GE Renewable Energy
– Original –
Technical Documentation
Wind Turbine Generator Systems
3MW Platform - 50 & 60 Hz
Bolt Torque Specification
2018 - Revision 11
3MW Platform:

2.X Gen 0 (PMG): 2.3- (94) & 2.5- (88)

2.X Gen 1 (PMG): 2.5- (100,103) & 2.75- (100,103)

2.X Gen 2 (DFIG): 2.5- (100,103,120); 2.75- (100,103,120); 2.85- (100,103)

3.x DFIG: 3.x- (103,120,130,137)
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Bolt_Torque_Specification_3MW_xxHz_EN_r11.docx
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Bolt Torque Specification
Table of Contents
1
General ............................................................................................................................................................................................................... 5
1.1
Purpose .................................................................................................................................................................................................... 5
1.2
Restrictions ............................................................................................................................................................................................. 5
1.3
Lubrication ............................................................................................................................................................................................. 7
1.3.1 Restrictions ........................................................................................................................................................................................ 7
1.3.2 Application ........................................................................................................................................................................................ 7
1.3.3 Preferred Lubricants ..................................................................................................................................................................... 7
1.4
Tools .......................................................................................................................................................................................................... 7
1.5
Bolt Torque Requirements ............................................................................................................................................................... 8
1.5.1 Preparation........................................................................................................................................................................................ 8
1.5.2 Generic Process .............................................................................................................................................................................. 8
1.5.3 Marking Fasteners ......................................................................................................................................................................... 9
1.5.4 Visual Inspections of Torqued/Tensioned Fasteners ..................................................................................................... 9
1.5.5 Inspection of Fasteners with Thread Locking Compound ...................................................................................... 10
2 Testing and Torque Instructions for Bolted Connections .......................................................................................................... 11
2.1
Instructions for the 10 % Installation Inspection for Bolted Connections (excluding blade bolts) –
Installation Inspection, BIM & Maintenance ....................................................................................................................................... 11
2.2
Instructions for Manual and Hydraulic/Electronic Torque-Controlled Tightening for the Annual
Maintenance (other than Blade Connections) ................................................................................................................................... 12
2.3
Axial Hydraulic Tensioning of Foundation Anchor Bolts.................................................................................................. 13
2.3.1 Instructions for the Hydraulic Tightening of Anchor Bolts During Assembly or Refurbishment (Only if
foundations are within GE´s scope) ................................................................................................................................................... 14
2.3.2 Instructions for the Hydraulic Testing of Anchor Bolts During Maintenance ................................................... 16
2.4
Typical Tower and Tower to Yaw Bearing Bolt Requirements...................................................................................... 19
2.4.1 Tower Flange Torque – Installation ..................................................................................................................................... 19
2.4.2 Tower Flange Torque – BIM and Maintenance ............................................................................................................... 20
2.5
Typical Nacelle Connection Requirements .......................................................................................................................... 21
2.5.1 Modular Nacelle ........................................................................................................................................................................... 21
2.5.2 BTP Nacelle ..................................................................................................................................................................................... 22
2.6
Typical Rotor Shaft/Hub Bolt Requirements......................................................................................................................... 24
2.7
Blade to Pitch Bearing Bolts Tightening Procedure .......................................................................................................... 27
2.7.1 Blade to Pitch Bearing Bolts Tightening Procedure – Only Down-Tower ........................................................ 27
2.7.2 Blade to Pitch Bearing Bolts Tightening Procedure for Single Blade Installation - ONLY Up-Tower .. 28
2.7.3 Instructions for Bolt Installation Inspection (10 % of Blade Bolts) ....................................................................... 29
2.7.4 Maintenance of Blade to Pitch Bearing Connection .................................................................................................. 30
2.8
Electrical Connections .................................................................................................................................................................... 35
2.8.1 Transformer Cable Terminals ................................................................................................................................................ 35
2.9
Tightening of the Tensioning Nuts for the Generator Elastic Mounts ....................................................................... 36
2.10 How to Determine Torque Associated with Pre-Loads.................................................................................................... 38
3 Torque Values............................................................................................................................................................................................... 39
3.1
Safety-Relevant Bolt Connections (Component Torque Chart) ................................................................................. 39
3.2
Electrical Connections – Tightening Torque ........................................................................................................................ 46
3.2.1 Standard Connections - Electrical ...................................................................................................................................... 46
3.2.2 Terminal Bolt Torque for Battery Connections (in Hub) ............................................................................................ 46
3.2.3 Transformer Cable Terminals ................................................................................................................................................ 47
3.2.4 Permanent Magnet Generator (PMG) Cabinets ............................................................................................................ 48
3.2.5 Doubly Fed Induction Generator (DFIG) Cabinets ....................................................................................................... 49
3.3
Standard Connections – Mechanical ...................................................................................................................................... 50
4 Tightening Torque Conversion Charts ............................................................................................................................................... 51
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5
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Bolt Torque Specification
4.1
Tightening Torques Mentioned in Section 3 ......................................................................................................................... 51
Appendix(es) .................................................................................................................................................................................................. 51
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Bolt Torque Specification
1 General
1.1 Purpose
This document defines the torque or tensioning requirements for all bolts used within the assembly, erection,
and maintenance of a 3MW Platform Wind Turbine Generator System (WTGS). This does not apply for customer
provided components.
1.2 Restrictions
Specifications/requirements may change at any time, check for updates prior to performing operations.
It is NOT acceptable to re-use previously torqued or tensioned hardware for components listed in table 3.1
“Safety-Relevant Bolt Connections (Component Torque Chart)“unless specified within the re-use column or
otherwise approved by GE Engineering. Unauthorized re-use of fasteners may cause them to fail.
Unless otherwise indicated by a Non-GE design requirement, Non-GE manufacturer requirement, or an update
from within GE, all hardware must be torqued to values indicated in the component torque chart in section 3.
Torque values defined on assembly drawings or assembly specifications from other vendors may supersede
the values indicated in this document. If in doubt consult GE Energy.
ATTENTION
For all level 1 components connections: Base Flange-To-Anchor bolt, Tower
Flange-to-Tower Flange, Top Tower Flange-To-Yaw Bearing, Rotor-To-Hub
Adaptor, & Rotor Blade-To-Pitch Bearing.
1) Mixing of fastener hardware (bolt, washer & nuts) between manufacturer's is
not authorized on each fastener location.
2) Two different manufacturer's fasteners may be used on one joint with no more
than 10 % of the fasteners being from the second manufacturer.
Requirements for re-use of fasteners:
If any condition is not met the hardware must be replaced.
A) Joint must not be loose and no more than 10 % of fasteners fail maintenance torque check.
B) No indication of prior re-use (punch mark or paint). No cracks, deformation (bending or stretching), and
no galling/deformation/damage on threads/washer.
C) Nut must be able to be run by hand over the threads above/through/below the engaged area.
Fasteners listed as single re-use have the following additional requirements:
A) No indication of prior re-use (as documented below)
B) Required documentation:
i.
Entry made in turbine log and written message on joint indicating re-use. If fasteners are
replaced at later time, then line out message on joint with date and make entry into turbine log.
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ii.
– Original –
Bolt Torque Specification
Stud ends are colored in with paint pen and if studs are exposed to weather the end must
additionally be marked by hitting it with a punch to indicate re-use.
Figure 1: Proper installation of a chamfered washer
Figure 2: Wedge locking washer (e.g. Nordlock) and installation
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Bolt Torque Specification
1.3 Lubrication
1.3.1 Restrictions
Lubrication must not be used when the fasteners are attached to or near electronic equipment unless specified
by the specific drawing or assembly procedure.
Lubrication must only be used in cases where indicated on the torque specification table.
1.3.2 Application
Remove any debris or contaminant and ensure that the threads are clean prior to applying. Use an appropriate
cleaner on all threads of the threaded holes to remove contaminants.
When lubrication is used, ensure that the lubricant completely covers the bolt threads and that there is 360 °
coverage.
Do not apply lubricant underneath the bolt head, on the washer faces, or on the nut faces.
1.3.3 Preferred Lubricants
The lubricant must demonstrate and allow for uniform application and even distribution on threads. Use of
lubricants not provided here may create significant risks. Only use lubricants identified within the Lubricant List.
1.4 Tools
CAUTION
Prevent Personnel Injury!
Hydraulic or electronic torque tools must react off other turbine components. It
is vital to keep hands and body parts in appropriate locations away from these
reaction points to prevent crush and pinch injuries.
ATTENTION
Only calibrated tool systems with a maximum torque tolerance of ± 6 % must
be used!
 The contractor for projects & installation, will have additional requirements
that outlined in the installation manual which include, but are not limited to,
daily tool calibration checks. To check measuring and test equipment for
damage and accuracy prior to each use. This is to ensure the measuring
equipment has not suffered deterioration in accuracy, prior to its next
calibration expiration date. Consult the installation manual for additional
information.
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Bolt Torque Specification
ATTENTION
Prevent damage to the WTGS!
Pressure, force, resistance, torque, distance, voltage, amperage and measuring
tools shall be calibrated against standards traceable to the National Institute of
Standards and Technology (NIST) measurement standards or ISO/IEC 17025 in
accordance with ISO 10012 or ANSI and all applicable local and national
standards.
1.5 Bolt Torque Requirements
1.5.1 Preparation
1. Ensure threads are clean and free of debris or burrs.
2. Check the flange surfaces for burrs and high spots or any foreign debris and correct as needed.
3. Where required, apply lubrication to the following areas:
z
All threads of a bolt for complete coverage.
z
Do not apply lubrication underneath the bolt head.
NOTE
This does not apply to tower bolts as the nuts are lubricated by the supplier nor
does it apply to torque controlled blind holes. There you must lubricate the bolt
head underneath, except for the underside pitch bearing stud bolt heads which
should not be lubricated.
4. Thread bolts/nuts by hand for the first 4 threads to ensure proper thread engagement.
1.5.2 Generic Process
1. If 18 or more bolts are arranged in a circular pattern, use the following tightening sequence. Number all
bolt sequentially per Figure 11 or sequentially in three groups (e.g. 1-22, 1-21, 1-21).
2. Unless otherwise indicated on the appropriate drawing, hardware must be torqued to values indicated in
section 3.
3. Torque values defined on the face of other vendor assembly drawings or assembly specifications may
supersede the values indicated in this document (cf. component torque chart in section 3). If in doubt,
please consult with GE Engineering.
4. During initial installation and major component exchange, torque bolts according to star-cross-pattern
unless otherwise described.
5. Do not perform torque check on same bolt until all bolts have been inspected.
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Bolt Torque Specification
1.5.3 Marking Fasteners
1.
All torqued bolts must be marked with a single straight unbroken line running down the side of the bolt
head, across the washer and onto the clamped part, with a permanent or oil-based marker.
2.
For installation, blue is preferable for a first torque and always use red for torque inspections.
Figure 3: Example tower flange bolt markings
1st final torque
final torque + 60 °
Figure 4: Proper torque marking of fastener
final torque + 90 °
final torque + 120 °
final torque + 150 °
final torque + 180 °
Figure 5: Example bolt marking for torque + angle fasteners
Note: Under certain circumstances, the stud or bolt may rotate slightly while being tensioned. This is not
necessarily a problem unless spelled out with a specific limit in this document. The final marking will look
slightly different than those images above.
3.
If threadlock is applied to fastener (outside of manufacturing), make circular mark on fastener head in
addition to standard marking.
1.5.4 Visual Inspections of Torqued/Tensioned Fasteners
Inspect each fastener for the following conditions:

Corrosion – note and report to GE Representative

Defects – unusual or unexpected wear

Movement:

Inspect existing mark on torqued fastener

If no visual movement, no further action is required

If indication of movement or the mark is illegible/missing, it is necessary to perform physical torque
check on individual fastener to maintenance values stated in sections 3 and 4.

If there was excess movement (> 20°) when performing this torque check, it is necessary to torque
check 100 % of the fasteners on the flange.

If more than 10 % of the total count of the connections nut/bolt can be turned more than 20° the angle
needs to be recorded and contact your GE representative so Engineering/Product Service Engineering
can be informed.
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Bolt Torque Specification
Figure 6: Torque marking – acceptable movement <20 °
1.5.5 Inspection of Fasteners with Thread Locking Compound
Note: This process does not apply to any fastener larger than M24. Any critical joint covered in section 3 of this
document does not apply either (unless specifically identified).
1.
Perform visual inspection of fastener per section 1.5.4. (Note: All glued (thread locker – i.e. LOCTITE)
fasteners should have torque marks applied during manufacture or commissioning.)
2.
Check hand tight (or small hand wrench far below fastening torque) to ensure that bolt has not sheared in
place.
3.
If fastener shows no indications of movement from steps 1 and 2, no further actions are required.
4.
Corrective actions if fastener has moved:

Remove existing fastener.

Re-use or replace fastener depending on criticality or condition of fastener.

Apply adequate thread lock compound (if not pre-applied on new fastener).

Reinstall fastener and apply proper torque per section 3 of BTS or assembly drawings.

Mark newly applied fastener per section 1.5.3.
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Bolt Torque Specification
2 Testing and Torque Instructions for Bolted Connections
2.1 Instructions for the 10 % Installation Inspection for Bolted Connections
(excluding blade bolts) – Installation Inspection, BIM & Maintenance
1.
A sample of 10 % of the bolts evenly distributed over the bolt reference circle is required on all connections
after the rotor has been installed and the complete compression load is on the tower. The same bolts
should not be checked during consecutive inspection cycles.
2.
Do not loosen the bolts and, using a hydraulic or torque wrench/spanner, pre-tighten to the referenced
maintenance torque values as required.
3.
If the nut/bolt can be turned beyond the original marked position by more than 20 ° (see Figure 7) using the
maintenance torque value, all bolts in the circle must be inspected and torqued to specification as
identified in the Maintenance torque values without unscrewing the bolts. If during an Installation
Inspection any bolt is found loose or not torque marked, all bolts in the circle must be inspected and
torqued as required.
4.
This is only required for Projects Installation: Note the date and name of the inspector on the flange that
was inspected and mark a line on the bolt to indicate the 10 % inspection was completed.
5.
If more than 10 % of the total count of the connections nut/bolt can be turned more than 20° the angle
need to be recorded and contact your GE representative so Engineering/Product Service Engineering can
be informed.
Figure 7: Torque marking – acceptable movement < 20 °
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Bolt Torque Specification
2.2 Instructions for Manual and Hydraulic/Electronic Torque-Controlled Tightening
for the Annual Maintenance (other than Blade Connections)
ATTENTION
All bolts have to be tightened in greaseless condition.
 Don’t use any lubricant.
1.
If no specific instructions, choose 10 % of the bolts at random and mark (see Figure 8). Do not perform
torque check on same bolt until all bolts have been inspected.
2.
Do not loosen bolts and, using a hydraulic screwdriver or torque spanner, pre-tighten to the reference
maintenance torque (see section 3).
3.
If a nut/bolt can be turned by more than 20 ° (see Figure 9) beyond its original position, all bolts must be
pre-tightened again with the required maintenance torque without unscrewing the bolts.
4.
If more than 10 % of the total count of the connections nut/bolt can be turned more than 20° the angle
need to be recorded and contact your GE representative so Engineering/Product Service Engineering can
be informed.
Figure 8: Torque marking
Figure 9: Acceptable movement < 20 °
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Bolt Torque Specification
2.3 Axial Hydraulic Tensioning of Foundation Anchor Bolts
NOTE
Follow the foundation designer’s maintenance recommendations.
NOTE
This section also applies to the anchor bolts installed.
The tightening/check is carried out around the circumference in a clockwise direction. Bolt no. 1 is located at
the bottom longitudinal weld and must be permanently marked, so that it can be identified as no. 1 in
subsequent measurements. This procedure applies to both the inner and outer anchor bolts.
Figure 10: Axial hydraulic tightening of foundation anchor bolts
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Bolt Torque Specification
2.3.1 Instructions for the Hydraulic Tightening of Anchor Bolts During Assembly or
Refurbishment (Only if foundations are within GE´s scope)
(Initial Tightening or Re-tightening)
The required pretension force can be found in the respective foundation design specification.
1.
Apply the required pretension force to the bolts.
2.
Mark the tightened bolts.
3.
Note the applied pretension force on the tower flange at bolt no. 1 (using a waterproof pen).
The following data must be documented for the initial or re-tightening of the anchor bolts:

Project name

Pad/WTGs Number

Date performed

GIB number

Identification of the tool used (pump, cylinder) with serial number and calibration date

Bolt designation and information

Design tensioning force (kN/KIPS)

Operator (e.g. personnel number)

Final pretension force or elongation
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Bolt Torque Specification
The specimen report "Anchor Bolt Tension Record" provided below shows the scope of the documentation.
Anchor Bolt Tension Record
Site Name:
WTG:
Maintenance cycle:
Tool type/model:
Design tension (KIPS):
Serial number:
Target Nut Displacement:
Calibration Date:
kN:
Bar:
Inside Flange
Outside Flange
Date Performed:
Date Performed:
Wind Speed:
Temperature:
Wind Speed:
Temperature:
Bolt # Movement
Bolt # Movement
Bolt # Movement
Bolt # Movement
Bolt # Movement
Bolt # Movement
1
36
71
1
36
71
2
37
72
2
37
72
3
38
73
3
38
73
4
39
74
4
39
74
5
40
75
5
40
75
6
41
76
6
41
76
7
42
77
7
42
77
8
43
78
8
43
78
9
44
79
9
44
79
10
45
80
10
45
80
11
46
11
46
12
47
12
47
13
48
13
48
14
49
14
49
15
50
15
50
16
51
16
51
17
52
17
52
18
53
18
53
19
54
19
54
20
55
20
55
21
56
21
56
22
57
22
57
23
58
23
58
24
59
24
59
25
60
25
60
26
61
26
61
27
62
27
62
28
63
28
63
29
64
29
64
30
65
30
65
31
66
31
66
32
67
32
67
33
68
33
68
34
69
34
69
35
70
35
70
Technician Signature:
Date:
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Bolt Torque Specification
2.3.2 Instructions for the Hydraulic Testing of Anchor Bolts During Maintenance
NOTE
These instructions provide an example of testing and reporting instructions.
Depending on contractual requirements and local/national requirements, this
inspection may be different. Refer to your maintenance contract to determine
what elements are included in the scope of supply.
Please obtain the required pretension force from the specific foundation design specification.
The following data must be documented for the anchor bolt maintenance:
z
Site name
z
Date
z
Tower/pad #
z
Maintenance cycle
z
Wind speed
z
Temperature
z
Tool type/model, serial number, and calibration date
z
Design tension (kN/KIPS)
z
Bolt designation
z
Names of technicians performing check
z
Nut movement
NOTE
Do not release the pre-tension of the bolts beforehand!
NOTE
Maintenance pre-tension load values and inspection requirements are based on
95 % of the site-specific installation value.
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Bolt Torque Specification
NOTE
Pre-tension load values and inspection requirements are solely dependent on the
foundation design criteria. Do not deviate from the foundation design criteria
found in the foundation design documentation.
NOTE
Intervals may be superseded by the specific foundation design documentation. If
design documents deviate from this cycle, it is required to follow those designs.
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2.3.2.1 Generic Tension Requirement – Non-GE Foundations
Maintenance on Non-GE designed foundations may vary in scope, tension value and frequency. The detailed
inspection and verification process will be obtained from the foundation design engineer, whether already
recorded in the design drawing or via a letter from the engineering firm. The customer may be required to
provide this information prior to scoping, quoting and performing the maintenance checks.
2.3.2.2 Generic Tension Requirement – GE Foundations
If any anchor bolt does not pass the directed maintenance checks the appropriate corrective action must be
followed as defined in section 2.3.2.3.
Break-in Maintenance
Pre-tensioning of 100 % of the anchor bolts to 100 % of the site-specific installation value is required during
break in maintenance unless specified differently per foundation design.
Subsequent Maintenance Cycles
Check the pre-tensioning value of the anchor bolts on the inner and outer flange and mark (at 95 % tension
value). Pre-tensioning is performed annually for the first 5 years, and once every 3 years thereafter unless
specified differently per foundation design.
2.3.2.3 Corrective actions for failed checks – GE Foundations
If any anchor bolt does not pass the check (indication of any movement), then 100 % of the anchor bolts on
that flange (inner or outer) must be checked (at 95 % tension value).
If 10 % of the anchor bolts on either flange (inner or outer) do not pass, then 100 % of the anchor bolts on the
opposite flange must be checked (at 95 % tension value).
Any anchor bolt that does not pass the check must be tensioned to 100 % of the site-specific installation value.
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Bolt Torque Specification
2.4 Typical Tower and Tower to Yaw Bearing Bolt Requirements
2.4.1 Tower Flange Torque – Installation
Typical Bolt (Star/Crossover Pattern)
First round installation torque: Start with 3 groups evenly distributed over the flange. Each group with 5 bolts in
a row (Blue pattern in Figure 11). Following bolts may be installed in sequence.
Second round installation step (torque or angle, as applicable) can be applied in sequence.
ATTENTION
Different tower flanges require different torque values!
 Ensure correct torque values are selected from the component torque chart
in section 3.
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2.4.2 Tower Flange Torque – BIM and Maintenance
Start at one location and continue evenly spaced around the flange until all selected nuts have been torqued.
Figure 11: Example for typical tower flange numbering scheme (green) and sequence for first round installation torque (blue). Applicable
for tower-to-tower L-flanges and to yaw bearing.
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2.5 Typical Nacelle Connection Requirements
2.5.1 Modular Nacelle
Connections for the roof panels:
Figure 12: Connections for the roof panels (modular nacelle)
In all connections except for 5A, B and C all M12 bolts connecting the roof panels to the steel structure have to
be checked with 7.5 Nm.
In connections 5A and 5C the M12 rods are also to be torqued with 7.5 Nm.
In connections 5B all threaded rods with one nut on top and one nut below bracket have to be checked with 25
Nm. First check lower nut, then check upper nut! All four threaded rods should be checked for correct
installation and correct hardware:
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Latches on the cable hatch on the third roof
panel:
For torque tightening specifications, please refer to
the component torque chart in section 3.
Figure 13: Latches on cable hatch
2.5.2 BTP Nacelle
The locations identified in Figure 14 and Figure 15 must be torqued according to the values in the component
torque chart in section 3.
Connections for the nacelle enclosure:
Figure 14: Connections for the nacelle enclosure (BTP nacelle)
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Connections for the roof panels:
Figure 15: Connections for the roof panels (BTP nacelle)
Latches on the cable hatch:
For torque tightening specifications, please refer to
the component torque chart in section 3.
Figure 16: Latches on cable hatch
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2.6 Typical Rotor Shaft/Hub Bolt Requirements
Figure 17: Typical hub adapter (sequential circular/pattern) –
48 & 52 fasteners hubs (2500 & 2570RE)
Figure 18: Hub adapter (double row sequential circular/pattern) – 90
fastener hubs (2900)
Installation of 48 Stud Hub (2500 hub, 88, 94, 100, 103):
1.
Maintain a minimum of 90 % of the rotor weight on the crane.
2.
Align the main shaft and rotor/hub with the crane and impact all nuts to ensure there is no gap
between the flanges prior to tightening the nuts.
3.
Install between 18 and 24 nuts to the initial torque value.
4.
Release the crane.
5.
Engage the hydraulic disc brake and rotor lock when installing washers and nuts.
6.
Torque-check the first 6 nuts to the initial torque value. If no movement (< 1/3 of a flat) move on to
step 7, otherwise recheck all the installed nuts.
7.
Roll the rotor either CW or CCW to access the next set of nuts.
8.
Engage the hydraulic disc brake and rotor lock when installing washers and nuts.
9.
Once 24 nuts are installed the rotor may be rolled to access the next 8 nuts. Tighten the nuts in a
sequential pattern by starting immediately after the last one tightened in the previous set.
10. Continue rolling the rotor to access 8 nuts at a time and tighten to the initial torque value,
continue the sequential pattern.
11. Repeat step 9 as necessary until you reach the first set of nuts installed. Torque-check all
accessible nuts to the initial torque value and then apply the angle, continue the sequential
pattern.
12. Roll the rotor to access the next set of accessible nuts installed. Torque-check these nuts to the
initial torque value and then apply the angle, continue the sequential pattern.
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13. Roll the rotor to access any remaining nuts. Torque-check these nuts to the initial torque value
and then apply the angle, continue the sequential pattern.
14. Perform 10 % torque check to the maintenance torque value.
Installation of 48/52 Stud Hub (2570/2570RE (rear entry) Hub, 2.0 MW ~ 107, 116, 127, 132):
1.
Maintain a minimum of 90 % of the rotor weight on the crane.
2.
Align the main shaft and rotor/hub with the crane and impact all nuts to ensure there is no gap
between the flanges prior to tightening the nuts.
3.
Install and tighten at least 32 nuts to the initial torque value.
4.
Release the crane.
5.
Engage the hydraulic disc brake and rotor lock when installing washers and nuts.
6.
Torque check the nuts installed to the initial torque value.
7.
Roll the rotor/hub either CW or CCW to access the remaining nuts.
8.
Engage the hydraulic disc brake and rotor lock when installing washers and nuts.
9.
Install and tighten remaining nuts to the initial torque value.
10. Torque-check the remaining nuts to the initial torque value.
11. Roll the rotor back to the original position.
12. Torque check first 6 nuts installed to the initial torque. If any move, torque-check all 32.
13. Apply the angle to all 32 nuts.
14. Roll the rotor/hub to access the remaining nuts installed.
15. Apply the angle to the remaining nuts.
16. Perform 10 % torque check to the maintenance torque value.
For Installation and Re-assembly for 2900RE, Rotor shaft – Hub (Adaptor)
Refer to 3.1 Component Torque Chart Section, for torque values & degree turns)
1.
Maintain a minimum of 90 % of the rotor weight on the crane.
2.
Align the main shaft and rotor/hub with the crane and ensure there is no gap between the flanges
prior to tightening the nuts.
3.
Install at least 50 nuts for the 2900 to the installation value given in torque chart – pen mark the
nut positions starting with 1st nut tightened on the flange.
4.
Release the crane.
5.
Torque-check all accessible nuts to the installation value given in torque chart.
6.
Roll the rotor either CW or CCW (~105 °) to access the next set of nuts (while ensuring adequate
fastening at the top of the joint).
7.
Install all remaining nuts to the installation value given in torque chart (alternate between rolling
rotor and securing nuts).
8.
Roll the rotor to access the first 50 nuts for the 2900 installed and torque check these first nuts in
sequential pattern.
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9. Roll the rotor/hub to access the remaining nuts, torque checking these nuts.
10. Apply the additional degree nut turn given in torque chart to the initial 50 nuts for the 2900
fasteners in a sequential pattern starting at one end.
11. Roll the rotor in the same direction to access the remaining nuts installed and apply the additional
degree nut turn to these fasteners continuing immediately after the last one tightened in the
previous set.
12. Perform 10 % torque check to maintenance value; refer to 3.1 Component Torque Chart section.
NOTE
The installation process was designed for the 48/52 fastener hubs (2500, 2570 &
2570RE) on 2.5-100/103 and 2.5-120 units respectively. For the 90-fastener hub
(2900) on the 3.2-130, the process remains the same except for the ability to
access additional fasteners at any one time. When installing the 2900 hub,
access to the initial ~50 fasteners will take the place of the 32 (referenced in the
work steps above).
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2.7 Blade to Pitch Bearing Bolts Tightening Procedure
2.7.1 Blade to Pitch Bearing Bolts Tightening Procedure – Only Down-Tower
Follow approximate pattern as illustrated in groups of three:
z
10 o’clock three bolts
z
2 o’clock three bolts
z
8 o’clock three bolts
z
4 o’clock three bolts
z
9 o’clock three bolts
z
3 o’clock three bolts
Figure 19: Torque the bolts as illustrated in groups of three and in
between the pattern
NOTE
For installation and major component exchange:
All bolts must be lubricated per the Lubricant List.
Prior to applying pre-torque value, all nuts must be installed and impacted in the
specified pattern on all three blades.
1. Apply pre-torque (check table in section 3.1) to these bolts and to the remaining bolts in between the
pattern. Continue pattern until all bolts are pre-torqued.
2. Pitch the blades to expose remaining studs and install washers and nuts.
3. Continue pattern and pre-torque all remaining hardware.
4. After all bolts have been pre-torqued proceed with degree nut turn, refer to 3.1 Component Torque Chart
section for the correct degree turn value.
5. Continue pattern to torque the exposed bolts between the 7 to 9 and 2 to 4 o’clock positions.
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2.7.2 Blade to Pitch Bearing Bolts Tightening Procedure for Single Blade Installation - ONLY
Up-Tower
The procedure below must be followed to tighten the bolts of the blade to pitch bearing joint:
1.
Install all exposed blade nuts on blade 1 using impact gun in 3 o’clock position, achieving a torque
between 50-95 % of the final pre-torque value specified in the Work Instructions for the bolted
connections. (Pitch and yaw movement not allowed)
2.
Release the tool from blade (Pitch and yaw movement not allowed)
3.
Turn blade 1 to 6 o’clock position using turn drive tool. (Pitch and yaw movement not allowed)
4.
With Blade 1 at 6 o´clock put all remaining bolts with impact gun using pitch to get to the remaining bolts.
When all bolts are torqued achieving a torque between 50-95 % of the final pre-torque value specified in
the Work Instructions for the bolted connections, park the blade in idling position (90 deg pitch) Pitch and
yaw movement are allowed again when torque is applied to all bolts.
5.
Apply final torque and nut turn to each bolt with blade pointing down (6 o’clock position) as described in
the following:
Mark the first bolt to be tightened. Loose each nut and apply the specified pre-torque (check table in
section 3.1) to all the bolts in the circle following a sequential order (one by one, per the sequence in Figure
20 left). Once the whole circle is completed, continue to re-apply the specified pre-torque to the bolts in the
initial half of the circle (one by one, per the sequence in Figure 20 right). Mark all pre-torqued bolts (white),
to ensure that 1.5 circles are torqued.
6.
7.
Apply the specified nut turn to all the bolts in the circle (one by one, per the sequence in Figure 20 left),
mark all bolts as usual.
8.
Turn Hub, lifting blade 2, repeat sequence step 1-7
9.
Turn Hub, lifting blade 3, repeat sequence step 1-7
10. When 100% of 3 blades bolts are torqued and degree turn is applied, crane can be de-commissioned
Figure 20: Blade to pitch bearing bolts tightening sequence: circular torqueing or nut turn of all the bolts in the circle (left) and only half
the bolts in the circle (right).
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BIM and Maintenance
In case one or more bolts are found loose, the following repair procedure must be followed.
z
z
z
If one nut is loose, the two adjacent bolts -the one on the left and the one on the right- must be
replaced
If two nuts in a row are loose, the four adjacent bolts -two on the left and two on the right- must
be replaced
If five nuts in a row are loose, ten adjacent bolts -five on the left and five on the right- must be
replaced
In case loose nuts and bolts are being detected during BIM (break-in maintenance) or thereafter, note the bolt
position and open a PAC case. Loose bolts must be reinstalled using thread locker as specified.
NOTE
For installation and major component exchange:
All bolts must be lubricated per the Lubricant List.
2.7.3 Instructions for Bolt Installation Inspection (10 % of Blade Bolts)
1. After completion of the rotor assembly, proceed to bolt installation inspection. Complete the 10 %
inspection of the bolts, evenly distributed over the bolted circle of the blades following the 3 Torque Chart
value. This should be performed with approved tooling or with a manual torque wrench to ensure that no
bolts are drastically under-tensioned. This inspection must be performed on the three blades.
ATTENTION
This torque value is never used for final torque. Mark these 10 % of the bolts
with a red paint pen.
2. If any nut moves more than 3 mm measured tangent to the washer edge (allowing for some flex of the
bolt shank), an error has occurred during installation. In this case, the nut must be fully loosened and all
installation, pre-torque and nut turn steps must be repeated on the affected nut. Then repeat step 1 but
inspecting 100 % of the bolts and repeat this step as applicable.
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2.7.4 Maintenance of Blade to Pitch Bearing Connection
NOTE
After loosening blade nuts but prior to re-tensioning, ensure blade bolts have not
backed out from blade assembly.
ATTENTION
A maximum of three non-sequential nuts per blade may be loosened at any
given time with rotor blades in any position (one if using an electronic torque
tool).
ATTENTION
Perform the hub entry procedure.
Apply necessary LOTO to axis cabinets to prevent movement of the blades.
2.7.4.1 Break-in Maintenance
Blade bolts break-in maintenance procedure is described below:
1. Visually inspect all hardware. If any nuts have misaligned paint marks document the position and
estimated degree of movement of affected bolts.
NOTE
Under normal conditions, the bolt tension may decrease through seating of the
bolt, but it is not normal for nuts to actually rotate on the bolt due to operation.
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Figure 21: Example of nut markings at installation (A), 1 month (B), and annual maintenance (C) (Stickers are a local practice - verify
local and national regulations)
2. Loosen up to three nuts at a time in any position of the joint.
3. Ensure blade bolts have not backed out from blade assembly. If the bolt / T-bolt moves when removing a
nut, follow instructions in section 2.7.4.3.
4. Apply 100 % of the pre-torque value specified in Component Torque Chart section 3.1 to every nut in one
operation. Nuts may be torqued in any order but ensure that no steps are missed on any nuts.
NOTE
It is common for the nuts to rotate 0 to 20 degrees beyond the earlier torque
mark.
5. Apply the corresponding nut turn angle to all of the loosened nuts with an accuracy of +/- 5 degrees or
approximately 4 mm at the nut corner. Right after, perform alignment marks across bolt end, nut, and
surrounding bearing surface before proceeding to the next nut to avoid losing track of the nuts that have
been torqued as the blade is pitched for access to all bolts.
NOTE
Steps 4-5 above are performed in one operation when using an electronic torque
tool and require that nuts are re-torqued one at a time.
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Once all accessible bolts have been re-torqued it will be necessary to pitch the blades to gain access to the
bolts behind the axis boxes.
6. Repeat steps 1-4 until all bolts on all blades have been properly torqued.
7. Document position and estimated degree of movement of any nuts that have a final position more than
30 degrees or half a flat away from the previous position. Contact the GE representative with details.
2.7.4.2 Annual Maintenance
1. Visually inspect 100 % of hardware. If any nuts have misaligned paint marks document the position and
estimated degree of movement of affected bolts.
2. Check 10 % of the nuts evenly distributed along the bolt circle. Position the blades to be re-tensioned at the
6:00, 10:00 and 2:00 o’clock rotor position (rabbit eared position).
NOTE
Under normal conditions, the bolt tension may decrease through seating of the
stud, but it is not normal for nuts to actually rotate on the bolt due to operation.
Figure 22: Example of nut markings at installation (A), 1 month (B), and annual maintenance (C)
(stickers are a local practice - verify local and national regulations)
3. Loosen one to three nuts evenly spaced around the bolt circle. The nuts should be taken off, the threads relubricated and the nuts re-applied until they are finger tight.
4. Ensure blade bolts have not backed out from blade assembly. If movement occurs, follow instructions in
section 2.7.4.3.
5. Apply 100 % of the pre-torque value specified in the Component Torque Chart section 3.1 to every nut in
one operation. Nuts may be torqued in any order but ensure that no steps are missed on any nuts.
6. Apply the corresponding nut turn angle to all of the loosened nuts with an accuracy of +/- 5 degrees or
approximately 4 mm at the nut corner. Right after perform alignment marks across each bolt end, nut, and
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surrounding bearing surface before proceeding to the next nut to avoid losing track of the nuts that have
been torqued as the blade is pitched for access to all bolts.
NOTE
It is common for the nuts to rotate 0 to 20 degrees beyond the earlier torque
mark.
NOTE
Steps 5-6 above are performed in one operation when using an electronic torque
tool and require that nuts are re-torqued one at a time.
Figure 23: Applying 120-degree nut turn
Figure 24: Non-permissible deviation (>20)
7. Once all accessible bolts have been re-torqued it will be necessary to pitch blades to gain access to bolts
behind the axis boxes.
8. Repeat steps 2-6 until all bolts on all blades have been properly torqued.
9. If any of the nuts checked during the annual 10 % bolt check presents a rotation larger than 30 degrees
beyond their initial position (nut to flange mark), 100 % of the bolts in the joint will be checked.
10. Document the bolt position and estimated degree of rotation of those nuts having a final rotation larger
than 30 degrees, or half a flat away, from the previous position. Contact a GE representative with details.
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2.7.4.3 Blade Bolt Movement Correction
This procedure is to be performed if a blade bolt / T-bolt is found loose or loosens during the nut removal.
Ensure that the bolt is seated in the barrel nut or bushing.
1. Remove bolt from blade assembly.
NOTE
If the hole in the blade and the hole in the bearing no longer align preventing the
removal of the bolt:
f Position the blade in the 6 o’clock rotor position, then try to adjust blade
position to bearing to align the holes and allow for removal of the bolt.
f If the blade to bearing adjustment cannot be made, once the bolt has been
loosened from the barrel nut, the barrel nut may be moved/removed from
the blade (depending on blade design).
2. Inspect bolt and barrel nut or bushing threads for damage.
NOTE
f If the barrel nut was removed, inspect the threads of the bolt as it travels
through the barrel nut hole.
3. Clean the bolt threads with degreaser.
4. Apply adequate permanent thread locking compound (i.e. LOCTITE 277) to the blade end of the bolt and
then assemble.
NOTE
Ensure that the bolt is seated in the barrel nut or bushing:
f Bolt should be screwed in to match the stud protrusion of bolts of
neighboring bolts. Studs on LM inserts do not bottom out.
f Apply adequate torque values (range) per table in section 3.1 to obtain
proper bolt seating.
5. Inspect the threads of the bearing end of the bolt and nut.
6. Clean the exposed bolt threads with degreaser.
7. Apply appropriate lubricant as described in section 1.3 Lubrication.
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ATTENTION
Ensure no lubricant gets applied to the bearing surface.
This can impact the clamping force applied to the bearing and blade structure
8. Reinstall bolts at appropriate torque values per table in section 3.1.
9. Apply circular mark on the bolt end face using permanent mark to indicate that thread locker has been
applied to the bolt.
NOTE
Reinstalling blade bolt removes original torque mark reference and does not
allow for the 30deg reference for torque marking check.
NOTE
If a blade bolt moves during nut removal, it is not necessary to check all the bolts
in the flange.
2.8 Electrical Connections
NOTE
For fasteners not specified in section 3.2.4 ‘Electrical Connections,’ use
standardized torque values from 3.2.1
2.8.1 Transformer Cable Terminals
ATTENTION
All electrical connections are to be torqued without lubricant!
NOTE
For Non-GE supplied transformers follow the manufacturer’s maintenance
recommendations.
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2.9 Tightening of the Tensioning Nuts for the Generator Elastic Mounts
Figure 26: Functional principle of the tensioning nut
Figure 25: Assembly situation
The complete tensioning nut consists of a nut (pos. 1), washer (pos. 2) and pressure bolts (pos. 3).
The pressure bolts (Figure 25, pos. 3) in the
tensioning nut may not protrude from the
nut on the pressure side (see Figure 27).
1.
Slip on the washer (Figure 25, pos. 2) and
then screw on the nut (Figure 25, pos. 1)
and fasten finger tight.
Figure 27: Screwing out the nut
ATTENTION
All components must rest against each other without a gap.
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2. Next screw out the nut (Figure 25, pos. 1)
by approx. a quarter turn.
(this results in a gap of approx. 1 mm).
3. First, fasten the M 10 pressure bolts
marked in Figure 28 (pos. 1, 2, 3, 4) finger
tight.
4. Then, tighten the M 10 pressure bolts to
13 Nm.
5. In the next pass tighten the M 10
pressure bolts to 26 Nm.
6. Next, tighten all eight pressure bolts one
after another in several passes, until all
bolts have been tightened to the
requisite torque of 26 Nm.
Figure 28: Tightening the pressure bolts
7. Apply torque marking on the individual
pressure bolts and the entire assembly
to the clamped flange per section 1.5.3.
Figure 29: Completely assembled tensioning nut
NOTE
The pressure bolts may not abut with the bearing face after the assembly (Figure
29).
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2.10 How to Determine Torque Associated with Pre-Loads
Depending on regional installation and major component exchange requirements, use this procedure to
determine torque associated with pre-loads (if applicable). Field adjustable, calibrated torque wrenches must
be used to tighten all tower flange bolts. Steps 1 through 9 must be performed at a minimum daily for each bolt
size and grade.
1.
A calibrated preload device, capable of use with the installation hardware shall be used. (I.E. Skidmore test)
2.
Follow all guidelines specified by the manufacturer of the device.
3.
Select at random, three-bolts, washer, and nut (bolt set-up).
4.
Use a steel spacer that matches the thickness of bolted tower flange for use with the tensioning pre-load
device.
5.
Determine the torque value required for each of the bolt, washer, and nut sets selected to obtain the
pretension value specified in the Component Torque Chart.
6.
Average the resulting three torque values and use this average for all tensioning for that day unless the
restrictions imposed in step 8 occur.
7.
Torque associated with preload results values must be recorded by installer in 3 locations: Daily Log, ICL
and Tower wall next to the flange bolts for future reference with date to indicate proper torque was
completed.
8.
This procedure will be repeated if the temperature changes by more than 20 degrees or weather
conditions change (rain stop and start, etc.).
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– Original –
Bolt Torque Specification
3 Torque Values
3.1 Safety-Relevant Bolt Connections (Component Torque Chart)
Connection
Tower anchor bolts
Hybrid tower concrete –
steel (see Appendixes)
Mat. -No./Type
Per foundation
designer
specification
Bolt
Size
Number
-
-
-
Per foundation
designer
specification
Instruction
Re-use
Allowed
Yes
Identification the hybrid tower type, Reference the vendor specific documents (designer spec) in
PLM for Installation & maintenance of Hybrid-tower anchor.
Yes
104W5057
M64
444W4984
100
M56
444W4984
90
M48
444W4984
80
M42
444W4984
70
M36
444W4984
105W1931P010
standard washers
60
60
Max 9000 Nm
See footnote 2
1st round 1400 Nm
2nd round 2800 Nm
See footnote 1
1st round 1920 Nm
2nd round +90° (± 10°)
-
M36
Max 13000 Nm
See footnote 2
1st round 2250 Nm
2nd round 4500 Nm
See footnote 1
1st round 3100 Nm
2nd round +90° (± 10°)
-
104W5057
Max 20000 Nm
See footnote 2
1st round 3250 Nm
2nd round 6500 Nm
See footnote 1
1st round 4450 Nm
2nd round +90° (± 10°)
-
104W5057
Max 30000 Nm
See footnote 2
1st round 5000 Nm
2nd round 10000 Nm
See footnote 1
1st round 6850 Nm
2nd round +90° (± 10°)
-
104W5057
1st round 7500 Nm
2nd round 15000 Nm
See footnote 1
1st round 10300 Nm
2nd round +90° (± 10°)
-
104W5057
st
First Installation
Per foundation
designer
specification
Tower flanges
(see Figure 11)
Tower head – yaw
bearing
Maintenance
Nut
Size
55
Max 5600 Nm
See footnote 2
1500 Nm
+ 60° (± 5°)
See footnote 1
15000 Nm
No
BIM: +15° (+5°)
See footnote 2a
No
BRM: 15000 Nm
10000 Nm
No
BIM: + 15° (+5°)
See footnote 2a
No
BRM: 10000 Nm
6500 Nm
No
BIM: + 15° (+5°)
See footnote 2a
No
BRM: 6500 Nm
4500 Nm
No
BIM: + 15° (+5°)
See footnote 2a
No
BRM: 4500 Nm
2800 Nm
No
BIM: + 15° (+5°)
See footnote 2a
No
BRM: 2800 Nm
2500 Nm
No
nd
1 round 50 % of final torque; 2 round 100 % of final torque.
2 In case the target angle of 90° is not reached within max torque value; contact GE representative for Engineering/Product Service
resolution
1
2a
Target angle of 15° might not be reached within max torque value specified for installation. Acceptable angles between 0° and 15°
(+5°).
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GE Renewable Energy
– Original –
First Installation
60
55
1500 Nm
+ 150° (± 5°)
See footnote 1
2500 Nm
No
M36
60
55/60
1500 Nm
+ 90° (± 5°)
2500 Nm
No
M36
60
55/60
2400 Nm
+ 120° (± 5°)
3800 Nm
No
M36
70
55/60
2400 Nm
+ 120° (± 5°)
3800 Nm
No
M36
5 x 12
55
2800 Nm
Tectyl conservation
2800 Nm
Yes
M36
5 x 12
55
3500 Nm
Tectyl
3500 Nm
Yes
M24
4 x 24
19
1000 Nm
1000 Nm
Yes
444W5078P001
M24
4 x 28
19
1000 Nm
1000 Nm
Yes
-
-
-
-
-
Visual Check
Yes
Upper part main frame –
Bottom part main frame
105W1931P020
M39
119
60
2500 Nm
+ 90° (± 5°)
3300 Nm
No
Bearing cover 1 – Main
frame (rotor side)
L14EP33100M11
L14EP33110M11
M24
20
36
See footnote 3
See footnote 4
Yes
1500 Nm
+ 90° (± 5°)
2500 Nm
2400 Nm
+ 120° (± 5°)
3800 Nm
2400 Nm
+ 120° (± 5°)
3800 Nm
(see Figure 11)
Yaw bearing –main
frame
Hydraulic yaw brake
caliper – main frame
Yaw drive –
bed plate
Yaw motor –gearbox
Rotor shaft –
Hub (Adaptor)
(see Figure 17)
Low-speed rotor lock
mounting
Number
105W1931P010
Wedge locking
(Nordlock) washers
M36
444W3498P001
Standard washers
Maintenance
Nut
Size
Connection
Bolt
Size
Bolt Torque Specification
Mat. -No./Type
115W2238P015
Wedge locking
(Nordlock) washers
444W3498P001
Wedge locking
(Nordlock) washers
105W1931P011
standard washers
105W1931P011
Wedge locking
(Nordlock) washers
ISO 4762
M24 x 120 - 10.9
2.x – 100, 103
2500
Standard Washers
2.x – 100, 103
2500
Wedge Locking
2.x – 103, 120
2570
Wedge Locking
2.x – 120
2570RE
Wedge Locking
3.x – 130, 137
2900RE
Fine Thread & Thick
Washers
3.X-130, 137
2900RE
Coarse Thread
Wedge Locking
M16 x 90 – 8.8
48
M36
48
55
48
Instruction
Re-use
Allowed
See
note
below
See
note
below
See
note
below
See
note
below
M39
52
60
3500 Nm
+ 120° (± 5°)
4700 Nm
M36
90
55
2400 Nm
+ 240° (± 5°)
2800 Nm
See
note
below
M36
90
55
2400 Nm
+ 120° (± 5°)
3800Nm
See
note
below
M16
8
24
210 Nm
210 Nm
Yes
1st round: vertical position, 500 Nm; 2nd round: horizontal position, 1000 Nm. In any case, the assembly must be done by slow relative
rotation between main shaft and main frame.
3
The torque support gearbox nuts, studs and spacers may be re-used 3 times after the initial tightening. The studs shall be clearly
marked to identify the number of times they have been re-torqued and shall be replaced after a total of 4 torque sequences.
4
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Bolt_Torque_Specification_3MW_xxHz_EN_r11.docx
GE Renewable Energy
Bolt
Size
Number
N/A
N/A
Flange –
Main shaft
105W1932P001
Flange –
Gearbox
Bolt Torque Specification
Maintenance
Nut
Size
First Installation
1
19
200 Nm
200 Nm
Yes
M36
20
-
1500 Nm
+ 90° (± 5°)
-
No
105W1932P001
M36
24
-
1500 Nm
+ 90° (± 5°)
-
No
Flange main shaft Flange gearbox
105W1931P004
M36
58
55
1500 Nm
+ 90° (± 5°)
2500 Nm
See
note
below
Shrink disc shaft –
Gearbox
N/A
M33
32
N/A
installation process
to obtain flush face
2210 Nm
Yes
114W2773P001
M36
16
55/60
1500 Nm
+ 270° (± 15°)
see footnote 4 & 5
2500 Nm
Yes
M20 x 55
DIN 6912
M20
2x4
17
464 Nm ± 23 Nm
464 Nm
± 23 Nm
Yes
M16 x 55
DIN 6912
M16
2x4
14
150 Nm ± 15 Nm
150 Nm
± 15 Nm
Yes
105W1931P010
M36
2
55
2800 Nm
2800 Nm
Yes
-
M24
4
36
730 Nm
730 Nm
Yes
All
-
-
-
per supplier
document
per supplier
document
Yes
L217P37B
normal nut
M30
4
46
1200 Nm
1200 Nm
Yes
107W6497P001
tensioning nut
M10
4x8
I6
See section 2.9
26 Nm
Yes
-
M20
16
30
450 Nm
with thread lock
compound
Visual Check
with thread
lock compound
No
-
-
3x4
-
15 Nm
Visual
-
105W1931P016
M36
20
55
1500 Nm
+ 90° (± 5°)
2500 Nm
No
L114AP21060M11
M12
-
19
86 Nm
86 Nm
No
L114AP29040M11
M20
-
30
410 Nm
410 Nm
No
Connection
Manual low - Speed rotor
lock operation
Torque support
Gearbox –
Main frame
Main bearing groove nut
– Lock screw
Brake –
Gearbox
Mat. -No./Type
High-speed rotor lock
mounting bolts
High speed coupler
Generator damper
Damper generator Generator frame
DFIG generator
Pfisterer plug
Generator frame –
Main frame
Spinner – Hub
(N/A 3.2-130 + design)
5
– Original –
Instruction
Re-use
Allowed
The torque support gearbox studs need to be installed properly in order to ensure proper fitment. To do so please follow these steps:
•
Hand tighten each torque support gearbox stud to the end of the thread.
•
Turn each torque support gearbox stud 360° back.
•
Start with tighten procedure.
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GE Renewable Energy
Connection
Nose cone step
assembly – Hub
(N/A 3.2-130 + design)
Pitch bearing Hub
Mat. -No./Type
Grade 10.9
w/Nordlock
Table 3.3 for others
Pitch drive - Hub
Pitch motor Gearbox
Rotor Blade – Pitch
bearing: 10 % inspection
Rotor blade - Pitch
bearing
GE blade designs
First Installation
3
30
410 Nm
3 x 70
55
1500 Nm
+ 120° (± 5°)
Instruction
410 Nm
2500 Nm
M36
3 x 91
55/60
3 x 104
1500 Nm
+ 150° (± 5°)
2500 Nm
+ 180° (± 5°)
3.3 Standard
Connections
Mechanical
3.3 Standard
Connections
Mechanical
Re-use
Allowed
Yes
See
note
below
No
2800 Nm
No
See
note
below
See
note
below
3 x 32
17
3.2-130
M16
3 x 28
24
All others - ISO 4762
M16 x 120
M16
3 x 18
14
295 Nm
295 Nm
Yes
3.2-130
L15DP25070
M16
3 x 18
14
295 Nm
295 Nm
Yes
All others - ISO 4014
M12 x 35 - 8.8 VZ
M12
3x4
18/19
84 Nm
+ Loctite 243
Visual Check
Yes
3.2-130 L114AP25050
M16
3x4
24
210 Nm
+ Loctite 243
Visual Check
Yes
All configurations
-
-
-
10 % @ 1000 Nm
1000 Nm
Yes
M36
3 x 68
60
500 Nm
+ 120° (± 5°)
500 Nm
+ 120° (± 5°)
Yes
550 Nm + 120° (± 5°)
550 Nm
+ 120° (± 5°)
200 Nm
210 Nm
GE 43
GE 46
(see Figure 19)
(Apply spray lubricant
per Lubricant List)
GE 50.2
Without stiffener
M20
Maintenance
Nut
Size
M12
GE 48.7
LM blade designs
Number
Bolt Torque Specification
All other
configuration
Without stiffener
Rotor blade – Pitch
bearing
Bolt
Size
All others (2500)
102W1404P001
2.5-120 (2570)
115W2238P011 and
P014
3.2-130 (2900)
444W0229P00
Axis cabinets Hub
– Original –
LM 45.7p
3 x 68
LM 48.7p
LM 58.7p
550 Nm + 120° (± 5°)
M36
3 x 92
60
500 Nm + 120° (± 5°)
LM 63.7p
(see Figure 19)
(Apply spray lubricant
per Lubricant List)
LM 67.2p/p2/p3
Rotor blade – Pitch
bearing (0.1m stiffener)
All GE blades
3 x 104
M36
LM design 48.7
3 x 68
60
550 Nm
+ 120° (± 5°)
500 Nm
+ 120° (± 5°)
Yes
550 Nm + 180° (± 5°)
550 Nm
+ 180° (± 5°)
500 Nm
+ 150° (± 5°)
500 Nm
+ 150° (± 5°)
Yes
550 Nm
550 Nm
Yes
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Connection
Rotor blade – Pitch
bearing (0.3m stiffener)
Blade studs to
blade/barrel nut
assembly
Mat. -No./Type
All blade designs
– Original –
Bolt
Size
M36
Number
3 x 68
Bolt Torque Specification
Nut
Size
60
GE Design
M36
-
N/A
LM Design
Maintenance
First Installation
Instruction
+ 150° (± 5°)
+ 150° (± 5°)
750 Nm + 180° (± 5°)
750 Nm
+ 180° (± 5°)
250 Nm
+ Loctite 277
See footnote
6&7
See footnote 6, 7 & 8
If applicable
+ Loctite 277
See footnote
6&8
See footnote
6, 7 & 8
108W5114P001
M30
3
46
60 Nm
+ Loctite 243
See footnote 9
Visual Check
See footnote 9
(see Figure 12, Pos. 1)
Ejot self-drilling
screw JT3 6.0 x 36
6
48
-
5 Nm
5 Nm
(see Figure 12 Pos. 2a, 2b,
4a, 4b)
Ejot self-drilling
screw JT3 5,5 x 2
5.5
112
-
5 Nm
5 Nm
M12
4
19
7.5 Nm
7.5 Nm
M12
7
19
7.5 Nm
7.5 Nm
Nose cone safety tie- off
eyebolt
Re-use
Allowed
Yes
Yes
Yes
No
Modular Nacelle
(see Figure 12, Pos. 1)
(see Figure 12, Pos. 3a)
DIN 931
M12 x 160 - 8.8
hot dip galvanized
DIN 931
M12 x 140 - 8.8
(see Figure 12, Pos. 2a, 2b)
DIN 931
M12 x 100 – 8.8
M12
16
19
7.5 Nm
7.5 Nm
(see Figure 12, Pos. 4a, 4b)
DIN 931
M12 x 100 – 8.8
M12
2
19
7.5 Nm
7.5 Nm
(see Figure 12, Pos. 6a, 6b)
DIN 931
M12 x 90 - 8.8
M12
2
19
7.5 Nm
7.5 Nm
(see Figure 12, Pos. 5a, 5c)
DIN 931
M12 x 50 - 8.8
M12
2
19
7.5 Nm
7.5 Nm
(see Figure 12, Pos. 2a, 2b)
DIN 931
M10 x 150 - 8.8
M10
12
17
49 Nm
49 Nm
(see Figure 12, Pos. 2a,
2b, 4a, 4b, 6a, 6b)
DIN 931
M10 x 140 - 8.8
M10
12
17
49 Nm
49 Nm
(see Figure 12, Pos. 3a, 3b)
DIN 931
M10 x 50 - 8.8
M10
16
17
49 Nm
49 Nm
(see Figure 12, Pos. 5b)
Threaded rod
M10 - 8.8
M10
4
17
49 Nm
49 Nm
See
note
below
In cases of reinstalling LM designed blade studs, contact GE Representative. All blade studs when reinstalled will require LOCTITE 277
or equivalent permanent thread lock compound.
6
Installation of blade stud may require higher torque application to ensure adequate seating and thread engagement – maximum
values up to 500 Nm may be applied.
7
8
Bolt should be screwed in to match the stud protrusion of bolts of neighboring bolts. Studs on LM inserts do not bottom out.
9
Thread-locker applied to all joints – checks to be performed per section 1.5.5 of this document. For installation, adapter placed hand
tight on bolt. Initial nut on bolt torqued to 120 Nm, locking nut bound to first nut and eye bolt attached to other end of adapter at
60 Nm.
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GE Renewable Energy
Connection
Mat. -No./Type
– Original –
Bolt
Size
Number
Bolt Torque Specification
Maintenance
Nut
Size
First Installation
Instruction
(see Figure 12, Pos. 3a, 3b)
DIN 931
M8 x 150 - 8.8
M8
8
13
hand tighten
hand tighten
(see Figure 12, Pos. 5b)
DIN 931
M8 x 35 - 8.8
M8
8
13
hand tighten
hand tighten
-
M16
24
24
210 Nm
visual
-
72
-
5 Nm
5 Nm
M16
48
24
140 Nm
140 Nm
M12
24
19
86 Nm
86 Nm
M12
33
19
86 Nm
86 Nm
M10
M10
17
49 Nm
49 Nm
M10
M10
17
49 Nm
49 Nm
M10
M10
17
49 Nm
49 Nm
Nacelle crane rail mount
Re-use
Allowed
BTP nacelle
Ejot self-drilling screw
JT3 5.5 x 25
See Figure 14, Pos. 2)
(see Figure 14, Pos. 1)
(see Figure 14, Pos. 1)
(see Figure 14, Pos. 1)
screw, hex cap,
M16 x 60, hot dip zinc
screw, hex cap,
M12 x 1.75 x 65,
hot dip zinc
screw, hex cap,
M12 x 1.75 x 55,
hot dip zinc
screw, hex cap,
M10 x 1.5 x 60,
hot dip zinc
screw, hex cap,
M10 x 1.5 x 50,
hot dip zinc
screw, hex cap,
M10 x 1.5 x 30
(see Figure 14,
Pos. 3 and 4)
screw, hex cap,
M8 x 1.25 x 35
M8
M8
13
25 Nm
25 Nm
(see Figure 15,
Pos. 5 and 6)
screw, hex cap,
M6 x 1.0 x 30
M6
M6
10
hand tighten
hand tighten
-
M16
24
24
140 Nm
visual
Nacelle Crane Rail
Mount
See
note
below
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– Original –
Bolt Torque Specification
Re-use Allowed NOTE
A single re-use of these fasteners is approved if all of the following conditions are
met. If any condition is not met the hardware must be replaced.
A) Joint must not be loose and no more than 10 % of fasteners fail
maintenance torque check.
B) No indication of prior re-use (punch mark or paint). No cracks,
deformation (bending or stretching), and no
galling/deformation/damage on threads/washer.
C) Nut must be able to be run by hand over the threads
above/through/below the engaged area.
Required documentation: Entry made in turbine log and written message on joint
indicating re-use; if studs replaced at later time then line out. Stud ends are
colored in with paint pen and if studs are exposed to weather the end must
additionally be marked by hitting it with a punch to indicate re-use.
Break-In-Maintenance NOTE
For all fasteners for any connection that becomes loose or replaced due to
maintenance, repair & component upgrade, one must follow all Break-InMaintenance requirements listed in the Bolt Torque Specifications. Any
connection effected by such work should begin a new set of BIM intervals and be
recorded In the WTG log.
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GE Renewable Energy
– Original –
Bolt Torque Specification
3.2 Electrical Connections – Tightening Torque
3.2.1 Standard Connections - Electrical
Size
Grade
5.8
8.8
10.9
12.9
IN lbs
Ncm
IN lbs
Ncm
IN lbs
Ncm
IN lbs
Ncm
M1.6
1
11.3
1
11.3
1
11.3
2
22.6
M1.9
1
11.3
1
11.3
2
22.6
2
22.6
M2
1
11.3
2
22.6
3
33.9
4
45.2
M2.2
2
22.6
3
33.9
4
45.2
5
56.5
M2.5
2
22.6
4
45.2
6
67.8
8
90.4
M3
4
45.2
8
90.4
11
124.3
13
146.9
M3.5
7
79.1
12
135.6
17
192.1
20
226
M4
10
113
18
203.4
25
282.5
30
339
M5
20
226
35
395.4
50
564.9
59
666.6
Ft lbs
Nm
Ft lbs
Nm
Ft lbs
Nm
Ft lbs
Nm
M6
3
4.1
6
8.1
9
12.2
10
14
M7
6
8.1
10
14
14
19
17
23
M8
8
10.8
15
20.3
21
29
25
34
M10
17
23
29
39
41
56
50
68
M12
29
39
51
69
72
98
86
117
M16
-
--
126
170
185
250
-
-
Note: Torque values are for lubricated bolts.
3.2.2 Terminal Bolt Torque for Battery Connections (in Hub)
Tightening Torque
Battery Model
in-lbs
Nm
3EP & XE13
50
5.6
16EP & XE16
50
5.6
26EP & XE30
60
6.8
42EP & XE40
60
6.8
70EP & XE70
60
6.8
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GE Renewable Energy
– Original –
Bolt Torque Specification
3.2.3 Transformer Cable Terminals
Application
Bolted joints at the bus
Size
M12 or M16
Torque
35 Nm +/- 5 or
80 Nm +/- 10
Notes
Do not torque unless a major fault
was detected or the bolt was
loosened for another reason.
Tap link and line lead
connection
M12 or M16
35 Nm +/- 5 or
80 Nm +/- 10
Do not strip the threads in
the inserts that are cast in
the winding.
Core clamping hardware
M16
120 Nm +/- 20
Torque core through bolts and
external clamping bolts.
Bolting core and coil assembly M24 or M20 or M16
to the base
230 Nm +/- 30 or
180 Nm +/- 30 or
90 Nm +/- 10
Do not over-tighten. Do not overcompress the vibration pads. Do
not loosen or remove hardware
after installation.
Bolting the core clamp to the
transformer base
M24 or M20 or M16
Bolting the transformer base
to the enclosure base
M24 or M20
230 Nm +/- 30 or
180 Nm +/- 30 or
90 Nm +/- 10
230 Nm +/- 30 or
180 Nm +/- 30
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– Original –
Bolt Torque Specification
3.2.4 Permanent Magnet Generator (PMG) Cabinets
3.2.4.1 Converter Cable Terminals
Connection Name
Asm. Torque Value in-lb (Nm)
X1: L1, L2, L3 (line cable lugs)
X3: L1, L2, L3 (generator cable lugs)
40 lbf-ft (54 Nm) @ M12 nut side
(per UL486A-B; Table 24)
X1: L1, L2, L3 (internal cables)
168 in-lb (19 Nm) @ M10 nut side
LC: 1, 2, 3, 4, 5, 6 common mode reactor
168 in-lb (19 Nm) @ M10 nut side
LL: 1, 2, 3, 4, 5, 6 line reactor
168 in-lb (19 Nm) @ M10 nut side
SHA1_2_BUS, SHB1_2_BUS, SHC1_2_BUS
converter line bus
168 in-lb (19 Nm) @ M10 nut side
SHA2_2_BUS, SHB2_2_BUS, SHC2_2_BUS
converter generator bus
168 in-lb (19 Nm) @ M10 nut side
LG: 1, 2, 3, 4, 5, 6 generator reactor
168 in-lb (19 Nm) @ M10 nut side
FUA, FUB, FUC
generator fuse cable connections fuse connection at BUS
168 in-lb (19 Nm) @ M10 nut side
96 in-lb (11 Nm) @ M8 nut side
X3: L1, L2, L3 (internal cables)
168 in-lb (19 Nm) @ M10 nut side
E1, E2, E3, EGND 300 in
300 in-lb (34 Nm) @ ball stud
3.2.4.2 PDP Cable Terminals
Connection Name
Asm. Torque Value in-lb (Nm)
entry cable lugs
L1, L2, L3
55 lbf-ft (75 Nm) @ M16 nut side
(per UL486A-B; Table 24)
INTERNAL CONNECTIONS BUS & cable lug
420 in-lb (47 Nm) @ M12 nut side
504 in-lb (57 Nm) @ M12 bolt side
168 in-lb (19 Nm) @ M10 nut side
202 in-lb (23 Nm) M10 bolt side
FUA, FUB, FUC line fuse BUS connections
168 in-lb (19 Nm) @ M10 nut side
96 in-lb (11 Nm) @ M8 nut side
Thread 1,2,3,4; L1, L2, L3 line cable lugs
40 lbf-ft (54 Nm) @ M12 nut side
(per UL486A-B; Table 24)
43Q1, 33Q1 NH 1 fuse holder lug connections
168 in-lb (19 Nm) @ M10 nut side
CCFU1, CCFU2, 33Q2, 35F1,2,3
NH 0, 00 fuse holder lug connections
96 in-lb (11 Nm) @ M8 nut side
43Q1 distortion filter contactor
96 in-lb (11 Nm) @ M8 nut side
DFR1, 2, 3 distortion filter resistor
168 in-lb (19 Nm) @ M10 nut side
420 in-lb (47 Nm) @ M12 nut side
DFC distortion filter capacitor
180 in-lb (20 Nm) @ brass terminal stud
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Bolt_Torque_Specification_3MW_xxHz_EN_r11.docx
GE Renewable Energy
– Original –
Bolt Torque Specification
3.2.5 Doubly Fed Induction Generator (DFIG) Cabinets
3.2.5.1 Converter Cable Terminals
Connection Name
Asm. Torque Value in-lb (Nm)
X2: LA, LB, LC (MV Transformer cable lugs)
54 Nm (480 in-lb)
X2: RA, RB, RC (Rotor cable lugs)
54 Nm (480 in-lb)
X2: AUXA, AUXB, AUXC (Aux Transformer cable lugs)
54 Nm (480 in-lb)
PEN Connections (Gen Rotor, MV Transformer, Aux
Transformer, Converter Frame, Walking Platform)
54 Nm (480 in-lb)
AC Line Fuse Terminals (ACLFU1A-ACLFUC2)
47 Nm (420 in-lb)
Distortion Filter Fuse Terminals (DFFUA/DFFUB/DFFUC)
47 Nm (420 in-lb)
Auxiliary Feed Fuse Terminals (AUXFUA/AUXFUB/AUXFUC)
19 Nm (168 in-lb)
Distortion Filter Capacitor Terminals (DFC1/DFC2: 1-3)
17 Nm (150 in-lb)
3.2.5.2 Low Voltage Distribution Panel
Connection Name
Asm. Torque Value in-lb (Nm)
Ground Cables (XPE.2, XPE.3, XPE.6)
112 in-lb (16Nm) @M8 nut side
3.2.5.3 Stator Switch Cabinet
Connection Name
Asm. Torque Value in-lb (Nm)
Line Connections: (L1, L2, L3)
442 in-lb (50 Nm) @ M12 nut side
Load Connections: (L1, L2, L3)
442 in-lb (50 Nm) @ M12 nut side
3.2.5.4 Auxiliary Transformer
Connection Name
Asm. Torque Value in-lb (Nm)
Mechanical Mounting points
86 Nm
690VAC Connections (H1, H2, H3)
54.0 Nm
400VAC Connections (X1, X2, X3)
27.12 Nm
CONFIDENTIAL - Proprietary Information. DO NOT COPY without written consent from General Electric Company and/or its affiliates.
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GE Renewable Energy
– Original –
Bolt Torque Specification
3.3 Standard Connections – Mechanical
8.8
10.9
V4A
stainless steel AISI
316
12.9
HV – (10.9)
Nm
ft lbf
Nm
ft lbf
Nm
ft lbf
Nm
ft lbf
Nm
ft lbf
M5
6
4
9
6
10
7
--
--
--
--
M6
10
7
15
11
17
13
--
--
--
--
M8
25
18
36
27
41
30
--
--
--
--
M10
50
37
71
52
83
61
27
20
--
--
M12
87
64
124
91
145
107
50
37
100
74
M16
220
160
310
230
355
262
115
85
250
185
M20
420
310
600
440
690
509
--
--
450
332
M24
730
540
1030
760
1200
886
--
--
--
--
M27
1050
775
1500
1107
1800
1328
--
--
--
--
M30
1450
1070
2000
1476
2400
1771
--
--
--
--
M36
2450
1808
3450
2546
4150
3063
--
--
--
--
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Bolt_Torque_Specification_3MW_xxHz_EN_r11.docx
GE Renewable Energy
– Original –
Bolt Torque Specification
4 Tightening Torque Conversion Charts
1 Nm = 0.7376 ft lbf
1.356 Nm = 1 ft lbf
4.1 Tightening Torques Mentioned in Section 3
Nm
ft lbf
Nm
ft lbf
Nm
ft lbf
Nm
ft lbf
Nm
ft lbf
84
62
295
218
620
457
2500
1844
10000
7376
105
78
315
232
720
531
2800
2065
15000
11064
200
148
450
332
800
590
3300
2434
210
155
500
369
1000
738
4500
3319
215
159
550
406
1500
1106
6500
4794
5 Appendix(es)
Anchorbolt_Tensioning_ConcreteHybrid_G04 + G99:
https://plm-wind.energy.ge.com/windplm/common/emxNavigator.jsp?targetLocation=content&objectId=15488.20533.53176.5424
Anchorbolt_Tensioning_ConcreteHybrid_G05:
https://plm-wind.energy.ge.com/windplm/common/emxNavigator.jsp?targetLocation=content&objectId=15488.20533.60991.59783
Anchorbolt_Tensioning_ConcreteHybrid_G07:
https://plm-wind.energy.ge.com/windplm/common/emxNavigator.jsp?targetLocation=content&objectId=15488.20533.36294.4073
Anchorbolt_Tensioning_ConcreteHybrid_G98:
https://plm-wind.energy.ge.com/windplm/common/emxNavigator.jsp?targetLocation=content&objectId=15488.20533.53934.53108
Note: You may need to copy & paste link to address bar.
CONFIDENTIAL - Proprietary Information. DO NOT COPY without written consent from General Electric Company and/or its affiliates.
UNCONTROLLED when printed or transmitted electronically.
© 2018 General Electric Company and/or its affiliates. All rights reserved.
Bolt_Torque_Specification_3MW_xxHz_EN_r11.docx
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