Report Turbine inspection WTG 12801, Oudelandertocht 11

Transcription

1 Report Turbine inspection WTG 12801, Oudelandertocht 11 Report No. V

2 Contents 1 Purpose Abbreviations General information Wind turbine main components Documents Logbook: Overview of recent maintenance Logbook: Transformer Logbook: Notable events Tower and towerbase Yaw system Cabinets nacelle Nacelle Gearbox and main shaft Generator and coupling Hydraulic system nacelle Rotor Conclusion Date: Page 2 of 21

3 1 Purpose On behalf of Vattenfall an inspection has been executed on the wind turbine. The purpose of the inspection is to determine the technical state of the wind turbine. 2 Abbreviations ok nok na nav nc info okay not okay not applicable not available not checked for information purpose Items marked with ok and info show no visual irregularities. All issues which are not acceptable are marked with nok. Items which are nok will be classified in three different classes. Class Clarification Description in report Priority Low An irregularity, which is not a safety issue, and is relatively easy to solve. Low Priority High An irregularity, which is not a safety issue, and is more serious and is more time and/or money consuming to solve. High Safety Issue Issues which concern the safety of the people working in the turbine. Safe Date: Page 3 of 21

4 3 General information Wind turbine name: Oudelandertocht 11 Wind turbine type: V /300KW - 690/50 R7035 Wind turbine S/N: Location: Middenmeer Hub height: 78 Total production [kwh]: (according to display) Total hours: 2306 (according to display) Nominal power [kw]: 1650 Year of installation: 2002 Date of inspection: Inspectors: P. den Braber D. Lagerweij B. van de Braak J. Langenbach 4 Wind turbine main components Component Type Year Serial number Nacelle V /300KW - 690/50 R Gearbox Winergy PEAS Revision gearbox Gearbox oil Texaco Meropa Generator Weier GEN DASG 450W A Aux. Generator ABB M2CG 315MB 4 B Blade 1 Vestas 32B - not legible Blade 2 Vestas 32B Blade 3 Vestas 32B - not legible Date: Page 4 of 21

5 5 Documents Component Remark 1 Operator manual Operating manual is available at the turbine. Machine directive 2006/45/EC, states as part of the Contents of instructions: (e) the drawings, diagrams, descriptions and explanations necessary for the use, maintenance and repair of the machinery and for checking its correct functioning; ok 2 Wiring diagram Wiring diagrams are not available at the turbine. Machine directive 2006/45/EC, states as part of the Contents of instructions: (e) the drawings, diagrams, descriptions and explanations necessary for the use, maintenance and repair of the machinery and for checking its correct functioning; nok 3 Hydraulic diagram Hydraulic diagrams are not available at the turbine. Machine directive 2006/45/EC, states as part of the Contents of instructions: (e) the drawings, diagrams, descriptions and explanations necessary for the use, maintenance and repair of the machinery and for checking its correct functioning; nok 4 Maintenance manual Maintenance manual is not available at the turbine. Machine directive 2006/45/EC, states as part of the Contents of instructions: (e) the drawings, diagrams, descriptions and explanations necessary for the use, maintenance and repair of the machinery and for checking its correct functioning; nok 5 Logbook Logbook is available at the turbine. ok Date: Page 5 of 21

6 6 Logbook: Overview of recent maintenance Year Type of maintenance Date of execution Maintenance schedule Commissioning E- 36 month service ½ B - 6 month service G - 60 month service ½ B - 6 month service M 11 year service ½ B - 6 month service N 48 month service ½ B - 6 month service O 12 month service Logbook: Transformer Date Event Transformer inspection Transformer inspection Transformer inspection Transformer inspection and repair Transformer inspection Date: Page 6 of 21

7 8 Logbook: Notable events Date Event Replaced RCC Generator exchange Gearbox exchange Exchanged all capacitors of phase-compensation Exchanged plain bearings blade A, B and C Exchanged 6 capacitors of phase-compensation New torque-arm dampers Replaced RCC-processor Arc detection installed in busbar section Repair and maintenance rotor blades Replaced RCC-processor Exchanged DE-bearing, NDE-bearing generator and RCC replaced Date: Page 7 of 21

8 9 Tower and towerbase Item Remark 1 Outside Graffiti present on the outside of the tower. nok High 2 Inside Oil visible inside the tower and on the ladder. nok High 3 Towerbase HV-switch overview Info Date: Page 8 of 21

9 4 Towerbase cabinet overview Info 5 Miscellaneous Bolt at the beam of the cable suspension is not tightened correctly. nok Low 6 Oscillation damper One of the supports of the oscillation damper is almost broken. Info NOTE: This problem is reported to the owner immediately and the owner has assured TeSuCon that the problem has been solved that same week. Date: Page 9 of 21

10 10 Yaw system Item Remark 1 Yaw bearing overview ok 2 Yaw ring teeth Yaw ring shows no irregularities. ok 3 Yaw pinions Yaw pinions show no irregularities. ok 4 Yaw gears Yaw gear at the front is slightly polluted with oil (arrow). nok Low Date: Page 10 of 21

11 11 Cabinets nacelle Item Remark 1 Controller ok 2 Compensation Cabinet ok 3 Connection boxes ok Date: Page 11 of 21

12 12 Nacelle Item Remark 1 Nacelle overview Info 2 Frame Turbine is equipped with a welded frame. Info 3 Nacelle housing Parts of the insulation are missing or damaged. nok Low 4 Weather station Info Date: Page 12 of 21

13 13 Gearbox and main shaft Item 1 Main shaft bearings Remark Grease of the bearings is a bit dark and only magnetic at the rear bearing. The main shaft is quite dirty (arrow). nok High 2 Radiators The flexible hoses of the radiators are starting to wear. nok Low 3 Manifold Oil present under the manifold. nok High Date: Page 13 of 21

14 4 CCJ-unit A CCJ-filter system is present in the turbine. ok 5 Gear oil system Leakage under the electrical oil pump. nok High 6 Hoses and pipes ok 7 Torque-arms Torque-arm system has been modified. Info 8 Paint / Corrosion ok 9 Brake-system overview Info Date: Page 14 of 21

15 14 Generator and coupling Item Remark 1 Coupling The composite parts of the coupling are in an acceptable condition. The bolts and washer of the connections are a bit corroded. ok 2 Aux. Generator Aux. generator is not connected to the gearbox. Info 3 Paint / Corrosion ok 4 RCC The RCC shows no visual irregularities. Info Date: Page 15 of 21

16 15 Hydraulic system nacelle Item Remark 1 Overview Info 2 Hoses ok 3 Leakage ok 4 Corrosion ok 16 Rotor Item Remark 1 Overview Info 2 Paint / Corrosion ok 3 Connection spinner Connection has not been reinforced. No cracks detected in the tubes. Info Date: Page 16 of 21

17 4 Hub cabinet overview Info 5 Connections cylinder to the blade The clearance of the link bearings of pitch cylinders A, B and C are 0,23 [mm], 0,23 [mm] and 0,28 [mm]. This is acceptable according to the Vestas Manual. ok Date: Page 17 of 21

18 6 Connections cylinder to the hub The clearance of the slide bearings of pitch cylinders A, B and C are 1,12 [mm], 0,91 [mm] and 1,18 [mm]. The clearances of A and C are not acceptable according to the Vestas Manual. nok High 7 Hydraulics inside the hub Several hoses in the hub are covered with oil and the inside of the main shaft is dirty. nok High 8 Hydraulics outside the hub ok Date: Page 18 of 21

19 9 Blade bearings Minor pollution with grease from the blade bearings. nok Low 10 Blade covers Three of the blade covers are defect. nok High Date: Page 19 of 21

20 11 Blades overview Green pollution visible on the surface of the blades. The protective tape at the leading edge of the blades is also damaged (arrow). nok High Date: Page 20 of 21

21 17 Conclusion The logbook shows that the turbine and the transformer have been maintained on a regular basis, according to the maintenance schedule of Vestas. The gearbox has been exchanged in 2011 and the generator in The RCC and the generator bearings have been replaced in Despite the blade maintenance/repair in 2015, there is loose tape visible at the tip of the blades. The overall condition of the turbine is quite acceptable for a thirteen year old turbine. There are however several issues (marked as nok in this report) present and it is recommended to solve these, in order to improve the condition of the turbine. D. Lagerweij TeSuCon B.V. Mercuriusweg NC Barneveld dl@tesucon.nl Date: Page 21 of 21

22 Report Gearbox inspection WTG 12801, Oudelandertocht 11 Report no. V

23 Contents 1. Purpose General Information Reporting setup Inspection results Summary Conclusion Gearbox inspection Oudelandertocht 11 WTG Date: Page 2 of 17

24 1. Purpose On behalf of Vattenfall an inspection has been executed on the wind turbine gearbox. The purpose of the inspection is to determine the technical state of the gearbox. The visual inspection of the gearbox has been executed with a GE Everest XLG3 Videoscoop. 2. General Information Turbine Information Wind turbine name: Oudelandertocht 11 Wind turbine type: V /300KW - 690/50 R7035 Wind turbine serial no: Location: Middenmeer Hub height: 78 Total production [kwh]: Total hours: 2306 Nominal power [kw]: 1650 Year of installation: 2002 Date of inspection: Inspectors: P. den Braber D. Lagerweij B. van de Braak J. Langenbach Gearbox Information Gearbox type: Winergy PEAS 4395 i = 78,659 Gearbox serial number: Production year gearbox: 2010 Revision: - Revision number: - Oil type: Texaco Meropa 320 Date of last oil change: Gearbox exchange date Gearbox has been exchanged on Gearbox inspection Oudelandertocht 11 WTG Date: Page 3 of 17

25 3. Reporting setup The next drawing shows a cross-section of a planetary gearbox with two linear stages with corresponding bearing positions. The drawing should be used as a reference for the bearing position only. Gearbox inspection Oudelandertocht 11 WTG Date: Page 4 of 17

26 4. Inspection results Picture 1 Picture 1 shows bearing position no. 1, the bearing of the planet carrier at rotor side. No irregularities. Picture 2 Picture 2 shows the bearing of the first planet wheel. No irregularities. Gearbox inspection Oudelandertocht 11 WTG Date: Page 5 of 17

27 Picture 3 Picture 3 shows the bearing of the second planet wheel. No irregularities. Picture 4 Picture 4 shows the bearing of the third planet wheel. No irregularities. Gearbox inspection Oudelandertocht 11 WTG Date: Page 6 of 17

28 Picture 5 Picture 5 shows bearing position no. 5, the bearing of the planet carrier at generator side. The bearing shows no irregularities. Picture 6 Picture 6 shows bearing position no. 6, the bearing of the low speed shaft at rotor side. The bearing shows no irregularities. Gearbox inspection Oudelandertocht 11 WTG Date: Page 7 of 17

29 Picture 7 Picture 7 shows bearing position no. 7, the bearing of the low speed shaft at generator side. The bearing shows no irregularities. Picture 8 Picture 8 shows bearing position no. 8, the bearing of the intermediate shaft at rotor side. The bearing shows no irregularities. Gearbox inspection Oudelandertocht 11 WTG Date: Page 8 of 17

30 Picture 9 Picture 9 shows bearing position no. 9, the bearing of the intermediate shaft at generator side. The bearing shows no irregularities. Picture 10 Picture 10 shows bearing position no. 10, the bearing of the high speed shaft at rotor side. The bearing shows no irregularities. Gearbox inspection Oudelandertocht 11 WTG Date: Page 9 of 17

31 Picture 11 Picture 11 shows bearing position no. 11, the bearing of the high speed shaft at generator side. The bearing shows no irregularities. Picture 12 Picture 12 shows bearing position no. 12, the bearing of the auxiliary high speed shaft at rotor side. The bearing shows no irregularities. Gearbox inspection Oudelandertocht 11 WTG Date: Page 10 of 17

32 Picture 13 Picture 13 shows bearing position no. 13, the bearing of the auxiliary high speed shaft at generator side. The bearing shows no irregularities. Picture 14 Picture 14 shows the active flank of the ring gear. No irregularities. Gearbox inspection Oudelandertocht 11 WTG Date: Page 11 of 17

33 Picture 15 Picture 15 shows one of the planet wheels. None of the planet wheels show irregularities. Picture 16 Picture 16 shows the active flanks of the sun pinion. No irregularities. Gearbox inspection Oudelandertocht 11 WTG Date: Page 12 of 17

34 Picture 17 Picture 17 shows the active flanks of the wheel of the low speed shaft in the linear stage. No irregularities. Picture 18 Picture 18 shows the active flanks of the pinion of the intermediate shaft in the linear stage. No irregularities. Gearbox inspection Oudelandertocht 11 WTG Date: Page 13 of 17

35 Picture 19 Picture 19 shows the active flanks of the wheel of the intermediate shaft in the linear stage. No irregularities. Picture 20 Picture 20 shows the active flanks of the pinion of the high speed shaft in the linear stage. No irregularities. Gearbox inspection Oudelandertocht 11 WTG Date: Page 14 of 17

36 Picture 21 Picture 21 shows the active flanks of the wheel of the high speed shaft in the linear stage. No irregularities. Picture 22 Picture 22 shows the active flanks of the wheel of the auxiliary high speed shaft in the linear stage. No irregularities. Gearbox inspection Oudelandertocht 11 WTG Date: Page 15 of 17

37 Picture 23 shows the oil level of the gearbox. Picture 23 Picture 24 Picture 24 shows the magnet of the gearbox. No steel particles are visible on the magnet. Gearbox inspection Oudelandertocht 11 WTG Date: Page 16 of 17

38 5. Summary The visual inspection of the gearbox shows no signs of severe pitting, major damages or extreme wear. There are no steel particles found on the magnet. 6. Conclusion The gearbox is in an acceptable condition. Dennis Lagerweij Barneveld, TeSuCon B.V. Mercuriusweg NC Barneveld The Netherlands Tel dl@tesucon.nl Web Gearbox inspection Oudelandertocht 11 WTG Date: Page 17 of 17