
(5 -16.6)
Uniform: Arc resistant (AR) shirt & AR pants or overalls (8 cal/cm²); at least
NFPA Category 2 or EN Class 1
2
4.1 to 8
(17 - 27.3)
3
8.1 to 25
Other PPE:
Safety glasses
Arc-rated face shield or arc flash suit hood
Hard hat (class E) (all new hardhats and required 1Q10)
All leather upper heavy duty work shoes – EH rated (all new shoes and
required by 1Q10)
5
1000 V or higher gloves and leather shells
6
Ear canal inserted hearing protection
7
Balaclava
1
2
3
4
Uniform: Arc resistant (AR) shirt and AR pants or overalls (8 cal/cm²); at least
NFPA Category 2 or EN Class 2
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Danger class
2
Cal/cm
(Joule/cm2)
(28 – 104)
– Original –
Installation Manual
Required Electrical PPE
Note: Underwear must be of cotton or other natural fiber.
Other PPE:
PPE same as level 2 plus
Arc-rated flash suit (jacket and pants) & flash suit hood
1000 V or higher gloves and leather shells
Layers of AR clothing must add to 25 cal/cm² or greater
Uniform: Arc resistant (AR) shirt and AR pants or overalls (8 cal/cm²); at least
NFPA Category 2 or EN Class 2
4
25.1 to 40
(104 – 167)
Over 40 cal/cm²
(Over 167 J/cm²)
Other PPE:
PPE same as level 2 plus
Arc-rated flash suit (jacket and pants) and flash suit hood
1000 V or higher gloves and leather shells
Layers of AR clothing must add to 40 cal/cm² or greater.
Arc blast potential must be heavily considered when this level of protection is
needed.
The preferred method is to reduce the risk level through engineering controls.
Table 7: Protective equipment for measurements on live components
Cal/cm2 denotes the unit up to which the PPE resists the released energy.
5 Preparatory Work
1.
Barricade and/or cordon off as per country specific the installation site to limit access to
unauthorized personnel.
2.
Check the lifting gear for proper inspections and certifications.
3.
Conduct a Pre-lift meeting, complete Job Safety Analyses (JSAs).
4.
Personnel not involved in crane lift operations must leave the crane work zone (danger zone)
before lift operations start.
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6 Foundation
ATTENTION
Confirm that the grounding ring(s), the installation rods and the soil resistivity
test verification report are complete in accordance with the respective
grounding specification.
Inspect the foundation for cracks/damage; report any foundation damage to
the customer and GE prior to erection activities.
Verify with Civil Superintendent that foundation has been cleared to start
tower assembly work and minimum required foundation submittals per
respective foundation specifications are complete.
DANGER
Electrical hazard!
Refer to the latest revision Energization Process Flow Chart and Verify GE and
Customer LOTO procedures are complementary.
Follow site specific LOTO policy if LOTO needs to removed or re-applied.
Ensure all pre- energization/de-energization checks per Site Specific LOTO
are adhered to prior to beginning any work.
Follow electrical PPE requirements in the Electrical Service Bulletin (Element
HS 13. 2C) for any electrical work on the WTG (See the EHS Outage Plan or
the Construction EHS Plan).
The Installation of the foundation is not part of this Installation Manual. Refer to the contract technical foundation
documents for details.
6.1 Tower Base Ring
The tower base ring is the bottom part of the tower. The PPM is placed inside the base ring on the foundation.
6.1.1 Drawings
See contract technical foundation documents.
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6.2 Identifying the Tower Base Ring
ATTENTION
Identify the tower base ring!
The positioning of the PPM differs depending on the type of tower base ring
[108 holes or 124 holes).
Tower Base Ring (75 m and 85 m)
Hole pattern for foundation – tower base ring
connection
54 x ø 55 mm – flange inside
54 x ø 55 mm – flange outside
Hole pattern for TBR – tower base section
connection:
115 x ø 52 mm.
Figure 2: Tower base ring (75 m & 85 m)
Tower Base Ring (98.3 m)
Hole pattern for foundation – tower base ring
connection
62 x ø 55 mm – flange inside
62 x ø 55 mm – flange outside
Hole pattern for TBR – tower base section
connection:
121 x ø 52 mm.
Figure 3: Tower base ring (98.3 m)
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Tower Base Ring (110 m and 120 m)
Hole pattern for foundation – tower base ring
connection
62 x ø 55 mm – flange inside
62 x ø 55 mm – flange outside
Hole pattern for TBR – tower base section
connection:
106 x ø 61 mm.
Figure 4: Tower base ring (110 m and 120 m)
Tower Base Ring (131 m)
Hole pattern for foundation – tower base ring
connection
80 x ø 55 mm – flange inside
80 x ø 55 mm – flange outside
Hole pattern for TBR – tower base section
connection:
147 x ø 52 mm
Figure 5: Tower base ring (131 m)
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6.2.1 Preparing the Foundation Anchor Bolts and Installing the Tower Base Ring
Reference Customer Information for the Anchor Bolt System.
General_Description_3MW-50Hz_foundation_anchorAdapt.
If tower base ring is already installed go to section 6.3
1.
Tap each bolt lightly to break the bolts free of cement seepage. Verify threads are free of cement
and defects.
2.
Verify anchor bolts are sealed where it meets the concrete to ensure that there is no water in the
anchor bolts sleeve that could cause corrosion and possibly freeze depending on the site location.
3.
Clean debris from the entire foundation surface. Any loose or adhesion-inhibiting parts and
cement slurry must be removed.
4.
Protect anchor bolts from grout area with foam or other means as indicated in customer and/or
GE foundation design specification to keep grout from adhering to the anchor bolts.
General_Description_3MW-50Hz_foundation_anchorAdapt
CUSTOMER SPEC: Request from customer.
5.
Remove the nuts and washers from the anchor bolts.
6.
Place the nuts and washers on the foundation at a sufficient distance from the anchor bolts so
they can be easily acquired when placing them back onto the bolts after tower base Ring is
lowered.
7.
All anchor bolts project at least 100 mm beyond lower tower base ring flange.
6.2.2 Preparing the Tower Base Ring
1.
Inspect the tower base ring interior, exterior, and flange for exposed metal surfaces, corrosion,
burrs, and high spots.
2.
Remove burrs and high spots using a course half-round file and buff the surface using medium
grit sandpaper. Remove corrosion using medium grit sandpaper and protect from corrosion (e.g.
cold galvanize) or as required per manufacturers specifications.
3.
Paint exposed metal surfaces of the interior and exterior of tower base ring per manufacturer’s
specifications. Ensure the correct paint and primer is used for interior or exterior repairs, consult
with GE` s representative for details.
4.
Completely clean and wash interior and exterior.
6.2.3 Verifying the Foundation is Level
1.
Please refer to customer and/or GE foundation specification to ensure the minimum/maximum
grout thickness per foundation design. General_Description_3MW-50Hz_foundation_anchorAdapt
Contact GE for the site-specific GE Tower Foundation Interface Specification.
Contact Customer for customer specific Foundation Interface Specification.
2.
Using a laser level, shoot four points per quarter between leveling locations, and mark the results
at each location. Return to the highest point recorded within the circumference and use as a
reference point.
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From reference point adjust the level locations by using metal shim plates to ensure the
minimum/ maximum grout thickness as required by foundation design. Do not put shims directly
underneath the door.
Contact GE for the site-specific GE Tower Foundation Interface Specification.
Contact Customer for customer specific Foundation Interface Specification.
6.2.4 Installing the Tower Base Ring
1.
To prevent a pinch point/crush hazard, place four 4 x 4 wood blocks on the foundation spaced
every 90 degrees between the anchor bolts.
2.
Prepare the foundation for applying grout in accordance with grout manufacturer's and
foundation designer's instructions.
3.
Attach the rigging and tag lines to the tower base ring.
4.
Instruct crane operator to hoist the tower base ring over the foundation and onto the anchor
bolts.
ATTENTION
Crushing hazard!
During Installation always ensure that hands, feet, and body are not between
any potential pinch points.
5.
Crew persons holding tag line will guide the tower base ring down over the anchor bolts onto the
foundation. Align the TBR over the anchor bolt in accordance with the foundation specification.
6.
Remove the four woodblocks after the tower base ring is safely installed over the anchor bolts on
the leveling metal shim plates.
7.
Verify the tower base ring is level in accordance with the foundation specification.
If the tower base ring is to be grouted now, install nuts with two turns per nut, raise the tower base
ring and re-insert the support (wood blocks); grout per manufacturer’s specifications, remove the
supports (blocks) and lower the tower base ring section, check level again. Ensure excess grout is
removed and the flange is clean.
8.
Install all nuts and washers, install washers (with chamfer facing away from flange) and nuts per
manufacturer's specifications onto the anchor bolts.
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9.
– Original –
Installation Manual
Tighten the top nuts with an impact wrench to approximately 100-foot pounds (150 Nm) at the
leveling shim pack locations. For GE foundation design refer to the 3MW Platform Bolt Torque
Specification mentioned in chapter 2.2. For all other designs refer to manufacturer design
specifications.
10. Final tensioning of anchor bolts is done after grout has cured according to manufacturer's
instructions.
11. In section 7 of the ICL enter:
Grout type, date and time, required grout strength achieved, Enter minimum grout compressive
strength required before the anchor bolts can be tensioned and actual measured bar (PSI) grout
break (proven by testing).
12. Ensure anchor bolts are clearly marked with a single line running down the threads nut washer
and clamped part extending beyond the protection caps. This will serve as a visual reference for
future maintenance inspections to indicate tensioning is complete.
13. Record pretension and elongation in kN and mm data respectively in the torque report. Refer to
foundation design specification.
14. Mark the centerline for the tower entry door on the upper flange of the tower base ring for PPM
and tower door centerline installation reference point.
15. Using a permanent marker neatly write the anchor bolt tension values on the inside tower wall:
(Pre-tension load (kN) =
Value =
Date:
)
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6.3 Preparing the Foundation
1.
Inspect the bottom and the top base ring
flange and the shell for exposed metal
surfaces, corrosion, burrs and high spots
and dirt from concreting.
2.
Remove burrs and high spots using a
coarse half-round file and buff the surface
using medium grit sandpaper. Remove
corrosion using medium grit sandpaper.
3.
Inspect the anchor bolts (anchor bolt size
M 48, hot dip galv) for dirt from concreting,
defects on the corrosion protection and
defects on the threads.
4.
Verify the tower base ring is leveled by
using a surveyor's level.
5.
Pretension the anchor bolts on the tower
base ring according to the specifications
of the foundation designer.
6.
Check again the level of the tower base
ring according to the tolerances of the
foundation designer.
7.
Install the protection caps on the bolts as
required per the foundation design.
Figure 6: Cleaning the surface of the foundation
ATTENTION
Water damage!
Verify no water accumulation is present inside the
foundation and/or in conduits.
If water is present, remove it and seal all
transformer and foundation conduit openings
to keep water out.
Figure 7: Installing the protection caps on the bolts
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8.
Shorten all plastic pipes, through which
the telephone line (option), fiber-optic
cables (for wind farm connection) and the
grid connection are subsequently routed,
by means of an angle grinder or a saw.
9.
Remove all sharp edges and install conduit
edge protection caps.
10. Verify ground cables are installed free of
defects and in the foundation in
accordance with the
"Requirements for the
Tower to Foundation Interface" document
and/or country- and local-specific
electrical code.
Installation Manual
Figure 8: Shortening the plastic pipes
NOTE
Meet grounding resistivity requirements!
The grounding resistivity requirements must be met before the tower is erected!
Where applicable, ground wires must be terminated at every stage of the
installation process!
11. Verify bolts, tools, and materials are
staged inside the base ring with enough
clearance from the flange.
Figure 9: Staging the bolts inside the tower base ring
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7 Pre-assembled Power Module (PPM)
The "Pre-assembled Power Module" is installed in the tower base of the Wind Turbine Generator System. The
PPM enables the transformer and medium-voltage switch gear to be integrated in the tower.
The PPM consists of the following three sections:
Section 1 (transformer level)
Section 2 (controller level)
Section 3 (converter level)
Section 3:
Converter level
Section 2:
Controller level
Section 1:
Transformer level
Figure 10: Structure of the 3-level PPM
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7.1 Safety Information for Installation of the PPM
ATTENTION
Secure against unauthorized entry/climbing!
If the first tower section is not installed on the same day as the PPM, the PPM
must be secured against unauthorized entry and climbing, in order to protect the
turbine from damage and people from injury.
This can be provided by disassembly of the bottom section of the ladder or
by a night security service.
The ladder and the fall protection systems must be checked as described in section 17 Installation of the
Ladder and Fall Protection System on page 344 before a new segment of the ladder is used.
All personnel concerned must wear their personal protective equipment (PPE) when carrying out work on
the PPM.
DANGER
Falling hazard!
Ensure that you are always protected by your PPE when carrying out work on
the PPM.
Use the hooking points marked in signal yellow which are located on each
platform (section).
DANGER
Life-threatening hazard - working under suspended loads!
Everybody must leave the danger area!
The banksman may not give a signal to raise or lower until everybody has left the
danger area.
Never stay under suspended loads!
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ATTENTION
Check the components!
All components must be checked for visible damage, deformations and
cracks which could affect their bearing capacity before assembly. Findings
have to be reported to the GE site representative.
The components must be stored and assembled in such a way that damage
which could adversely affect their stability or bearing capacity and thereby
lead to safety hazards is prevented.
ATTENTION
Crushing hazard!
During Installation always ensure that hands, feet, and body are not between
any potential pinch points.
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7.2 Overview of the Hooking Points
A total of three safety hooking points for personal falling protection are provided in the PPM. They are marked
in signal yellow and are located on the controller level, two on columns and one above the transformer level
hatch for rescue from this level.
The hooking points must be used when carrying out work which requires removal of the installed fall
protection systems or safety rails.
Transformer Level Consideration when working on the Pre-Assembled Power Module (PPM)
Please make sure that no object (like a cable or a long toll) goes into the transformer level from other levels
while the medium voltage or auxiliary transformers are energized.
Figure 11: 3-level PPM – Hooking points
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7.3 Overview of the Installation Sequence
The 3-level PPM is constructed in eight primary steps, which are described in detail in the following section. The
graphic shows an initial overview of the steps to be carried out.
1.
Place the transformer level
(section 1) on the foundation.
Install the ladder components.
2.
Assemble the converter onto
its support frame. (The
converter fan shrouds will be
installed after tower door
section has been installed).
3.
Place the converter with its
support frame (section 3) onto
the controller level (section 2).
4.
Place the controller/ converter
assembly (sections 2 and 3)
onto the transformer level
(section 1) and secure the twist
locks.
8.
Ensure the shrouds are
dismantled before lowering
down the base section.
5.
6.
7.
Alternatively, place the
controller level (section 2) onto
the transformer level
(section 1) and secure the twist
locks.
Place the converter with its
support frame (section 3) onto
the controller/transformer
assembly(sections 1 and 2).
Install the temporary rail
Connect the door section to
alignment system for the
the base ring. Assemble the
installation of the door section stairs.
of the tower.
Ensure the shrouds are
dismantled before lowering
down the base section.
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9.
10.
Install the converter fan shrouds, the platform cover plates to close the gaps around the
converter. Assemble the power meter and shadow monitoring boxes (when required) as well as
hatches, steps, railings, brackets and ladders in the transformer, controller and converter
levels.
Extend the four vibration
dampers. Assemble the air
inlet ducts.
ATTENTION
Check the wind speed!
The PPM must be secured against tipping over from a wind speed of
v = 25 m/s. This can be provided by bracing the PPM with chain hoist.
All PPM components must remain protected from elements such as moisture, rain, snow, contaminants such
as dirt, dust, oil, rodents and damage during installation process.
The installer must hold available protection material for storage e.g., tarps - shrink wrap - taking into
consideration condensation and freezing weather.
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11. All PPM components must remain
protected from elements such as
moisture, rain, snow, contaminants such
as dirt, dust, oil, rodents and damage
during installation process.
12. The installer must hold available
protection material for storage e.g., tarps shrink wrap - taking into consideration
condensation and freezing weather.
Figure 12: Example PPM transformer and controller level covered
with a tarp
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7.4 Assembling the PPM
WARNING
Due to large sail area the base section must be installed immediately after
installing anything above the transformer.
WARNING
Take care when working on the low-loading trailer
Work on the loading platform of the low-loading trailer may only be carried
out when it is stationary. All personnel must leave the loading platform
before the low-loading trailer is moved.
DANGER
Falling hazard!
Retractable lanyards or temporary fall arrest system shall be used until the
permanent fall arrest system is installed.
DANGER
Falling hazard!
Ensure that you are always protected by your PPE when carrying out work on
the PPM.
Use the hooking points marked in signal yellow which are located on the
controller level (section 2).
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WARNING
Keep free all passageways and
escape ways!
Do not obstruct with tools or
construction material.
DANGER
Prevent damage to the WTGS!
When lifting PPM components, ensure the load is stabilized to prevent
unexpected swing and potential contact with other objects and to ensure the
cribbing will not shift.
Platform (Section)
Drawing number
Structure of the PPM, DTE assembly
117W6882, 444W8673; For 131m request latest version from GE
engineering.
Transformer platform (Section 1)
117W6871, 444W6900
Controller platform (Section 2)
117W6997, For 131m request latest version from GE engineering.
Converter platform (Section 3)
117W6892, 44W8727
Assembly Drawing Ladder DTE
117W6917, 444W7063 (131 and 85 m); 444W9057 (110 m)
Assembly Drawing Converter
Request latest version from GE engineering.
Operation Manual for Cast Resin
Transformers without enclosure
DT4622
Table 1: Requisite installation Diagrams
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– Original –
1.
Cut holes from the lifting points. The
packaging must be maintained until the
nacelle is installed.
2.
Remove all the securing devices located
between the low-loading trailer and the
PPM section.
3.
Remove any loose parts which could drop
out while lifting the section.
4.
Carry out the Transformer Receiving
Inspection.
Installation Manual
Figure 13: Unpacking the transformer platform
5.
Attach an M39 bolt-on attachment swivel
with a lifting capacity of 15 t at each pillar
of section 1 (transformer level).
6.
Lash the section by means of the bolt-on
attachment swivels.
NOTE
Minimum length of lashes (chains or slings) to lift
the transformer level is 6000 mm.
Adjust the rigging as required to ensure the
transformer is level.
7.
Before lifting, lash a tag line to each of two
opposed points, in order to prevent the
section from swinging during the lifting
operation.
8.
This allows the section to be guided
without danger.
Figure 14: Attaching an M39 bolt-on attachment swivel
Figure 15: Guiding the section
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7.5 Installing the Fit Up Aid Tool (Transformer Alignment Brackets)
1.
Before lowering the transformer platform, care shall be taken that the right tool is used and fixed
in the pre- marked holes, see following drawing.
Hole "1" is located centrally in front of the
tower door, (N). next to the tower
manufacturer 0 reference mark and or as
identified by the civil contractor.
The position of the tower door is pad
specific, in relation to the position of
conduits.
2.
75/85 m RH bracket in hole 15 & 16
Counting counter-clockwise from hole "1"
insert alignment brackets for the 75/85 m,
98.3 m, 110 m or 120 m tower
configuration.
Reference illustrations.
75/85 m LH bracket In hole 44 & 45
98.3 m RH bracket in hole 16 & 17
98.3 LH bracket in hole 46 & 47
110/120 m RH bracket in hole 14 & 15
110/120 m LH bracket in hole 40 & 41
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NOTE
Refer to specific tower drawing for correct fit up aid tool as bolt hole pattern
varies for different hub heights (HH) and hole “x” will vary.
3.
Secure the two alignment brackets to the
tower base ring flange with hardware.
Ensure the templates are oriented correctly
and the right size hardware is used to
prevent movement of the alignment
templates during installation of the
transformer.
Figure 16: Transformer alignment templates
ATTENTION
Prevent damage to the WTGS!
When lifting PPM components, ensure the load
is stabilized to prevent unexpected swing and
potential contact with other objects.
4.
5.
Give detailed instructions to the crane
operator to swing the section over the
tower base ring.
Figure 17: Transformer Positioning
Slowly lower the section. An erecting
engineer must be positioned at each
template to supervise the lowering of the
PPM.
DANGER
Crushing hazard!
During Installation always ensure that hands,
feet, and body are not between any potential
pinch points. Use tag lines to guide the load.
Figure 18: Transformer Positioning
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6.
– Original –
Installation Manual
Insert the transformer platform between
the brackets of the fit-up aid tool. First
dock the transformer platform to the left
bracket, and then pull it against the right
bracket.
Figure 19: Transformer Positioning 75/85m
7.
Loosen nut A completely.
8.
Loosen nut C.
Figure 20: Aligning the transformer level
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9.
– Original –
Installation Manual
Place a water level or spirit level on the
flange of the tower base ring.
10. Hold it to the pillar of the transformer
platform.
11. Measure the distance from the top surface
of the pillar flange to the bottom surface
of the water level and adjust the
adjustment nut B resulting in a distance of
611 mm.
Depending on ground thickness shim plates
may be required.
NOTE
Consult with engineering prior to using shim
plates!
12. Hold nut B and using a torque wrench with
a crows-foot torque nut C to 200 Nm
against nut B.
Figure 21: Aligning the transformer level
13. Repeat this adjustment at the other three pillars.
14. If needed, use a bottle jack as required to adjust level. Ensure all four feet are set firmly on the
foundation, the PPM Transformer oriented correctly on the foundation for ease of access to the
walkway through the tower entry door.
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15. After positioning the section, remove all
hoisting gear, tag lines and attachment
swivels and the fit up aid tool.
Figure 22: Disconnecting the rigging
16. Terminate the foundation ground leads to
the transformer grounding bus bar in
accordance with the foundation tower
interface specification, torque the bolts
and mark them with a paint pen.
Figure 23: Termination of foundation grounds.
17. Place step (FN 3) in its final position.
18. Drill holes into the concrete floor to install
the anchor bolts (FN 15, 16 and 17) per
drawing no. 117W6917/444W7063/
444W9057.
A
19. Bolt the brackets (FN 4) to the step.
20. Place the converter coolant drain barrel
inside the base ring.
B
A - Barrel
B - Step
Figure 24: Floor step.
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21. Perform Insulation Resistance test and
Transformer Turns Ratio (TTR) as
prescribed in the Transformer
manufacturer manual.
Request latest version from GE engineering.
NOTE
Transformer testing must be completed
before tower erection.
22. Provide a copy of the test results to GE.
Figure 25: Transformer manual for TTR instructions
ATTENTION
The transformer coils and all other equipment
must remain protected from elements such as
moisture, rain, snow, contaminants such as
dirt, dust, oil, rodents and damage during
installation process.
The installer must hold available protection
material for storage e.g., tarps - shrink wrap taking into consideration condensation and
freezing weather.
Figure 26: Equipment protected from elements
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23. Stage the ladder parts inside the tower for
later installation according to drawing
117W6917/444W7063/444W9057.
WARNING
Do not use the transformer ladder unless it is
fully installed according to drawing.
Figure 27: Staging the ladder system at the transformer level
24. Remove all packaging material from the
converter and the converter support
frame.
25. Remove all the securing devices located
between the low-loading trailer and the
PPM section.
26. Remove any loose parts which could drop
out while lifting the section.
27. Carry out the Converter Level Receiving
Inspection.
28. Offload the converter and the converter
support frame on a level surface near the
tower assembly area.
Figure 28: All equipment protected from elements
29. Remove the shipping material from the
converter fans and remove the 4 loose fan
plenum covers and place them aside.
A - 4 plenum covers are shipped loose on top of the fan
A
Figure 29: Fan plenum covers
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30. Loosen the hardware to remove the
square covers bolted to the top of the fan.
B
B - Cover
Figure 30: Fan square covers
31. Remove the converter fan top covers to
allow access to the lifting point.
32. Remove the covers and place them aside.
33. Screw the hardware back onto the fan
bolts for later use.
Figure 31:Removing the square cover
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34. Place the fan plenum covers inside the
tower base section and secure with rope.
The fan plenum covers will be installed on
the converter fans after the base section is
installed over the PPM.
Figure 32:Place the fan plenum covers inside the tower base
section
35. Remove the three cross braces and the
two-heat exchanger protective covers that
are bolted to the top of the converter
cabinet.
Reference the latest ESS DTA drawing.
Figure 33: Cross braces and the two heat exchanger protective
covers
36. Remove the two fan top covers and place
them aside.
A - Heat exchanger protective covers
A
Figure 34: Heat exchanger protective covers
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37. Remove the motor fan assembly shipping
crate hardware.
Figure 35:Shipping crate hardware
38. Attach rigging to the two fan lifting points.
39. Lift the converter fans on top of the
converter.
Figure 36: Lifting the converter fan motor
40. Align over the converter cabinet bolt
holes.
41. Remove the rigging.
Figure 37: Placing the fan motor ontop of converter
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42. Install and tighten all hardware according
to the torque values provided in 105T5350.
Figure 38: Securing the fan motors with hardware
43. Open converter support frame and ensure
all PSL parts are accounted for.
If any parts are missing contact GE site
representative.
Figure 39:Converter support frame/PSL
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44. Remove all shipping material from the
converter support frame.
Figure 40: Converter support frame
45. Attach the rigging to the converter.
NOTE
The slings must be long enough so that there
is not pressure put against the converter fan
motors.
Alternatively, a spreader bar is used to keep
the sling pressure off from the fan motors
46. Remove the shipping crate hardware.
ATTENTION
Crushing hazard!
Be aware of and keep your body away from
pinching points during assembly operations.
Figure 41: Rigging and removing DTE from shipping crate
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47. Lift the converter and place it on top of the
converter frame.
48. Ensure the load is stabilized before
installing the mounting hardware.
Figure 42: Placing the converter over the support frame
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49. Apply thread locking compound to the
mounting hardware.
50. Install the hardware to secure the
Converter DTE to the converter frame.
Reference the latest ESS DTA drawing.
Figure 43: Installing the hardware
51. Tighten all bolts with an impact wrench
not to exceed the final torque specified in
114W8775.
Figure 44:Tightening hardware with an impact wrench
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52. Torque all hardware to the values
provided in 114W8775.
Figure 45: Torquing the hardware
53. Remove all packaging material from the
top of section 2 (controller level).
54. Remove all the securing devices located
between the low-loading trailer and the
PPM section.
55. Remove any loose parts which could drop
out while lifting the section.
56. Carry out the Controller Level Receiving
Inspection.
Report any issues to the GE site
representative.
57. Place the hatches, steps and railings for
the controller level per drawing 117W6917
and 117W6882/444W8673 on the platform
for later installation and secure all items
against falling with tension belts. For
131m request latest version from GE
engineering.
Figure 46: Exposing the top of the controller
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58. Ensure all hatches, steps and railings for
the controller level are accounted for.
Contact GE site representative if any parts
are missing.
59. Optional: Place the hatches, steps and
railings for the controller level per drawing
117W6917 and 117W6882/
444W8673 on the platform for later
installation and secure all items against
falling with tension belts. For 131m
request latest version from GE
engineering.
Figure 47: Accounting for platform parts
60. Instruct the crane to lift the converter over
the controller level.
ATTENTION
Use two-way radios!
A two-way radio is required for communication
between the crane operator and the erecting
engineer.
Precise instructions for the required changes in the
position of the tower sections can be given by this
means.
Figure 48: Placing converter over controller
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ATTENTION
Crushing hazard!
Be aware of and keep your body away from pinching points during assembly
operations.
61. Align the converter leg holes to the
controller level guide pins.
Figure 49: Aligning converter over controller
62. Install the hardware on all 4 legs.
Figure 50: Installing the hardware
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63. Tighten the hardware with a ratchet
and/or impact wrench not to exceed the
final torque.
Figure 51: Tightening the hardware
64. Using a torque wrench and back up
wrench, torque the hardware according to
the torque values provided in
117W6892/444W8727.
Figure 52: Torquing the hardware
65. Detach the rigging from the converter
lifting points.
DANGER
Equipment failure hazard
The hardware that connects the converter to
the converter frame and the converter frame
to the controller is not rated to lift the weight
of the controller unit. Do not attempt to lift the
controller and converter unit together using
the converter lifting eyes.
Figure 53: Removing the rigging
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DANGER
Falling hazard
If an employee is working at a height that exposes them to a potential fall,
fall arrest equipment must be used, and 100 % tie-off at all times is required.
66. Install a new set of rigging connected to
the four controller lifting points.
NOTE
The slings must be long enough so that there
is no pressure put against the converter fan
motors.
Alternatively, a spreader bar is used to keep
the sling pressure off of the fan motors
Figure 54: Connecting the the rigging to the controller lifting
points.
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67. Instruct the crane operator to lift the
controller/converter over the transformer.
ATTENTION
Crushing hazard!
Be aware of and keep your body away from
pinching points during assembly operations.
Figure 55: Lifting the controller/converter over the transformer
68. Align the controller /converter over the
transformer ensuring the correct
orientation i.e., the MVSG over the cable
tray/grid cables.
Figure 56: Aligning the the controller/converter over the
transformer
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69. Connect the sections by locking the
interlocking devices of the two sections.
The interlocking devices are locked by
means of a service key in accordance with
the manufacturer's specification.
70. Ensure proper locking, by loosening,
pushing up and turning to engage the
interlocking device.
71. Verify a second time the locking devices on
all four corners are engaged tight and
marked with a pint pen.
A - Lock nut
A
Figure 57: Engaging the four lock nuts
72. Tap the four lock nuts clockwise with a
hammer until it is tight.
Alternatively use Twist Lock Wrench
Jost 915.259.000 Type Universal.
Figure 58: Tightening the four lock nuts
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73. Install four ratchet straps to stabilize the
load while tower base section is installed.
Figure 59: Securing the PPM with rachet straps
74. Detach the rigging from the controller
lifting points.
Figure 60: Removing the rigging
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Option 2: Installing controller level on top over the transformer first and then installing the converter on
top the controller.
75. Instruct the crane operator to slowly lift
the controller level and lower it on to the
interlocking devices (twist locks) of
section 1 (transformer level).
NOTE
Ensure the shrouds are dismantled before
lowering down the base section.
Figure 61: Mounting controller level section 2 on transformer
level section 1
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76. Connect the sections by locking the
interlocking devices of the two sections.
The interlocking devices are locked by
means of a service key in accordance with
the manufacturer's specification.
77. Ensure proper locking, by loosening,
pushing up and turning to engage the
interlocking device.
78. Verify a second time the locking devices on
all four corners are engaged tight and
marked with a paint pen.
A - Lock nut
A
Figure 62: Engaging the four lock nuts
79. Tap the four lock nuts clockwise with a
hammer until it is tight.
Alternatively use Twist Lock Wrench
Jost 915.259.000 Type Universal.
Figure 63: Tightening the four lock nuts
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80. Prepare the converter as described in the
previous section.
NOTE
The slings must be long enough so that there
is no pressure put against the converter fan
motors.
Alternatively, a spreader bar is used to keep
the sling pressure off of the fan motors.
81. Instruct the crane operator to slowly lift
converter level (section 3) and lower it on
to the controller level (section 2).
DANGER
Falling Hazard
If an employee is working at a height that
exposes them to a potential fall, fall arrest
equipment must be used, and 100 % tie-off at
all times is required.
82. Secure the sections with the hardware as
described in previous section.
Figure 64: Mounting converter level, section 3 on controller level
section 2
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83. Detach the PPM from the crane.
Figure 65: Detach the rigging from the converter lifting points.
84. Complete the assembly of the PPM after the first tower section has been lowered onto the tower
base ring. Details will be given in section 8.4. Completing the PPM Assembly.
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8 Tower
Quantity
Description
2
AC extension cord, 100’
2
Bucket, canvas, 5 gallon
1
Bull pin to align flanges
ar
Cable tie, ship loose
1
Caulking gun
1
Container, gasoline
ar
Crimp tool – vendor specific
1
Cutter, cable (safety cable)
ar
Decals, warning label
ar
Die set- vendor specific
2
Duffel bag, canvas
1
File set, various, 12”
1
Generator, 6.5 kW with GFCI
ar
Heat shrink, ship loose
1
Ladder, extension, 16’
1
Ladder, step, 10’
ar
Lubricant, spray
1
Mop, sponge, heavy duty
ar
Paint pen, purple
ar
Paint, tower touch up, exterior
ar
Paint, tower touch up, interior
1
Pressure washer, with 120’ hose
3
Radio, two-way
ar
Rags
1
Ratchet, ½” drive
ar
Rigging
ar
Sandpaper, medium grit
1
Screwdriver set
ar
Sikaflex®, 262
1
Socket, 60 mm, ½-inch drive
1
Socket, deep, 24 mm, ½-inch drive
ar
Splices, ship loose
1
Stripper, cable
2
Tagline, nylon rope
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Quantity
– Original –
Installation Manual
Description
ar
Tape, electrical
1
Torch, propane or heat gun
1
Water tank, 500 gallon
1
Qualified wrench, torque, hydraulic or electric
1
Wrench, combination, 2-3/8 inch
3
Wrench, combination, 24 mm
2
Wrench, combination, 50 mm
1
Wrench, combination, 9/16 inch
1
Wrench, impact, 1” drive
8.1 First Tower Section
WARNING
Take care when working on the low-loading trailer!
Work on the loading platform of the low-loading trailer may only be carried
out when it is stationary. All personnel must leave the loading platform
before the low-loading trailer is moved.
ATTENTION
Check the wind speed!
The tower may only be erected in accordance with section 4.1 ‘Operations
Involving the Use of a Crane’.
ATTENTION
Prevent damage from the WTGS!
If the nacelle cannot be mounted immediately and the "open" tower has to
remain without a nacelle (e.g. overnight), only three tower sections may be
mounted In this case, the top tower flange must be protected against the effects
of the weather by suitable means.
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WARNING
Overhead suspended load!
Never work under a suspended load. Always confirm accurate load center of
gravity, lifting gear and equipment securely attached, Make sure all
personnel, vehicles, equipment, and materials are clear of the crane tail and
load swing. All lifting must be done in strict accordance with the installers lift
plan and applicable job safety analysis must be reviewed prior to all lifts.
WARNING
Lifting heavy loads!
Prior to lifting all heavy loads, a pre-lift meeting with all parties involved is
required. (The crane operator, the rigger, the supervisor, the signalman, and
any other personnel involved, such as area safety, tag line holders). All lifting
must be done in strict accordance with the installers lift plan and applicable
job safety analysis must be reviewed as well.
WARNING
Uneven/Slippery surfaces!
Uneven surfaces are present due to the shape of the WTG equipment. Slippery
surfaces may be present during wet or icy conditions.
Use caution when walking into any WTG surface that is not designed as
permanent walkaway.
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Installation Manual
8.1.1 Inspecting the Tower Section
1.
If the tower will be immediately installed remove the transport tarp and the tower straps from the
tower flange. Fold up the transport tarp. Leave tarp and tower straps on if the tower will remain in
storage.
2.
Perform the Tower Receiving Inspection. Inspect the tower for signs of shipping damage. Contact
the GE site representative if damage is found.
3.
Visually inspect all bolted connections for attaching the platform and ladder to the tower wall, the
cable tray to the tower wall and cable clamps to the tray, the fall arrest system to the ladder or
safety cable stand-offs to the ladder.
If any tower internal loose bolts are found contact GE site representative. The bolt has to be removed
and replaced with a new bolt with new thread locker and then be torqued to the right torque in
accordance with the tower internals assembly manual.
NOTE
Tower internal hardware is glued with thread locking. If it gets checked with torque,
the thread locking will be disturbed and the bolt may become loose during WTG
operation.
4.
Inspect the fall arrest system mounting hardware and inspect the safety cable for kinks or cuts. If
the cable is damaged contact GE's site representative.
5.
Inspect the interior, exterior, and flanges for exposed metal surfaces, corrosion, burrs, and high
spots.
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Installation Manual
8.1.2 Preparing the Tower Section
DANGER
Fall hazard!
Tower internal surface can represent a slippery surface during cleaning
operations. Please be aware of the work environment and try to mitigate the
risk by avoiding to walk over slippery surfaces.
Once the tower sections are installed there is a danger of falling through open
floor due to uninstalled hatches and flaps.
Close these before beginning the work!
Figure 66: Example temporary cover plate over open hole
1.
Remove burrs and high spots using a course half-round file and buff the surface using medium
grit sandpaper. Remove corrosion using medium grit sandpaper and spray cold galvanized
compound.
Repair any minor damaged paint surfaces preparing surface and applying the paint or primer per
manufacturer’s instructions.
Any major paint damage must be reported to GE representative and repaired in accordance with
the manufacturer's instruction.
Tower internal cleaning:
2.
Any loose, lightly imbedded or accumulated dirt/debris must be removed from the tower internal
surfaces to prevent short or long term contamination by falling down tower to the electrical
components.
Tower external cleaning:
3.
Any material or contaminate that affects the life expectancy of the coating and any accumulated
mud or other material that can become dislodged during operation must be removed. Cosmetic
appearances are the customer’s decision for level of cleanliness.
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E – EL Contracts: Cosmetic appearances are the customer’s decision for level of cleanliness.
ELI – ELIF – ELIFT Contracts: Cosmetic appearances are GE´s decision for level of cleanliness if WTG
installation is in GE scope.
It is recommended that cleanliness is clearly defined and understood by all parties prior to first unit
installation preferably during the pre-installation meeting (PIM).
4.
Verify the cables are secured in the cable
tray with ties and clamps. Verify the cables
are secured below the deck to prevent
damage to cables and PPM.
5.
Attach safety signs in the tower.
Figure 67: Example of cables secured in cable tray
6.
Install the fall arrest system or check the
pre-assembled fall arrest system as per
manufacturer’s instructions before
erecting the first tower section.
Fall restraint system is required to allow
ascent to the top of the segment.
Figure 68: Fall arrest system at base section
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8.1.3 Example Attachment and Usage of the Lifting Gear
8.1.3.1 Plate Lifting Gear
8.1.3.1.1 Attachment of Plate Lifting Gear
NOTE
For handling of the lifting devices refer to the supplier’s documentation
Please refer to outline drawing for the lifting point. Below pictures are for
reference only.
WARNING
Take care when working on the low-loading trailer
Work on the loading platform of the low-loading trailer may only be carried
out when it is stationary. All personnel must leave the loading platform
before the low-loading trailer is moved.
1.
Install the temporary rail alignment
system plates for the installation of the
tower base section.
Critical to Quality:
2.
Brackets must be installed as shown in
illustration to prevent damage to
converter.
A
A. Tower flange bolt hole numbers
B: Tower configuration
B
Figure 69: Example Right hand and Left hand brackets for a
75/85 HH tower.
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NOTE
Refer to specific tower drawing for correct
anti rotation device as bolt hole pattern varies
for different hub heights (HH) and hole “x” will
vary.
NOTE
Confirm correct brackets are being used as
bolt hole patter may be different for each hub
height.
3.
Mount two lifting plates on the bottom
flange of the base section.
If installing plates with tower on a horizontal
position, use a crane or an aerial lift to reach
the mounting positions.
4.
Mount one more lifting plate on the
bottom flange of the tower section at the
12 o'clock position.
Use a crane or an aerial lift to reach the
mounting positions.
DANGER
If installing the plates after the tower is in the
vertical position, ensure the tower is
supported by matts prior to installing the
plates to keep personnel from reaching under
a suspended load.
Figure 70: Example Right hand and Left hand brackets installed
on a 75/85 HH tower base flange.
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8.1.3.1.2 Lifting the Tower Section from the Low-loading Trailer
DANGER
Falling objects hazard warning!
Do not stand in front of or under the tower opening under any
circumstances.
Inspect the tower section before the lifting to remove any tool material that
could fall down while it is being set upright.
ATTENTION
Check the wind speed!
The tower may only be erected in accordance with section 4.1 ‘Operations
Involving the Use of a Crane’.
ATTENTION
Check the wind speed!
If the nacelle cannot be mounted immediately and the "open" tower has to
remain without a nacelle (e.g. overnight), only three tower sections may be
mounted. In this case, the top tower flange must be protected against the effects
of the weather by suitable means.
NOTE
Use two-way radios!
A two-way radio is required for communication between the crane operator and
the erecting engineer.
Precise instructions for the required changes in the position of the tower sections
can be given by this means.
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ATTENTION
Risk from lifting heavy loads!
Prior to lifting all heavy loads, a pre-lift meeting with all parties involved is
required (crane operator, rigger, supervisor, signalman, truck driver if
applicable, area safety, tag line holders and any other personnel involved). All
lifting must be done in strict accordance with the installers lifting plan and
applicable job safety analyses must be reviewed prior to commencing work.
ATTENTION
Risk from overhead suspended load!
Never work under a suspended load. Make sure all people, vehicles,
equipment and materials are clear of the crane tail and load swing.
1.
Slightly raise the tower section.
2.
Remove the transport braces located
between the tower section and the lowloading trailer.
Figure 71: Lifting the tower section from the low-loading trailer
3.
Bring the tower section to a vertical
position by means of the main and support
crane per the site-specific lift plan.
The main crane lifts the load while the
support crane lowers the load.
Precise coordination between the two crane
operators is essential.
Figure 72: Raising the tower section
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Figure 73: Raising the tower section
DANGER
Crushing hazard!
During installation always ensure that hands, feet, and body are not between
any potential pinch points. Enter the area to remove the counter plate only
after the load is stabilized on the wood or support frames with the crane
holding the load.
4.
Instruct the crane operator to slowly lower
the tower section
onto a wood or steel mat with sufficient
dimensions and load capacity as shown in
the adjacent Figure 74.
or alternatively
Figure 74: Example of removing the counter plate
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5.
onto a specific support frame (put up on a
wood or steel mat) with sufficient
dimensions and load capacity as shown in
the adjacent Figure 75.
6.
Ensure the load is stabilized and unhook
the lifting plate on the bottom tower
flange from the support crane.
Installation Manual
Figure 75: Example of wooden support frame
7.
Lash four tag lines to the bottom tower
flange.
Lash a tag line to each of two opposed
points, in order to prevent the section from
swinging during the lifting operation.
This allows the section to be guided without
danger.
Figure 76: Tag line on the tower flange
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8.1.3.2 HTS ACTEK WKA System
8.1.3.2.1 Attachment of HTS ACTEK WKA System
1.
Mount 4 hooking points on top tower
flange as shown in Figure 77.
Ensure that the hooking points form a
rectangle.
The D-rings of the WKA-B-Flex are attached
to the exterior of the tower.
Figure 77: Arrangement of the hooking points
NOTE
For handling of the lifting devices refer to the supplier’s documentation
Please refer to outline drawing for the lifting point. Below pictures are for
reference only.
WARNING
Take care when working on the low-loading trailer!
Work on the loading platform of the low-loading trailer may only be carried out
when it is stationary.
All personnel must leave the loading platform before the low-loading trailer is
moved.
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2.
– Original –
Installation Manual
Attach the guide pulleys to the crane hook
by means of two ropes (steel or textile).
Figure 78: Mounting the hooking points
3.
Using suitable shackles, connect one end
of the rope to the top right-hand hooking
point and the other end of the rope to the
bottom right-hand hooking point.
4.
Using suitable shackles, connect one end
of the rope to the top left-hand hooking
point and the other end of the rope to the
bottom left-hand hooking point.
Ensure that the guide pulleys of the two
steel ropes do not cross.
Figure 79: Position of the hooking points on the flange
5.
Mount two hooking points on the bottom
tower flange as shown in Figure 80.
6.
Using suitable shackles, connect the
hooking points to the hook of the support
crane.
Figure 80: Hooking points on the bottom tower flange
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8.1.3.2.2 Lifting the Tower Section from the Low-loading Trailer
DANGER
Falling objects hazard warning!
Do not stand in front of or under the tower opening under any
circumstances.
Any objects or materials remaining in the tower or any inadequately secured
cables could fall out of the tower while it is being set upright.
ATTENTION
Check the wind speed!
The tower may only be erected in accordance with section 4.1 ‘Operations
Involving the Use of a Crane’ If the nacelle cannot be mounted immediately and
the "open" tower has to remain without a nacelle (e.g. overnight), only three tower
sections may be mounted.
In this case, the top tower flange must be protected against the effects of the
weather by suitable means.
ATTENTION
Check the wind speed!
If the nacelle cannot be mounted immediately and the "open" tower has to
remain without a nacelle (e.g. overnight), only three tower sections may be
mounted.
In this case, the top tower flange must be protected against the effects of the
weather by suitable means.
NOTE
Use two-way radios!
A two-way radio is required for communication between the crane operator and
the erecting engineer.
Precise instructions for the required changes in the position of the tower sections
can be given by this means.
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Installation Manual
DANGER
Risk from lifting heavy loads!
Prior to lifting all heavy loads, a pre-lift meeting with all parties involved is
required (crane operator, rigger, supervisor, signalman, area safety, tag line
holders and any other personnel involved). All lifting must be done in strict
accordance with the installers lifting plan and applicable job safety analyses
must be reviewed prior to commencing work.
DANGER
Risk from overhead suspended load!
Never work under a suspended load. Make sure all people; vehicles,
equipment and materials are clear of the crane tail and load swing.
1.
Slightly raise the tower section.
2.
Remove the transport braces located
between the tower section and the lowloading trailer.
Figure 81: Lifting the tower section from the low-loading trailer
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3.
Installation Manual
– Original –
Bring the tower section to a vertical
position by means of the main and support
crane.
Figure 82: Raising the tower section
The main crane lifts the load while the
support crane lowers the load.
Precise coordination between the two crane
operators is essential here.
Figure 83: Raising the tower section
DANGER
Crushing hazard!!
During installation always ensure that hands, feet, and body are not between
any potential pinch points. Enter the area to remove the counter plate only
after the load is stabilized on the wood or support frames with the crane
holding the load.
ATTENTION
Risk from lifting heavy loads!
When lifting WTGS components, ensure the load is stabilized to prevent
unexpected swing and potential contact with other objects.
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4.
– Original –
Installation Manual
Instruct the crane operator to set the
tower on wood blocks or a steel frame per
previous step 4 on page 92 with the crane
holding approximately 80% of the load.
Figure 84: Tower on wood blocks
5.
Ensure the load is stabilized, check the
stability of the wooden blocks and soil.
6.
If stability is OK, proceed to remove the
tail pick lifting equipment.
7.
Release the connection from the support
crane to the hooking points on the bottom
tower flange.
8.
Remove the hoisting rings from the
bottom tower flange.
Figure 85: Removing the hooking points
9.
Lash two tag lines to the bottom tower
flange.
Lash a tag line to each of two opposed
points, in order to prevent the section from
swinging during the lifting operation.
This allows the section to be guided without
danger.
Figure 86: Tag line on the tower flange
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8.1.4 Assembling the First Tower Section
1.
Ensure that the arrangement of the nuts,
bolts, washers is correct.
The level of the washers must always point
towards the nut and bolt head respectively.
Figure 87: Arrangement of the bolts
2.
Apply a 12 mm Sikaflex®-252 or a
comparable sealing material between the
outer edge and the holes of the tower base
ring.
Figure 88: Applying Sikaflex®-252
ATTENTION
Danger of collision!
Lower the tower section slowly and carefully. A collision between the tower
section and the platform must be avoided, since this could cause damage.
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DANGER
Falling hazard!
Ensure that you are always protected by your PPE when carrying out work on
the PPM.
Use the hooking points marked in signal yellow which are located on each
platform (section).
ATTENTION
Overhead suspended load!
Never work under a suspended load.
Always confirm accurate load center of gravity, lifting gear and equipment
securely attached,
Make sure all personnel, vehicles, equipment, and materials are clear of the
crane tail and load swing.
All lifting must be done in strict accordance with the installers lift plan and
applicable job safety analysis must be reviewed prior to all lifts.
8.1.4.1 Installing the Guide Rail System
The guide rail system will be attached to the
controller and transformer level posts located on the
opposite side of the tower entry door.
The controller level guide rail system can be installed
on the controller level prior to installing the controller
converter over the transformer, this way the work is
done closer to the ground.
The transformer rail posts can be installed later after
the controller/converter is placed over the
transformer. This way the team will not fight
alignment of the posts when staking the PPM.
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1.
– Original –
Installation Manual
Verify all guide rail system parts are accounted for and in good condition. Reference drawing
D7988-10 Main Assembly PPM Rail System.
Quantity
Description
1
Top left rail post
1
Bottom left rail post
1
Top right rail post
1
Bottom right rail post
2
Bottom left rail clamps large size rail clamps part# 8
2
Bottom right rail clamps medium size rail clamps part# 8
6
Controller level rail clamps small size part #7
Part #7 controller small clamps,
3 each.
Part #7 controller level small clamps,
3 each.
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Part# 6, transformer level (Bottom
left large rail clamps) 2 each.
Part# 8, transformer level (Bottom
right small rail clamps) 2 each.
Part#3 Top left rail post
Part#3 Top right rail post
Part#4 Bottom left rail post
Part#5 Bottom right rail post
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8.1.4.1.1 Assembling the Rail Assembly
1.
Assemble the controller level LH and RH
rail assembly. Attach part #7 to part #3
and secure with carriage bolt nut and
washer. Tighten the hardware.
Part #7
Part #3
Figure 89: Controller level LH and RH rail assembly.
2.
Assemble the transformer level LH rail
assembly.
3.
Top bracket part#7: Attach part #7 to the
top of part #4 and secure with carriage
bolt nut and washer. Tighten the
hardware.
4.
Lower brackets part#6: Attach part #6 to
the lower and middle brackets of part #4
with gusset facing down and secure with
carriage bolt nut and washer.
5.
Leave the hardware loose to allow part# 6
brackets to pivot.
Top Bracket Part #7
Part #4
Lower Brackets Part #6
Figure 90: Transformer level LH rail assembly.
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6.
Assemble the Transformer level RH rail
assembly.
7.
Top bracket part#7: Attach part #7 to the
top of part #4 and secure with carriage
bolt nut and washer. Tighten the
hardware.
8.
Lower brackets part#8 (large Brackets):
Attach part #8 to the lower and middle
brackets of part #5 with gusset facing
down and secure with carriage bolt nut
and washer.
9.
Leave the hardware loose to allow part# 8
brackets to pivot.
Top Bracket Part #7
Part #5
Lower Brackets
Part #8
Figure 91: Transformer level RH rail assembly.
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8.1.4.1.2 Installing the Controller Level Guide Rail System
1.
Measure and mark the Controller Level
posts located on the opposite side of the
tower entry door.
1080 mm
74 mm
63.5 mm
1080 mm
Figure 92: Marking the controller post
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2.
Position the LH upper rail assembly
primary support against the left hand side
post of the controller level.
3.
The tapered end of the post is pointing
down.
B
A - Primary support
A
B - Controller level LH post
Figure 93: Positioning the rail post against the controller post
4.
Position the magnet latch arm assembly
on the backside of the post.
A - Primary support
B - Magnet latch assembly
A
B
Figure 94: Positioning the magnet latch assembly
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5.
Latch the primary support to the magnet
latch assembly.
6.
Adjust the latch bolts as required to
prevent the latches from disengaging
and/or over stressing and damaging the
latches.
Installation Manual
– Original –
Figure 95: Rail system latches to magnet latch assembly
7.
Adjust the rail assembly as required and
latch the next primary support to the
controller post.
Figure 96: LH controller post
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8.
– Original –
Installation Manual
Repeat steps to install the RH rail
assembly on the RH controller post.
Figure 97: RH controller post
9.
Insert the pins to prevent the latches from
disengaging.
Figure 98: Securing rail system latches with safety pin
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8.1.4.1.3 Installing the Transformer Level Rail Assembly
1.
If required measure and mark the
transformer Level posts located on the
opposite side of the tower entry door.
63.5 mm
972 mm
867 mm
2.
Position the RH rail assembly primary
support against the bottom of the RH side
post of the controller level.
3.
Push the post up inserting it onto the
tapered end of the upper rail assembly
post.
C
4.
If required remove the carriage bolt and
reinstall after the primary support is
latched against the post.
D
B
A
Figure 99: Securing RH lower brackets part#7 (small brackets)
A - Carriage bolt
B - Controller level upper rail assembly post
C - Controller level RH Post
D - RH rail assembly primary support
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5.
Position the magnet latch arm assembly
on the backside of the post.
Installation Manual
– Original –
A
A - Magnet latch assembly
B - Primary Support
B
Figure 100:Securing LH lower brackets part#7 (small brackets):
6.
Latch the primary support to the magnet
latch assembly. Adjust the latch bolts as
required to prevent the latches from
disengaging and/or over stressing and
damaging the latches.
Figure 101: Rail system latches to magnet latch assembly
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7.
– Original –
Installation Manual
Adjust the rail assembly as required and
position the lower two primary supports
against the transformer post.
Figure 102: Securing RH lower brackets part#6 (medium
brackets):
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8.
– Original –
Installation Manual
Repeat steps to position the LH rail
assembly.
Figure 103: Securing lower brackets part#8 (large brackets)
9.
Ensure all pins are correctly inserted to
prevent latches from disengaging.
Figure 104: Securing rail system latches with safety pin
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For reference:
The following drawings show the rail assembly
location in relation to the anti-rotation devices
mounted to bottom flange of the base section. These
illustrations apply to tower configurations
75/85 m HH, 98.3 m HH, 110 m HH or 120 m HH and
131 m HH respectively.
NOTE
Typical view is from the top of tower looking
toward the ground.
Figure 105: Tower flange bolt hole configurations for 75/85 mHH, 98.3 HH, or 110/120 m HH. For 131m request latest version from GE
engineering.
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Installation Manual
8.1.4.2 Installing the Base Section over the PPM
1.
Rearrange the converter to transformer
cables out of the walkway and/or the
tower flange path to prevent damage.
2.
Rearrange the grid to transformer cables
away from tower flange path to prevent
damage.
Figure 106: Securing thec ables
3.
Remove the grounding boss bolts prior to
installing the base section to prevent
cable damage when installing the tower
section over the PPM.
Figure 107: Ground boss location on the flange
4.
Verify hole 1 on the tower base ring is
clearly identified. This hole matches the
tower center line mark provided by
customer and will align with hole 1 of the
tower base flange.
NOTE
Typical customer door center line is marked by the
customer's foundation contractor and is located at
90 degrees from the foundation conduits.
5.
Mark the inside and outside face so that
the marks are clearly visible during
installation of the base section.
Figure 108: Example TBR with customer provided tower door
centerline marks
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– Original –
6.
Prior to lifting the tower base section
identify and mark hole 1, this is located on
the tower flange centered directly below
the tower door.
7.
Place a mark with duct tape on the outside
face of the tower flange so that the marks
are clearly visible during installation of the
base section.
Figure 109: Tower base door center line marks
8.
Prior to lifting the tower install four
taglines to help stabilize the tower when
guiding the tower over the PPM.
Figure 110: Install four taglines
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DANGER
Crushing hazard!
Do not put your hands between the flanges. Danger of serious crush injuries.
Ensure that you keep a safe distance from the flanges. During Installation
always ensure that hands, feet, and body are not between any potential
pinch points.
9.
The tower section will be positioned over
the PPM using the rail system to maintain
tower stability while guiding the tower
over the converter cabinet without
causing damage.
10. Supporting personnel will be positioned at
each corner holding tension on the tag
lines to maintain control of the base
section while it is being lowered.
11. Instruct the crane operator to bring the
tower section slowly over the PPM.
Figure 111: Lowering the first tower section
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12. Instruct the crane operator to slowly lower
the tower section over the PPM until the
anti-rotation plates make contact with the
rail system.
Figure 112: Lowering base until anti-rotation plates make
contact with the rail system.
13. Instruct the tag line personnel to maintain
slight pressure from the tower base flange
to the PPM guide rails as the base section
is being lowered over the PPM/converter
cabinet.
Figure 113: Base section being lowered over the PPM/converter
cabinet
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14. Instruct the tag line personnel as required
to maintain tension to ensure the tower
flange clears the ladder and all other PPM
components as it is being lowered.
15. The foreman directing the lift needs to
ensure that no excessive pressure is being
applied to the guide rail system and the
load is floating barely touching on the way
down.
Figure 114: Load is floating barely touching on the way down.
16. Place four wood blocks of the appropriate
size.
17. Firmly lower the base onto the woodblocks
with the crane holding the load, aligning
the pins to the TBR holes and ensuring the
tower door flange marks are aligned.
Critical to Safety:
The bull pins keep the tower section from
being moved during wind gusts and prevents
pinch points.
18. Remove the tag lines and the antirotational devices.
Figure 115: Bull pins to keep the tower section aligned
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Critical to Quality:
19. Ensure that the tower base door is
correctly aligned with the mark on the
tower base ring flange.
A
A - Base flange door
B - Tower base Ring flange door mark
B
Figure 116: Base flange and TBR doo marks
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20. A ladder is placed inside the PPM prior to
the base being installed. It is resting
against the PPM and then positioned to
the tower wall (door combing) for access
to the transformer level. We have ample
clearance due to not installing the
fan/duct work under the tower door until
after tower installation. - A man lift can be
used for entrance as well.
DANGER
Danger of falling down!
Once the tower base section is installed there is a
Danger of falling through open floors due to
uninstalled hatches and floor plates.
Figure 117: Temporary ladder placed outside to access tower
Use extreme caution when accessing the
tower and transformer level!
21. The blocks need to be removed to
complete the application of the Sikaflex®.
Once the blocks are removed the Sikaflex®
can be applied safely by a crew member
from the outside.
22. The bull pins stay engaged while the
blocks are removed. The blocks are
pushed out with a bar from the inside to
prevent hands/body parts from crushing
hazard.
Figure 118: Removing the blocks and guide pins inserted tp TBR.
DANGER
Crushing hazard!
During removal of woodblocks and application of Sikaflex® always ensure
that hands, feet, and body are not between any potential pinch points.
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Critical to Quality:
23. Keeping hands away from danger zone
carefully apply a continuous (NO GAPS) 12
mm bead of Sikaflex® or equivalent on the
remaining face at the top flange of the
tower base section. Cover the area
between the outside edge and the holes
ensuring no gap so water cannot
penetrate inside the tower.
Figure 119: Application of Sikaflex®.
Critical to Quality:
24. Ensure that the door is correctly aligned.
B
A - Foundation bolt door marks
B - Base section hole 1 mark
C - Tower base ring hole 1 mark
C
A
Figure 120: Example tower door markings
25. Instruct the crane operator to lower the
tower section down further.
Figure 121: Tower flanges small gap outside
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26. Lower the tower section but leave a small
gap of approx. 10 cm. The gap provides
some room for maneuvers to insert all the
bolts.
27. Insert all the bolts in the flange. The bolts
are pushed through the flange from below
and the nut is tightened from above.
28. Once all the bolts are finger-tight, the
tower can be let down completely.
Figure 122: Tower flange small gap inside
CAUTION
Wear hearing protection!
Proper hearing protection must be worn when working with any electrical or
hydraulic impact tooling!
Always assess the next task at hand. If 85 decibels will be exceeded, hearing
protection must be worn.
Observe requirements for hearing protection per your company's policies.
DANGER
Pinch point - Crushing hazard!
When working with hydraulic and pneumatic torque tooling, ensure that your
hands and any part of your body are not between any pinch points (i.e. any
part of your body is not between the tool reaction arm and back up pressure
surface). Ensure personnel are properly trained on safe operations of
hydraulic and pneumatic tools.
29. Using an impact wrench tighten all bolts in
a star pattern/rolling triangle.
Reference the 3MW Platform Bolt Torque
Specification for final torque.
Figure 123: Impact wrench
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DANGER
Danger of collapse!
Only after all bolts have been tightened by means of the impact wrench the
lifting gear can be detached.
30. Remove the lifting gear from the top tower
flange.
31. If required after base tower installation
the service platform (lift) must be put on
the base tower upper platform for later
installation.
32. Remove the guide rail system, secure all
hardware for future use.
Figure 124: Removing the lifting gear
DANGER
Pinch point - Crushing hazard!
When working with hydraulic and pneumatic torque tooling, ensure that your
hands and any part of your body are not between any pinch points (i.e. any
part of your body is not between the tool reaction arm and back up pressure
surface). Ensure personnel are properly trained on safe operations of
hydraulic and pneumatic tools.
33. Perform the final torque using qualified torque tooling and mark with a paint pen. Legibly record
torque values in 3 locations: ICL, Daily Torque Log and on the tower wall next to the flange bolts
directly across from, the ladder.
34. Details of the required torques can be found in the 3MW Platform Bolt Torque Specification.
35. Verify no gap is present between the tower flanges.
36. If a gap is present, do not proceed until the gap is closed, ensure Sikaflex® was applied properly
and contact a GE Energy site representative for further instructions
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Installation Manual
37. Remove any paint residues or dirt from the
ground straps boss to ensure perfect
contact of the ground strap with the tower
sections.
Figure 125
38. Mount the ground straps between the
tower flange sections. Torque the bolts
and mark them with a paint pen.
Figure 126
8.2 Installing the Entrance Stairway
WARNING
Fall hazard!
When the stairs cannot be installed due to space limitations between rotor
and stairs, the installer must provide temporary safe means of egress to the
tower that meet the local standards.
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1.
Pre-assemble the modules on a horizontal
surface (e.g. trailer) beginning with the
longest modules at the top of the stair (1,
2) and consequently adding module (3).
2.
The single step module (4) can only be
mounted at the bottom of the stair.
3.
Support the stairway on point "A".
4.
Add the top module (5).
5.
Check the complete stair assembly for
loose hardware/damage prior to
installing.
6.
Attach round slings to the stairway at
point "B" and secure them against shifting.
Figure 127: Pre-assembling the modules of the stairway
Figure 128: Adding the top module
Figure 129:Lifting the stairway
7.
Lift it slowly towards the door section by
means of a crane or similar.
Figure 130: Lifting the stairway
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8.
– Original –
Installation Manual
Tighten the hardware with an impact
wrench. Do not exceed final torque.
Torque all bolts and mark with paint pen.
Figure 131
9.
Adjust the stairway as required so the top
platform at the entrance door is
horizontal.
Figure 132
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10. If foundation dimensions do not fit, add or
remove optional single step modules.
Figure 133
11. If applicable, install tower door stair
ground lead. Ensure mating surface is
clean, torque and mark with paint pen.
12. Connect the grounding cable at the
bottom of the stairway.
Figure 134
13. Temporarily support the ladder legs
ensuring the ladder is level until final
grading done.
Figure 135: Installation of the stairway completed
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Installation Manual
8.3 Adjusting the Entrance Door
1.
Adjust the entrance door according to the
adjoining figure.
Figure 136: Adjusting the entrance door (1)
2.
Adjust the entrance door according to the
adjoining figure.
Figure 137: Adjusting the entrance door (2)
3.
Adjust the entrance door according to the
adjoining figure.
4.
Secure the tower door to prevent
unauthorized entry i.e., (install a key lock
cylinder).
Figure 138: Adjusting the entrance door (3)
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ATTENTION
The transformer coils and all other equipment must remain protected from
elements such as moisture, rain, snow, contaminants such as dirt, dust, oil,
rodents and damage during installation process.
The installer must hold available protection material for storage e.g., tarps shrink wrap - taking into consideration condensation and freezing weather.
If grid is not available after tower installed and extreme weather is
anticipated, it is recommended to temporarily seal tower door filter inlets to
prevent snow/dust from entering the tower.
8.4 Completing the PPM Assembly
DANGER
Falling hazard!!
Once the tower base section is installed there is a Danger of falling through open
floor due to uninstalled hatches and flaps.
Close these before beginning the work!
CAUTION
Know what you are lifting!
When the weight exceeds the limit for a single person, or if the load is awkward /
difficult to maneuver due to shape or size.
Request the help of a second person,
Transfer the load into smaller containers or use the crane or a fork lift.
Reference assembly drawings for weights.
1.
Verify all hatches and hand rails are accounted for and in good condition. Contact GE site
representative if any issues are found.
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DANGER
Falling hazard!!
Once the tower base section is installed there is a
danger of falling through open floors due to
uninstalled hatches and floor plates.
Close open holes before beginning the work!
DANGER
Falling hazard!!
Use caution when walking into the tower to
install the floor plates or performing any other
work.
2.
Remove the transport shipping braces.
3.
Remove the transformer shipping braces.
Figure 139
Figure 140
4.
Inspect for any loose hardware and debris
inside the coils.
Figure 141
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5.
– Original –
Installation Manual
Assemble the hatches,
steps and railings at the
controller level according
to installation drawing
117W6882/444W8673.
For 131 m request latest
version from GE
engineering.
Figure 142
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6.
Install the
controller/transformer
ladder mounting bracket to
the controller platform.
Reference Drawing
117W6917/444W7063/
444W9057.
7.
In the transformer level
install the foundation step.
8.
Mount the two ladder
mounting brackets.
– Original –
Installation Manual
Figure 143
9.
Position the ladder against
the upper and lower
mounting brackets, and
install the hardware.
10. Tighten the hardware
according to torque values
provided in the assembly
drawing.
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Figure 144
11. Install the fan covers on converter fans.
Tighten the hardware.
Reference the latest ESS DTA drawing.
12. Remove all the shipping material from the
covers.
Figure 145: Assembling shrouds on converter fans
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13. Assemble the fan shrouds around the
converter fans.
Reference the latest ESS DTA drawing.
14. Remove all tools debris from the fan
shroud
Figure 146
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15. Assemble the earthquake absorbers (pos.
nos. 15, 16, 17 and 70, 72, 75, 76, 77) at the
controller level according to assembly
drawing 117W6882/444W8673. For 131m
request latest version from GE
engineering.
Figure 147: Assembling earthquake absorbers at the controller
level
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16. Uncoil the converter
coolant drain hose.
17. Connect it to the bottom of
the converter.
18. Route the hose down
through ladder trays and
place the other end inside
the drain barrel in the
transformer level.
Figure 148: Converter coolant drain hose
at the transformer level.
19. Verify all cooler fans parts are accounted
for.
Contact GE site representative if any parts
are missing.
NOTE
Cooling fan design could be different. Refer to the
specific turbine configuration to determine task
applicability.
Figure 149
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20. Install the cooler fan under tower door
floor plate according to assembly drawing
117W5906 (Assembly Ventilator).
A
B
C
Figure 150: Installing the cooler fan under tower door
A - Air duct
B - Fan motor
C - Tower door floor plate
21. Unbolt and lift the tower door floor plate.
DANGER
Falling hazard!!
Danger of falling through open hatches and flaps.
Close these before beginning the work!
Figure 151: Removing the door floor plate.
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22. Install the fan motor and air duct and
tighten the hardware according to
assembly drawing.
NOTE
Support the cooler fan duct during installation
with a rope or similar to prevent accidental
movement.
Figure 152: Installing the cooler fan under tower door
23. Reinstall the door floor cover, adjust for
correct clearance and tighten hardware.
Figure 153: Installing coolers and hoses at the transformer level
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9 Assembling the Following Tower Sections
WARNING
Take care when working on the low-loading trailer!
Work on the loading platform of the low-loading trailer may only be carried
out when it is stationary. All personnel must leave the loading platform
before the low-loading trailer is moved.
ATTENTION
Check the wind speed!
The tower may only be erected in accordance with section 4.1 ‘Operations
Involving the Use of a Crane’.
ATTENTION
Prevent damage from the WTGS
If the nacelle cannot be mounted immediately and the "open" tower has to
remain without a nacelle (e.g. overnight), only three tower sections may be
mounted In this case, the top tower flange must be protected against the
effects of the weather by suitable means.
WARNING
Overhead suspended load!
Never work under a suspended load.
Always confirm accurate load center of gravity, lifting gear and equipment
securely attached.
Make sure all personnel, vehicles, equipment, and materials are clear of the
crane tail and load swing.
All lifting must be done in strict accordance with the installers lift plan and
applicable job safety analysis must be reviewed prior to all lifts.
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WARNING
Lifting heavy loads!
Prior to lifting all heavy loads, a pre-lift meeting with all parties involved is
required. (The crane operator, the rigger, the supervisor, the signalman, and any
other personnel involved, such as area safety, tag line holders). All lifting must be
done in strict accordance with the installers lift plan and applicable job safety
analysis must be reviewed as well.
DANGER
Crushing hazard!
During Installation always ensure that hands, feet, and body are not between
the any potential pinch point.
WARNING
Risk of Falling objects!
Never remain in front or underneath the tower opening.
Whilst the tower is being erected any object or material that remains in the tower
or inadequately secured cable can fall out of the tower.
The process requires lifting and lowering equipment inside the tower and working
with, and staging, tools and materials on all tower platform levels. There are
many gap openings around the platforms and possible open personnel and tool
hatches. Personnel will be working with small parts and tools which can fall
through the holes or open hatches.
Always ensure all equipment and tools are secured in closed tool bags.
All tools will be secured and tether rope will be utilized as required
Cover all hole openings that create a risk of falling objects as required.
All tower internal tool/materials hoisting operations must be performed by
properly trained personnel using the properly rated hoisting equipment,
rated certified lifting bags, hooks with safety latch.
Before use, take a moment to inspect all hoisting equipment and bag(s) to
ensure there is no damage, cuts/tears, or signs of excessive rubbing/wear.
Lifting equipment will be carefully coordinated. Two-way communication
must be available via radio.
All non-essential personnel must clear the area before hoisting operations
begin. Never remain in front or underneath the tower opening.
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Quantity
– Original –
Installation Manual
Description
2
AC extension cord, 100’
2
Bucket, canvas, 5 gallon
1
Bull pin to align flanges
ar
Cable tie, ship loose
1
Caulking gun
1
Container, gasoline
ar
Crimp tool – vendor specific
1
Cutter, cable (safety cable)
ar
Decals, warning label
ar
Die set- vendor specific
2
Duffel bag, canvas
1
File set, various, 12”
1
Generator, 6.5 kW with GFCI
ar
Heat shrink, ship loose
1
Ladder, extension, 16’
1
Ladder, step, 10’
ar
Lubricant, spray
1
Mop, sponge, heavy duty
ar
Paint pen, purple
ar
Paint, tower touch up, exterior
ar
Paint, tower touch up, interior
1
Pressure washer, with 120’ hose
3
Radio, two-way
ar
Rags
1
Ratchet, ½” drive
ar
Rigging
ar
Sandpaper, medium grit
1
Screwdriver set
ar
Sikaflex®, 262
1
Socket, 60 mm, ½-inch drive
1
Socket, deep, 24 mm, ½-inch drive
ar
Splices, ship loose
1
Stripper, cable
2
Tagline, nylon rope
ar
Tape, electrical
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Quantity
– Original –
Installation Manual
Description
1
Torch, propane or heat gun
1
Water tank, 500 gallon
1
Qualified wrench, torque, hydraulic or electric
1
Wrench, combination, 2-3/8 inch
3
Wrench, combination, 24 mm
2
Wrench, combination, 50 mm
1
Wrench, combination, 9/16 inch
1
Wrench, impact, 1” drive
9.1.1 Inspecting the Tower Section
1.
If the tower will be immediately installed remove the transport tarp and the tower straps from the
tower flange. Fold up the transport tarp. Leave tarp and tower straps on if the tower will remain in
storage.
2.
Perform the Tower Receiving Inspection. Inspect the tower for signs of shipping damage. Contact
the GE site representative if damage is found.
3.
Visually inspect all bolted connections for attaching the platform and ladder to the tower wall, the
cable tray to the tower wall and cable clamps to the tray, the fall arrest system to the ladder or
safety cable stand-offs to the ladder.
4.
If any tower internal loose bolts are found, contact GE site representative. The bolt will have to be
removed and will have to be replaced with a new bolt with new thread locker and then torqued to
the right torque in accordance with the tower internals assembly manual.
NOTE
Tower internal hardware is glued with thread locking. If it gets checked with torque,
the thread locking will be disturbed and the bolt may become loose during WTG
operation.
5.
Inspect the fall arrest system mounting hardware and inspect the safety cable for kinks or cuts.
6.
If the cable is damaged contact GE's site representative.
7.
Inspect the interior, exterior, and flanges for exposed metal surfaces, corrosion, burrs, and high
spots.
Critical to Safety:
8.
On the tower top section verify the tower hoist is properly mounted onto the tower frame. Inspect
all hoist mounting brackets looking for missing or cracked welds.
Refer to the hoist manufacturer's installation/mounting instructions.
Critical to Safety:
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9.
– Original –
Installation Manual
If Service Lift option is required, check if handrail gates are installed. If not, install handrail gates
according to the supplier instruction. Handrail gates are part of the Service Lift kit.
9.1.2 Preparing the Tower Section
DANGER
Fall hazard!
Tower internal surface can represent a slippery surface during cleaning
operations. Please be aware of the work environment and try to mitigate the
risk by avoiding to walk over slippery surfaces.
NOTE
Note the arrangement of the transportation braces!
The exact arrangement of the transportation braces is specified by a banksman
or the site lead.
1.
Remove burrs and high spots using a course half-round file and buff the surface using medium
grit sandpaper. Remove corrosion using medium grit sandpaper and spray cold galvanize
compound.
2.
Repair any minor damaged paint surfaces preparing surface and applying the paint or primer per
manufacturer’s instructions.
3.
Any major paint damage must be reported to GE representative and repaired in accordance with
the manufacturer's instruction.
Tower Cleanliness:
4.
Tower internal cleaning: Any loose, lightly imbedded or accumulated dirt/debris must be removed
from the tower internal surfaces to prevent short or long term contamination by falling down
tower to the electrical components.
5.
Tower external cleaning: Any material or contaminate that affects the life expectancy of the
coating and any accumulated mud or other material that can become dislodged during operation
must be removed. Cosmetic appearances are the customer’s decision for level of cleanliness.
E – EL Contracts: Cosmetic appearances are the customer’s decision for level of cleanliness.
ELI – ELIF – ELIFT Contracts: Cosmetic appearances are GE´s decision for level of cleanliness if WTG
installation is in GE scope.
It is recommended that cleanliness is clearly defined and understood by all parties prior to first unit
installation preferably during the pre-installation meeting (PIM).
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6.
– Original –
Installation Manual
Verify the cables are secured in the cable
tray with ties and clamps. Verify the cables
are secured below the deck to prevent
damage to the cables and PPM.
Figure 154: Example for securing of the cables
7.
Install the fall arrest system or check the
pre-assembled fall arrest system as per
manufacturer’s instructions before
erecting the tower section.
8.
Fall restraint system is required to allow
ascent to the top of the segment.
WARNING
Falling hazard!!
If the fall arrest system is not available a
temporary fall arrest system must be provided
by the installer and removed after the
permanent fall arrest system is installed. This
applies to all mid sections.
Figure 155: Temporary fall arrest system tower mid-section
segments
Despite the temporary system a certified tieoff point must be used at all times.
Figure 156: Top section fall arrest system
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9.
Installation Manual
– Original –
After the tower section is stacked, position
the parts (bolts, nuts, washers, sealing
material, cable crimps, shrink sleeves etc.)
and tools needed to make the connection
to the next tower section on the platform
of the tower section currently being
prepared and secure them against falling
off.
10. Do not exceed the weight rating of the
platform, parts and tools must be evenly
spread on the platform and must not
interfere with opening the hatch.
Figure 157: Positioning the parts and tools on the platform
11. For the top section verify the hoist is
secured with all the hardware marked as
torqued.
Figure 158
NOTE
Repeat this section for towers with additional tower sections.
9.1.3 Attachment and Usage of the Lifting Gear
Depending on the variant of the lifting gear used, repeat the steps in sections
8.1.3.1 Plate Lifting Gear
8.1.3.2 HTS ACTEK WKA System.
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Installation Manual
9.1.4 Installing the Tower Section
1.
Position the parts (bolts, nuts, washers,
sealing material, cable crimps, shrink
sleeves etc.) and tools needed to make the
connection to the next tower section on
the platform of the tower section currently
being prepared.
If this is a top section the permanent fall
arrest system must be lowered down the
ladder and secured at the bottom of the top
section.
Figure 159: Positioning the parts and tools on the platform
Figure 160: Positioning the parts and tools on the platform
2.
If applicable, before lifting the top section,
prepare the tower section to avoid the
effect of wind induced tower vibrations
transverse.
Reference Installation of Coil Avoiding Wind
Induced Tower Vibrations Transversal to the
Wind Direction
3MW.X_Tower(System)_Tower Vibration
Avoidance System Installation.
Figure 161: Example rope fixed and coiled around the tower
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3.
– Original –
Installation Manual
Apply 12 mm Sikaflex®-252 or a
comparable sealing material between the
outer edge and the holes of the previously
installed tower section.
This prevents moisture entering into the
tower from the outside.
Figure 162: Applying sealing agent to the flange
4.
Instruct crane operators to lift the tower
into the upright position.
Figure 163
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– Original –
5.
Remove the tail pick crane rigging.
6.
Instruct the crane operator to slowly lower
the tower section over the previously
installed tower section.
7.
Guide the tower section by means of the
tag lines, in order to prevent it from
swinging.
The tower section is received by two
erecting engineers protected by safety
devices standing on the tower platform of
the first tower section.
This facilitates the subsequent alignment of
the tower section.
Installation Manual
DANGER
Fall hazard!
Personnel must be 100 % tied off and clear of
the load at all times.
Figure 164: Lifting the tower section
WARNING
Crushing hazard!
Once the tower reaches the appropriate elevation, personnel must stay
below the flange, until the tower section is near or directly over the tower to
be installed.
Do not reach outside the tower flange perimeter.
Always ensure that hands, feet, and body are not between any potential
pinch points.
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– Original –
8.
Giving precise instructions to the crane
operator, lower the tower section until one
flange is positioned above the other as
shown in Figure 165.
9.
Turn the tower section until the hole
patterns of the flanges are lined up with
each other and the two flanges can be
fixed in position with four bolts.
10. Insert four opposed bolts in the tower
flange to serve as fixing aids.
11. Insert ladder and rail joints. Take good
care that the segments of the ladder and
the rail of the fall protection system are
well aligned and joined properly.
Figure 165: Aligning and fixing the tower in position
12. Lower the tower section but leave a small
gap of approx. 10 cm.
The gap provides some room for maneuver
to insert all the bolts.
13. Insert all the bolts in the flange.
The bolts are pushed through the flange
from below and the nut is tightened from
above.
Figure 166: Connecting the flanges using bolts
14. Ensure that the arrangement of the nuts,
bolts, washers is correct. The bevel of the
washers must always point towards the
bolt head and the nut respectively.
Once all the bolts are finger-tight, the tower
can be let down completely.
Figure 167: Alignment of the washers
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Installation Manual
CAUTION
Wear hearing protection!
Proper hearing protection must be worn when working with any electrical or
hydraulic impact tooling!
Always assess the next task at hand. If 85 decibels will be exceeded, hearing
protection must be worn.
Personnel must wear ear protection when noise levels reach or exceed local
regulations. Observe requirements for hearing protection per your
company's policies.
WARNING
Pinch point - Crushing hazard!
When working with hydraulic and pneumatic torque tooling, ensure that your
hands and any part of your body are not between any pinch points ( e.g. any
part of your body is not between the tool reaction arm and back up pressure
surfaceEnsure personnel are properly trained on safe operations of hydraulic
and pneumatic tools.
15. Using an impact wrench tighten all bolts in
a star pattern/rolling triangle.
Reference the 3MW Platform Bolt Torque
Specification for final torque.
16. Mount the ladder splice section between
the base and the mid and splices as
required on additional tower mid sections.
17. Connect the ladder between the tower
sections and torque the bolts to
25-30 ft-lbs. For Haka rail climb system,
install splice plates to top and mid section
connection. Install the u-bolt to the ladder
rung.
Figure 168: Tightening the flange bolts
DANGER
Danger of collapse!
Only after all the bolts have been tightened by means of the impact wrench
the lifting gear can be detached.
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Installation Manual
– Original –
18. Remove the lifting gear from the top tower
flange. If this is the topmost section lower
the safety cable to the bottom of the
tower.
19. Remove the temporary fall arrest system
from tower section.
Figure 169: Removing the lifting gear
20. Now tighten all the bolts to the required torque by means of a hydraulic low-clearance wrench.
21. Details of the required torques can be found in the 3MW Platform Bolt Torque Specification.
Critical to Quality:
22. Verify no gap is present between the tower flanges.
23. If a gap is present, do not proceed until the gap is closed, ensure Sikaflex® was applied properly
and contact a GE Energy site representative for further instructions.
DANGER
Pinch point - Crushing hazard!
When working with hydraulic and pneumatic torque tooling, ensure that your
hands and any part of your body are not between any pinch points (e.g. any
part of your body is not between the tool reaction arm and back up pressure
surface).
Ensure personnel are properly trained on safe operations of hydraulic and
pneumatic tools.
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Installation Manual
24. Remove any paint residues or dirt from the
ground straps to ensure perfect contact of
the ground strap with the tower sections.
25. Mount the ground straps between the
tower sections. Torque the bolts and mark
them with a paint pen. Write the torque
data on tower wall.
26. Write torque data next with flange bolt
torque/10 % torque values.
Figure 170: Ground straps
27. Install the deflector plates to the tower
wall below the tower flange connections.
Figure 171: Example flange deflector plate
Figure 172: Deflector plates below the tower flanges
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– Original –
28. Uncoil and lower the safety cable to the
bottom of the tower base section. Care
must be taken to ensure that the safety
cable is not kinked.
29. Thread the cable through the eyebolt.
Install the thimble, remove all of the slack
in the cable and tighten the clamps (2
each). Ensure the cable clamps are
oriented correctly U-bolt “saddle” is
positioned against the cable going up the
tower and the U-bolt positioned against
the short end of the wire (never saddle a
dead horse).
Figure 173: Painting the flanges
30. Tension the safety cable until the sway is
removed (do not over tension). Cut off
excess cable using steel cable cutters.
Leave a two-inch tail. To prevent injury
wrap electrical tape around the end of the
cable tail until there is not exposed
strands.
Refer to the fall arrest manufacture
technical manual for final inspection of the
fall arrest system.
31. Remove the temporary fall arrest system
from all previous segments.
Figure 174: Fall arrest cables attched to the bottom of the tower
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Installation Manual
9.2 Corrosion Protection
1.
The flanges on all sections are
subsequently painted again to guarantee
reliable corrosion protection.
Review SDS and make sure to wear
appropriate PPE.
Figure 175: Painting the flanges
9.3 Checking/Adjusting the Railing Doors
1.
Open the railing door up to 90° and check
if it closes automatically.
2.
If not, check if the hinges are installed in
accordance with the supplier manual.
3.
If not, adjust the upper hinge ('A' including
spring element) to be parallel to the door
and railing.
4.
Adjust the lower hinge 'B' in exactly the
same way as the upper hinge, except both
parts must be angled approx. 35° to the
outside.
5.
Check if the catch 'C' closes properly. If
not, adjust it accordingly.
6.
Check the handrail for loose mounting
hardware and tighten as required.
Figure 176: Checking/adjusting the railing doors
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Installation Manual
10 Nacelle
NOTE
Rotors with 2900 hub are installed utilizing the Single Blade Installation Method
(SBI). Reference the single blade installation and the Temporary Yaw and Gearbox
oil pump systems GEI for:
Installing the unbalanced rotor turning gear before the nacelle leaves the
ground.
Qualified installation personnel to work with a GE site representative to help
Identify power source to the top box to enable the Yaw and Gearbox oil
pump systems.
NOTE
If generator is shipped separately, install the Generator according to 2.X_Machine
Head_Generator. Install on the Ground and high-speed coupling according to
Coupling specific vendor technical specifications.
WARNING
Risk from overhead suspended load/Crushing hazard!
Be aware of transport trailer Air ride systems!
Do not access through nacelle bottom hatch if air ride is being adjusted.
The nacelle has to be accessed through the roof hatch.
Quantity
Description
2
AC extension cord, 100’
2
Bar, connecting, 2’
ar
Bolts, nuts, and washers
2
Bucket, canvas, 5 gallon
1
Caulking gun
1
Container, gasoline
2
Duffel bag, canvas
1
File set, various, 12”
1
Generator, 6.5 kW with GFCI
2
AC extension cord, 100’
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Quantity
– Original –
Installation Manual
Description
2
Bar, connecting, 2’
ar
Bolts, nuts, and washers
2
Bucket, canvas, 5 gallon
1
Caulking gun
1
Container, gasoline
2
Duffel bag, canvas
1
File set, various, 12”
1
Generator, 6.5 kW with GFCI
1
Knife, putty
1
Ladder, extension, 16’
ar
MoS2 anchor brand jet lube, spray (For galvanized bolts only reference the bolt torque
specification)
1
Mop, sponge, heavy duty
ar
Paint pen, purple
1
Pressure washer, with 120’ hose
3
Radio, two-way
1
Ratchet, ½-inch drive
ar
Rigging
ar
Sandpaper, medium grit
ar
Sikaflex®, 262, ship loose
1
Socket, 46 mm, ½-inch drive
1
Socket, 50 mm, ½-inch drive
1
Socket, deep, 19 mm, ½-inch drive
1
Socket, deep, 24 mm, ½-inch drive
2
Tagline, nylon rope, 500’ (150 m ¾" for 80 m HH and up to 200 m ¾" for 100 m HH tower)
1
Water tank, 500 gallon
1
Wrench, Allen, 10 mm
1
Wrench, Allen, 12 mm
1
Wrench, combination, 24 mm
1
Wrench, combination, 50 mm
1
Wrench, crescent, 12-inch
1
Wrench, impact, 1-inch drive
1
Qualified wrench, torque, hydraulic or electric
1
Socket, 60 mm, 1-inch drive (for 1.x-100/103)
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– Original –
Recommended or Equivalent Temporary Fall Protection Parts Americas
Quantity
Description
1
3/8 lifeline with snap hook 30 ft. (5901003)
1
4 ft. sling (shocker) WLL 5000 lbs
1
5/8 bolt type anchor shackle 3-1/4 t WLL
1
12 inch softener
ar
Wire rope clips
ar
Thimble
ar
Cable tie
Temporary Fall Protection Parts Europe
Quantity
Description
1
Aluminum pipe hook RHK 60 with stitched rope termination with identification label serial number
1
Guided-type fall arrester SK 12- 16
1
Work positioning rope as per EN 358 12 or 14 mm core sheathed rope
1
Strap-type energy absorber as per EN 355
EN 355
NOTE
A temporary fall arrest system may need to be installed for protection while
transferring from the yaw deck to the nacelle if alignment will not allow for direct
transfer from yaw deck to nacelle. This must be identified while the machine
head is on the ground so that the temporary fall arrest can be installed.
The figure below illustrates which orientations of the nacelle relative to the tower
door can result in obstruction of both nacelle ladders.
Contact GE site representative for technical assistance.
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Installation Manual
A temporary fall arrest system may need to be
installed for protection while transferring from
the yaw deck to the nacelle if alignment will
not allow for direct transfer from yaw deck to
nacelle. This must be identified while the
machine head is on the ground so that the
temporary fall arrest can be installed.
The figure below illustrates which orientations of
the nacelle relative to the tower door can result
in obstruction of both nacelle ladders.
Contact GE site representative for technical
assistance
Figure 177: Orientations of the nacelle relative to the tower door
If applicable install a temporary fall protection:
1.
Inspect the cable:
2.
Verify a min. of 30 feet in length of 3/8
approved personal fall protection safety
cable with one eyelet.
3.
Inspect for damage such as broken wires.
4.
Verify labels are present and fully legible.
Cable must be rated to support 5,000 lbs.
5.
Inspect the snap hook ensure the gate lock
correctly.
6.
If the safety cable has wire rope clips
verify they are tight.
Figure 178: Example fall arrest protection parts installation
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A retractable lanyard can be utilized where
allowed by local regulations.
7.
Prior to lifting the machine head secure
the retractable lanyard. Secure a rope and
hook to the bottom of the ladder to be able
to reach from the yaw deck after the
machine head is positioned on the tower.
Figure 179: Example fall arrest protection parts installation
8.
Attach a softener between the sling cable and the gearbox lifting point.
9.
Double wrap the sling cable onto approved anchor point e.g., gearbox lifting point.
10. Attach anchor type shackle to the cable sling, verify the cotter pin is secure.
11. Hook the temporary safety cable to the shackle.
12. Ensure there is true engagement of hook to the shackle and that the hook gate is locked.
13. Use fall-arrest PPE and Ladsafe/TufTug to transfer from the tower to the nacelle. Adhere to
climbing rules at all times.
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Installation Manual
Figure 180
NOTE
A temporary cover shall be placed over the elevator opening at the yaw deck to
avoid potential fall of persons/materials through it.
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10.1 Inspecting the Nacelle
Carry out Nacelle Receiving Inspection. Inspect the machine-head for signs of shipping damage. Contact the
GE site representative if damage is found.
10.2 Preparing the Nacelle
DANGER
Risk from overhead suspended load/Crushing hazard!
Be aware of transport trailer Air ride systems.
Do not access through nacelle bottom hatch if air ride is being adjusted.
The nacelle has to be accessed through the roof hatch.
1.
Remove the shipping plastic (A) from the
transportation cap locations and from the
back of the nacelle.
A – Shipping plastic
Figure 181: Shipping plastic
2.
Remove the tarpaulin and shipping locks
from the rotor flange.
3.
Clean nacelle and apply touch-up paint (as
necessary).
4.
Verify the cables are secured in a loose
knot to protect cables from pinching and
are covered with shrink-wrap. Remove
tarpaulin for return shipping (if
applicable).
Figure 182: Example of the nacelle
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Installation Manual
WARNING
Fall hazard!
When climbing on top of the nacelle roof, always
ensure the ladder is secured with rope to the rail.
Use the following rules when using a ladder to
inspect equipment.
Check the ladder for damage prior to use.
Remove from service if damaged.
Use electrician's (fiberglass) ladders only.
Maintain 3-point contact while
ascending/descending the ladder.
Buckle rule: stay substantially at the center of
the ladder.
No carrying anything (camera in pocket, ok).
Secure ladder with one person at the bottom
of ladder holding it and one climbing.
Extend the ladder 3-rungs over top edge.
No climbing to the top of the ladder.
The person at bottom will maintain control of
the ladder until the ladder is secured with
rope.
Figure 183: Securing ladder to nacelle
Position the ladder at a 4-1 angle.
If applicable:
5.
Climb inside the nacelle and remove the
transportation fixtures (C) located at the
rear end of the generator support frame.
The fixtures are attached to the frame with
bolt pin and cotter pins. Remove all
hardware (C and B) and secure for later
return to place of origin.
A - Floor cover (to be installed after removing the transportation
fixtures)
B - Clevis pins 2pcs
C - Transportation fixture
Figure 184: Transportation fixtures
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6.
Installation Manual
– Original –
After removing the transportation fixtures
install the floor covers (A). Torque the
hardware and mark with a paint pen.
Refer to 114W5454.
Figure 185: Floor cover
If applicable:
For rail transport the transportation caps
114W5386P001 and 114W5387P001 are
supplied loose inside the nacelle enclosure. The
caps are marked left and right for correct
installation.
Also refer to 114W5454 and 114W5453.
Figure 186: Transportation caps
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7.
Clean and dry the marked surfaces where
the sealant will be applied.
8.
Apply a continuous 3-4 mm bead of
sealant (GE part 104W5085P001) all
around between the fiberglass parts
(GE parts 114W5386P001/ 114W5387P001)
on each side of the line of bolts as shown
in adjacent figure. Apply just before
bolting.
9.
Make sure that the caps are properly
sealed.
Installation Manual
ATTENTION
Temperature range for application of sealant (GE
part 104W5085P001) is from + 5°C to + 40°C.
Figure 187: Applying a bead of sealant at outer flange
Application of sealant only within the
temperature range permitted!
ATTENTION
Danger of water ingress!
Take good care to seal this detail (A) water
tight.
Figure 188: Applying a bead of sealant at inner flange
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– Original –
10. Attach the caps with hardware according
to GE drawings 114W5453 and 114W5454.
Exterior
Type 2 connection (9 bolts in total):
115W6720P001 weld nut, M8
104W9989P001 rivet, ST/ST 5/32X5/8,
round head
L415AP17 washer, plain, M8
L14DP17035 SCREW, hex cap, M8 X 1.25
X 35
392A1652P001 thread locking
compound, medium strength
Figure 189: Exterior hardware
Interior
Type 1 connection (4 bolts in total):
L14AP19050T screw, hex
cap,M10X1.5X50
L415P19T washer plain,M10
L216P19B lock nut, prevailing torque,
M10 X 1.5
Figure 190: Interior hardware
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ATTENTION
Awkward postures!
Tight spaces. Use caution.
11. Seal around all edges of the cap, at each
bolt head and specifically take good care
around the detail marked (B) in the
adjacent figure.
12. Inside, add nuts to bolts (A), L215P17 lock
nut, prevailing torque, M8 X 1.25M
(2 places).
Figure 191: Seal around edges
If you want to install obstruction lights continue
with Step 15. If you do not install any obstruction
lights:
13. Seal the drill holes in the nacelle roof with
a cover plate and sealant (GE part
104W5085P001).
14. Seal the edge of the plate and bolts with a
bead of sealant (GE part 104W5085P001)
to keep moisture out.
Figure 192: Cover plate
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If applicable:
15. Install the exterior aviation light support
posts (A) as required for the particular
WTGS.
Figure 193: Aviation light support posts
16. Drill holes (H) (40 mm ) at the location of
the lights.
Refer to 115W2558.
H – Hole locations for aviation light cables
17. Feed the cables for the aviation lights
through these holes and then through the
black PVC-conduit pipes under the nacelle
roof.
Refer to 108W6416.
Figure 194: Holes for aviation light cables
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18. Install the aviation light support posts and
seal around the bottom edges with sealant
(GE part 104W5085P001).
Seal all four bolt heads and washers water
tight with sealant (GE part 104W5085P001).
Refer to position (A) in the adjacent figure.
19. Under the baseplate and against the
nacelle roof surface add one bead of
sealant (GE part 104W5085P001) around
the center cylinder, refer to position (B) in
adjacent figure.
Figure 195: Aviation light seal
20. Install the optional aviation lighting.
Refer to the site-specific documentation.
See GE drawing 108W6416 for the routing
and connectors of the aviation light cables
to their terminations.
Figure 196: Optional aviation lighting
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21. The weather station is shipped inside the
nacelle, remove the packaging and lift the
weather station up to the roof.
22. Install the weather station platform and
bolt in place using the fixing accessories
provided. Tighten the fixing accessories to
the requisite torque and mark them with a
marker pen.
Details of the required torques can be found
in the 3MW Platform Bolt Torque
Specification.
23. Seal the edge of the plate and bolts with a
bead of Sikaflex® or equivalent to keep
moisture out.
24. Route anemometer and wind vane cables
through nacelle top hole, to the cable tray
inside the nacelle to the terminal box.
Figure 197: Weather station 2.85-103 to 2.75-120
Figure 198: Weather station 3.2-130 to 3.6-137
25. Inside the nacelle, in the oil cooler cabinet
on the rear of the nacelle, attach the
electrical grounding braids.
When the unit arrives at the wind park, the
grounding braids are mounted at
location (B).
26. Disconnect the braids (from location B)
and mount them to the welded-on
cylinder (A) on the weather mast
baseplate.
Figure 199: Connecting grounding braids to MET mast base
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27. After completing work in the cooler
compartment, replace the loose oil cooler
floor plate in its position.
28. Retighten all hardware.
29. Terminate wires per point to point.
30. Inspect the rear of the nacelle back
compartment for loose debris, trash and
install the fiber glass cover with the
hardware provided.
31. Install the tarpaulin between the back of
the generator and the back of the nacelle.
Figure 200: Replacing oil cooler floor plate
32. Check the hydraulic hand pump for proper
functioning and loose hardware and leaks.
33. Verify that 80 liters of gearbox oil are
present and properly secured in the
nacelle.
34. Activate the desiccant breather by pulling
the o-ring seal if applicable.
35. Check the yaw bearing threads for
cleanliness. Remove contaminants with a
tap if necessary.
36. Verify the gear ring to tower flangemating surface is clean.
37. Check the hydraulic/ gear oil/ cooling
hoses and fittings are tight.
Report any oil leaks to GE prior to flying the
nacelle.
Figure 201: Hydraulic hand pump for the rotor lock
38. Verify the main flange to hub flangemating surface is clean.
39. Verify all hub-mounting nuts and washers
are present.
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40. Check inside the top box cabinet for
rodent, debris.
Figure 202
41. Check cables at the top box, below the
generator and the cables coiled below the
main shaft for possible damage due to
rodents or transportation handling.
Contact GE site representative if any
damage is found.
Figure 203
42. Verify the nacelle floor hatch is closed and
carabineer available.
If not present, contact GE representative.
Figure 204
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43. If applicable remove the shroud cover of
the rotor main shaft.
44. Ensure that grounding brushes in main
shaft is present and free of damage.
Bracket(s) may have to be removed for
rotor installation torque.
Figure 205
45. If applicable, verify the nacelle internal
crane is in the properly locked position.
Secure from side to side and front to back
movement by placing temporary
restraining ropes.
Figure 206: Push nacelle crane to locked position
46. Install temporary fall arrest system for
equivalent for transferring from the yaw
deck to the nacelle once installed.
WARNING
Falling hazard!
If an employee is working at a height that exposes
them to a potential fall, fall arrest equipment must
be used, and 100 % tie-off at all times is required.
A retractable lanyard or hard fix tie off points may
be utilized.
Figure 207
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WARNING
Falling hazard!
If the nacelle yaw deck ladders cannot be deployed correctly due to
orientation of the machine head, a temporary fall arrest system can be
installed to safely transfer between the tower and the machine head.
This must be identified while the machine head is on the ground so that
the temporary fall arrest can be installed.
47. Rotate the high-speed coupler to align the
rotor lock pin with a hole on the
perforated rotor lock disk. This ensures
that the rotor can be locked in the Yposition during hub entry and if needed in
the future.
Figure 208
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10.3 Lifting the Nacelle
ATTENTION
Check the wind speed!
The nacelle may only be installed in accordance with section 4.1 ‘Operations
Involving the Use of a Crane’.
If the nacelle cannot be mounted immediately and the "open" tower has to
remain without a nacelle (e.g. overnight), only three tower sections may be
mounted. In this case, the top tower flange must be protected against the
effects of the weather by suitable means.
Refrence General_Description_MW-xxHz_WindSpeedLimitations.
10.3.1 Lifting Gear for the Nacelle
NOTE
Please refer to outline drawing for the lifting point.
Below pictures are for reference only.
10.3.2 Attachment of the Lifting Gear
1.
Verify the gear ring to tower flangemating surface is clean.
2.
Remove the hatch and the cover over the
lifting lugs of the nacelle and place them
inside the nacelle.
3.
Attach two guide ropes to the lifting beam.
4.
Attach the lifting beam to the crane.
Figure 209: Remove the roof hatches
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5.
Installation Manual
– Original –
Instruct the crane operator to position the
lifting beam over the nacelle and bring the
lifting gear to the lifting lugs.
Figure 210: Positioning the lifting gear
Arrangement of the lifting lugs in the nacelle:
6.
The arrangement of lifting lugs is shown in
adjacent figure.
Confirm lifting strap clearance at all
locations before putting tension on the
straps.
Figure 211: Lifting lugs in the nacelle
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WARNING
Avoid equipment damage!
Use caution when attaching the lifting gear so that damage does not occur
to the hydraulic power unit, yaw motors or any cables.
7.
Attach lifting gear to the front lifting lugs.
Figure 212: Attaching the nacelle
The lifting gear is attached to the lifting lugs
on the top of the bedplate.
Figure 213: Lifting lugs on the main bearing
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8.
– Original –
Installation Manual
Attach lifting gear to the left and right rear
lifting lugs.
Figure 214: Lifting lugs on the base frame
NOTE
Two more lifting lugs are located on the left and
right of the rear of the base frame. The shackles
are attached to these by means of sling loops.
9.
Once the lifting beam is secured to the
nacelle, attach one guide rope to the main
shaft and the other to the rear tie-off point
on top of the nacelle to make it easier to
make adjustments during the lifting
operation.
Figure 215: Lifting lugs on the base frame
ATTENTION
Danger of equipment damage!
Only apply tag lines to load rated fixing points.
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10. Pick up the lifting belts slightly without
lifting the load.
11. Turn the spindle until the suspension is
over the center of gravity of the load.
12. If an incorrect angle arises, it can be
corrected later under load.
NOTE
The center of gravity needs to be adjusted for
lifting the nacelle with or without gearbox or
generator.
Figure 216: Aligning the load
WARNING
Crushing hazard!
During Installation always ensure that hands,
feet, and body are not between any potential
pinch points.
13. After all pre-installation work has been
finished inside the nacelle the transport
ring needs to be removed before the
nacelle is installed on top of the tower.
14. The crane matts/cribbing must be
positioned on the ground, in relation to the
transport fixture.
3 meters (approx. 12”) off the ground (heavy
crane matts or 12”x12” timbers, are
standard dunnage) and that allows access
through the rear floor tool hatch.
Figure 217: Positioning of crane matts/cribbing
WARNING
Lifting heavy loads!
Prior to lifting all heavy loads, a pre-lift meeting with all parties involved is
required. (crane operator, rigger, supervisor, signalman, and any other
personnel involved, such as area safety, tag line holders). All lifting must be
done in strict accordance with the installers lift plan and the applicable job
safety analysis must be reviewed as well.
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15. After receiving the starting signal from an
authorized person (i.e. the danger zone is
safe and free of workers) start lifting up
the nacelle.
Refer to the site-specific plan.
16. Lift up the nacelle from the ground –
approx. 1 m-2 m.
Figure 218: Lifting up the nacelle
17. Put down the nacelle on crane
matts/cribbing to support the nacelle.
18. Reduce the hook load by max. 30 % and
check the stability of the crane
matts/cribbing and underground while
reducing the hook load.
19. Wait approx. 5 min, then check the
stability again.
20. If stability is not sufficient go back to step
14 above, otherwise continue.
Figure 219: Example Nacelle supported by crane matts/cribbing
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21. Remove all bolts between transportation
fixture and yaw bearing to loosen the
transportation fixture.
22. Unhinge the hooks from the nacelle-totower fit-up aids.
The transport fixture is now detached from
the nacelle.
Figure 220: Shipping fixture of 3.2-130 to 3.6-137
Figure 221: Shipping fixture of 3.2-130 to 3.6-137
DANGER
Risk from overhead suspended load!
After finishing the removal of the hardware for the shipping fixture and
ensuring the load is stable all personnel must exit the nacelle prior to
beginning the lifting.
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23. After receiving the starting signal from an
authorized person (i.e. the danger zone is
safe and free of workers) start lifting up
the nacelle. Refer to the site-specific plan.
24. Instruct the crane operator to lift the
nacelle approximately 40 cm from the
transport ring. Stabilize the load and verify
the nacelle is level.
Figure 222: Lifting and stabilizing the load
25. Instruct the crane operator to hoist the
nacelle into position above the top of the
tower.
26. Ensure the appropriate tension on the
taglines is maintained to keep the nacelle
stabilized during the lifting process.
Figure 223: Lifting the nacelle
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10.4 Assembling the Nacelle
WARNING
Crushing hazard!
Do not put your hands between the flanges. Danger of serious crush injuries!
Ensure that you keep a safe distance from the flanges.
1.
Use the fit-up aids to facilitate the
positioning of the nacelle on the tower
flange. The fit-up aids have to be
positioned on the inside of the tower
flange.
2.
Giving precise instructions to the crane
operator lower the nacelle until the hole
pattern of one flange is positioned exactly
above the other.
Figure 224: Fit-up aids for the nacelle
NOTE
Do not mix bolts and nuts from different manufacturers in bolted flange
connections!
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3.
Installation Manual
– Original –
Insert four opposed bolts in the flange to
serve as alignment aids.
Critical to Quality:
4.
Ensure all the bolts engage by hand before
using the impact wrench or torqueing the
bolts. If bolts do not fully engage due to
bad threads, contact GE prior to final
torqueing and or disconnecting the crane.
Figure 225: Capturing the nacelle
5.
If the unit requires a service lift installed,
install the service lift backup brackets to
the flange using longer bolts according to
drawing 117W5670.
6.
Install the remaining washers and bolts in
the yaw deck.
7.
After all bolts have been installed, instruct
the crane operator to lower the nacelle
completely on to the tower flange.
Figure 226: Installing service lift backup brackets to the flange
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DANGER
Pinch point – Crushing hazard!
When working with hydraulic and pneumatic torque tooling ensure that your
hands and any part of your body are not between any pinch points (i.e. no
part of your body is between the tool reaction arm and the back up pressure
surface).
Ensure personnel are properly trained on safe operations of hydraulic and
pneumatic tools.
NOTE
Uncontrolled torque increase!
When the electric torque wrench has switched off after reaching the preset
torque, it may not be switched on again on the same bolt, since this causes an
uncontrolled torque increase.
CAUTION
Wear hearing protection!
Proper hearing protection must be worn when working with any electrical or
hydraulic impact tooling!
Always assess the next task at hand. If 85 decibels will be exceeded, hearing
protection must be worn.
Observe requirements for hearing protection per your company's policies.
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8.
Using an impact wrench tighten all bolts in
a star pattern/rolling triangle.
9.
Reference the 3MW Platform Bolt Torque
Specification for final torque.
DANGER
Fall hazard!
If the nacelle yaw deck ladders cannot be
deployed correctly due to orientation of the
machine head, a temporary fall arrest system
can be installed to safely transfer between the
tower and the machine head.
This must be identified while the machine
head is on the ground so that the temporary
fall arrest can be installed.
Figure 227: Tightening the bolts
10. Remove the crane lifting gear.
11. Remove the tag lines and secure to lifting
gear.
12. Instruct the crane operator to move lifting
gear out of the work area.
13. Remove the fit-up aids as required.
DANGER
Danger of collapse!
Before the assembly of the rotor, all bolted connections between the tower
sections and between the tower and the nacelle must be tightened as per
the document 3MW Platform Bolt Torque Specification.
WARNING
Pinch point – crushing hazard!
When working with hydraulic and pneumatic torque tooling ensure that your
hands and any part of your body are not between any pinch points (i.e. no
part of your body is between the tool reaction arm and the back up pressure
surface).
Ensure personnel are properly trained on safe operations of hydraulic and
pneumatic tools.
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14. Perform the final torque using qualified
torque tooling and mark with a paint pen.
Details of the required torques can be found
in the 3MW Platform Bolt Torque
Specification.
15. Replace the cover over the lifting lugs on
the roof of the nacelle, add the steel bars,
and connect the bolts.
16. Close the roof hatch.
17. If applicable, fit the lamps in the lighting
fixture and mount the covers.
18. Connect the optional temporary or
permanent aviation lighting.
Refer to manufacturer's instructions.
19. Inspect the interior of the tower for
scratches and bare metal surfaces. Apply
latex-based paint as per the
manufacturer's instructions.
Figure 228: Closing roof hatch
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11 Hub
Quantity
Description
ar
Cribbing
1
8’ Extension Ladder
3
Radio, two-way
Per lift plan
Rigging
2
Tagline, nylon rope, 20’
1
Tape measure, 100’
Typical Hub Configurations
Typical 2500/2570
Figure 229: Utilized on 120m Rotor diameter and smaller
Typical 2900
Figure 230: Utilized in 130m Rotor diameter and larger
Both hub configurations require the use of 3
lifting plates attached to the bearings to
offload as shown on the illustration. Request
outline drawings for bearing bolt hole pattern
from GE representative to aid in lifting plate
customer design.
Figure 231: Hub lifting gear
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11.1 Inspecting the Hub
Carry out Hub Receiving Inspection. Inspect the hub for signs of shipping damage. Contact the GE site
representative if damage is found.
WARNING
Electrical hazard!
Stored energy may be present within electrical cabinets. Consult with GE
engineering to identify the voltages that could be present.
ATTENTION
Check components!
All components must be checked for visible damage, deformation and cracks
prior to assembly!
The components must be stored and mounted in such a way that any
damage is avoided that could adversely affect the standing stability or loadbearing capacity and could thus cause potential accidents.
Please contact the GE site representative if damage is found.
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11.2 Lifting the Hub
Remove the transportation frame only if final assembly can be accomplished immediately (store with
transportation frame attached).
ATTENTION
CRITICAL TO SAFETY!
Rotors cannot be assembled with intent to store. If rotors are not installed
within 30 days after assembly, the installer must begin a documented
maintenance cycle. GE will provide lubricant and directions, but it is the
installer’s responsibility for executing and submitting documentation to GE.
ATTENTION
CRITICAL TO SAFETY!
Only use devices specifically designed for lifting the hub. Do not use the
transportation tie-down brackets for lifting the hub. The transportation
tie-down brackets are strictly used for transportation tie-down only and are
not load rated for lifting. Moving the hub prior to blade assembly is to be
done using three load rated lifting brackets fixed to the three lifting points.
NOTE
Please check the outline drawing for the lifting points.
Below pictures are for reference only.
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1.
– Original –
Installation Manual
If required remove the transport tarp from
the hub to attach the rigging.
To protect the hub from the elements,
remove the shipping materials only if final
assembly can be accomplished immediately
(store with shipping materials attached).
The nose cone may be shipped inside the
machine head and will be removed during
installation of the generator.
Figure 232: Example Hub transportation
2.
Offload the nose cone near the area where
the rotor will be assembled.
Figure 233: Typical nose cone lifting eye supplied with the hub,
3 each.
Figure 234: Example nose cone offloading
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11.2.1 Attaching the Lifting Gear
ATTENTION
Avoid damage!
Use caution when attaching the lifting gear so that no cables or hoses inside
the hub are damaged or pinched.
1.
Mount three lifting lugs to the bearing of
the hub for unloading from the trailer.
Figure 235: Hub lifting gear
Figure 236: Typical hub lifting locations
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Critical to Quality:
Lifting bar method may be used only when
shrink wrap has been removed to reposition
the hub during rotor assembly.
2.
Do not use the lifting bar to offload the
hub if the hub will remain in storage.
ATTENTION
Danger of equipment damage!
The hub must be sealed to prevent damage!
Do not damage the shrink wrap!
The hub must be sealed to prevent water from
entering the hub.
3.
Attach a tag line to the transportation
frame to stabilize and safely offload the
hub.
4.
Lift the hub from the transportation
trailer.
Figure 237: Lifting bar method
Figure 238: Tag line on the transportation frame
5.
2900 rotor hubs will be staged and
prepared in accordance with the latest
Single Blade Installation GEI.
6.
2900 hubs do not require 1m clearance
from the ground. Ensure the hub is staged
and stabilized over appropriate bearing
surface support.
Figure 239
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7.
The hub must be set down on a firm
horizontal surface that can support the
weight of an assembled rotor.
8.
Lay a wooden bed over the area for setting
down the hub. Check that the area is
horizontal, in order to exclude stressing of
the blade bearings during the manual
blade pitching.
NOTE
It is recommended for 120 m and larger rotors to
use a rotor assembly stand if a stand is not
available proceed to Step 9.
9.
Ensure there is a clearance of 1 m
minimum between the ground and the
shipping fixture feet to allow blade
pitching.
10. Detach the tag line from the hub. Detach
the lifting lugs to the bearing ring of the
hub.
1m
Figure 240
11. If applicable remove any dirt or temporary
surface coatings from the inner and outer
bearing surfaces.
12. Clean the hub and touch up any damage
to the paint.
Figure 241: Clean coating from the bearing surface
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13. Ensure the correct quantity of blade
mounting hardware nut/washers is at
hand.
Figure 242: Example blade mounting hardware
14. If hub arrives with metal covers installed,
remove the metal covers covering the
bearing teeth to prevent damage to studs
and allow access to torque bolts. Bolt
must be discarded and replaced with new
ones after the blades are installed.
Figure 243: Remove the bearing metal covers
Figure 244: Example bearing metal cover
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12 Rotor Blades
ATTENTION
Rigging requirements!
Rigging requirements are based on the site-specific lift plan. Consult with GE
to obtain equipment outline drawings, containing bolt hole patters and
approved lifting points, weights and dimensions.
12.1 Inspecting the Rotor Blades
ATTENTION
Check components!
All components must be checked for visible damage, deformation and cracks
prior to assembly!
The components must be stored and mounted in such a way that any damage is
avoided that could adversely affect the standing stability or load-bearing
capacity and could thus cause potential accidents.
Please contact the GE site representative if damage is found.
1.
Check the blade support position and blade condition. The blade must not touch metal fixtures.
Report to GE representative as required.
2.
Inspect the blade studs for damaged threads and corrosion.
3.
Inspect the bearing and blade mating surfaces for high spots or protrusion.
4.
Ensure the blade root access doors in the blades are closed and the handles are in locked position
or
ensure the blade closeout cap hardware is tight on the blades.
5.
Inspect the zero reference plates for damage.
6.
Ensure the blade surface is free of any contamination like dirt or salt from sea or land transport. If
not ok, clean the blade surface accordingly.
7.
Inspect the blade tip drain holes for blockage (all three blades). Inspect hole to ensure it is clear. If
blockage is encountered, contact GE representative.
8.
All blade damage must be reported and blade repair must be done in accordance with
manufacturer’s recommendations.
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12.2 Offloading the Rotor Blades
NOTE
For handling of the lifting devices refer to the supplier’s documentation.
Please refer to outline drawing for the lifting point.
WARNING
Mind the maximum allowable wind speed!
For technical data to calculate the maximum allowable wind speed for crane
activities, especially on parts and systems with a high sail area with respect
to system weight, refer to the document:
Component_SailArea_DragCoef_Generic-xxHz.
WARNING
Take care when working on the low-loading trailer!
Work on the loading platform of the low-loading trailer may only be carried
out when it is stationary. All personnel must leave the loading platform
before the low-loading trailer is moved.
DANGER
Risk from overhead suspended load!
Never work under a suspended load. Make sure all people, vehicles,
equipment and materials are clear of the crane tail and load swing.
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WARNING
Blade handling - use certified lifting points only!
When handling blades on shipping fixture(s) specific blade manufacturer's
handling instructions for the specific blade configuration (e.g. 114W3337 for the
48.7 m blade or 103W2754 for the 50.2 m blade or 109W3740 for the 58.7 m
blade) must be reviewed with the crews and understood prior to commencing
work.
Only use lifting points that are designated by the blade manufacturer for
lifting. DO NOT use transportation tie down points for lifting!
Only use lifting points that are rated with enough capacity to lift the entire
weight of the blade.
If unsure, always consult with GE Technical Advisors and GE Blade Engineers
prior to handling individual blades and/or blades in shipping fixtures.
CAUTION
Use caution when operating heavy equipment around personnel and wind
turbine components.
1.
Remove the rear lighting gear from the
blade.
2.
Remove the entire lashing and all twist
locks to unload the blades from the truck.
Figure 245: Example for blade rear lighting
The recommended method for lifting the blade requires the use of one crane with a spreader bar.
The spreader bar must be capable of handling both the 29 m and the 37.5 m positions of the tip fixture.
Alternatively, lifting the blade requires the use of two cranes with 35 t load capacity each.
Both cranes will need to be coordinated to keep both fixtures as even as possible.
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Figure 246: Reaction Loads for Lift Z=0 - Z=29000
Figure 247: Reaction Loads for Lift Z=0 - Z=37500mm
Critical to Safety:
3.
Ensure the twist locks on the tip fixture are
in the locked position before proceeding to
lift.
Figure 248: Twist locks
Figure 249: Lifting the tip fixture
The tip fixture requires four D-Rings and four steel cables attached to crane.
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ATTENTION
Danger of equipment damage!
If two straps are used make sure that the straps are hooked to fixture in
opposite corners (refer to figure).
Figure 250: Lifting the root fixture
The root fixture requires 2 D-Rings and 2 cables attached to crane.
4.
Attach rigging to approved lifting points on the blade fixture.
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5.
– Original –
Installation Manual
If using single crane with lifting bar install a tag line to stabilize the load.
DANGER
Danger of blade destruction and serious personal injury!
It is strictly forbidden to lift the blade solely at the tip fixture or the root
fixture!
Figure 251: Lifting points
6.
Lift the root and tip fixtures slowly and evenly.
The lifting/handling accelerations must be limited to 3 m/s² (0.3 g).
Figure 252: Allowed vertical and transversal lifting cable angles
The allowed hoisting cable or sling angles are limited to +0 °/-3 ° in the vertical direction and 60 ° in
the transversal direction.
Figure 253: Leveled lifting
The maximum allowed shipping fixture inclination when lifted is 3 °.
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Alternatively, the blade can be lifted off the trailer
with two forklift trucks.
NOTE
Important for tandem lifting!
Each forklift truck shall be de-rated by 20%.
Hoist ropes to remain vertical at all times.
Good communications are crucial.
Figure 254: Unloading the blade with two forklift trucks
Figure 255: Unloading the blade with two forklift trucks
Figure 256: Unloading the blade with two forklift trucks
Figure 257: Unloading the blade with two forklift trucks
Figure 258: Unloading the blade with two forklift trucks
ATTENTION
Danger of equipment damage!
If two straps are used make sure that the straps are hooked to fixture in
opposite corners (refer to figure).
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Example 58.7 LM super pack and stack shipping fixture. Refer to 109W3740.
7.
The 58.7 blades are shipped with the
trailing and leading edge in a horizontal
position.
8.
Refer to the latest revision 109W3740 for
approved lifting points and handling
methods.
The package shall be lowered onto a near flat ground surface.
9.
Verify a maximum of 200 mm flatness deviation.
This is the permissible tolerance without damaging the blades.
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Figure 259: Blade positioned permissible flatness deviation (max. 200 mm)
10. In case of an uneven surface, lower down the blade package until the first fixture touches the
ground.
11. Then line the other fixture by supporting it with adjustment shims (e.g. wooden or metal blocks).
Both transport fixtures need to be laid down on the ground evenly.
Figure 260: Blade positioned with adjustment shims A (flatness deviation more than 200 mm)
Likewise, a maximum of 100 mm flatness
deviation on ground is allowed in transversal
direction.
12. In case of an uneven surface, lower down
the blade package until the first fixture
touches the ground.
13. Then line the other fixture by supporting it
with adjustment shims (e.g. wooden or
metal blocks).
Figure 261: Blade positioned with adjustment shims A (flatness
deviation more than 100 mm)
NOTE
If blades are not installed immediately, always secure the blades during
storage to prevent damage during high winds.
For complete storage instructions refer to the document 3MW
Platform Storage Manual.
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12.3 Preparing the Blades
1.
Check the blade bolts for damage and even projection. Correct damaged threads and remove high
spots with a file.
2.
Remove corrosion with wire brush.
3.
If threads and high spots cannot be corrected or corrosion cannot be removed, contact the GE site
representative.
NOTE
Please check the outline drawings for the lifting points. Below pictures are for
reference only. Measure the blade lifting points against dimensions provided
in blade handling drawing to make sure they are correct.
NOTE
If blade de-icing equipment will be installed refer to work instruction for
blade de-icing equipment installation.
4.
Remove all dirt or non-permanent surface
coating materials on the bolts, blade end
face, and bearing face.
5.
Remove any water and debris from the
root end of the blade.
6.
Check carefully and remove any shipping
bracket washers lodged between the
blade closeout and the inside wall of the
blade.
7.
Apply lubricant per 3MW Platform Bolt
Torque Specification to 100 % of the
threads on the blade studs.
Review Materials Safety Data Sheet (SDS)
prior to use. Shake the spray can thoroughly
for a minimum of one minute. The lubricant
will have a silvery appearance (if clear,
continue shaking the can).
Figure 262: Clean flange
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8.
Preparing the 58.7 Blades:
Once the fixture is removed, remove the
shipping hardware from the root.
9.
Support the blade root by straw bales or
equivalent and/or crane if installing the
blade immediately to the hub.
– Original –
Installation Manual
Figure 263
10. Support the shipping fixture by crane or
forklift to remove the weight from the
shipping fixture hardware.
11. Loosen and remove the shipping fixture
hardware.
12. Remove the shipping fixture and place out
of the work area.
Figure 264
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13. Once the shipping fixture is removed
locate the blade studs for installation.
These bolts are secured to the shipping
fixture.
Contact GE site representative if bolts are
missing.
Figure 265
14. Apply Loctite 277 to the new stud.
Review Materials Safety Data Sheet (SDS).
15. Install ensuring the stud projection
matches the other studs.
NOTE
Studs do not bottom out.
Verify the projection of the stud matches the
others.
Figure 266
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Figure 267: Reference marking
A – 0-reference mark
B – Name plate
C – 0-reference marking plate
D –Reference line
E – Highlighted stud end
16. Highlight the 0-reference mark (A) on the
face and inside the edge of the blade using
a red paint pen.
17. Place a red paint pen line (D) across the
face of the blade flange centered with the
0-reference mark (A).
18. Highlight the end of the stud (E) directly
left of the 0-reference mark using a red
paint pen.
Figure 268: Reference marking
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12.4 Blade Handling
NOTE
Blade and rotor damage prior to installation!
CRITICAL TO QUALITY AND SAFETY:
When abnormally high ground winds are anticipated, it is recommended that the
contractor reschedules this activity and to double up on blade handling and
control resources prevent blade damage.
Each site shall assess the need for additional blade and assembled-rotor tiedown arrangement. Locations and instances which demonstrate high groundlevel winds warrant additional consideration which may include: Additional
standard tie-downs and anchor points, further assessment of cribbing and
dunnage and the potential for cribbing and dunnage to sink into the ground.
WARNING
Blade and rotor damage during installation!
In high wind prone areas, do not build rotors until ready to install. Stress caution
on building rotors too far in front of installation. "Pay attention to the Weather
forecast", When abnormally high ground winds are anticipated, it is
recommended that the contractor double up on dead men and use a strap with a
higher minimum tensile strength then 5000 lbs. each Leg during rotor assembly
and storage.
Use blade tip socks to secure rotor back to the tower for increased stability in
high wind events.
Build rotor on the transportation frame and/or hub stand to increase
footprint and stability. Include compaction in the rotor hub assembly area. In
known soft soil conditions require increased dunnage foot print for
component stability.
Ensure all tie down straps are tight and strong enough for the application.
Fully assembled rotors ensure zero degree blade orientation if rotor cannot
be installed.
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The rotor blades are marked with center of
gravity marks. These marks help to balance
the blades.
Figure 269: Example Center of gravity
Several marked fastening points are located
on each rotor blade.
1.
Support the blade for lifting or storage as
labeled in accordance with specific blade
manufacturer drawings.
Consult with GE representative for specific
blade drawings.
Figure 270: Example Lift here and Support points.
ATTENTION
Danger of damaging the blade!
Do not deviate sling location from blade manufacturer specified lifting
locations under any circumstances without written approval from the GE
blade engineer.
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ATTENTION
Danger of damaging the blade!
Always check the trailing and leading edge protectors for padding to prevent
blade damage.
Always check the trailing and leading edge protectors for any debris that
could damage the blades.
Make sure Vortex generators (VG's) are protected and use the correct trailing
edge protection method according to blade handling drawing.
CAUTION
Use caution when operating heavy equipment around personnel and wind
turbine components.
2.
After the rotor blade has been lifted off the
trailer, remove the top section (A) of the tip
fixture if rotor will be assembled.
3.
Loosen the threaded torque bar (B).
4.
Remove the pin rod (C) holding the top
portion of the padding.
Figure 271: Example 48m GE Tip Fixture positioning
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5.
Installation Manual
– Original –
Lift the top portion of the padding (D) and
remove it from the fixture to prevent blade
damage when rotating the blade.
NOTE
Replace all brackets with hardware after the
blade is removed from the fixture.
Figure 272: Lift padding and remove
6.
For single or double crane lift: Position crane(s) to lift the blades at the specified lifting locations
per specific blade drawing.
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12.4.1 Example: Double Crane Lift
1.
Place and center protective caps (for leading edge and trailing edge) at lifting locations as per
specific blade drawing.
2.
Place and center slings at lifting locations as per specific blade drawing. Refer to drawing for min.
sling width and length.
Figure 273: Example only sling position for double crane lift
If the blade is shipped in a degree position, first
rotate blade so the trailing edge is facing up.
3.
Using properly sized lifting equipment
support the root fixture with a separate
crane or forklift. Secure a line (A) to the
upper left corner of the root fixture (B).
4.
Slowly lift the root fixture (B) until the
blade rotates into vertical position as
required per blade specific drawing.
Figure 274: Lifting root fixture
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5.
Once the blade is vertical and stabilized,
lift the blade with the main crane until the
load is supported.
6.
Remove the root fixture and store outside
of the work area.
Installation Manual
ATTENTION
Danger of damaging the blade!
Do not deviate sling location from blade
manufacturer specified lifting locations under
any circumstances without written approval
from the GE blade engineer.
Figure 275: Example removing root fixture
12.4.2 Example: Single Crane Lift
1.
Place and center protective caps (for
leading edge and trailing edge) at lifting
locations as per specific blade drawing.
2.
Place and center slings under a spreader
bar at specified lifting locations per
drawing.
Refer to drawing for min. sling width and
length.
Figure 276: Example place slings and spreader bar
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3.
– Original –
Installation Manual
Adjust the slings length above the
spreader bar so that the hook is on the
same vertical line as blade CG (Center of
Gravity). Front 48.7 25' and Rear 22' 3 "
If using a chain fall, ensure the chain fall or
spreader must not make contact with the
blade.
Figure 277: Example lifting with spreader bar
4.
Lift the blade by the root fixture, rotating
the blade so that the trailing edge (TE) is
vertical (pointing up) with a separate
crane or forklift.
Care must be taken to ensure the trailing
edge does not lean and place too much
pressure against the slings.
5.
Once the blade is vertical and stabilized,
lift the blade with the main crane until the
load is supported.
ATTENTION
Figure 278: Example lifting blade until load is supported
Danger of damaging the blade!
The chain fall or spreader must not make
contact with the blade.
Do not deviate sling location from blade
manufacturer specified lifting locations under
any circumstances without written approval
from the GE blade engineer.
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6.
Installation Manual
– Original –
Once the blade is stabilized remove the
root fixture and store it outside of the
work area.
WARNING
Operating the fork lift!
Do not operate the fork lift if you don't have
the required training. The stability of the
forklift is determined by the location of its
center of gravity.
Ensure that the load is evenly distributed on
the forks while travelling.
Figure 279: Example placing fix out of work area
Follow the equipment operating manual.
7.
If the blade is not balanced during lifting,
using the chain fall adjust sling length
above spreader bar to keep blade
balanced during lifting.
ATTENTION
Danger of damaging the blade!
Do not deviate sling location from blade
manufacturer specified lifting locations under
any circumstances without written approval
from the GE blade engineer.
Figure 280: Example blade balanced
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Installation Manual
13 Rotor
120 m diameter and smaller can be installed as a completely assembled rotor.
130 m rotor diameter and larger must be installed utilizing Single Blade Method the Single Blade Process (SBI).
Refer to the latest GEI- for Single Blade Installation.
13.1 Preparing the Rotor
NOTE
E-palms are a delicate electronic device. Care must be taken of these units
including storage in warm environment to prevent battery failure.
Abused or failed e-palms must be sent by customer to vendor for repair.
NOTE
If hubs have been in long term storage inspect the battery chargers for signs
of water damage and corrosion and report to the GE representative to
ensure corrective action is taken before the units are commissioned.
NOTE
For the GE pitch systems it is not required to pitch the bearing to 360 °.
Immediately after the blades are pitched for storage or installation, place the
battery box switches in the off position on each axis cabinet and install a single
tie wrap to axis 1 power switch.
NOTE
For cold weather climate axis box heaters may be switched to the on position.
Contact GE site representative for details or use and external heat source.
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Quantity
Description
ar
Brush, wire
1
File set, various, 12”
1
Water cooled generator minimum 6.5 kV
1
(Water cooled recommended) 25 kVA generator minimum 400 V; 400 volt AC (+/- 10%) 3 phase
power generator. (400 VAC generators are not common in some countries, however you can use
a common 480 VAC generator with the output voltage turned down to 440 VAC on the pitch
system) use a 5c-6 AWG cable (L1-L2-L3-Ground and Neutral) and appropriate grounding from
the generator to a grounding rod as required.
1
400 VAC fusible disconnect box
1
Ladder, step, 10’
ar
MoS2 anchor brand jet lube, spray
ar
Paint pen, red
3
Radio, two-way
ar
Rags
1
Ratchet, ¾-inch drive
Per lift plan
Rigging
ar
Sandpaper, medium grit
1
Socket, 50 mm, ¾-inch drive or 55 mm for 2500 hub
2
Tagline, nylon rope, 100’
1
Wrench, combination, 50 mm
1.
Remove shrink-wrap material around the outer edge of the hub bearing prior to installing each
blade. Do not remove from all three bearings at once.
2.
Verify that the nuts and washers are staged in the hub for blade assembly.
3.
Rotate the blade bearing ring to the desired position for blade installation.
4.
Inspect the hub, pitch motors and pitch cabinets for signs of water and humidity. If water is
present, dry the affected components before any operation. Report any rust/damage as
necessary before operating the pitch system. Operating the pitch system with humidity could
cause damage to the equipment.
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Installation Manual
13.1.1 GE Pitch Control System (MSS Hub Pitch System)
1.
Follow the steps below to operate the GE pitch system.
ATTENTION
E-palms are a delicate electronic device. Care must be taken of these units
including storage in warm environment to prevent battery failure.
Abused or failed e-palms must be sent by customer to vendor for repair.
ATTENTION
Ensure cables are properly secured with cable gland strain relief to prevent
from accidently pulling cables and creating an arc flash.
ATTENTION
Prior to energizing the hub controls. The Hub controller cabinet will need to
be closed and hinges locked in the closed position. DO NOT open while
energized.
Cable routing through the door is not acceptable.
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DANGER
Electrical hazard!
Only trained and qualified personnel must perform electrical wiring tasks in
the hub and operate the portable generator.
The temporary power cable must be inspected for damage before each use.
Route the power cable between the generator and the temp disconnect fuse
box.
Route the power cable between the hub control box and the temp
disconnect fuse box.
The cable must be additionally protected against mechanical damage as
required and to prevent a tripping hazard.
Inside the hub route the cable through J-box using the proper size cable
gland provide maximum strain relief to the temporary power cable.
Power cable must be ferruled to ensure proper termination.
Ensure the J-Box is closed prior to energizing the generator.
The temporary generator must be properly grounded.
Temporary generator Site Specific LOTO must be adhered to.
2.
Before energizing the hub open the cabinet doors for Axis 1 and Install the jumpers from terminal
AEPC terminal J8 to AEPC-TB1.
Figure 281: Factory terminal block TB1
Figure 282: Factor terminal block J8
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Figure 283: Jumper configuration
– Original –
Installation Manual
Figure 284: Jumpers installed
107W4129p001 harness
109W1126p001 connectors
3.
Zip-tie all the three 89° limit switches.
NOTE
The bearings will not pitch using the Exor ePalm10
handheld if the 89° limit switches are not
activated.
Figure 285: 89° limit switch
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4.
Terminate the temporary power cable to
hub.
5.
The hub junction box comes with a M63
hole cover. Remove the J-Box hole cover
and save and ensure the cover is re
installed after the hub assembly is
completed.
The installer is responsible for procuring the
strain relief to secure the temp power cable
to the hub junction box.
6.
Use a 5c-6 AWG cable (L1-L2-L3-Ground
and Neutral).
7.
Ensure the generator is properly grounded
to earth as required.
Figure 286: J-Box cable strain relief
8.
Install a 40 amp fusible disconnect box
between the hub and the generator.
Critical to Safety:
9.
Mount the fusible disconnect box inside
the hub between the hub and generator.
Figure 287: Disconnect box
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Installation Manual
10. Terminate the power cable between the
fuse disconnect box and the center box
inside the hub. Use the correct tool (flat
blade screw driver width 5.5 mm) to
prevent hardware damage.
11. Connection points:
Conductor
Term
Pin
L1
X3
1
L2
X3
2
L3
X3
3
N
X3
4
PE
X3
5
Figure 288: Wires terminated the hub J-Box terminal block
ATTENTION
Electrical hazard!
CRITICAL TO SAFETY:
Close all Junction boxes.
Ensure the generator is grounded to earth prior to energizing hub.
Verify 400 VAC power switch is in the off position.
Follow manufacturers operation procedures for energizing the generator.
After energizing Check the voltage output to ensure proper operation of the
pitch system.
ALC Sensor Target Verification:
12. Identify the Axis 1 by marking the blade
bearing closest to the hub shaft flange.
Axis 1 is the down blade (tail pick blade).
Figure 289: Verify were axis 1 is located for ALC verification
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DANGER
Be aware of internal and external pinch points. Ensure all personnel are
clear from pinch point and the crush zone prior to beginning operating the
pitch system.
NOTE
1
2
Item 1 - Ensure the control box auto/manual
switch is on manual.
Item 2 - The axis box selector switch corresponds
with blade being pitched.
Figure 290: Selecting pitch mode ('manual')
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Installation Manual
– Original –
13. Connect the Exor ePalm 10 to the port
provided on the hub controller cabinet.
14. The blade bearing can now be rotated left
or right having control with the EXOR 10
ePalm.
A – Auto\Manual Selector Switch
B – Blade Access Selector Switch
C – 400VAC power switch
A
B
C
D
D - EXOR ePalm connection port
Figure 291: Connection e-palm
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The following overview is displayed:
Handheld
F1 IP Address View
F2 Jog View
F3 Cal View
F4 Status View
F5 Rotor Assembly
If the hub is on the ground (not connected to rest of turbine) press F5 for hub assembly mode the
following page is displayed:
Assembly Request Set
F8 Return
15. Navigate to the Jog View by pressing the F2 button.
The following page is displayed:
Jog View
F8 Home
F7 Cal View
F1 Axis 1 Jog View
F2 Axis 2 Jog View
F3 Axis 3 Jog View
16. Navigate to the view for the blade to be jogged by pressing F1, F2 or F3.
The following overview is displayed:
Axis 1 Jog
F8 Home
F7 Cal View
F1 Fwd
F2 Rev
F3 Stop
F4 FFWd
F5 FRev
17. Make sure that the E-stop pushbuttons on the handheld and axis box 1 are out.
18. Press the dead-man switch so that it clicks once, neither all the way in nor all the way out.
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Installation Manual
13.1.2 GE Pitch Control System (For Turbines with PTB Hub Pitch System)
1.
Before energizing the Hub open the cabinet doors for Axis 1 and Install the jumpers from terminal
AEPC terminal J8 to AEPC-TB1.
2.
Add the following jumpers to the AEPC card in axis cabinet 1:
Terminal points J8.1 to
TB1.3
Terminal points J8.2 to
TB1.1
Terminal points TB1.2 to
TB1.9
Terminal points TB1.4 to
TB1.8
Figure 292: Factory terminal block TB1
Figure 293: Jumper configuration1
Figure 294: Remove factory terminal block TB1 from the AEPC
card.
Figure 295: Install J8 jumper connector to J8 in AEPC card
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Figure 296: Install TB1 jumper terminal block to TB1 terminal
block in AEPC card
3.
Installation Manual
– Original –
Figure 297: Jumper installed
Zip-tie all three 89 ° limit switches.
NOTE
The bearings will not pitch using the Exor ePalm10
handheld if the 89 ° limit switches are not
activated.
Figure 298: 89° limit switch
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4.
Terminate the temporary power cable to
hub.
5.
The hub junction box comes with a M63
hole cover. Remove the J-Box hole cover
and save and ensure the cover is re
installed after the hub assembly is
completed.
6.
The installer is responsible for procuring
the strain relief to secure the temp power
cable to the hub junction box.
7.
Use a 5c-6 AWG cable (L1-L2-L3-ground
and neutral)
8.
Ensure the generator is properly grounded
to earth as required.
Installation Manual
Figure 299: J-Box cable strain relief
9.
Install a 40 amp fusible disconnect box
between the hub and the generator.
Critical to Safety:
10. Mount the fusible disconnect box inside
the hub between the hub and generator.
Figure 300: Disconnect box
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11. Terminate the power cable between the
fuse disconnect box and the PTB box inside
the hub. Use the correct tool (hex tool
width 5.5 mm) to prevent hardware
damage.
Connection Points:
Conductor
Term
Pin
L1
X3
1
L2
X3
2
L3
X3
3
N
X3
4
PE
X3
5
Figure 301: Example connect 400 Volt AC 3 phase power
12. Cable size: use a 5c-6AWG cable as
required
Connection Port and Switches Provided on Top
of Axis 1 Control Cabinet:
D
E
F
A - Exor ePalm 10
B - 400V AC power switch
C - EXOR ePalm AEPC connection port
D - AEPC bypass switch
E - Blade axis selector switch
C
F - Auto\Manual selector switch
G - Emergency E-Stop switch
I
G
H - Handheld E-stop
I - Battery switch (DO NOT REMOVE CABLE TIE)
H
B
A
Figure 302: Connecting e-palm
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ATTENTION
Electrical hazard!
Close the Junction box.
Ensure the generator is grounded to earth prior to energizing hub.
Verify 400 VAC power switch is in the off position.
Ensure the generator is grounded to earth prior to energizing hub.
Check the voltage output to ensure proper operation of the pitch system.
13. Switch the AC disconnect in axis box 1 to
the 'ON' position.
Wait several minutes for the DC link to
charge.
Figure 303: AC disconnect
14. To jog using the Exor ePalm handheld:
Make sure the handheld E-stop is out.
Figure 304: Handheld E-Stop
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15. Press in E-stop bypass button on axis 1
control cabinet and keep pressed in until
the handheld is connected.
Figure 305: E-Stop bypass button
16. Unplug the E-stop bypass plug on axis 1
cabinet.
Figure 306: E-Stop bypass plug
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17. Plug the Exor ePalm10 handheld into the
axis cabinet 1 plug. If the HTM file cannot
be found unplug it, wait a minute and
plug it back in.
18. Release the AEPC bypass button.
Figure 307: Pitch Terminal Box
19. Turn the 'auto/manual' switch to
'manual'.
NOTE
If the handheld is removed without pressing the
bypass switch the turbine safety chain will open.
Figure 308: Auto manual/switch
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The following overview is displayed:
Handheld
F1 IP Address View
F2 Jog View
F3 Cal View
F4 Status View
F5 Rotor Assembly
20. If the hub is on the ground (not connected to rest of turbine) press F5 for hub assembly mode the
following page is displayed:
Assembly Request Set
F8 Return
21. Navigate to the Jog View by pressing the F2 button.
The following page is displayed:
Jog View
F8 Home
F7 Cal View
F1 Axis 1 Jog View
F2 Axis 2 Jog View
F3 Axis 3 Jog View
22. Navigate to the view for the blade to be jogged by pressing F1, F2 or F3.
The following overview is displayed:
Axis 1 Jog
F8 Home
F7 Cal View
F1 Fwd
F2 Rev
F3 Stop
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Installation Manual
F4 FFWd
F5 FRev
NOTE
Contact the GE site representative if the blade pitch system does not operate
correctly.
23. Make sure that the E-stop pushbuttons on the handheld and axis box 1 are out.
24. Press the dead-man switch so that it clicks once, neither all the way in nor all the way out.
25. Press the F1 or F4 button to go toward the 90 degree limit switch or F2 or F5 to go toward the zero
degree limit switch.
26. Verify that the nuts and washers for the assembly of the rotor blade are available in the hub.
27. Remove the shrink-wrap from the outer edge of the hub bearing before you install the respective
rotor blade.
28. Actuate the blade bearing 360 degrees in each direction to ensure sufficient lubrication is present
in the bearing. Top up grease as necessary. If the bearing does not actuate, you must verify that
the connector of the pitch motor fan is correctly seated in the junction box. Also verify that the
portable auxiliary generator is generating sufficient amperage to drive the Pitch Drive Control
Box.
29. Rotate the blade bearing ring to the desired position for blade installation.
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Installation Manual
13.2 Attachment of the Blades
WARNING
Crushing hazard!
During the approach of the rotor blade to the hub, ensure that nobody is
located between the rotor blade and the hub.
Ensure that you keep a safe distance from the flanges.
1.
Before mounting the first blade, ensure
the pitch gear rings are free of debris.
Follow the respective recommendations of
the blade manufacturer when attaching the
lifting gear to the rotor blades.
2.
Attach tag lines to stabilize the load.
3.
Carefully lift the rotor blades from the
transportation frames to avoid damage.
Follow the respective recommendations of
the blade manufacturer.
Figure 309: Bringing the rotor blade to the hub
WARNING
Crushing hazard!
During Installation always ensure that hands, feet, and body are not between
any potential pinch points.
WARNING
Mind the maximum allowable wind speed!
For technical data to calculate the maximum allowable wind speed for crane
activities especially on parts and systems with a high sail area with respect
to system weight refer to the document
Component_SailArea_DragCoef_Generic-xxHz.
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4.
When lifting the blades with a single crane
a minimum of two persons shall maintain
control of the blades with the tag lines
during the alignment and installation of
the blades on the hub.
5.
Verify that two the limit switches on each
blade are not damaged.
Installation Manual
Figure 310: Guiding the rotor blade
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Installation Manual
13.3 Assembling the Rotor
ATTENTION
Hazard – working under suspended loads!
Never work under suspended loads!
DANGER
Crushing hazard!
During rotor assembly ensure that hands, feet and body are not positioned
between the blade flange and the hub flange!
CAUTION
Wear hearing protection!
Proper hearing protection must be worn when working with any electrical or
hydraulic impact tooling!
Always assess the next task at hand. If 85 decibels will be exceeded, hearing
protection must be worn.
Observe requirements for hearing protection per your company's policies.
ATTENTION
Uncontrolled increase in torque!
Once the electric or hydraulic torque wrench has reached the final set torque
value switch the tool to the off position and remove it from the bolt. Do not
reset or switch on the tool on the same bolt as this will result in an
uncontrolled increase in torque.
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Installation Manual
ATTENTION
Danger of potential failure!
Rotors must be completely assembled once work begins; no partially torqued
assemblies are allowed.
Once a rotor is assembled, it must be immediately final torqued. Assembly
without torqueing exposes individual bolts to undue stress and can lead to
potential failure.
The blade stud to the immediate left of the 0degree reference mark must mate with the hole
to the right of the zero mark on the hub provided
by manufacturing.
Figure 311: Blade bolt marks
Figure 312: Hub bearing bolt hole marks
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1.
Installation Manual
– Original –
Utilizing the cranes and the PDCB/ePalm
align the blade bolts through the pitch
bearing flange holes on the hub. Take
precaution when installing the blade
screw bolts that no bolts are bent.
DANGER
Crushing hazard!
During Installation always ensure that hands,
feet, and body parts are not between any
potential pinch points.
Figure 313: Blade to hub alignment
2.
The top edge of the blade flange must
make contact with the bearing flange.
3.
Ensure that the gap is less than 5 mm
around the entire blade to bearing
connection prior to releasing the blade
from the crane. Verify the limit switches
are undamaged.
Figure 314: Checking the contact
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CAUTION
Wear hearing protection!
Proper hearing protection must be worn when working with any electrical or
hydraulic impact tooling!
Always assess the next task at hand. If 85 decibels will be exceeded, hearing
protection must be worn.
Observe requirements for hearing protection per your company's policies.
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4.
If applicable remove corrosion inhibitor
from the inner bearing face prior to
installing washers and nuts.
5.
Position washers and nuts (located inside
the hub) on the exposed bolts on the 3 and
9 o’clock position.
6.
Install the washers with the bevel on the
inside diameter pointing outwards toward
the nut.
The nuts shall be installed with the marks
pointing outwards. Do not apply any
lubricant to the washers or nuts.
7.
Tighten the exposed bolts on the
7 to 9 and 2 to 4 o’clock positions.
8.
Using an impact wrench achieve a torque
between 50-95 % of the final pre-torque
value specified in the Work Instructions for
the bolted connections.
Do not use impact tooling that exceeds
95 % of the pretension torque!
Refer to the 3MW Platform Bolt Torque
Specification.
9.
Install all accessible hardware at the
exposed positions before removing the
crane load.
Installation Manual
Figure 315: Exposed positions and torque in progress
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Installation Manual
WARNING
Rotating parts -Pinch point - Crushing hazard!
When working with hydraulic and pneumatic torque tooling, ensure that your
hands and any part of your body are not between any pinch points (e.g. any
part of your body is not between the tool reaction arm and back up pressure
surface.
Ensure personnel have been properly trained on the safe use of hydraulic
and pneumatic tools.
10. Position blocks/fixtures with pressed
straw bales or another soft support under
the manufacturer labeled support points
of the blades to ensure the blade tip does
not make contact with the ground.
11. Remove the crane and repeat steps 1 (on
page 240) through 10 (on page 243) for the
other two blades. All three blades must be
installed before the nuts are tightened up
to 100 % of the pre-torque value.
Once the third blade has been installed, the
weight shall be evenly distributed and the
blade support blocks/fixtures can be
removed.
Figure 316: Example blade support
12. Use calibrated torque tools to torque all
accessible nuts to 100 % of the pre-torque
value listed in the 3MW Platform Bolt
Torque Specification.
Torque bolts using the bolt torque pattern
specified in the 3MW Platform Bolt Torque
Specification.
13. Verify blade perimeter is clear of
personnel and equipment, and pitch
blades as required to expose and pretorque remaining hardware.
14. Once pre-torque is complete check
between bearing surface and blade flange
to ensure there are no gaps. If a gap is
present repeat steps 12 thru 13 above till
no gaps are present.
Figure 317: Use a calibrated torque tool
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– Original –
15. Mark the bolts with a visible paint pen
once the pre-torque value has been
attained. A straight line is marked from
the bolt end face, nut, and washer and
bearing face.
Figure 318: Nut at 100 % pre-torque
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Installation Manual
WARNING
Rotating parts – Pinch point – Crushing hazard!
When working with hydraulic and pneumatic
torque tooling, ensure that your hands and
any part of your body are not between any
pinch points (e.g. any part of your body is not
between the tool reaction arm and back up
pressure surface).
Ensure personnel have been properly trained
on safe operations of hydraulic and
pneumatic tools.
Figure 319: Torque tool
16. Apply final nut turn 120 ° or two flats with
an accuracy of ±5 °as specified in the 3MW
Platform Bolt Torque Specification. The
final nut turn can be achieved in any
desired bolt pattern.
17. Make a color alignment mark on the screw
bolt, nut and surrounding bearing surface
of each bolted connection before going to
the next nut.
This is necessary to avoid losing track of
which nuts have been tightened (as the
blade is pitched to reach all screw bolts).
Figure 320: 120 degree or 2 nut flats
18. Verify blade perimeter is clear of personnel rigging and auxiliary equipment, and pitch the blades
as required to access and apply final nut turn (120 ° or two nut flats with an accuracy of ±5 °) to
the remaining bolts.
If a stud rotates more than 10 degrees during the nut turn contact the GE site representative.
19. Repeat steps 16 through 18 above for the remaining blades.
20. Verify blade perimeter is clear of personnel, rigging and auxiliary equipment, and pitch the blades
as required verify pitch alignment.
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21. Verify the alignment of each blade by
individually pitching the blades to
0 degrees. Rotate until the blade is in the
horizontal position and the 0-reference
mark is in the hub sight.
22. Verify the alignment of each blade by
pitching the blades (individually) to 0
degrees. Rotate until the blade is in the
horizontal position and the zero-reference
mark is in line with the hub zero reference
bracket (hub gun sight).
23. In this blade position, insert a straight
edge through the hub gun sight to help
align the blade zero-degree mark to hub
gun sight.
Figure 321: Zero reference mark in the hub sight
24. Mark a straight line with a (paint pen and
punch mark marks) with a center punch
tool. Initial, date & note "0 degrees" next to
each paint pen reference mark.
A - DR - Zero Degrees -01-30-2013
A
Figure 322: Extend the marking with a marker pen
25. Verify that the hand rail and nose cone
bolts have been torqued and marked with
a paint pen.
26. Inspect both ends of the hand rail
mounting brackets looking for damage,
missing or cracked welds.
Figure 323: Checking the hand rails and nose cone bolts
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27. Install the cover plates over the pitch
bearing using the provided M16 hardware
along with medium strength thread
locking compound.
28. Torque and mark bolts with a paint pen.
Figure 324 Installing the steps over the pitch bearing teeth
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13.4 Assembling the Nose Cone and Final Rotor Assembly Work
NOTE
Use of a retractable or a positioning lanyard is recommended.
1.
Nose cone mating surface to hub shall be
flat and clean of any contaminant.
2.
Ensure bolt hole threads are clean and
free of debris.
NOTE
If the nose cone is installed before the
installation of the blades only remove the
shipping material from the bolt mounting
locations on the hub. Leave the other shipping
material attached to the hub to protect it from
the elements.
The shipping material can be removed prior to
assembling the rotor.
Figure 325: Remove shipping material from bolt mounting
locations on the hub
NOTE
Use hand tools only. Impact tools will damage
fiberglass.
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3.
– Original –
Installation Manual
Attach the lifting gear to the three lifting
lugs of the nose cone.
DANGER
Crushing hazard!
During Installation always ensure that hands,
feet, and body are not between any potential
pinch points.
Figure 326: Lifting the nose cone
Prior to installing the nose cone:
4.
The nosecone will have to be set on
temporary cribbing to remove the
shipping supports.
Wrench size is 24 mm.
Figure 327:
5.
Instruct the crane operator to slowly lift
the nose cone and position it onto the hub.
Figure 328: Lifting the nose cone
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6.
Installation Manual
– Original –
Bolt the nose cone onto the rotor hub.
Critical to Quality:
7.
Ensure the nose cone connection to hub is
flat prior to torqueing. Check bolt hole
alignment. After bolting, no gap allowed
between mating surfaces, hub to nose
cone. Do not force into position or over
torque hardware.
ATTENTION
Safety relevant bolt connection!
Glue bolt with middle hard thread locker.
8.
Torque and mark the bolts with a paint
pen in accordance with the latest revision
Assembly Spinner to Hub DWG. 115W5268
and /or 114W4337.
Contact GE representative for thread locking
compound and assembly issues.
9.
Remove the lifting gear.
Figure 329: Bolting on the nose cone
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Hub manhole cover tether:
10. Verify the hub manhole tether is available.
If not present contact GE representative.
Figure 330: Attaching the karabiner to the handle on hub cover
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11. Once the hub installation is finished,
unhook the karabiner from the handle and
wrap the tether around the nose cone
steel frame to prevent it from moving
while the rotor is turning. Use the
karabiner to fix it into position and make
sure it is correctly secured.
A:
Carabiner
B:
Tether cable
c:
Nose cone steel frame
Figure 331: Hub cover tether secured to nose cone steel frame
13.5 Final Rotor Assembly Work
WARNING
Electrical hazard!
Stored energy may be present within electrical cabinets.
Consult with GE engineering to identify the voltages that could be present.
1.
Inspect all three blades for handling damage and report damage to GE site representative. All
fiberglass damage must be repaired prior to rotor installation.
2.
Verify that the light fixtures are not damaged.
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3.
If applicable, verify the oil sight glasses for each pitch drive are protected from impact damage.
4.
Secure any loose cable bundles that will
flap back and forth to prevent damage.
5.
Properly dispose of trash and debris from
the interior of the hub.
6.
Before exiting the hub verify the entire hub
is clean and free of debris and loose tools
that can cause damage.
7.
Clean the interior of the hub with biodegreaser cleaner.
Figure 332: Example desiccant packs
ATTENTION
If wind turbines will be idling without grid connection refer to the document
Idling_Manual_3MW-DFIG-xxHz prior to removing desiccants packs.
ATTENTION
Risk of equipment damage!
Please make sure that no loose equipment remains in or on the hub!
Loose material left inside the hub will tumble when the rotor brakes are
released and the rotor starts to spin creating dust debris damaging electrical
components.
Loose material such as desiccant packs, manuals, cable ties, tools, and rags
must be removed out of all hub cabinets.
Loose cables must be secured with cable ties to prevent damage when rotor
starts spinning.
Bolted desiccant packs must be securely bolted to the cabinets.
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On the day of rotor installation:
8.
Verify blade perimeter is clear of personnel, rigging and auxiliary equipment, and rotate all three
blades to –90 degrees (trailing edge facing up).
9.
Follow site-specific LOTO to de-energize the hub.
10. Disconnect the 400 V power cable.
11. Hub 400 V J-Box keys must be removed and turned over to GE.
12. Cut the cable ties from the limit switches.
13. Ensure the battery switches are in the "off" position and zip-tied.
14. Ensure the pitch boxes are de-energized.
15. Verify the manuals and desiccant packs in the hub main controller and axis boxes are removed.
Critical to Safety and Quality:
16. In the hub, remove the following terminal
block jumpers from the AEPC card in axis
cabinet 1 after the rotor has been
assembled:
Terminal points J8.1 to TB1.3
Terminal points J8.2 to TB1.1
Terminal points TB1.2 to
TB1.9
Terminal points TB1.4 to
TB1.8
Figure 333: Removing J8 jumper connector
Figure 334: Removing TB1 jumper terminal block
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17. Re install factory terminal block to prevent
damage due to loose cables flapping back
and forth in the AEPC card.
Figure 335: Installing factory terminal block
Figure 336: Factory terminal block re-installed
18. Verify all cabinet doors are properly latched, ratchet straps are installed and loose strap ends are
secured.
19. Ensure the hardware is secured and the manhole cover is mounted and tethered.
20. Use a high-pressure cleaner to remove all dirt and debris from the exterior of the rotor assembly.
WARNING
Potential hazards and environmental considerations associated with the use
of a pressure washer!
Possible environmental impact based on local codes.
Excessive chemicals that have a potential negative impact on the environment
must be removed before pressure washing.
High pressure energy:
Potential exposure to contaminated water and/or other chemicals.
High pressure is generated by the pressure washer and has the
potential to inject contaminated and/or other chemical treated
water into body parts if personnel are careless and/or not trained
properly. Follow manufacturers operation procedures and warnings.
Walking working surfaces – un even slippery surfaces.
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13.6 Lifting the Rotor
13.6.1 Example Lifting Gear - Lifting Tool for 100 m and 103 m Rotor Diameter
Typical Hub Configurations
Typical 2500/2570
Typical 2900
Figure 337: Utilized on 120 m Rotor diameter and smaller
Figure 338: Example 2900 hub
Always Confirm Rotor lifting Equipment (Spiders) for
2500 and/or 2570 hubs
2900 hub and larger must be installed utilizing Single
Blade Method the single blade Process (SBI). Refer to
the latest GEI- for Single Blade Installation.
NOTE
The Installer is responsible to confirm hub configuration to ensure you have the
correct lifting gear information. If you have any questions, contact your GE
representative for clarification.
Caution: For 2500 Spiders confirm orientation of spider to prevent improper
lift angle.
NOTE
Please refer to outline drawing for the lifting point.
Below pictures and process are for reference only.
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1.
– Original –
Installation Manual
Unscrew the threaded rods, in order to
retract the safety bolts.
Figure 339: Unscrew the threaded rods
The safety bolts must securely engage in the
load-bearing plates of the rotor for lifting.
Figure 340: Pins of the rotor lifting gear
2.
Adjust the lifting gear to the respective
rotor diameter in accordance with the
manufacturer's instructions.
Figure 341: Adjusting screws
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3.
Installation Manual
– Original –
Figure with retracted safety bolts, before
the lifting gear is placed on the rotor.
Figure 342: View of the lifting gear
4.
Verify that the pins of the adjustable lifting
gear are securely locked as shown in
Figure 343 and Figure 344.
Figure 343: View of the lifting gear
Figure 344: View of the lifting gear
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13.6.2 Attaching the Rotor Lifting Gear
1.
Attach the lifting gear to the main crane.
2.
Bring the lifting gear to the rotor spider.
Figure 345: Bringing the lifting gear to the rotor
3.
Mount the lifting gear in accordance with
the manufacturer's instructions.
Figure 346: Mounting the lifting gear
Figure 347: Lifting gear attached to the rotor spider
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13.7 Installing the Rotor (Hub with Blades)
ATTENTION
Check the wind speed!
The rotor may only be installed in accordance with section 4.1 ‘Operations
Involving the Use of a Crane’.
ATTENTION
Mind the lift plan!
The sail area and drag coefficient of the rotor must be incorporated through the
lift plan. Static loads and dynamic loads must be verified by the crane operator.
Personnel not involved in crane lift operations must leave the crane work zone
(danger zone) before lift operations start.
Any person not involved with installation or crane lift operations shall be a
minimum of two lengths of the crane boom height away from the work being
performed.
ATTENTION
Risk of rework!
Before installing the rotor, one of the holes in the perforated disk on the main
shaft has to be exactly aligned with the rotor lock piston.
The rotor must be mounted in the Y-position. At a maximum its position may
deviate only one flange boring from the centric position (symmetric position
of the rotor blades)!
Failure to install the rotor in the Y-position in relation to the main shaft
markings will require removal and repositioning of rotor.
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WARNING
CRITICAL TO QUALITY to the safe operation of the turbine and to personnel
safety!
Verify the foundation bolts have been tensioned/torqued, and all tower
flange bolts have been torqued. The GE Energy technical advisor will have
the option to verify all paint pen marks are present at all bolted connections
and the tower exterior is clean and free of damage prior to rotor installation.
Inspect the interior and exterior pitch bearing seals. Look for cracked,
gapped, missing or otherwise damaged seals. The seals must be smoothly
seated around the entire bearing perimeter. If the seal is damaged contact
the GE site representative.
ATTENTION
Prevent damage from the WTGS!
If the rotor cannot be installed at this time, pitch all three blades back to the
0-degree position. Secure the rotor with ropes to suitable anchoring points.
Also secure the leading edge of each blade (approx. 40 cm from the tip) to
anchoring points using tag lines. Place protective mats between the blade
and the tag lines to prevent damage.
ATTENTION
Risk of Equipment Damage!
Close axis box panels, close the hub main access hatch, ensure all hardware
is present and secure.
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1.
Prior to lifting the rotor, starting with tail
pick blade rotate to -90 degrees and
attach crane. After tail pick blade is secure
rotate the remaining two blades to -90
degrees (trailing edge facing up).
On the blade opposite the rotor lifting gear:
2.
Place and center blade vendor specific
leading edge (LE) and trailing edge (TE)
protective caps at lifting locations as per
specific blade drawing.
Figure 348: Placing LE&TE protective caps
WARNING
Danger of damaging the blade!
Always check the trailing and leading edge protectors for padding to prevent
blade damage.
Always check the trailing and leading edge protectors for any debris that
could damage the blades.
NOTE
CRITICAL TO QUALITY:
Projects with multiple blade configurations ensure blade vendor specific
edge protection is utilized.
3.
Place and center slings at lifting locations as per specific blade drawing.
Refer to drawing for min. sling width and length.
4.
Attach the sling to the hook of the support crane.
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Installation Manual
Example tag lines on non-serrated blades:
5.
Place blade bags over the tips of blades
no. 2 and 3. Attach a tag line to each bag.
Continue with step 9 on page 266.
ATTENTION
Danger of damaging the blade!
Do not tie tag lines to hub handrails, tie tag
lines to the rigging only.
Figure 349: Blade bags mounted non serrated blades
Blades with serrations:
Lifting blades with serrations can be accomplished by using a quick disconnect tool or equivalent that allows
the installation team release the tail pick rigging without the use of man basket.
NOTE
Quick release tool is installer's responsibility to procure. GE can provide "Technical
Guidance" for the hub fixture. A man basket will be needed to disconnect the
support crane if you choose not to use quick disconnect.
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Example tag lines on serrated blades:
6.
Place blade sleeves for tag lines on the 2nd
and 3rd blades.
7.
Close the sleeve and insert the locking pin
in the opening mechanism.
8.
Attach a rope to the pin to unlock/open
the sleeve after the rotor is installed.
Figure 350: Typical sleeves
Figure 351: Placing tag lines on serrated blades
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DANGER
Life-threatening hazard - working under suspended loads!
Everybody must leave the danger area!
The banksman may not give a signal to raise or lower until everybody has left
the danger area.
Never stay under suspended loads!
ATTENTION
Check the components!
All components must be checked for visible damage, deformations and
cracks which could affect their bearing capacity before assembly. Findings
have to be reported to the GE site representative.
The components must be stored and assembled in such a way that damage
is prevented which could adversely affect their stability or bearing capacity
and thereby lead to safety hazards.
DANGER
Crushing hazard!
During installation always ensure that hands, feet, and body are not between
any potential pinch points.
ATTENTION
Mind the weather conditions!
The crane operator is responsible for monitoring the weather conditions at
all times and determining when a safe lift of the rotor is possible.
The tag lines must be secured to a suitable point (fastening point on a
vehicle) at all times.
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ATTENTION
Danger of equipment damage!
If the rotor assembly makes contact with any object it must be inspected
before the installation proceeds.
9.
Reach under the hub and loosen the guide pin (approximately 2.5 cm) directly beside the handrail
between the two lifting lugs. This will allow the rotor to be installed more easily.
10. Verify the rotor is stabilized. Loosen and
remove the nuts and washers from the
transportation frame below the hub.
Figure 352: Removing the shipping hardware
WARNING
Do not remove the hub bolts!
The bolts and the threads could be damaged.
Figure 353: Example damaged stud
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11. When lifting the rotor the mounting flange
must be kept perpendicular to the
shipping fixture flange as much as
possible to prevent the studs from binding
on the fixture bolt holes and damaging
bolt threads.
12. Instruct the crane operators to carefully
lift the rotor horizontally and from a safe
distance verify the shipping fixture is loose
and bolts are not binding against the bolt
holes.
13. Continue lifting until the studs clear the
shipping fixture.
Figure 354: Keeping the hub flange perpendicular to the shipping
fixture
ATTENTION
CRITICAL TO QUALITY!
Check for foreign debris on flanges!
The hub is a friction-critical connection and must therefore be thoroughly
cleaned of all foreign debris or dirt. If any foreign debris is found on the
surface or pinched between the flanges after the installation, the rotor may
have to be removed and cleaned.
CRITICAL TO SAFETY!
If flange surface cleaning is required, the rotor will need to be supported
(stabilized) on a stand or cribbing with the crane holding the load to allow safe
access for personnel to clean the flange and/or bolt holes as required.
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14. Lift the rotor by means of the main and
support crane, so that the lower rotor
blade cannot touch the ground while the
rotor is being set upright.
There must be permanent communication
between the erecting engineers and the
crane operators while the rotor is being set
upright by the cranes, in order to lift the
rotor without any danger.
The rotor is set upright by the main crane
lifting the rotor, while the support crane
lowers the bottom rotor blade.
Figure 355: Setting the rotor upright
15. Remove the lifting gear of the support
crane from the rotor. Instruct the operator
of the support crane to swing the jib out of
the lifting area to ensure the main crane
does not collide with the tag lines.
NOTE
If the blades have serrations a man basket will
be needed to disconnect the support crane.
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Installation Manual
Blades with serrations:
Lifting blades with serrations can be accomplished by using a quick disconnect tool or equivalent that allows
the installation team release the tail pick rigging without the use of man basket.
NOTE
Quick release tool is installer's responsibility to procure. GE can provide "Technical
Guidance" for the hub fixture. A man basket will be needed to disconnect the
support crane if you choose not to use quick disconnect.
16. The rotor can be safely guided from the
ground by means of the two tag lines
attached to the top rotor blades per blade
manufacturer's instructions.
Maintain the tension of the tag lines to
control the rotor movement.
The taglines can be anchored to a
counterweight or vehicle but it is Critical to
Quality to ensure any tag line pull or tug for
flange alignment must be done manually.
Pulling the tag line with a moving vehicle is
not authorized.
Figure 356: Examples to help control and stabilize the rotor with
taglines
17. Verify the high-speed shaft shroud in the
nacelle is removed to allow manual
rotation of the high-speed coupler when
mating the rotor to the main-shaft.
Figure 357: High-speed shaft
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DANGER
Crushing hazard!
When installing or removing the rotor, ensure that your hands or any part of
your body are not between the machine head and the rotor pinch point crush
zone.
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18. Instruct the crane operator to lift the rotor
so that it is level with the main shaft.
Figure 358: Rotor level with the main shaft
19. Rotate the high-speed coupler to align the
hub studs with the main shaft while
ensuring that the rotor lock is aligned with
a hole on the perforated rotor lock disk.
This ensures that the rotor can be locked
in the Y-position during hub entry.
Figure 359: Rotor lock pin is aligned with a hole on the perforated
rotor lock disk
Figure 360: Example rotor in Y position
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WARNING
Rotating parts!
Untied long hair, loose clothing (e.g. flapping coats, tops with wide sleeves or
trousers with wide trouser legs) as well as scarves, ribbons, headscarves or
jewelry may not be worn during installation work! There is a fundamental
danger of injury through being caught, pulled in or picked up by rotating
components! Clothing must be adapted to the respective work and the
weather conditions.
WARNING
Rotating parts!
During application of the rotor lock always ensure that hands, feet, and body
are not between the any potential pinch points e.g. high-speed coupling,
brakes disc, mounting flanges.
WARNING
Rotating parts – Pinch point – Crushing hazard!
When the main shaft is rotating, ensure that your hands and any part of your
body are not in contact with the pinch point of the main shaft. Also ensure
clothing and PPE are not caught in rotating parts (e.g. any part of your body
is not between the main shaft and nacelle wall, hub and nacelle wall).
Ensure the personnel are properly trained on safe operations of the rotor lock
and the secondary brake.
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WARNING
Hydraulic disc brake and high-speed rotor lock use!
The installer must personally ensure all personnel assigned to work activities
inside the WTGS are properly trained on the use of the hydraulic disk brake
and rotor lock.
The installer must ensure the hydraulic disc brake and rotor lock are 100 %
engaged and locked out before
attempting to pre-tighten and torque hardware after aligning the
main shaft during rotor installation and after rotor is fully engaged
onto the main shaft,
disconnecting the main crane and removing it out of the working
area after the rotor has been installed,
performing any work outside or inside of the hub after rotor has
been installed,
performing any work inside or outside the nacelle near exposed
rotating components after the rotor has been installed.
All employees must ensure the hydraulic disk brake and high-speed rotor
lock is 100 % locked out before exiting to the top of nacelle.
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20. Insert the guide pin in the main shaft.
Again, ensure that the rotor lock is aligned
with the rotor lock disk to ensure ther
rotor is in the Y position when the rotor
lock pin is engaged for hub entry.
ATTENTION
Risk of rework!
Failure to install the rotor in Y-position in relation
to the mainshaft markings will require removal
and repositioning of the rotor.
Figure 362: Hub stud aligned and engaged with the specific main
shaft bolt hole
WARNING
Danger to life and equipment!
If damaged during rotor installation bolts can be
exchanged by hand tools or by hand.
A maximum of two bolts may be exchanged
while the rotor is mounted.
All further exchanges/repairs have to be
carried out on the ground.
Figure 361: Example rotor in Y position hand rail centered
perfectly with the center of the machine head.
Figure 363: Rotor lock pin is aligned with a hole on the perforated
rotor lock disk and hand rail centered perfectly with the center of
the machine head
Figure 364: Example rotor in Y position hand rail centered
perfectly with the center of the machine head.
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ATTENTION
Risk of equipment damage!
The rotor must be guided precisely to prevent
damage to the slipring wires.
21. Instruct the crane operator to move the
rotor so that it fully engages with the main
shaft.
WARNING
Risk of equipment damage!
If for any reason the rotor is mounted in a
wrong position, the rotor position needs to be
corrected imediately at the time of
installation/before torqueing the hub bolts.
22. Tighten the guide pin flush with the other
hub adapter studs. Failure to tighten the
guide pin prior to releasing the rotor
brakes can result in damage to equipment.
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23. Install washers and nuts on all accessible
hub adapter bolts by means of an impact
wrench.
24. Before removing the lifting gear from the
rotor at least 16 screws with 80-90 % of
the final torque must be applied.
Figure 365: Tightening the nuts
WARNING
Danger to life and equipment!
If damaged during rotor installation bolts can be exchanged by hand tools or by
hand.
A maximum of two bolts may be exchanged while the rotor is mounted. All
further exchanges/repairs have to be carried out on the ground.
CAUTION
Wear hearing protection!
Proper hearing protection must be worn when working with any electrical or
hydraulic impact tooling!
Always assess the next task at hand. If 85 decibels will be exceeded, hearing
protection must be worn.
Observe requirements for hearing protection per your company's policies.
WARNING
Pinch point – Crushing hazard!
When working with hydraulic and pneumatic torque tooling, ensure that your
hands and any part of your body are not between any pinch points (e.g. any
part of your body is not between the tool reaction arm and back up pressure
surface).
Ensure the personnel are properly trained on safe operations of hydraulic
and pneumatic tools.
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25. Turn the pressure relief valve of the
hydraulic hand pump in a clockwise
direction and pump the arm of the hand
pump to activate the brake.
WARNING
Rotating parts – Pinch point – Crushing hazard!
During application of the rotor lock always
ensure that hands, feet, and body are not
between the any potential pinch points e.g.
high-speed coupling, brakes disc, mounting
flanges.
26. Check the (high-speed) hydraulic disc
brake for proper functioning.
27. Make sure that the blades are in pitch
position of 85° (feathered position).
28. Using the hydraulic disc brake apply and
release the brakes as needed to stop the
rotor and align the (low-speed) rotor lock
pin to the perforated disc.
Figure 366: Hydraulic disc brake and hydraulic hand pump
29. The following pictures show an example
WTG that is on the ground with the rotor
lock pin aligned and fully engaged into the
perforated disc.
A
B
A - Perforated disc
B - Rotor lock pin cylinder
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WARNING
Rotor lock must not be used to stop rotation!
Never use the rotor lock to stop drive train
rotation. The hydraulic hand brake must be
used to stop the rotation.
WARNING
Both rotor locks (high-speed shaft and lowspeed shaft) have to be used for 130 m and
137 m rotor diameter (redundancy requirement).
Figure 367: Low-speed shaft rotor lock with lock and tag to apply
LOTO
30. Engaging the pin of the low-speed shaft
(LSS) rotor lock:
Ensure that the appropriate hole of the
rotor lock disk and the pin are aligned.
Use a wrench with an opening of 17
mm and turn the spindle in counter
clockwise direction until the pin is
completely engaged.
Insert the locking pin and attach lock
and tag (LOTO).
31. Engaging the high-speed shaft rotor lock:
Pull out the spring-loaded locking pin of
the rotor lock to enable the crank
mechanism and advance the rotor lock
as far as possible.
If necessary, briefly actuate/release the
"rotor brake" by the switch on the gear
box, in order to disengage the brake for
a short time, thereby placing the brake
disk in a better position.
Fully engage the rotor lock until the
locking pin locks home again at the
lower position and attach lock and tag
(LOTO).
Figure 368: High-speed shaft rotor lock with lock and tag to
apply LOTO
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32. Turn the pressure relief valve of the
hydraulic hand pump in a clockwise
direction and pump the arm of the hand
pump to activate the secondary brake
(hydraulic disc brake).
Figure 369: Hydraulic disc brake
33. The lifting gear can be removed after the
threaded rods have been unscrewed.
WARNING
Fall hazard!
Wear PPE to prevent yourself from falling
down!
WARNING
Figure 370: Detaching the lifting gear
Danger of falling objects!
Do not stand under the load.
Beware of falling tools and objects. Wear
protective helmet!
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34. Instruct the crane operator to remove the
crane from the work area.
35. Release rotor lock and secondary brake to
allow blade rotation.
36. Install and torque the remaining
hardware.
37. Remove the blade bags and the tag lines
as the blade rotates.
NOTE
If the blades have serrations a man basket will be
needed after the rotor has been installed to
remove protective caps and tag lines.
Figure 371: Detaching the lifting gear
ATTENTION
Danger of equipment damage!
As the rotor is pin-wheeling with the brake and rotor lock disengaged, listen
within the nacelle for any loose materials, parts or tools remaining in the hub.
Reapply the brake prior to installing the washers and nuts and disengage the
brake prior to rotating the rotor.
WARNING
Rotating parts – Pinch point – Crushing hazard!
When the main shaft is rotating, ensure that your hands and any part of your
body are not in contact with the pinch point of the main shaft. Also ensure
clothing and PPE are not caught in rotating parts (e.g. any part of your body
is not between the main shaft and nacelle wall, hub and nacelle wall).
Ensure the personnel are properly trained on safe operations of the rotor lock
and the secondary brake.
Critical to Quality to the safe operation of the turbine, and to personnel safety:
38. Apply final torque to all hub adapter hardware per 3MW Platform Bolt Torque Specification.
39. Place a paint pen mark across each stud, nut and flange face.
40. Clear the hub adapter flange area and disengage the rotor lock
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41. Disengage the hydraulic rotor brake.
42. Slowly rotate the rotor with the tag lines to allow installation of the next set of accessible nuts.
WARNING
Rotating parts – Pinch point – Crushing hazard!
When working with hydraulic and pneumatic torque tooling, ensure that your
hands and any part of your body are not between any pinch points (e.g. any
part of your body is not between the tool reaction arm and back up pressure
surface).
Ensure the personnel are properly trained on safe operations of hydraulic
and pneumatic tools.
43. Repeat steps as required. Tighten all hub
adapter nuts by means of an approved
torque tool.
44. Check nuts #1, 2, 3, 4, 5 or more as
required with maintenance torque to
ensure tension has not released. If any
nuts are loose, verify 100% of the
connection until all are torqued.
The 10% inspection cannot be performed
until 100% is torqued.
Details of the required torques can be found
in the 3MW Platform Bolt Torque
Specification.
45. Mark the bolts, nuts and adjacent flange
surface of each bolted connection with a
colored line.
Figure 372: Mark the bolted connections
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46. Mark the torque values on the fiberglass
wall for later reference.
Figure 373: Mark the bolted connections
47. Disengaging the low-speed shaft rotor
lock:
To disengage the pin:
Remove the LOTO lock from the safety
bolt.
Disengage the safety bolt to ensure no
damage is done to the safety bolt and
or pin.
Use a wrench with an opening of
17 mm and turn the spindle in
clockwise direction until the pin is
completely disengaged.
Figure 374: Disengage the low-speed shaft rotor lock pin using a
wrench
48. Disengaging the high-speed shaft rotor
lock:
Remove the lock and tag (LOTO).
Pull out the spring-loaded locking pin
of the rotor lock to enable the crank
mechanism and turn the rotor lock
gear out of the brake disk gear as far
as possible.
Make sure that the spring-loaded
locking pin is engaged.
Rotor lock is open.
Figure 375: Disengage the high-speed shaft rotor lock pin
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14 Checks
If during an IIP inspection any bolt is found loose or not torque marked, all bolts in the circle must be inspected
and torqued as required.
1.
Ensure the hub-mounting bolts are 100 % torqued.
2.
Perform a 10 % torque inspection on hub adapter nuts. The 10 % torque inspection will be spread
out evenly on the hub adapter flange.
3.
Re-install the hub adapter flange cover.
ATTENTION
Rotating parts – Pinch point – Crushing hazard!
When main shaft is rotating, ensure that your hands and any part of your
body are not in contact with the rotating parts of the main shaft and highspeed shaft. Also ensure clothing and PPE are not caught in rotating parts
(e.g. any part of your body is not between the main shaft or high-speed shaft
or brake disc).
Ensure the personnel are properly trained on safe operations of the rotor lock
and the secondary brake.
To check the brake pad and disc for uniform
distance (brake pads must be centered and
not drag on the disc).
4.
Apply the rotor lock.
5.
Bleed the pressure from the system.
6.
With the brake completely open, inspect
the air gap between the brake pad and
disc for uniform distance.
If the distance is even, continue with step 12
below. If the distance is uneven, adjust the brake
as follows:
Figure 376: Checking air gaps
7.
Loosen the lock nut.
8.
Adjust the air gap between the brake pad and the disc by turning the screw. (Adjustment gap
consult with GE site representative).
9.
Tighten the lock nut.
10. Assure application of Rotor Lock LOTO following the appropriate LOTO procedure before entering
the hub.
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ATTENTION
Danger of equipment damage!
In the hub, confirm the following terminal block jumpers from the AEPC card in
axis cabinet 1 have been removed:
Terminal points TB1.2 to TB1.9
Terminal points TB1.4 to TB1.8
Terminal points J8.1 to TB1.3
Terminal points J8.2 to TB1.1
Ensure the manufacturer terminal block is connected.
Reference section 13.5 Final Rotor Assembly Work.
11. Seal hub and shaft joint/connection:
Execute hub entry procedure. Engage
the rotor and hydraulic brake.
Apply Sikaflex® from inside between
hub and shaft joint / connection.
Figure 377: Sikaflex®
12. Verify the nacelle top rigging hatch is installed.
13. Verify that the front and rear hatches in the nacelle roof are closed and latches are engaged.
14. Verify the floor hatch is secured.
15. Clean scuff marks from the tower interior.
16. Apply touch-up paint as necessary.
17. Once the rotor is installed, the high-speed coupling cover must be completely installed, all
hardware must be accounted for and snug tight.
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18. Remove all tools and debris from the interior of the nacelle.
WARNING
Rotating parts – Pinch point – Crushing hazard!
When the main shaft is rotating, ensure that your hands and any part of your
body are not in contact with the pinch point of the main shaft. Also ensure
clothing and PPE are not caught in rotating parts (e.g. any part of your body
is not between the main shaft and nacelle wall, hub and nacelle wall).
Ensure the personnel are properly trained on safe operations of the rotor lock
and the secondary brake.
19. Release the rotor lock.
WARNING
Prevent damage from the WTGS!
The installer must ensure that the rotor lock and the high-speed brake are
released after the crane has moved out of the area and work has been
completed. Never leave the rotor lock and the brake applied overnight.
20. Perform a 10 % torque inspection of all
the tower flange connections.
Figure 378: 10 % Inspection
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21. Perform a 10 % torque inspection of
anchor bolts. The 10 % torque check
marks need to be clearly visible for future
maintenance inspections.
Figure 379: Example anchor bolt 100 %torque and 10 % marks
22. In order to provide a reliable corrosion
protection, paint the flanges once again.
Referto SDS.
23. Clean scuff marks from tower interior.
24. Apply touch-up paint as necessary.
25. Ensure all the work is inspected in
accordance with the Installation Checklist
(ICL) and Installation Inspection Procedure
(IIP).
Figure 380: Applying touch up paint
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15 Cables
DANGER
Electrical hazard!
Refer to the latest revision Energization Process Flow Chart and Verify GE and
Customer LOTO procedures are complementary.
Follow site specific LOTO policy if LOTO needs to removed or re-applied.
Ensure all pre- energization/de-energization checks per Site Specific LOTO
are adhered to prior to beginning any work.
Follow electrical PPE requirements in the Electrical Service Bulletin (Element
HS 13. 2C) for any electrical work on the WTG (See the EHS Outage Plan or
the Construction EHS Plan).
CAUTION
Awkward postures / Reach / Fall Hazard!
The cable access points are located in limited space and difficult to reach areas.
If an employee is working at a height that exposes them to a potential fall, an
appropriate ladder and/or fall arrest equipment must be used as required,
and 100 % tie-off at all times. A retractable lanyard can be utilized.
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15.1 Slip Ring Wires
DANGER
Rotating parts – Danger of crushing
During application of the high-speed brake always ensure that hands, feet,
and body are not between any potential pinch points e.g. high-speed
coupling, brake disc, mounting flanges. The high-speed coupling can only be
stopped using the hydraulic brake.
WARNING
Rotating parts – Pinch point – Crushing hazard!
When the main shaft is rotating, ensure that your hands and any part of your
body are not in contact with the pinch point of the main shaft. Also ensure
clothing and PPE are not caught in rotating parts (e.g. any part of your body
is not between the main shaft and nacelle wall, hub and nacelle wall).
Ensure the personnel are properly trained on safe operations of the rotor lock
and the secondary brake.
WARNING
Rotating parts!
Untied long hair, loose clothing (e.g. flapping coats, tops with wide sleeves or
trousers with wide trouser legs) as well as scarves, ribbons, headscarves or
jewelry may not be worn during installation work! There is a fundamental
danger of injury through being caught, pulled in or picked up by rotating
components! Clothing must be adapted to the respective work and the
weather conditions.
DANGER
Rotor Lock not to be used to stop rotation!
Never use the low-speed shaft rotor lock or high-speed shaft rotor lock to
stop drive train rotation. The hydraulic hand brake must be used to stop the
rotation.
No hub entry on wind speeds > 14 m/s, 12 m/s with 120, 130 and 137 meter
rotors.
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1.
Perform hub entry procedure (apply LOTO
Rotor Lock LOTO).
2.
Check the (high-speed) hydraulic disc brake
for proper functioning.
3.
Make sure that the blades are in pitch
position of 85° (feathered position).
4.
Using the hydraulic disc brake apply and
release the brakes as needed to stop the
rotor in the Y position.
5.
Apply the low-speed shaft rotor lock and
the high-speed shaft rotor lock.
Figure 381: Hydraulic disc brake and hydraulic hand pump
Figure 382: Rotor stopped in the Y-position
The following pictures show an example WTG
that is on the ground with the rotor lock pin
aligned and fully engaged into the perforated
disc.
A - Perforated disk
A
B
B - Rotor lock pin cylinder
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WARNING
Rotor lock must not be used to stop rotation!
Never use the rotor lock to stop drive train
rotation. The hydraulic hand brake must be
used to stop the rotation.
WARNING
Both rotor locks (high-speed shaft and low-speed
shaft) have to be used for 130 m and 137 m rotor
diameter (redundancy requirement).
6.
Engaging the pin of the low-speed shaft
(LSS) rotor lock:
Ensure that the appropriate hole of the
rotor lock disk and the pin are aligned.
7.
Use a wrench with an opening of 17 mm
and turn the spindle in counter clockwise
direction until the pin is completely
engaged.
Insert the locking pin and attach lock
and tag (LOTO).
Engaging the high-speed shaft rotor lock:
Pull out the spring loaded locking pin of
the rotor lock to enable the crank
mechanism and advance the rotor lock
as far as possible.
8.
Figure 383: Low-speed shaft rotor lock with lock and tag to apply
LOTO
If necessary, briefly actuate/release the
"rotor brake" by the switch on the gear
box, in order to disengage the brake for a
short time, thereby placing the brake
disk in a better position.
Fully engage the rotor lock until the
locking pin locks home again at the
lower position and attach lock and tag
(LOTO).
Figure 384: High-speed shaft rotor lock with lock and tag to
apply LOTO
Apply LOTO lock to prevent the locking pin from accidentally disengaging.
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9.
– Original –
Installation Manual
In an energized tower verify all applicable breakers, switches, and overloads in the top box and
hub main controller are in the “Off” position. If applicable, place the UPS switch in the off position.
10. Enter the hub.
11. Verify all batteries and main switches for each axis box are in the “Off” position.
12. Confirm all temporary jumpers have been removed.
13. Confirm the bypass plug of the AEPC card is disconnected and the current plug for the AEPC card
is connected.
14. Retrieve the conduit from the top box and place it in the hub.
15. Using the hub junction box key, open the
box cover.
Figure 385: Junction box cover
16. Prior to running the slip ring cables
through the conduit, check all cables for
pinched and/or damaged insulation and
exposed strands. If damage is found, the
slip ring cables must be replaced.
Notify GE site representative if any damage is
found.
Figure 386
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17. Do not remove any electrical tape covering
wire ends.
18. Remove the elbow from the conduit.
19. Feed the cable bundle through the conduit.
B
A - Flex conduit
A
B - Slip ring wires
Figure 387
20. Feed the cable bundle through the access
hole of the hub junction box.
21. Install the elbow and the seal of the hub
junction box onto the conduit.
22. Tighten the flex conduit lock ring (see
arrow in adjacent figure).
A - Junction box hole
B
B - Locking ring
C - Elbow or connector
A
C
Figure 388
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23. Secure the slip ring flex conduit to the
brace with a minimum of 4 cable ties and
route it correctly to the junction box.
24. Route the cable bundle neatly in the
junction box. Remove the tape from the slip
ring cable bundle.
Figure 389: Secure slip ring flex conduit to the brace
25. Terminate the cables in the hub junction
box. Contact the GE site representative for
the latest wiring chart.
The following tooling is recommended to
prevent damage to wire terminal:
(Wago 5.5 mm) screwdriver
or
Clutch Type G Power Bit, 3/16, 2 In L
Grainger Item # 1YHY3
Brand IRWIN
Mfr. Model # 3052036
UNSPSC # 27112814
Figure 390
26. Use caution when inserting the ferrules into the terminals. Make sure that the ferrule is inserted
into the block and not behind the block. Do not over tighten the screw of any terminal onto the
plastic sheath of the ferrule.
27. Perform a wire pull test on every wire after terminating to ensure that no wires are loose.
28. Check for wire strands and remove them from the cabinet.
29. Perform a pull test on each conductor to ensure proper termination.
30. Verify the wire runs are neat and secured with cable ties if necessary.
31. Remove all materials and tooling from the slip ring junction box.
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NOTE
Prevent damage to the WTGS!
Loose cabinet doors will tumble and damage
equipment inside the hub when the rotor is
spinning.
32. Close and secure the hub junction box
doors. Verify the locking mechanism is
engaged.
Figure 391: Verify the lock clip is engaged
33. If applicable, install straps on the hub
main control cabinet and each axis box.
Figure 392
34. Inspect all three hub axis cabinet doors, ensure all lock mechanisms are properly engaged.
ATTENTION
Prevent damage to the WTGS!
Loose manuals/desiccant bags will pulverize create dust and debris damaging
the equipment if they are left inside the hub while the rotor is spinning
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ATTENTION
Prevent damage to the WTGS!
Make sure, that all cables are fixed to prevent damage!
35. Verify entire hub is clean and free of trash, debris and loose tools that can cause damage.
36. Verify the hub access cover is re-installed and all hardware is present.
37. Disengaging the low-speed shaft rotor
lock:
To disengage the pin:
Remove the LOTO lock from the safety
bolt.
Disengage the safety bolt to ensure no
damage is done to the safety bolt and
or pin.
Use a wrench with an opening of
17 mm and turn the spindle in
clockwise direction until the pin is
completely disengaged.
Figure 393: Disengage the low-speed shaft rotor lock pin using a
wrench
38. Disengaging the high-speed shaft rotor
Lock:
Remove the lock and tag (LOTO).
Pull out the spring-loaded locking pin
of the rotor lock to enable the crank
mechanism and turn the rotor lock
gear out of the brake disk gear as far
as possible.
Make sure that the spring-loaded
locking pin is engaged.
Rotor lock is open.
Figure 394: Disengage the high-speed shaft rotor lock pin
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39. Always adhere to Rotor lock LOTO
procedures.
40. Check the (high-speed) hydraulic disc
brake for proper functioning.
DANGER
Clear all personnel and equipment from all
rotating parts, pinch/crush hazard areas.
Figure 395
41. Release the hydraulic disc brake:
Verify the low-speed rotor lock is fully
retracted (disengaged from the
perforated disc) and is not dragging.
Verify the brakes are mechanically
released, the high-speed brake pads are
centered and not dragging on the disc.
Verify the rotor is completely free and
can rotate.
42. Contact GE personnel if brake disc is
dragging.
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15.2 Lowering the Power, Control & Communication Cables
DANGER
Danger of falling!
The safety harness must always be fastened as described in the Safety
Manual!
DANGER
Falling objects hazard!
Cables are heavy and may require multiple crew members located thought the
tower and or equivalent mechanical means as required to lower cables in a
controlled manner.
If the cables begin to fall uncontrollably do not attempt to stop them as this
can cause serious injury.
DANGER
Falling hazard!
If an employee is working at a height that exposes them to a potential fall, an
appropriate ladder and/or fall arrest equipment must be used as required,
and 100 % tie-off at all times. A retractable lanyard can be utilized.
NOTE
Always lower the cables in a hand over hand fashion.
Never drop the cables as this can cause internal damage to the conductors.
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Figure 396: Work at saddle
WARNING
Electrical hazard!
High/medium voltage grid may be present inside the turbine, collection system
terminates at the 2nd level switch gear.
Verify that the customer LOTO plan and the GE LOTO plan are
complementary to ensure the equipment is de-energized.
Site specific LOTO must be implemented before work begins.
WARNING
Electrical hazard!
The rotor must be locked before performing phase check and electrical validation
testing and before terminating the generator cables.
Verify appropriate energy isolation procedures are followed based on local
standards and/or GE requirements. I.e. local standards, customer LOTO plan
and GE LOTO plan must be complementary to ensure the equipment is deenergized.
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ATTENTION
Ensure the E-stop, yaw switch & control cables are pulled out of way so that
they do not get tangled and to prevent damage during cable drop – Verify
enough slack is present to attach control boxes to plate on the opposite side.
CAUTION
Know what you are lifting!
When the weight exceeds the limit for a single person, or if the load is awkward /
difficult to maneuver due to shape or size:
Request the help of a second person.
Transfer the load into smaller containers or use the crane or a fork lift.
Reference assembly drawings for weights.
ATTENTION
Extreme Cold Weather Sites:
Cold weather sites may require warming up the cables before handling to
prevent damage to the cable insulation and to remove the cable bundle memory.
Refer to Work Instructions - Cold Weather Cable Installation Guidelines for
recommendations.
CAUTION
Awkward postures / Reach / Fall hazard!
The cable access points are located in limited space and difficult to reach areas.
If an employee is working at a height that exposes them to a potential fall, an
appropriate ladder and/or fall arrest equipment must be used as required,
and 100 % tie-off at all times. A retractable lanyard can be utilized.
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The Power, Control & Communication Cables are shipped inside the machine. It is recommended coordinating
with the mechanical installer to ensure the cables are not disturbed, tangled or damaged during the nacelle
and rotor installation process. Any damage to the cables must be reported to GE site representative.
The cables are terminated to the top box and
routed through a series of cable trays and coiled
towards the front of the machine head
underneath the main shaft.
1.
If applicable, while the unit is on the
ground check the cable arrangement and
re arrange as required in the sequence
that better suits the installer’s process
ensuring that the cables do not get
damaged.
Figure 397
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2.
– Original –
Installation Manual
The crew member located in the nacelle
will sort/identify as required and lower the
control and communication cables down
through the yaw deck opening with the
assistance of a crew member located on
the yaw deck, starting with the largest
diameter cable first.
NOTE
When lowering the cables provide sufficient
amount of slack so that the cables are not
placing too much load on any object and
cables do not get damaged due to friction,
sharp objects or damage to the insulation due
to cable weight.
Figure 398: Lowering the cables
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3.
The crew member on the yaw deck will
carefully help support the weight and
lower the cables through the hole opening
down to the crew member located at the
cable guide platform (saddle deck).
4.
Provide a sufficient amount of slack
between the yaw deck cable guide
platform and the nacelle so that the cables
are not putting a load on the cable bundle
to prevent chaffing damage.
5.
Allow adequate clearance over the hoist,
ladder, and safety cable anchor and the
safety climbing system.
6.
The nacelle/ yaw deck crew person will
advise the saddle crew when there is
enough slack left on the cable bundle to
form the required drip loop at the saddle.
7.
The saddle crew will temporarily secure
the cable ensuring there is enough cable
slack to form the required drip loop.
8.
Refer to next chapter for final drip loop
dimensions.
Installation Manual
Yaw deck
NOTE
CRITICAL TO QUALITY AND SAFETY!
Ensure the cables are secured in multiple
locations through the tower ensuring the
weight of the cable and temporary cable
support means are sufficient and do not
damage or cut into the insulation.
NOTE
Saddle deck
CRITICAL TO QUALITY!
When securing cables to cable tray(s) or other
means verify that the cables do not exceed
the cable size specific minimum bend radius
at all places where they would be likely to
damage the insulation on conductors.
Figure 399
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9.
– Original –
Installation Manual
Verify that the length of the power, control
and communication cables allow for
termination in the main controller MCC,
LVDP and CCC cabinet in the PPM before
proceeding.
10. Coil the excess cables and secure out of
the working area.
11. Keep the cables separated and untangled
as much as possible as this will make it
easier for the crews to help build the final
cable bundle down the tower later on
through process.
12. When lowering the fiber optic cable, take
care that it is not crushed, pinched
between sharp objects, or bent sharply
(smallest bend radius 113 mm), as this will
cause permanent damage to the cable.
13. Lower the hoist power cable located at the
bottom of the top section with the
communication cable bundle.
14. If applicable: If the aviation lighting is
installed and terminated to the top box,
the power and photocell cables must be
lowered down the tower with the other
power, control and communication cables.
Figure 400
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15. After all the control and communication
cables have been lowered arrange the
cables in a bundle keeping the cables
uniform and straight.
50cm
16. Tape the cables together temporarily
using insulating tape at intervals of 50 cm
to form a bundle. Start at the yaw deck
and continue down to the saddle.
Figure 401
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17. Lower the cable down through the top
platform, and lead them over and behind
the cable guide platform down to the
bottom of the tower.
Rotor 690 V
Rotor PE
6 kV
18. Arrange the control / communication
bundles on the right side of the saddle
(when viewed facing the tower wall).
PE & Neutral
400 V
tor PE
Comm bundle
19. Form the communication cable bundle
final drip loop per the dimensions provided
in the next chapter.
20. Secure the cable bundles to the cable tray
under the saddle with cable ties in a cross
pattern.
21. Continue bundling the cable routing it to
the tower cable tray maintaining the
minimum bend radius.
Figure 402: Identification of the cable bundles
Figure 403: Typical “NEW” BoM Structure for 110mHH (Cable
transition below the saddle)
Figure 404: Typical “OLD” TPH structure for 98.3mHH (Cable
transition below the saddle)
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22. On the tower cable tray secure bundle
with cable ties on every rung for the first
12 rungs and every third rung after that
on the tray.
Figure 405: Typical “NEW” BoM Structure for
110mHH (Cable transition below the saddle)
Figure 406: Typical “OLD” TPH structure for 98.3mHH (Cable
transition below the saddle)
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23. The fiber optic cable is routed on the
outside of the bundle and secured with
cable ties to the cable bundle between
every rung for the first 12 rungs on the
tray. After 12 rungs, ties can be spaced to
between every third rung all the way down
the tower.
Figure 407
24. Allow enough excess cable to
accommodate the bridge at the tower
flange connections. Finish forming at the
bridge locations during rotor, stator, and
ground cable installation.
Figure 408
25. At the bridge locations secure the power
and communication cables at every rung
on the cable bridge and every third rung
after that.
Figure 409
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26. Terminate the lights and receptacles at
each level per the latest tower 109W3886
schematics.
27. Connect the lighting and power sockets.
Figure 410
Figure 411
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DANGER
Falling hazard!
If an employee is working at a height that
exposes them to a potential fall, an
appropriate ladder and/or fall arrest
equipment must be used as required, and 100
% tie-off at all times. A retractable lanyard
can be utilized.
A
28. At the converter level the communication
cables will transition to the right onto the
horizontal cable tray and then down
through vertical tray.
29. When cables go from horizontal to vertical
ensure the minimum bend radius is
maintained.
B
30. On the vertical tray located next to the
light fixture the cables will be positioned
on the left hand side of the cable tray.
A - Horizontal cable tray
B - Vertical cable tray cables secured on the left-hand side
Figure 412
31. The communication bundle at the
converter level will be located on the left
side of the cable tray going down to the
Controller/Transformer level.
Figure 413
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DANGER
Falling hazard!
If an employee is working at a height that
exposes them to a potential fall, an
appropriate ladder and/or fall arrest
equipment must be used as required, and 100
% tie-off at all times. A retractable lanyard
can be utilized.
32. On the controller/transformer level
continue securing the cable bundle to the
cable tray with cable ties.
Figure 414
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33. On the transformer level transition the
cable bundle from the tower cable tray
over the DIN Rail.
34. Secure cables to the upper DIN rail with
cable clamps allowing for a 100 to 150mm
drip loop between the tower and the DIN
rail.
35. From the DIN rail route the cables to the
transformer cable tray and into the
MCC/LVDP.
Refer to the latest point to point drawing for
cable designations.
Figure 415
ATTENTION
Excess cable!
The GE WTG has extra cable for the service loop. Upon customers request the
cables can be cut back and re-ferruled for appearance purposes. Customer will
be responsible for additional ferrules and responsible to ensure proper
identification of the cables is completed.
ATTENTION
Cutting cables - CRITICAL TO QUALITY!
When cutting around the circumference of the outer insulation of a multi
conductor cable, care must be taken not to cut or nick the insulation of the
inner conductors. Always inspect for damaged or cut strands near the outer
insulation and repair as needed.
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ATTENTION
Wire ferrules - CRITICAL TO QUALITY!
All wires must be ferruled. When crimping ferrules, always select the proper
crimping tool for the job. Do not use a ring crimper to crimp a ferrule and vice
versa.
When applying ferrules or ring terminals, make sure that the conductors are
stripped to fill the entire length of the barrel. The insulation of the conductors
must be fully inserted against the plastic base. No copper should extend
from either end of the ferrule or ring.
Always check the crimp for broken or bent pins and make sure the terminal
will not pull off the wire.
36. Secure the cables with cable clamps at the
DTA access point.
41.
37. Inside the cabinet, route to the cables
through the cable trays to the terminal
blocks ensuring the appropriate bend
radius is provided.
38. Terminate the wires in the respective
terminal block in MCC/LVDP/CCC
according to the latest point to point
drawing.
Critical to Quality:
39. Verify all wires are ferruled. Use caution
when inserting the ferrules into the
terminals. Make sure the ferrule is inserted
into the block and not behind the block. Do
not over tighten the screw of a terminal
onto the plastic sheaf of the ferrule.
2222222222222222
40. Perform a wire pull test on each wire after
terminating to ensure that no wires are
loose.
Figure 416
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15.3 Lowering the Generator, Rotor, Stator & Ground Cables
The stators, rotor, and 400 V are shipped inside the machine coiled towards the front of the WTG underneath
the main shaft. Any damage to the cables must be reported to GE site representative.
1.
In the WTG Identify the cable bundles:
1 trefoil for the stator cables (L1, L2 &
L3)
1 PE (stator ground)
3 trefoils for the rotor cables with
K - L - M in each
rotor ground
1 trefoil 400 V (L1, L2 & L3)
1 PE
1 Neutral
A - Rotor cables
B - 6 kV stator cables
A
B
Figure 417: Generator stator connection – 6 kV and rotor cables
2.
If cables are not marked open the
generator rotor collector box to identify
the different phase cables K – L - M.
Multiple Generator configuration cables may
need to be rotated for other turbine
configurations.
Figure 418: Rotor cables from generator junction box K, L, M
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3.
Installation Manual
– Original –
Identify the cables in cable bundles below
the components from the generator to the
gearbox.
The new position of the cable bundles must
allow some space between the cables.
4.
Put new cable ties around the bundles all
along the cables.
5.
Use several cable ties along the power
cables to fix them in bundles.
6.
Ensure bend of the cables does not exceed
the minimum bend radius.
222222
Generato
r
Figure 419
The crew person located in the nacelle must
separate the stator and ground cables and
mark them with phase tape.
7.
Secure the phase cable sets before entry
and after exit of the double cable guide
platform by means of cable ties at
intervals of 15 cm.
8.
Ensure cable ties do not create pressure
points or sharp edges and do not contact
other cables.
9.
Verify that the cables are routed evenly
and do not cross.
10. Cable from waterfall will be arranged
different which will affect spacer
arrangement.
11. Add cable designations.
Figure 420
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12. The crew person located in the nacelle
must lower the cables down through the
yaw deck opening one at a time with the
assistance of a crew person located on the
yaw deck.
Yaw deck
Saddle deck
Figure 421
13. The crew person located on the yaw deck
must lower the cables down through the
yaw deck hole to the cable guide platform
(saddle).
Figure 422
14. Route the cables through the tower
collector ring located between the yaw
deck and the saddle.
Verify that the cables are routed evenly and
do not cross.
A
A - Collector ring
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Figure 423
15. After all the cables are lowered, install the
support plate to the beam at the yaw deck.
16. Install the switch buttons to the support
plate.
Ensure the switch buttons face towards the
back (generator side), away from the cable
bundle.
A
A – Generator side
A
Figure 424
Figure 425: Install the switch plate and buttons
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17. Once all cables are lowered five spacers
have to be installed along the cable line.
The position of the spacers is defined in the
adjacent figure.
+- 50mm on all spacers.
Dimensions are taken from center to center
of the spacers.
NOTE
This does not apply to 3.8. The 3.8 design has 3
spacers only. Consult with GE representative for
latest GEI.
Figure 426: Distribution of the spacers (measure given in m)
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18. Identify the cable trefoils/bundles as they
were laid from this point to down tower.
19. Keep the same trefoils/bundles and tie
them together with cable ties.
NOTE
Make sure that the heads of all cable ties
around the cable bundles are pointing
outwards to avoid damages to the other
cables.
Rotor 690 V
Rotor PE
6 kV
PE & Neutral
400 V
tor PE
Comm bundle
Figure 427: Distribution of the cables
20. Prepare all spacers by removing the metal
band.
Figure 428:
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21. Beginning with the top spacer at the yaw
deck, position the spacer in between the
cable bundle and push the cable
trefoil/bundle into the spacer slots as
shown in adjacent figure.
Figure 429: Preparation of the spacers
22. Arrange the communication cable bundles
in the upper most spacer with the 6 kV and
the 690 trefoils opposite of the
communication bundles.
NOTE
There may be some variation in the arrangement
depending on the yaw angle of the machine head
to the cable saddle. In some cases it may require a
minimum of crossing of trefoils between the
lowest spacer and the saddle deck. See Figure
426: Distribution of the spacers (measure given in
m) as reference.
Figure 430: Distribution of the cables
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The spacer does have eight chambers. The
picture shows the top view of the spacer:
50 Hz:
Chamber 1 3x1x150qmm
Chamber 2 1x1x240qmm (PE)
Chamber 3 3x1x240qmm
Chamber 4 3x1x240qmm
Chamber 5 3x1x240qmm
Chamber 6 3x1x95qmm (400V)
Chamber 7 all 10 control cable (24V and
230V cable)
Chamber 8 2x 1x95qmm(N, PE), 1x
1x50qmm (PE)
Figure 431: Distribution of the cables
60 Hz:
Chamber 1 3x 1x350kcmil
Chamber 2 1x 1x535kcmil (PE)
Chamber 3 3x 1x535kcmil
Chamber 4 3x 1x535kcmil
Chamber 5 3x 1x535kcmil
Chamber 6 3x 1x3/0AWG (400V)
Chamber 7 all control, 24V and 230V
cable (~10x)
Chamber 8 2x 1x3/0AWG (N, PE), 1x
1x1/0AWG (PE)
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23. Measure the location of the spacer and
adjust as required to the dimensions
provided in illustration in previous for
distribution of the spacers.
Figure 432
24. Install and tension the metal band.
25. Tighten the bolt using the Allen key, size 8,
until the clamping strap ends touch (max.
torque 35 Nm!).
Figure 433
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26. Repeat steps for the remaining spacers,
using a scaffold for installation of the
spacers 2, 3 and 4.
Figure 434: Finished spacers
27. Once the spacers are installed, lower the
fiber optic through the center of the
spacers.
28. Secure the fiber optic to the
communication cable bundle and to each
spacer with a cable tie.
29. If applicable, remove any cable tie sharp
ends and or wrap the cable tie ends with
electrical tape to protect other cables
from damage.
Figure 435
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DANGER
Fall hazard – Open holes! Falling hazard!
If an employee is working at a height that
exposes them to a potential fall, an
appropriate ladder and/or fall arrest
equipment must be used as required, and
100 % tie-off at all times. A retractable
lanyard can be utilized.
800 mm
Cover open holes as required.
30. The installer located at the cable guide
platform has to route the cables over the
cable guide platform and form an initial
drip loop measuring approx. 1-1.5 m (42
inches) from the cable tie location to the
bottom of the drip loop.
Figure 436: Lowering the cables down further
31. If applicable, temporarily install two cable ties around each cable securing it back to itself
immediately below the cable guide platform to support the extra cable weight.
32. The final drip loop must extend at least 800 mm below the cable guide platform measured from
the bottom of the saddle to the top of the drip loop. Ensure sufficient clearance to surrounding
mechanical parts.
33. Pull the cables through the remaining cable tray in the tower top.
34. The twist shall be evenly distributed throughout the cables bundles.
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35. Pull the generator stator and ground and
all other cables over the cable saddle.
Rotor 690 v
Rotor PE
6 kV
PE & Neutral
400 V
tor PE
Comm bundle
36. They are arranged in this order for best
transition to the cable ladder in the tower.
Critical to Quality:
37. Secure cables with cable ties ensuring that
the heads of all cable ties around the cable
bundles are pointing outwards, and no
sharp ends are left on the ties to avoid
damages to the other cables.
No cable ties
between spacers
38. Pull the ground cables through the
transition cable tray and secure with cable
ties.
12 -15in. below the cable
saddle tie holes.
39. Verify that the cables are properly
supported at the transition.
40. If applicable, cut the cable ties securing
each cable to itself below the cable guide
platform.
No cable ties
in this area
Figure 437: Identification of the cable bundles
41. Pull the cables through the remaining
cable tray in the tower top.
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42. Apply High temp protection tape to the
cables in accordance with the latest GEI.
Figure 438: High temp protection tape application area
NOTE
Refer to “1.6-100_2.x_xxHz_WDI_RETR_cable_ArmorcastInst” for application
of adhesive permeated fiberglass.
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43. Install adhesive permeated fiberglass (e.g.,
Armorcast) to power cable, exposed to the
cable collector rings and „Platform A‟
opening to avoid cable wear during
operation.
NOTE
3.8 uses bumper design and does not require
Armorcast. Reference the Latest GEI.
44. The Installation shall be done by wrapping
each trefoil of power cables starting
approx. 15 cm below and ending approx.
15 cm above the collector ring.
45. To cure the adhesive permeated
fiberglass, spray it with pure water after
wrapping. Secure the adhesive permeated
fiberglass with a cable tie at both ends.
Figure 439: Example Armorcast application area
46. Ensure adhesive permeated fiberglass
mixture is consistent with manufacturer
specification to ensure adhesive
permeated fiberglass is adhered to the
cables correctly.
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15.3.1 Arranging the Cables at the Transition between the Cable Saddle and the Tower
Cable Tray
Once the drip loop has been formed and the cables are secured to the saddle, the cables can then be arranged
between the saddle and the tower cable tray. The sequence in which the cables are secured between the
saddle and the tower tray does not matter as long as:
The correct cable phasing order is maintained for best transition to the cable ladder to match the
cable arrangement in the tower with minimal crossing of cables.
The minimum bend radius of the cables is not exceeded.
Cables are protected from sharp edges e.g., metal or cable tie sharp ends.
Enough cable ties are used to support the weight of the cable to protect the cables from cables
from chaffing against each other.
NOTE
The switch is located in the machine head and will be installed in manufacturing.
Since the communication cables will not be spliced, the cable bundle can be
formed and secured to the cable tray with cable ties all the way down the tower
as per previous chapter.
There are two different tower electrical internal designs:
“OLD” TPH structure for 98.3 m HH
“NEW” BoM Structure for 110 m HH
Figure 440: Cable trays at saddle
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Plastic Cable Ties
Plastic cable ties are required to secure the cables to the Cable tray transition below the saddle. All Cable ties
must be installed with an installation gun set to 104lbs +/- 8lbs or 463N +/- 36N of tension. The installation gun
must be approved with plastic zip tie vendor to provide consistent pressure and cleanliness.
Cable tie installation instructions:
1.
Connect 2 cable ties together to form 1
long cable tie with two tie heads.
2.
Wrap cable tie around trefoil bundle and
rung by looping flat across bundle in front
and then diagonally around rung in back.
See adjacent figures
Figure 441
Critical to Quality:
3.
Tighten ties to 104lbs +/- 8lbs or 463N +/36N of tension.
4.
Ensure that all slack is removed from ties
before tightening and cutting off tails with
installation gun.
Figure 442
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15.3.1.1 Arranging the Cables at the Transition between the Cable Saddle and the Tower
Cable Tray “OLD” TPH Structure for 98.3mHH
1.
Bundle the trefoils maintaining cable
arrangement continuity coming off of the
saddle i.e., one of each phase per trefoil.
2.
Match the cable arrangement coming off
of the saddle to the cable arrangement in
the tower with minimal crossing of the
cables.
3.
When routing the cables over to the tower
tray, allow for gradual bend radius of
cables without exceeding the minimum
bend radius allowed depending on the
cable size.
4.
Secure the cables to the cable trays on
suitable position with cable ties forming
the proper bend radius.
5.
Using a cable tie cut tool ensure the cable
zip‐tie tail is cut even with the buckle to
avoid any sharp edges. This applies to all
zip tie installation.
NOTE
Per the NEC (NFPA 70) 300.34:
Conductors must not be bent to a radius of
less than 8 times the outside diameter of the
conductor (or cable) measured from the inside
of the bend for non-shielded conductors. For
shielded conductors the requirement is 12
times the outside diameter. This requirement
is both for during and after installation. If the
above requirement cannot be met, contact GE
engineering before proceeding.
For purposes of this document “exceeding”
the minimum bend radius shall mean bending
the conductor to a radius less than the NEC
requirements as listed above.
Figure 443: Example “OLD” TPH structure for 98.3 m HH
The bend radius of the conductor shall be
measured from the inside of the bend of the
conductor.
6.
On the tower cable tray identify the approximate location of the splice to ensure there are cable
rungs available above the splice to apply cable ties to support the splice.
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15.3.1.2 Arranging the Cables at the Transition between the Cable Saddle and the Tower
Cable Tray “NEW” BoM Structure for 110mHH
1.
Bundle the trefoils maintaining cable
arrangement continuity coming off of the
saddle i.e., one of each phase per trefoil.
2.
Match the cable spacing arrangement
coming off of the saddle to the cable
arrangement in the tower with minimal
crossing of the cables.
3.
Secure the cables to the cable trays with
cable ties and neoprene/steel tie as
required as per the latest engineering
directive
4.
Using the appropriate cable tie tool setting
apply tension and cut the regular cable
ties and the steel ties even with the buckle
to avoid any sharp edges. This applies to
all zip tie installation.
NOTE
Per the NEC (NFPA 70) 300.34:
Conductors must not be bent to a radius of
less than 8 times the outside diameter of
the conductor (or cable) measured from the
inside of the bend for non-shielded
conductors. For shielded conductors the
requirement is 12 times the outside
diameter. This requirement is both for
during and after installation. If the above
requirement cannot be met, contact GE
engineering before proceeding.
For purposes of this document “exceeding”
the minimum bend radius shall mean
bending the conductor to a radius less than
the NEC requirements as listed above.
The bend radius of the conductor shall be
measured from the inside of the bend of the
conductor.
5.
Figure 444: Example transitioning cables over to the cable
tray“NEW” BoM Structure for 110 mHH
On the tower cable tray identify the approximate location of the splice to ensure there are cable
rungs available above the splice to apply cable ties to support the splice.
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DANGER
Fall hazard!
If an employee is working at a height that
exposes them to a potential fall, an
appropriate ladder and/or fall arrest
equipment must be used as required, and 100
% tie-off at all times. A retractable lanyard
can be utilized.
Typical cable arrangement below the saddle
deck.
Communication and other power cables are
routed and secured to the small horizontal cable
tray in the field.
Stator/Rotor cables are secured by the tower
manufacturer.
Figure 445: Cables below the yaw deck “NEW” BoM Structur
15.4 Installing the Cable for the Cable Untwisting Switch
NOTE
The switch is located in the machine head and will be installed in manufacturing.
On site only final work on the switch is required!
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15.5 Splicing the Stator, Generator and Ground Cables
Only technicians qualified to perform work on Medium Voltage equipment should be performing electrical
connections or testing.
The stator, generator and ground cables 400 V and other PE cables are pre - installed in the machine head and
in each tower section by manufacturers respectively. The field teams will verify that the cables are in good
condition prior to lifting the tower. Once the tower is erected the installer will splice the cables at each tower
level ensuring the correct phase rotation and markings of the cables are maintained through the tower.
All splicing activities must comply with the following requirements:
Crimp the connectors using a crimp tool setup approved by the manufacturer of the connector
that meets applicable IEC/UL/CSA electrical codes and standards.
The tool must have the ability to induce pump pressure and compression of the crimp head on a
daily basis.
Intermixing of products and tooling of several vendors is possible if the vendors have carried out
respective testing and provided written approval. Deviation from this requirement can result in
cancelation of UL certification.
For 6 kV cables; follow manufacturer’s instructions provided with the 6 kV kit.
Where applicable reference latest revision GEI _GE.all_Tower (System)_Power Cable Splice and
Lug Installation_575V_690V.
The electrical insulation for the splices must be applied in accordance with the vendor specific
application procedures.
WARNING
Crushing hazard!
Before using the crimping tool, read the operating manual and the safety
information contained therein.
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General Overview of the Cable Arrangement at Each Level Prior to Installation
1.
Prior to lifting the tower verify cables on
each section are secured, undamaged and
labeled accordingly.
2.
If cables are not labeled it is
recommended to label the cables for ease
of identification during cable splicing once
the tower is erected.
6 kV stators L1-L2-L3.
Rotors K – L - M.
400 V
Lights and Receptacles
Hoist
Contact GE site representative if any issues
are found.
3.
Figure 446: Example top of tower
Verify that the cable ends on the top and
the bottom of the tower section are long
enough to make the splice once the tower
is erected.
Contact GE site representative if any issues
are found.
Figure 447: Example bottom of the tower
Figure 448: Example cable tray below the saddle
Figure 449: Example converter level
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Overview of the Final Cable Arrangement at Each Level
A: Top section:
Typical cables splice arrangement at transition
between the cable saddle and the tower cable tray.
Rotor
690V
Rotor 6 kV 400 V PE & Comm bundle
PE
Neutral
lights
receptacles
B: Tower Flanges:
Typical cable splice arrangement at flanges.
Rotor
690V
Rotor 6 kV 400 V PE & Comm bundle
PE
Neutral
lights
receptacles
C: Converter level:
Typical cable arrangement at the converter level.
A
Comm bundle
lights
PE &
Neutral
400 V 6 kV
Rotor
PE
receptacles
The 690 V rotor cables will transition into the
converter rotor cabinet.
A - 6 kV splice
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D: Typical cable arrangement and tie
configuration at the tower flange above splice.
Cable ties can be secured over the cold shrink,
but shall not be placed over the region that
covers the mastic, and on the side of the mastic
that is away from the splice. In order to avoid
this situation, the cable tie can be secured on the
vertical rail of the cable ladder if needed, and not
on the horizontal rung.
Figure 450
F: Typical cable arrangement and tie
configuration a tower flanges below splice.
Figure 451
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G: On the converter level
4.
Secure the 6 kV cables between the SSC
and the converter level splice to the cable
tray with cable ties allowing for enough
extra cable slack to make the connection
and both ends.
The cables ties on the 6 kV cables are
applied after splicing to ensure cable ties
are not placed over the insulation.
On this section power and ground cables
(400 and 690 V) are long enough to reach its
final termination point.
Figure 452
5.
Splice the stator and rotor cables below the cable saddle according connector specific
instructions.
The following requirements must be complied with:
Crimp the connectors using a crimp tool setup approved by the manufacturer of the connector
that meets applicable IEC/UL/CSA electrical codes and standards
The tool must have the ability to induce pump pressure and compression of the crimp head on a
daily basis.
Intermixing of products and tooling of several vendors is possible if the vendors have carried out
respective testing and provided written approval. Deviation from this requirement can result in
cancelation of UL certification.
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“NEW” BoM Structure for 110mHH (Cable transition splices below the saddle)
Figure 453
Figure 454
“OLD” TPH structure for 98.3mHH (Cable transition splices below the saddle)
Figure 455
Figure 456
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6.
Prepare and splice the 6 kV trefoil for the
stator cables (L1, L2 & L3).
7.
The 6 kV cables will be measured, cut and
spliced in strict accordance with the
manufacture splicing instructions.
8.
Manufacturer methods must be followed
and recommended tools and materials
must be used.
9.
Extreme care must be used to avoid any
contamination e.g. debris or moisture of
the splice.
– Original –
Installation Manual
10. Splice 1 PE (stator ground).
Figure 457
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11. The multiple layers of 6 kV electrical
insulation are applied in strict accordance
with the manufacture instructions.
12. Remove excess conductive paste to
prevent arcing.
Figure 458
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13. Splice the 3 trefoils for the rotor cables
with K - L - M in each and 1 rotor ground.
14. The Rotor cables will be measured, cut and
spliced in strict accordance with the
connectors’ manufacture splicing
instructions.
15. Splice manufacturer methods must be
followed and recommended tools and
materials must be used.
Figure 459
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16. The rotor electrical insulation is applied in
strict accordance with the manufacture
instructions.
17. Remove excess conductive paste to
prevent arcing.
Figure 460
18. Splice the 1 trefoil 400 V (L1, L2 & L3).
1 PE
1 Neutral
The cables will be measured, cut and spliced
in strict accordance with the splice
manufacture splicing instructions.
Manufacturer methods must be followed
and recommended tools and materials must
be used.
Figure 461
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19. The electrical insulation is applied in strict
accordance with the manufacture
instructions.
20. Remove excess conductive paste to
prevent arcing.
Figure 462
21. Secure the trefoils to the cable trays with
cable ties above and below the splices.
22. Repeat steps at all applicable tower levels.
23. Remove all trash and debris from the
tower.
Figure 463
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24. Apply High temp protection tape to the
cables in accordance with the latest GEI.
Typical applied between the top of midsection and bottom of the top section splice
Refer to the latest GEI for the application of
fire protection tape.
Figure 464
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16 Signs and Labeling to be Attached to the Wind Turbine Generator
System by the Operator/Owner
In accordance with DIN EN 50308; (or equivalent for US and ASIA poles); the operator/owner of the Wind
Turbine Generator Systems (WTGS) is obliged to attach additional warning signs to the WTGS. These are
intended to cover safety aspects which are not related to the scope of supply of the manufacturer of the Wind
Turbine Generator Systems.
The warning signs must state that
it is dangerous and prohibited for unauthorized persons to enter or climb the WTGS,
it is prohibited to remain in the vicinity of the WTGS while work is being carried out outside the
nacelle,
deposits of ice which have formed on the rotor blades (depending on the location of the WTGS)
could be thrown a considerable distance from the WTGS.
17 Installation of the Ladder and Fall Protection System
Immediately after the installation of a ladder section, the correct installation of the ladder and fall protection
equipment must be checked.
ATTENTION
The inspection of the ladder and fall protection equipment must be
performed by a qualified person only!
ATTENTION
The inspection must be repeated after any repair!
The subsequent inspection intervals must be adapted to the respective operational conditions. The intervals
depend on the frequency of use, the load during use and the frequency and seriousness of the defects found in
the preceding tests. Verification of regular inspection is essential for warranty claims. Follow the vendor's
inspection protocol.
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18 Connections
DANGER
Danger of electrical shock!
Uncontrolled stored energy: Make sure that all components are
de-energized.
DANGER
Electrical hazard!
Remove any water accumulation from the foundation prior to setting up
foundation electrical connections.
WARNING
Pinch points!
Use the hooking points marked in signal yellow which are located on each
platform (section).
WARNING
Falling hazard!
Personnel must be attached to a specified tie-off point at all times.
WARNING
Slip trip hazards!
Ensure that you are always protected by your PPE when carrying out work on
the PPM.
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18.1 Electrical Connections at PPM
DANGER
Electrical hazard!
Refer to the latest revision Energization Process Flow Chart and Verify GE and
Customer LOTO procedures are complementary.
Follow site specific LOTO policy if LOTO needs to removed or re-applied.
Ensure all pre- energization/de-energization checks per Site Specific LOTO
are adhered to prior to beginning any work.
Follow electrical PPE requirements in the Electrical Service Bulletin (Element
HS 13. 2C) for any electrical work on the WTG (See the EHS Outage Plan or
the Construction EHS Plan).
CAUTION
Awkward postures / Reach / Fall Hazard!
The cable access points are located in limited space and difficult to reach areas.
If an employee is working at a height that exposes them to a potential fall, an
appropriate ladder and/or fall arrest equipment must be used as required,
and 100 % tie-off at all times. A retractable lanyard can be utilized.
18.1.1 PAS00 Grounds:
1.
Set up the connections of the ground bus bar as per the latest electrical wiring diagram.
Where required cables will be routed through cable trays and secured with cables in a pattern on
every rung.
Where required cables must be protected from sharp edges/chaffing or other hazard that could
potentially damage the cable in any way and cause an arc flash.
Consult with GE site representative for torque data recording requirements and location.
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2.
– Original –
Installation Manual
Remove all paint residues or dirt from the
tower flange ground bosses to ensure
perfect contact of the ground cables with
the tower sections.
Figure 465: Removing paint residues from the tower flange
3.
Route the four 4 ground wires between the
tower flanges and PAS00 ground bus bar
laying the cables on the floor
unobstructed.
4.
Mount the ground straps to the tower
flange with hardware ensuring the correct
washer is utilized. Torque the bolts and
mark them with a paint pen.
5.
Write the torque data on a visible location
for IIP inspection.
A
A - PAS00 bus bar
Figure 466: Connecting the ground cables
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6.
Bolt the ground straps to PAS00 ground
bus bar.
7.
Torque the bolts and mark them with a
paint pen. Write the torque data on a
visible location for IIP inspection.
Installation Manual
– Original –
A
A - PAS00 bus bar
Figure 467
Foundation ground leads:
8.
Position foundation ground lead(s) against
the PAS00 ground bus bar.
9.
Position the lug against the cable and the
bus bar hole to mark the cable.
10. Cut the ground leads ensuring there is
sufficient cable to insert into the lug
barrel.
11. Attach the lug to ground lead and crimp
the lug according the lug manufacturer’s
instructions.
12. Mount the ground straps to PAS00 ground
bus bar with hardware ensuring hardware
is oriented correctly. Torque the bolts and
mark them with a paint pen. Write the
torque data on a visible location for IIP
inspection.
Figure 468
13. Repeat steps for all remaining cables.
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Installation Manual
Flange Grounds:
14. Mount the ground straps between the
tower flanges with the correct hardware.
15. Torque the bolts and mark them with a
paint pen. Write the torque data on a
visible location for IIP inspection.
Figure 469
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Ground cable potential PAS00 to the PE bus
bar PAS01 of the controller level.
16. Cables are terminated from 1 end by WTG
manufacturer. The Installer will uncoil and
route the ground cable through the cable
tray to PAS01 bus bar located between the
transformer and controller level.
A
17. Red dotted line shows approximate
routing location.
18. Terminate the pre-lugged cable to the
PAS01 ground bus bar with hardware
ensuring hardware is oriented correctly.
Torque the bolts and mark them with a
paint pen. Write the torque data on a
visible location for IIP inspection.
A - PAS01 bus bar
Figure 470
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– Original –
19. Connect the ground cable potential PAS01
between the PE bus bar PAS01 of the
controller level to the transformer level
leg.
Installation Manual
A
20. Torque the bolts and mark them with a
paint pen. Write the torque data on a
visible location for IIP inspection.
A - PAS01 bus bar
Figure 471
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21. Route the ground cable potential between
the AUX 690 V PE the PE bus bar PAS02 of
the converter level.
A
22. Secure the cable to cable tray with the
AUX 690 V L1-L2-L2 cables with cable ties.
23. Torque the bolts and mark them with a
paint pen. Write the torque data on a
visible location for IIP inspection.
24. Route the ground cable between the tower
to the PE bus bar PAS02 of the converter
level.
A - PAS02 bus bar
Figure 472
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18.2 Electrical Connections and Testing Requirements
DANGER
Life-threatening hazard! Danger! Electricity!
Before performing any work on or in electrical equipment within the WTG you
must be trained on the safety and operation of that specific model and
manufacturer of equipment.
Personnel performing this work are required to request training for
operating, assembling of the SSC cabinet 30 days before performing this
work.
Only technicians qualified to perform work on Medium Voltage equipment
should be performing electrical connections or testing.
Field Tests
Before performing any work on or in electrical equipment within the WTG you must be trained (by
manufacturer or manufacturer trained representative) on the safety and operation of that
specific model and manufacturer of equipment. Field testing of installed MVSG and SSC cabinets
to be completed by an electrical contractor qualified to perform work per manufacturer manual.
This test is required to check internal parts were not damaged during transportation and
handling. Contact GE for equipment manuals. This work must be conducted by an electrical
contractor or technician who is trained and certified by the regionally required Testing or
Regulatory agency (i.e. NETA in the USA) for the equipment and voltage level being worked on and
the testing being performed. Consult the Authority Having Jurisdiction (AHJ) for specific
requirements.
The cable assembly between the switch gear and the transformer supplied by GE will be VLF
tested by the installer. Contact GE for acceptable test voltage.
Electrical contractors must complete insulation integrity testing IR/Hipot/VLF test where applicable per
the latest revision of 104W2311:
Transformer winding to converter 690 V cables
Converter to generator 690 V cables
Converter to auxiliary transformer
6 kV configuration: cable connection from transformer to synchronization switch and
synchronization switch to generator
400 tower cables
400 V auxiliary transformer to LVDP
34.5 kV cables from MVSG to transformer
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ATTENTION
For all cable runs, the cables must be disconnected from the equipment on
both ends.
NOTE
Verify electrical validation tests for installed MV cable assembly between
switchgear and high side transformer is complete according to 104W2311.
ATTENTION
Some country electrical codes or regulations may require additional testing for
the generator stator and rotor ground/PE cables.
All crimping activities must comply with the following requirements:
Crimp the connectors using a crimp tool setup approved by the manufacturer of the connector
that meets applicable IEC/UL/CSA electrical codes and standards.
The tool must have the ability to induce pump pressure and compression of the crimp head on a
daily basis.
Intermixing of products and tooling of several vendors is possible if the vendors have carried out
respective testing and provided written approval. Deviation from this requirement can result in
cancelation of UL certification.
For 6 kV cables; follow manufacturer’s instructions provided with the 6kv splice kit.
Reference document: GE.all_Tower (System)_Power Cable - Splice and Lug Installation Procedure
inside Tower and/or specific vendor crimping instructions where applicable.
T-Body Connectors: Refer to the T-Body manufacturer`s instructions. Contact GE for equipment
manuals.
The electrical insulation for the splices must be applied in accordance with the vendor specific
application procedures.
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1.
– Original –
Installation Manual
Verify the protection settings in the switch
gear are per the specific wiring diagram.
ATTENTION
Danger of equipment damage!
Protect cables from sharp edges when
inserting cables into the MVSG cabinet. Closely
inspect cables after installation to ensure
there is no damage.
Figure 473: Connection of MVSG/transformer (examples)
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18.3 Medium Voltage Cables between the Grid and MVSG (Grid and Next Turbine)
DANGER
Life-threatening hazard! Danger! Electricity!
Before performing any work on or in electrical equipment within the WTG you
must be trained on the safety and operation of that specific model and
manufacturer of equipment.
Personnel performing this work are required to request training for
operating, assembling of the SSC cabinet 30 days before performing this
work.
Only technicians qualified to perform work on Medium Voltage equipment
should be performing electrical connections or testing.
Refer to Technical_Description_3MW-DFIG-xxHz_MVCableInst Requirements for the Medium Voltage Cable to
Switchgear Interface.
1.
If the cables are routed into foundation
prior to installing the PPM, ensure these
cables are undamaged secured from
possible damage during installation of the
PPM and the base section.
Figure 474
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Overview of typical MVSG
DANGER
Life-threatening hazard! Danger! Electricity!
Before performing any work on or in electrical equipment within the WTG you
must be trained on the safety and operation of that specific model and
manufacturer of equipment.
Personnel performing this work are required to request training for
operating, assembling of the SSC cabinet 30 days before performing this
work.
Only technicians qualified to perform work on Medium Voltage equipment
should be performing electrical connections or testing.
DANGER
Life-threatening hazard! Danger! Electricity!
Before performing any work on or in electrical equipment within the WTG you
must be trained on the safety and operation of that specific model and
manufacturer of equipment.
Personnel performing this work are required to request training for
operating, assembling of the SSC cabinet 30 days before performing this
work.
Only technicians qualified to perform work on Medium Voltage equipment
should be performing electrical connections or testing.
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MVSG Panels are removed by pulling the cover up and then away from the cabinet.
Grid
Next Turbine
WTG transformer
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2.
After the base section is installed carefully
route and protect the cables between the
foundation and MVSG GRID and if
applicable route the Grid cables for the
Next WTG.
3.
Secure the cables to the transformer cable
ladder.
Refer to: Technical_Description_3MW-DFIGxxHz_MVCableInst Requirements for the
Medium Voltage Cable to Switchgear
Interface.
4.
Verify correct phasing between grid and
MVSG and mark the cables with phase
tape.
5.
Terminate the cables in MVSG grid and/or
next turbine respectively.
Refer to:
Technical_Description_3MW-DFIGxxHz_MVCableInst Requirements for the
Medium Voltage Cable to Switchgear
Interface.
Installation Manual
Figure 475
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18.4 Connection of the HV Cables between MVSG and the Transformer
DANGER
Life-threatening hazard! Danger! Electricity!
Before performing any work on or in electrical equipment within the WTG you
must be trained on the safety and operation of that specific model and
manufacturer of equipment.
Personnel performing this work are required to request training for
operating, assembling of the SSC cabinet 30 days before performing this
work.
Only technicians qualified to perform work on Medium Voltage equipment
should be performing electrical connections or testing.
Use these instructions in conjunction with the Transformer (vendor specific) Operation & Maintenance Manual
and Insulation Integrity testing 104W2311:
1.
Carefully route the cable between the
transformer and the MVSG as detailed in
provided assembly drawings.
A: Cables are routed from the transformer
level up to the controller level through the
cable openings located on the floor of the
MVSG.
B: Cables are secured with cable ties to the
cable tray located on the transformer level.
C: The other end of the cables are routed to
the transformer terminals maintaining the
respective phase rotation sequence.
A
2
ATTENTION
Connections in installer's scope!
These connections may only be carried out by
a certified party.
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C
B
3
1
Figure 476
1 - Transformer terminals
2 - MVSG
3 - Cable tray located in the transformer level
2.
Remove the (MVSG to Transformer) panels.
Pull the cover up and then away from the
cabinet.
Figure 477
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3.
– Original –
Installation Manual
Inspect the inside of the MVSG ensuring
the cable support brackets are present
and the bushings are undamaged.
Any issues found must be reported to GE
site representative.
Figure 478
4.
Inside bottom of MVSG: Remove cable
access floor panel.
Figure 479
5.
Inspect the HV cable for damage to the
insulation or connectors.
6.
Carefully push the cables up into the
MVSG maintaining the correct phase
sequence.
7.
Verify correct phasing between
transformer and MVSG and mark the
cables with phase tape.
Figure 480
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8.
Verify that the minimum bend radius as
recommended by cable manufactures is
not exceeded.
9.
Secure the cables to the cable ladder with
cable ties providing the maximum strain
relief possible to the cable and terminals.
10. The cable must be additionally protected
against mechanical damage with a cable
protection tube or cover depending on the
used cable type and size.
Figure 481
11. In the transformer; Route the three cables
to the respective terminals ensuring no
mechanical strain to the cable/terminals.
A
12. Inspect the transformer contact terminals
for any damage.
13. Test 34.5 kV cables according to
104W2311.
14. Test the MVSG according to
manufacturer’s testing protocol.
15. Terminate the 34.5 kV cables to the
transformer ensuring the cable contact
leads and terminals are prepared as
required in accordance with the
transformer Operation & Maintenance
Manual.
16. Install the connection bar at the same
time of installing 34.5 kV high voltage
cable.
17. Using a torque wrench, ensure all bolted
connections are tightened to the values
given in the transformer Operation &
Maintenance Manual.
Torque 34.5 kV terminals
Torque adjustment tap hardware
18. Mark the hardware with a paint pen.
19. Record the torque values in and area as
agreed to with the IIP inspectors for the
final inspection.
Figure 482: 34,5 kV connections
A - 34.5 kV terminals
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Figure 483: Connection bar
20. Cover the terminals with silicon fabric as
directed by the transformer Operation &
Maintenance Manual.
Figure 484
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21. Route and terminate the 34.5 kV
concentric grounds to MVSG ground bar.
22. Torque the hardware and mark with a
paint pen.
Figure 485
Critical to Quality:
23. The installer is required to read,
understand and follow the required TBody connector’s installation procedures
prior to commencing the work.
Critical to Quality:
24. Only trained experienced personnel may
perform this work.
25. In the MVSG cabinet, prepare cables as per
the T-body and cable manufacturer’s
instructions.
26. Do not cut or nick the insulation.
Figure 486
27. In the MVSG cabinet, prepare bushings as
per the T-body manufacturer’s
instructions.
Figure 487
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28. In the MVSG cabinet, install the T-Body
and tighten to bushing in accordance with
the T-Body manufacturer’s instructions.
29. Terminate the concentric neutrals to the
bus bar.
30. Torque the hardware and mark with a
paint pen.
NOTE
If MV cable shield is not passing through CT
(current transformer) - usually, when CT is
attached on MVSG bushing- refer to Figure 488
for routing details.
If MV cable shield does pass through CT it must be
returned through CT, in order to cancel out shield
currents sensed by CT (see Figure 489).
Figure 488: Example 1
Figure 489: Example 2
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31. Ensure the rubber seals are installed
correctly and or apply foam to seal cable
entry point.
32. Any unused holes must be sealed.
33. Remove all tools and debris from inside of
the cabinet.
34. Reinstall the door panels.
NOTE
Do not leave cabinet panels open. Cabinet
panels must be closed at the end of the shift
or as soon as the work is complete.
Figure 490
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18.5 690 V Transformer to Converter CAE Cabinet
1.
Inspect the 690 V cable for any damage to
the insulation.
2.
Carefully route the cable between the
transformer and the converter as detailed
in provided assembly drawings.
A: cables are pushed up from the
transformer level.
B: through the controller level floor opening
C: up the cable tray located between the
MCC and the SSC cabinets.
D: Into the converter CAE cabinet through
cable glands.
1
D
1 - Bottom of CAE cabinet
2 - Controller level
3 - Transformer level
C
2
B
A
3
3.
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4.
Secure the cable to the cable tray with
cable ties in sets of two. This tray is
located in controller level between the SSC
and the MCC cabinets.
5.
The illustration shows 1 set of two cables
on the MCC side of the tray and the other
two sets on the SSC side of the cable tray.
NOTE
MCC
Where applicable, cables must be protected
from sharp edges/chaffing or other hazard
that could potentially damage the cable in
any form and cause an arc flash.
SSC
Figure 491
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6.
Verify correct phasing between
transformer and converter and mark the
cables with phase tape.
7.
In the converter level: Push the cables
through the cable glands maintaining the
correct phase designation.
Installation Manual
Figure 492
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8.
In the converter level CAE cabinet: Position
cable against the busbar, Position the lug
against the cable and center the lug/bus
bar holes to mark the cable.
9.
Move the cable outside of the cabinet and
cut the cable ensuring there is sufficient
cable to insert into the lug barrel.
Installation Manual
Figure 493
10. Attach the lug to the cables and crimp the
lug according the lug manufacturer’s
instructions.
Figure 494
11. Perform testing of the cables in
accordance with the Insulation Integrity
Testing procedure 104W2311.
12. Terminate the cable(s) to the bus bar
ensuring hardware is oriented correctly.
Torque the bolts and mark them with a
paint pen. Write the torque data on
cabinet door.
13. Verify the cable glands are tight.
Repeat steps for all remaining cables.
14. Remove all tooling and debris form the
cabinet.
Figure 495
15. Close the Cabinets doors.
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18.6 6kV Cables between the Transformer and SSC Cabinet
DANGER
Life-threatening hazard! Danger! Electricity!
Before performing any work on or in electrical equipment within the WTG you
must be trained on the safety and operation of that specific model and
manufacturer of equipment.
Personnel performing this work are required to request training for
operating, assembling of the SSC cabinet 30 days before performing this
work.
Only technicians qualified to perform work on Medium Voltage equipment
should be performing electrical connections or testing.
DANGER
Electrical hazard!
Refer to the latest revision Energization Process Flow Chart and Verify GE and
Customer LOTO procedures are complementary.
Follow site specific LOTO policy if LOTO needs to removed or re-applied.
Ensure all pre- energization/de-energization checks per Site Specific LOTO
are adhered to prior to beginning any work.
Follow electrical PPE requirements in the Electrical Service Bulletin (Element
HS 13. 2C) for any electrical work on the WTG (See the EHS Outage Plan or
the Construction EHS Plan).
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18.6.1 6kV Cables between the Transformer and SSC Cabinet Schneider Configuration
DANGER
Danger of personal injury and damage to the equipment!
Failure to isolate the WTG from the Grid and any other energy sources i.e., (UPS,
capacitors etc.) can result in unintended exposure to energization. Confirm the
Wind Turbine is de-energized in accordance with the Site Specific LOTO.
Installation, operation, and service are performed only by experienced
personnel trained in this specific configuration of equipment.
CAUTION
Awkward postures / Reach / Fall Hazard!
The SSC cable access points are located in limited space and difficult to reach
areas below and above the cabinet.
If an employee is working at a height that exposes them to a potential fall, an
appropriate ladder and/or fall arrest equipment must be used as required,
and 100 % tie-off at all times. A retractable lanyard can be utilized.
DANGER
Hand crush, cuts and burns risk!
Hands are exposed to mechanical dangers (cutting, grazing, pinching, and
crushing), and to danger from heat and cold (from touching hot objects and
convected heat).
In these cases protective gloves must be worn.
Use caution when working around exposed rotating components while the
rotor is turning.
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1.
Use caution not to damage
components when working in or
around the back of the SSC
cabinet.
2.
Remove back panel of the SSC
cabinet.
100% tie off is required.
3.
A: Route 3 6 kV cables between
the transformer and the SSC
cabinet.
4.
B: Secure the cables to the lower
support DIN rail with cable ties.
5.
C: Secure cables to the upper DIN
rail with cable clamps.
6.
D: Perform testing in accordance
with 104W2311.
7.
E: Maintaining the proper phasing
push cables through the hole
openings into the SSC cabinet.
8.
F: Maintaining the correct phasing
terminate the cables on the
transformer side L1 – L2 – L3.
9.
G: Maintaining the correct
phasing terminate cables on the
SSC side L1 – L2 – L3.
10. H: Torque the hardware on both
transformer and SSC ends and
mark with a paint pen.
Installation Manual
– Original –
G
E
SSC
C
A
B
F
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11. In the transformer, route the concentric
neutrals from each cable and terminate to
the designated grounding point.
12. Torque the hardware and mark with a
paint pen.
Figure 496
13. In the SSC, route the concentric neutrals
from each cable and terminate to the
designated grounding point.
14. Torque the hardware and mark with a
paint pen.
Figure 497
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15. Remove the insulator caps and place
outside of the cabinet to allow for
connection final inspection. Insulator
boots must be reinstalled after IIP is
complete.
Figure 498
16. Once the IIP is complete cut a hole the size
of the cable/ heat shrink diameter.
17. Install the boot covering each one of the
termination points.
Figure 499
18. Inspect inside the cabinet, on top and around connectors in SSC and transformer.
19. Remove any debris that can potentially cause an arc flash event in SSC and transformer.
20. This may require the removal of panels and use of mirror and flash light as required.
21. Verify no loose or misplaced tooling is left attached to the bus bars in SSC and Transformer.
22. Look for misplaced hardware, such as nuts, washers, and bolts that may have fallen near or
around the SSC and transformer.
23. Using a mirror and a flashlight, verify manufacturer materials such as loose manuals or loose
cables are not left in SSC and Transformer.
24. Inspect for debris or damaged cables in SSC and transformer.
25. Close all cabinet doors at the end of shift and/or after completion of work.
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– Original –
Installation Manual
18.6.2 6kV Cables between the Transformer and SSC Cabinet LimitAmp Configuration
DANGER
Life-threatening hazard! Danger! Electricity!
Before performing any work on or in electrical equipment within the WTG you
must be trained on the safety and operation of that specific model and
manufacturer of equipment.
Personnel performing this work are required to request training for
operating, assembling of the SSC cabinet 30 days before performing this
work.
Only technicians qualified to perform work on Medium Voltage equipment
should be performing electrical connections or testing.
DANGER
Electrical hazard!
Refer to the latest revision Energization Process Flow Chart and Verify GE and
Customer LOTO procedures are complementary.
Follow site specific LOTO policy if LOTO needs to removed or re-applied.
Ensure all pre- energization/de-energization checks per Site Specific LOTO
are adhered to prior to beginning any work.
Follow electrical PPE requirements in the Electrical Service Bulletin (Element
HS 13. 2C) for any electrical work on the WTG (See the EHS Outage Plan or
the Construction EHS Plan).
DANGER
Danger of personal injury and damage to the equipment!
Failure to isolate the WTG from the Grid and any other energy sources i.e., (UPS,
capacitors etc.) can result in unintended exposure to energization. Confirm the
Wind Turbine is de-energized in accordance with the Site Specific LOTO.
Installation, operation, and service are performed only by experienced
personnel trained in this specific configuration of equipment.
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CAUTION
Awkward postures / Reach / Fall Hazard!
The cable access points are located in limited space and difficult to reach areas.
If an employee is working at a height that exposes them to a potential fall, an
appropriate ladder and/or fall arrest equipment must be used as required,
and 100 % tie-off at all times. A retractable lanyard can be utilized.
DANGER
Hand crush, cuts and burns risk!
Hands are exposed to mechanical dangers (cutting, grazing, pinching, and
crushing), and to danger from heat and cold (from touching hot objects and
convected heat).
In these cases protective gloves must be worn.
Use caution when working around exposed rotating components while the
rotor is turning.
Opening De Energized SSC cabinet during installation
DANGER
Life-threatening hazard! Danger! Electricity!
Before performing any work on or in electrical equipment within the WTG you
must be trained on the safety and operation of that specific model and
manufacturer of equipment.
Personnel performing this work are required to request training for
operating, assembling of the SSC cabinet 30 days before performing this
work.
Only technicians qualified to perform work on Medium Voltage equipment
should be performing electrical connections or testing.
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Installation Manual
– Original –
Critical to Quality and Safety:
Reference the latest GEI for opening the SSC
LimitAmp cabinet doors.
Upper compartment = Low Voltage compartment
Lower compartment = High Voltage compartment
Figure 500: Upper and Lower compartment
1.
Remove the two isolation barriers.
Figure 501: Isolation Barriers
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2.
– Original –
Installation Manual
Loosen the black cable clamps that secure
cables going into the top cabinet
compartment.
A
Figure 502: View from outside of the cabinet (exterior
left hand side cover removed
Figure 503: Interior divider cover (Transformer cable routing)
A - Wind Ground Cable Clamp
3.
Verify 3 sets of cable clamps and saddles
are present.
Figure 504: Cable clamps
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Installation Manual
On the Transformer Level:
DANGER
Life-threatening hazard! Danger! Electricity!
Before performing any work on or in electrical
equipment within the WTG you must be
trained on the safety and operation of that
specific model and manufacturer of
equipment.
Personnel performing this work are required
to request training for operating, assembling
of the SSC cabinet 30 days before performing
this work.
Figure 505: 6 kV cables coiled on top of transformer
Only technicians qualified to perform work on
Medium Voltage equipment should be
performing electrical connections or testing.
The three 6kV cables are shipped terminated
and coiled on top of the transformer as shown
on the illustration.
4.
Inspect for damage and that the cables
are labeled correctly. These cables will
need to be terminated if they are shipped
loose.
CAUTION
Awkward postures / Reach / Fall Hazard!
The PPM cable access points are located in limited space and difficult to reach
areas.
If an employee is working at a height that exposes them to a potential fall, an
appropriate ladder and/or fall arrest equipment must be used as required,
and 100 % tie-off at all times. A retractable lanyard can be utilized.
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Installation Manual
– Original –
5.
A: Route 3 6 kV cables between the
transformer and the SSC cabinet.
6.
B: Secure the cables to the lower support
DIN rail with cable ties.
SSC
A
B
B
Figure 506: Cables secured to DIN rail
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7.
Installation Manual
– Original –
C: Secure the cables to the upper DIN rail
with cable clamps.
C
C
Figure 507: Cables secured below the SSC cabinet
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– Original –
8.
Push the cables up through the hole
openings into the SSC cabinet maintaining
the proper phasing sequence.
9.
Align the cable lugs to the bus bar. Ensure
there is enough length to terminate
without putting strain on the cable or
exceeding the minimum bend radius.
Installation Manual
10. Ensure lugs are oriented correctly in
relation the bus bar and tighten the pinch
block and cable glands.
11. Perform testing in accordance with
104W2311.
ATTENTION
For all cable runs requiring testing, the cables
must be disconnected from the equipment on
both ends for testing purposes.
Figure 508: Pinchblocks
Figure 509: Routing the cables through the SSC cabinet
(Note: Picture shown without internal equipment for illustration
purposes)
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Installation Manual
12. Maintaining the correct phasing terminate
cables on the SSC side L1 – L2 – L3 bus bar.
13. Torque the hardware on both transformer
and SSC ends and mark with a paint pen.
Reference the 3MW Bolt Torque
Specification.
Figure 510: SSC side L1 – L2 – L3 Bus bars
Critical to Quality:
14. Apply Electrical Insulation Linerless
Rubber Splicing Tape 130C in accordance
with Appendix – A Taping the Upper
Connection.
ATTENTION
CRITICAL TO QUALITY:
Failure to apply the tape as prescribed can
lead to catastrophic damage to equipment.
Figure 511: Electrical Insulation Linerless Rubber Splicing Tape
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Installation Manual
15. Terminate the concentric neutrals to the
nearest equipment grounding bus bar
shown on the illustration.
Reference the 3MW Bolt Torque
Specification.
Figure 512: Concentric neutral Cable Termination Point
16. Terminate the Ground to the equipment
grounding bus bar shown on the
illustration.
Reference the 3MW Bolt Torque
Specification.
Figure 513: Wind Ground Cable Termination Point
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Installation Manual
17. If applicable: Maintaining the correct
phasing terminate the cables on the
transformer side L1 – L2 – L3.
Reference the 3MW Bolt Torque
Specification.
Figure 514: Transformer side L1 – L2 – L3
Figure 515: Transformer side L1 – L2 – L3
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18. If applicable: In the transformer, route the
concentric neutrals from each cable and
terminate to the designated grounding
point.
19. Torque the hardware and mark with a
paint pen.
Reference the 3MW Bolt Torque
Specification.
Figure 516: Concentric neutrals terminated to transformer side
20. Terminate SSC Ground to the PE bus bar
PAS01 of the controller level. The bus bar
is located near the transformer access
hatch.
Reference the 3MW Bolt Torque
Specification.
Figure 517: PE Bus Bar PAS01
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Installation Manual
– Original –
18.7 690 V Converter CAE Cabinet to AUX Transformer
1.
Inspect the 690 V converter to AUX
transformer cables for damage to the
insulation.
2.
Carefully route the cable between the AUX
transformer and the converter CAE
cabinet as detailed in provided assembly
drawings.
A: Cables are routed from the AUX
termination points to the cable tray on the
bottom of the Aux and right hand side of the
Aux transformer.
B: Cables are secured with cable ties to the
cable tray located on the right hand side of
the AUX transformer.
C: Cables transfer to the horizontal cable
tray located on the top right hand side of the
transformer (cable tray is part of the bottom
of the controller level).
D: Route the cables to the cable tray located
on the controller level on the back left hand
side of the LVDP.
E: Route the cables on the cable tray located
on top of LVDP and the SSC cabinets.
F: Route cables into the converter CAE
cabinet through cable glands.
1
F
E
LVDP
D
C
B
1 - Bottom of CAE cabinet
2 - Auxiliary transformer
2
A
Figure 518
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3.
4.
Installation Manual
– Original –
Verify the power cables between converter
CAE cabinet and AUX transformer are
phased correctly and phasing is
maintained when pushing the cables into
the CAE cabinet.
A
Test 600 V cables between converter CAE
cabinet and AUX transformer according to
104W2311.
A - Inside of CAE Cabinet at converter level
B - Bottom of CAE cabinet
View from top of MCC cabinet
1
2
3
1
2
3
B
Figure 519: 1, 2, 3 front to back of the cabinet
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5.
Set up the connections (690 V) between the
converter cabinet and AUX transformer as
per the labeling.
6.
Write phasing and testing date, company
name and initials inside the door of the
cabinet.
7.
Verify the cables are correctly lugged as
per lug manufacturer's instructions.
8.
Verify the power cables from AUX
transformer to converter are terminated,
torqued and marked with a paint pen.
9.
Write torque value on the inside of the
door.
10. Record the torque values in the torque
report.
Installation Manual
Figure 520
11. Perform a wire pull test to ensure the
cable connectors are not loose.
12. Inspect inside the cabinet, on top and around connectors in the converter remove any
tools/debris that can potentially cause an arc.
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– Original –
18.8 400 V LVDP to AUX Transformer
1.
Inspect the (400 V AUX transformer to
LVDP) cables for damage to the insulation.
2.
Carefully route the cable between the
LVDP cabinet and the AUX transformer as
detailed in provided assembly drawings.
A: Cables are coiled secured with cable ties
to the cable tray located on the right hand
side of the AUX transformer below the LVDP.
B: Cables are routed to the cable tray
located on the right hand side of the AUX
transformer.
C: Alow for a gradual drip loop between the
cable clamps located directly below the
termination point of each cable and cable
tray.
D: Route cables to termination points in AUX
transformer.
1
LVDP
A
1 - LVDP cabinet factory terminated side
2 - AUX transformer termination point
B
2
D
C
Figure 521
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3.
Verify the power cables between
AUX transfomer and LVDP are phased
correctly.
4.
Test 400 V cables according to 104W2311.
5.
Set up the connections (400 V) between
AUX transformer and LVDP as per the
labeling.
6.
Write phasing and testing date, company
name and initials inside the door of the
LVDP cabinet.
7.
Verify the cables are correctly lugged as
per lug manufacturer's instructions.
8.
Verify the power cables from auxiliary
transformer to LVDP are terminated,
torqued and marked with a paint pen.
9.
Write torque value as agreed to with the
IIP inspector for reference during IIP
inspection.
Installation Manual
A
10. Record the torque values in the torque
report.
11. Perform a wire pull test to ensure the
cable connectors are not loose.
Figure 522
A - AUX transformer 400 V termination points.
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12. Route the ground cable between LVDP and
AUX transformer.
13. Terminate the cable in the ground bus bar
14. Route the gray cable W1926.06 208V
Supply between LVDP and
AUX transformer.
Th
an
ks
ag
ai
n
15. Terminate the cables in the auxiliary
cabinet per the latest point to point
drawing.
Figure 523
16. Inspect inside the cabinet, on top and around connectors in the LVDP and auxiliary transformer.
17. Remove any debris that can potentially cause an arc.
18. This may require the removal of panels and use of mirror and flash light as required.
19. Verify no loose or misplaced tooling is left attached to the bus bar.
20. Look for misplaced hardware, such as nuts, washers, and bolts that may have fallen near or
around the LVDP and auxiliary transformer bus bar.
21. Using a mirror and a flashlight, verify manufacturer materials such as loose manuals or loose
cables are not left in LVDP and auxiliary transformer bus bar.
22. Inspect for debris or damaged cables.
23. Close all cabinet doors at the end of shift and/or after completion of work.
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Installation Manual
– Original –
18.9 Control/Communication between MCC/SSC and the Converter CCC Cabinet
Cables/conduits are routed from the MCC and SSC through a series of cable trays and secure with cable ties.
1.
Verify the cables are not rubbing against any hardware or sharp edges.
2.
A: In the controller level
identify the conduits
designated for CCC
cabinet level. Reference
the point to point
drawing.
5.
7.
3.
G: Maintaining the correct hole
designation, push cables up into
the CCC cabinet. Tighten the cable
glands as required.
4.
F: Lay and secure
cables over the tray
located above the
MVSG.
B: Start below MCC and
SCC onto cable tray
below.
6.
E: Route and secure to
vertical cable tray.
C: Below LVDP cabinet,
push the cables trough
cable tray located
between the controller
and transformer level.
8.
D: Pull cables out and
up the cable tray
located on the right
hand side of the MVSG
cabinet.
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9.
– Original –
Installation Manual
In the converter level open the CCC
cabinet.
10. Route the cables to the respective
terminal block.
11. Verify the cables are ferruled.
Figure 524
12. Terminate the wires according to the
latest point to point drawing.
Figure 525
Figure 526
13. Perform a pull test to ensure the connection is not loose.
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Installation Manual
14. On the top of the converter cabinet: route
the cables for the 2 converter fans through
the holes located on top of the CCC
cabinet.
Figure 527
15. Inside the CCC cabinet route the cables
through cable tray.
16. Verify the cables are ferruled.
17. Terminate the wires according to the
latest point to point drawing.
Figure 528
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Installation Manual
18. Route and secure the Ethernet cable.
19. Terminate to designated port according to
the latest point to point drawing.
20. Perform a pull test on all cables to ensure
the connection is not loose.
21. Vacuum and/or remove any debris, e.g.
wire strands, metallic shavings, tools,
unaccounted for hardware and
animal/rodent debris.
22. Close all cabinet doors.
Figure 529
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Installation Manual
18.10 Control/Communication AUX Cables between MCC/SSC and the Transformer
Junction Box. TransformerLevel
Cables terminated to MCC and SCC cabinet side and cables are shipped coiled on the controller level.
1.
2.
A: From the MCC and
SCC push the cables
trough cable tray
located between the
controller and
transformer level.
A
B: Route and secure
the cables down the
cable tray. Notice
cables are on the
inside of the tray and
excess cable coiled.
B
Figure 530
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3.
Installation Manual
– Original –
C: From the bottom of
the cable tray route
the cable over and
into the AUX
transformer junction
box maintaining
correct cable hole
designation for each
cable.
C
Figure 531
4.
In the controller level identify the conduits
containing the cables that will be routed
from the MCC/SSC to the junction box
located in the transformer level.
Reference the point to point drawing.
Figure 532
5.
Move the cables to the back of the
MCC/SSC.
Figure 533
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6.
– Original –
Installation Manual
Route the cables through the cable tray
located between the controller cabinet
and the transformer level.
Figure 534
7.
Once all the cables are pulled to the other
side of the transformer, route the cables
to the vertical cable ladder securing the
conduits on the inside of the cable ladder
with cable ties.
Figure 535
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8.
– Original –
Installation Manual
Open the junction box and route the
cables to the respective terminal block.
Ensure the conduits are secure off of the
ground.
Figure 536
9.
Terminate the wires according to the
latest point to point drawing.
Figure 537
10. Vacuum and/or remove any debris, e.g.
wire strands, metallic shavings, tools,
unaccounted for hardware and
animal/rodent debris.
11. Reinstall J-Box cover.
Figure 538
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Installation Manual
18.10.1 PT – 100 Cable and Tower Door Exhaust Fan
1.
Route the PT-100 cable between the MCC
and the Junction box located in the top of
the auxiliary transformer.
2.
Terminate the wires according to the
latest point to point drawing.
3.
Pull test the wires to ensure cables are
terminated correctly.
Figure 539
4.
Route the cable between the MCC and the
exhaust fan motor terminal box.
5.
Terminate the wires according to the
latest point to point drawing.
6.
Pull test the wires to ensure cables are
terminated correctly.
Figure 540
7.
Refer to the latest point to point drawing and consult with GE site representative for other cables
not covered under these procedures.
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– Original –
18.11 Connect the 400 V Auxiliary Cables (Top Box) to LVDP
The 400 V cables are installed in each tower section by tower manufacturers. The field teams will splice cables
at each tower level. The following steps cover transition between the base section cable tray into the LVDP
cabinet.
1.
A: 400 V Transition from the
tower cable tray to the DIN
rail allowing for enough slack
to form a 170 mm drip loop.
2.
B: Secure the cables to the
DIN Rail with cable clamps.
B
A
Figure 541
3.
Verify the power cables
(400 V) between the converter
and the Top Box are phased
correctly.
4.
Write phasing date inside the
door of cabinet.
5.
C: Route the cables through
the cable tray and secure
with cable ties.
C
C
A
Figure 542
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6.
Installation Manual
– Original –
D: Maintaining the correct phase
rotation, push cables up into the LVDP
cabinet through the cable glands.
D
Figure 543
7.
Measure the cables against the
termination point.
8.
Pull the cables outside the cabinet and
cut them to the appropriate length.
Figure 544
9.
Strip and remove the insulation and take
care not to damage conductors.
10. Apply a ferrule to each one of the cables
according to vendor instructions.
11. Complete test per 104W2311.
12. Mark the cable ends with electrical tape
or other means in accordance with the
applicable electrical code.
Figure 545
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13. Terminate the converter to auxiliary
transformer power cables, torque and
mark them with a paint pen.
14. Write torque value, company name, date
and initials on the back of the cabinet.
15. Record the torque values in the torque
report.
16. Pull test all cables by hand to ensure
conductors and hardware are not loose.
17. Ensure cable glands are tight.
18. Inspect inside the cabinet, on top and
around connectors in the converter.
19. Vacuum and/or remove any debris, e.g.
wire strands, metallic shavings, tools,
unaccounted for hardware and
animal/rodent debris. Remove any debris
that can potentially cause an arc.
Figure 546
18.12 Connect the Power Cables (690 V) from the Generator to Converter Cabinet
The 690 V cables are installed in each tower section by tower manufacturers. The field teams will splice cables
at each tower level. The following steps cover transition between the base section cable tray into the rotor
cabinet in the converter level.
The following requirements must be complied with:
Crimp the connectors using a crimp tool setup approved by the manufacturer of the connector
that meets applicable IEC/UL/CSA electrical codes and standards.
The tool must have the ability to induce pump pressure and compression of the crimp head on a
daily basis.
Intermixing of products and tooling of several vendors is possible if the vendors have carried out
respective testing and provided written approval. Deviation from this requirement can result in
cancelation of UL certification.
Document: GEI _GE.all_Tower (System)_Power Cable Splice and Lug Installation_575V_690V.
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1.
Verify the power cables (690 V) between
the converter and the generator are
phased correctly.
2.
Write phasing date inside the door of
cabinet.
– Original –
Installation Manual
Figure 547: Cables prior to connecting
3.
Ensure cables trefoils are routed per
drawing and secured to the tower cable
tray. Ensure the cables are parallel and
not crossed.
4.
Ensure the cables are not resting against
any sharp edges.
5.
Maintaining the correct phase rotation,
push cables into the rotor cabinet through
the cable glands.
NOTE
Note the cable labeling!
Refer to the document:
GEI _GE.all_Tower (System)_Power Cable
Splice and Lug Installation_575V_690V.
Figure 548: Cables pushed into the Rotor Cabinet
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6.
Place the lug against the bus bar aligning
bolt hole(s).
7.
Place the cable against the lug and mark
the cable allowing for enough cable to be
inserted into the lug barrel for final crimp
and ensuring there is a nice cable
transition from the tower cable tray into
the cabinet as shown on the illustration.
Installation Manual
– Original –
Figure 549: Marking the cables to cut
8.
Pull the cables outside the cabinet and cut
them to the appropriate length.
Figure 550
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9.
– Original –
Installation Manual
Place the lug against the cable to mark the
correct cable insulation strip length that
will be inserted into the barrel. Allow for
enough cable to be inserted into the lug
barrel for final crimp in accordance with
the connector’s manufacturer crimping
requirements.
10. Strip and remove the cable insulation and
take care not to damage conductors.
11. Install heat shrink sleeves over the cables.
12. Install the lugs.
Figure 551
13. Crimp lugs per manufacturer's
instructions.
Ensure no strands are cut or outside the
connector.
14. Complete the tests per the latest revision
104W2311 Insulation Integrity Test
Procedure.
Figure 552
15. Apply heat shrink in accordance vendor
application instructions.
16. Mark the cable ends with electrical tape or
other means in accordance with the
applicable electrical code.
Figure 553
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– Original –
Installation Manual
17. Ensuring the correct hardware
orientation, terminate the rotor cabinet
bus bars, torque and mark them with a
paint pen.
18. Write torque value, company name, date
and initials on the back of the cabinet.
19. Record the torque values in the torque
report.
20. Pull test all cables by hand to ensure
conductors and hardware are not loose.
21. Ensure cable glands are tight.
22. Inspect inside the cabinet, on top and
around connectors in the converter for
misplaced tools or hardware.
Figure 554
23. Vacuum and/or remove any debris, e.g.
wire strands, metallic shavings, tools,
unaccounted for hardware and
animal/rodent debris. Remove any debris
that can potentially cause an arc.
24. Close the rotor panel.
Figure 555
DANGER
Danger of equipment damage!
If a tool or hardware is dropped anywhere inside the cabinets or unaccounted
for, or damaged cables are found, do not energize the turbine until missing or
unaccounted parts or tools have been found and removed.
Report to GE's site manager immediately if parts or tools cannot be found.
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– Original –
Installation Manual
18.13 Connecting the 6 kV Generator Stator Cables to the Stator Switch Cabinet SSC
DANGER
Life-threatening hazard! Danger! Electricity!
Before performing any work on or in electrical equipment within the WTG you
must be trained on the safety and operation of that specific model and
manufacturer of equipment.
Personnel performing this work are required to request training for
operating, assembling of the SSC cabinet 30 days before performing this
work.
Only technicians qualified to perform work on Medium Voltage equipment
should be performing electrical connections or testing.
The 6 kV cables are pre-installed in the machine head and in each tower section by manufacturers
respectively. The field teams will lower the cables from the WTG to the tower and splice cables at each tower
level ensuring the correct phase rotation sequence and marking of the cables are maintained thought the
tower. The following steps cover transition between the tower and the SSC cabinet in the PPM controller level.
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6 kV cables are spliced at the
converter level and routed
through the cable tray and
secured with cable ties down to
the controller level back of the
SSC cabinet.
Cables transferring between the
tower and SSC
– Original –
Installation Manual
Front Side 6 kV Generator to
Schneider SSC Connections
Back side of the Schneider SSC
cabinet
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– Original –
1.
Verify the stator cables (6 kV) between
Generator, Tower and SSC are phased
correctly.
2.
Mark the cables with electrical tape or
other means in accordance with the
applicable electrical code.
3.
Write the phasing date inside the door of
cabinet.
4.
Verify the stator lugs at the generator are
isolated.
Installation Manual
ATTENTION
For all cable runs, the cables must be
disconnected from the equipment on both
ends for testing purposes.
Figure 556
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– Original –
Installation Manual
DANGER
Fall hazard!
If an employee is working at a height that
exposes them to a potential fall, an
appropriate ladder and/or fall arrest
equipment must be used as required, and 100
% tie-off at all times. A retractable lanyard
can be utilized.
5.
Remove back panel of the SSC cabinet and
Route 3 6 kV cables between the tower
and the SSC cabinet.
Secure cables to the upper DIN rail with
cable clamps.
Figure 557
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6.
– Original –
Installation Manual
Maintaining the proper phasing sequence
push the cables through the hole openings
into the SSC cabinet.
Figure 558
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7.
Open the SCC cabinet door
In some SSC configurations the 6 kV bus
bars are located behind the ceramic fuses.
8.
Carefully remove the fuses and place in
safe area to prevent damage.
GE Limitamp SSC does not require removal
of the fuses.
– Original –
Installation Manual
Figure 559
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9.
– Original –
Installation Manual
In SSC cabinet: Remove the 3 plastic
covers to expose the bus bar connecting
points.
Figure 560
10. Position the cables against the respective
bus bar.
11. Measure and cut the cables to length.
12. Install the concentric neutrals.
Figure 561
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– Original –
Installation Manual
13. Crimp the cables per splice
manufacturer's instructions.
14. Apply heat shrink sleeves per
manufacturer’s instructions.
15. Perform a pull test after the cables have
been spliced to ensure the cable
connectors are not loose.
16. Perform test between SSC and generator
(6 kV stator cable connections) according
to GE procedure 104W2311.
17. Maintaining the correct phase rotation
sequence terminate cables on the SSC bus
bars L1 – L2 – L3.
18. Torque the hardware and mark with a
paint pen.
ATTENTION
CRITICAL TO QUALITY!
Figure 562
While torqueing the hardware, DO NOT use
the red bracket for support and avoid any
external pressure on the red bracket.
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– Original –
Installation Manual
19. In the SSC, route the concentric neutrals
from each cable and terminate to the
designated grounding point.
20. Torque the hardware and mark with a
paint pen. Inspect inside the cabinet, on
top and around connectors in SSC.
Figure 563
18.13.1 Connecting the 6 kV Generator Stator Cables to the Stator Switch Cabinet SSC
LimitAmp Cabinet
DANGER
Life-threatening hazard! Danger! Electricity!
Before performing any work on or in electrical equipment within the WTG you
must be trained on the safety and operation of that specific model and
manufacturer of equipment.
Personnel performing this work are required to request training for
operating, assembling of the SSC cabinet 30 days before performing this
work.
Only technicians qualified to perform work on Medium Voltage equipment
should be performing electrical connections or testing.
The 6 kV cables are pre - installed in the machine head and in each tower section by manufacturers
respectively. The field teams will lower the cables from the WTG to the tower and splice cables at each tower
level ensuring the correct phase rotation sequence and marking of the cables are maintained thought the
tower. The following steps cover transition between the tower and the SSC cabinet in the PPM controller level.
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– Original –
6 kV cables are spliced at the
converter level and routed
through the cable tray and
secured with cable ties down to
the controller level back of the
SSC cabinet.
Installation Manual
Front Side 6 kV Generator to GE
SSC Connections
Verify the stator cables (6 kV)
between Generator, Tower and
SSC are phased correctly.
Maintaining the correct phase
rotation, push cables into the SSC
cabinet through the cable
glands.
Cables transferring between the
tower and SSC secured to the DIN Rail
with fast clamps. Adjust the cable as
required maintaining the required
Cables are secured with cable ties minimum bend radius for the 6kv
to the tower cable tray located
cable.
behind the SSC cabinet.
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– Original –
Installation Manual
18.13.1.1 Routing and Terminating Cables to the Bus Bars
1.
Align the cable lugs to the bus bar. Ensure
there is enough length to terminate
without putting strain on the cable or
exceeding the minimum bend radius.
2.
Adjust the cables as needed to provide
spacing between the cables to conform to
regional standards.
3.
Test the cable in accordance with
104W2311 prior to terminating the cables.
DANGER
Electrical Hazard!
Cable ends need to be isolated on both ends to
prevent contact with other equipment during the
test.
ATTENTION
Figure 564: Aligning the cable terminals to the bus bar
For all cable runs that require testing, the
cables must be disconnected from the
equipment on both ends for testing purposes.
4.
Once IR testing is completed ensure the
lugs are oriented correctly in relation the
bus bar and tighten the cable glands and
cable clamps.
Critical to Quality:
5.
Place the cables so that the cable
connector is resting against the inside of
the bus bar and aligned with the center
hole as shown on the illustration.
6.
Maintaining the correct phasing terminate
cables on the SSC side L1 – L2 – L3. .
7.
Torque the hardware and mark with a
paint pen.
8.
Reference to the 3MW bolt torque
specification.
Figure 565: Cables bolted to the bus bars
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Installation Manual
– Original –
Critical to Quality:
9.
Apply Electrical Insulation Linerless
Rubber Splicing Tape 130C in accordance
with Appendix – A Taping the Lower
Connection.
Critical to Quality:
Failure to apply the tape as prescribed can
lead to catastrophic damage to equipment.
Figure 566: Electrical Insulation Linerless Rubber Splicing Tape
applied
10. Terminate the concentric neutrals to the
nearest equipment grounding bus bar
shown on the illustration.
Reference to the 3MW bolt torque
specification.
Figure 567: Equipment grounding bar
11. Verify the stator cables (6 kV) between
Generator, Tower and SSC are phased
correctly.
12. Mark the cables with electrical tape or
other means in accordance with the
applicable electrical code.
13. Write the phasing date inside the door of
cabinet.
14. Verify the stator lugs at the generator are
isolated.
Figure 568: (6 kV) stator cables at Generator
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– Original –
Installation Manual
15. Inspect inside the cabinet, on top and around connectors in SSC cabinets and transformer.
16. Remove any debris that can potentially cause an arc flash event in SSC and cabinets and
transformer.
17. This may require the removal of panels and use of mirror and flash light as required.
18. Verify no loose or misplaced tooling is left attached to the bus bars in SSC and Transformer.
19. Look for misplaced hardware, such as nuts, washers, and bolts that may have fallen near or
around the SSC and transformer.
20. Using a mirror and a flashlight, verify manufacturer materials such as loose manuals or loose
cables are not left in SSC and Transformer.
21. Inspect for debris or damaged cables in SSC and transformer.
22. Re-install all isolation barriers.
23. Close all cabinet doors at the end of shift and/or after completion of work.
WARNING
CRITICAL TO QUALITY!
Failure to account for all hardware or remove all tooling and debris can result in
catastrophic damage to equipment.
18.13.2 Critical to Quality Testing and Inspections
Generator
1.
Confirm proper phasing and all testing according to 104W2311 is done.
2.
Terminate the stator/rotor and ground cables in the generator per point to point drawing.
3.
Write torque value, company name, date and initials on the outside the generator cover.
4.
Record the torque values in the torque report.
Converter – 400 V
1.
Confirm proper phasing and all testing according to 104W2311is done.
2.
Terminate the 400 V cables in the LVDP per point to point drawing.
3.
Write torque value, company name, date and initials on the inside of the converter cover.
4.
Record the torque values in the torque report.
Converter – 690 V
1.
Confirm proper phasing and all testing according to 104W2311 is done.
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Installation Manual
– Original –
2.
Terminate the rotor and ground cables in the converter per point to point drawing.
3.
Write torque value, company name, date and initials on the inside of the converter cover.
4.
Record the torque values in the torque report.
Generator to (SSC) – 6 kV
1.
Confirm proper phasing and all testing according to 104W2311 is done.
2.
Terminate the stator and ground cables in the synchronization switch per point to point drawing.
3.
Write torque value, company name, date and initials on the outside of the synchronization switch
cover.
4.
Record the torque values in the torque report.
Transformer to (SSC) – 6 kV
1.
Confirm proper phasing and all testing according to 104W2311 is done.
2.
Terminate the stator and ground cables between the transformer to synchronization switch per
point to point drawing.
3.
Write torque value, company name, date and initials on the outside of the synchronization switch
cover and near the transformer connection visible for inspection.
4.
Record the torque values in the torque report.
5.
Terminate the ground cable in the generator junction box per the latest point-to-point-drawing.
6.
Write torque value, company name, dates and initials on the inside of the cover in an area visible
to inspectors.
7.
Terminate the stator cables in the generator junction box per the latest point-to-point-drawing.
8.
Write torque value, company name, dates and initials on the inside of the cover in an area visible
to inspectors.
9.
Re-terminate the ground cables to the grounding bus bar in the PPM.
10. Re-terminate the stator cable lugs in the converter threads.
Prior to Closing Cabinet Panels or Completion of Work.
1.
Inspect inside the cabinet, on top and around connectors.
2.
Remove any debris that can potentially cause an arc flash event.
3.
This may require the removal of panels and use of mirror and flash light as required.
4.
Verify no loose or misplaced tooling is left attached to the bus bars and in any of the transformer
coils.
5.
Look for misplaced hardware, such as nuts, washers, and bolts that may have fallen near or
around the any of the electrical connectors, bus bars or transformer coils.
6.
Using a mirror and a flashlight, verify manufacturer materials such as loose manuals or loose
cables are not left in any of the equipment/electrical components.
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– Original –
7.
Inspect for debris or any damaged cables.
8.
Close all cabinet doors at the end of shift and/or after completion of work.
Installation Manual
NOTE
The final installation of the climb assist or the service platform (lift) must be
performed as per manufacturer's instructions.
The installation and commissioning certification must be added to the Job
Site Book.
18.14 Installing the Floodlighting
1.
Mount the fixture of floodlight and motion
sensor above the tower entry door on the
outside of the tower.
2.
Connect the installation box to the supply
lines of the fixture. Refer to the
manufacturer's instructions.
3.
Connect the power cable inside the main
controller cabinet as per the electrical
wiring diagram.
4.
The final adjustment of the light fixture is
as required during maintenance activities.
Figure 569: Floodlighting
19 Ground Resistance Test
1.
Perform the CE ground resistance test as per the document:
2.5-100_xxHz_WDI_allComp_TestEN60204
(if required by the electrical codes of the respective country).
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Installation Manual
– Original –
20 Verify the Gearbox and Generator Alignment
Refer to:
Document: 2.x_WDI_gearbox_alignment
Document: 2.x_xxHz_WDI_generator_aligning
NOTE
After rotor installation has been completed the installer will verify the alignment
of the gearbox in accordance with the WDI 2.x_WDI_gearbox_alignment and
use tolerances given in the WDI. Consult with GE to obtain the WDI applicable to
each unit.
NOTE
If cables are not installed prior to Generator Alignment, ensure that the
cables are protected from damage and falling objects.
NOTE
After gearbox alignment has been completed the installer will verify the
alignment of the generator in accordance with the WDI
2.x_xxHz_WDI_generator_aligning and use tolerances given in the coupler
specified drawing. Consult with GE to obtain coupler drawings applicable to
each unit.
1.
Ensure a blank copy of the coupler drawing does indeed match the coupler for the unit being
worked on. Verify generator axial, angularity, and offset is within specified tolerances. If it is not,
move the generator in the appropriate direction per WDI so that axial, angularity, and offset are
within specified tolerances. Consult with GE for the current alignment report form. The final
alignment must be verified by GE and the alignment report must be placed in the Job Site Book.
2.
Ensure all guards and hardware have been properly installed.
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– Original –
Installation Manual
21 Remaining Work
After all the work has been concluded, the entire Wind Turbine Generator System must be cleared.
DANGER
Check the WTGS – especially the control cabinets – before concluding the
work!
Remove all loose parts, tools and materials from the WTGS – especially from
the control cabinets.
Tools and materials left behind in the control cabinets can lead to an arc flash or
unsafe working conditions for the service engineers when the turbine is
commissioned.
DANGER
Hazard at the generator junction box!
Remove rotor lock LOTO:
Disengage the rotor lock.
Verify the rotor locking accessories are properly secured.
Open the high-speed shaft brake valve and check that the pressure gauge
reads 0 bar, then close the valve.
Verify the brakes are mechanically released, the high-speed brake pads are
centered and not dragging on the disc.
Verify the rotor is completely free and can rotate.
21.1 Mechanical Completion
Mechanical completion shall be in accordance with the contract language.
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Installation Manual
22 Transport Fixtures
1.
Consult with the GE site representative to establish the fixture return sequence schedules/ in
accordance with Logistics procedures (LOG).
22.1 Downtower Equipment (PPM)
1.
Return small parts, tie-downs and transportation frames to the place of origin.
22.2 Tower
1.
Return transportation frames, transport braces, tie-downs, small parts and tarpaulins to the
place of origin.
22.3 Nacelle
1.
Disassemble, band and palletize transportation frames and small parts, as required, and load
them onto a transport vehicle.
2.
Return the feet or welded fixtures, small parts, and shaft cover to the place of origin.
22.4 Hub
1.
Return small parts, tie-downs and transportation frames to the place of origin.
22.5 Nose Cone
22.6 Blades
1.
Disassemble, band and palletize transportation frames and small parts as required, and load
them onto a transport vehicle.
2.
Return transportation frames, supports, small parts, tie-downs to the place of origin.
22.7 Special Tool Return
PPM bumper rails
E-palms
Blade edge protectors
PPM alignment jig
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