IT MAN PRV 02 (IT Manutenção Preventiva SA) Complementação

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Título do documento: Instrução de Trabalho 
 
IT-MAT-PRV-002 
Manutenção Preventiva Semi-Anual (SA) - 
Complementação (Manutenção LOW WIND) 
Revisão: 0A
 
Folha 1 de 5
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Controle de Revisão 
Revisão Data Item Descrição das Alterações 
0A 22/03/2013 Elaboração da Instrução Operativa - IT-MAN-PRV-002 
 
 
 
 
 
 
 
 
 
 
 
 
Distribuição de Cópias: Núcleo de O&M - BioEnergy 
Redigido por: 
Eng° Waldemar A. Rezende 
Visto: 
Verificado por: 
Eng° Helber Oliveira 
Visto: 
Aprovado por: 
Eng° Waldemar A. Rezende 
Visto: Data: 22/03/2013 
GE Proprietary And Confidential, No Re-Production Without Written Permission
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Check parameter page 22 (“enable error”) and ensure that all error 
messages are enabled.
3.8.1 1.6-100 - Platform A
Visual Inspection: Fastening, damaged insulation, cable basket, cable 
spacers, rubber mat, and cable guides.
3.9 Cable Twist Switch
Visual Inspection: Damage, dirt, debris, secure attachment of switch, 
cable, and weight. 
GE 1.X MW WTG 
Low Wind Split Scope 
Maintenance Checklist
This is a supplement to the Revision 17 maintenance manual 
1.xSerie_xxHz_OM_allComp_Maintenancex.ENxxx.17, applicable TIL's, 
ETCs, or WDIs. All personnel performing maintenance activities must 
understand the contents of the maintenance manual and have access 
to a copy.
Site Name: WTG Number: Date:
Press the E-Stop on the Cabinet Door and Verify on Visupro
Function test. Ensure PLC and PC operate for at least five minutes 
after power is turned off.
Cycles:Record value of parameter 26.1 (“No. of switching operations of the circuit breaker”) 
Maintenance: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 Other: WTG COD Date:
Rev. 17 40811 SR#:
2.2.5 UPS
Energize the turbine and place in "Stop" mode. Then Press the "E-
stop" located on the front of the cabinet door and verify fault 
condition.
Carry out a visual check of the nacelle. In doing so, check for 
tightness and cracks. In addition, check for defective lamps and 
sockets and check for missing or loose bolted connections.
Function Test: Yaw twist value to nacelle twist, verify 0 twist of 
nacelle corresponds with PLC value, and nacelle rotations accuratly 
corresponds to PLC values.
Visual Inspection: Look for cracks and detached pieces. Reattach 
detached pieces with spray adhesive. 
2.2.4 Turbine PC
Task Description and additional information
Task Performed & No 
defects found?
Notes, Comments, or Explanations
Low Wind Maintenance Checklist
Color of paint pen used for torque checks This maintenance cycle____________________ Last maintenance cycle_____________________
Function test UPS. Ensure PLC and PC operate for at least five 
minuets after power is turned off.
2.2 Non-ESS
2.1.5 Main Control Cabinet
2.1 ESS 
2. Down Tower Assembly
2.1.4 Turbine Control
2.1.3 Cabinet Ventilation System
Function test that the fan is working correctly and is free of 
obstruction. (Switch fan on and off)
Function Test: The wind vane and anemometer for proper function of 
the sensors and the proper operation of the heating elements
3.8 Yaw Deck
Function Test: The cable twist switch.
Check attachment: nacelle to the base frame, safey rails/attachment 
points, and weather station, obstruction light (optional), grounding 
straps and ventilation for security.
4. Machine Head
4.1 Nacelle
Visual Inspection: Ensure the overall Nacelle is clean and free of all 
foreign debris such as old parts, dirt, grease, oil, trash, etc.
4.3 Meterological Mast
GE Proprietary And Confidential, No Re-Production Without Written Permission
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18
IF APPLICABLE
19
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Function Test Non-ESS: Change the parameter then idle the turbine, 
verify the WTG results are correct due to the altering the IFM 
parameters. 
4.11.4 T2A Auxiliary Transformer (If Equipped)
Visual Inspection: Dirt, debris, cable connections, and the 
transformer mount bolts.
4.12.1.1 Yaw System Mounting Bolts (If Equipped)
Tool#__________
4.7 Bedplate and Generator Frame
4.12 Yaw System
No
Generator mount-to-Bedplate
Lubricate as required, only if yaw system is noisy or vibrates. 
Function Test Emergency Stop: Press E-Stop button and verify error 
message on status log for each button.
10% Torque Check
Function Test: Check operation of the light as configured.
Yes
Measure Puck Wear NOTE: Use outer-most non threaded hole. Snap 
ring may need to be moved to access correct hole. In the Table Below "Reference Measurement for Yaw Brake Pads" the 1st row is to be populated with data from Break-In maintenance, or 
the oldest date the measurements were taken. The 2nd row is to be 
populated with current cycle measurements.
Function Test Rotor Lock Switch: Check by pushing lock until switch 
actuates. Verify operation on status log.
Tool #____
4.5 Obstruction Light/Aviation Lights (if equipped)
Visual Inspection: Loose or missing hardware, damage to lenses, and 
cleanliness. Clean lenses.
4.11.3 IFM/Rotational Over Speed Sensor
M36 bolts = 2800Nm
Funtion Test Twist Switch: Verify proper operation of the cable twist 
switch.
Function Test Over Speed Monitor: Check signal indication from 
proximity sensor to top box
Measured Value of 
Maintenance 3 pistons 
(2nd Column)
Function Test ESS: Verify connection on WETA board.
Function Test Vibration Switch: Check by pushing pendulum to either 
side to actuate switch inside. Verify operation on status log.
Check 10% of the yaw friction system mounting bolts. Refer to the 
bolt toque specification document for guidance. 
YAW BRAKE TENSIONING TO BE COMPLETED WITH WINDS AT LESS THAN 15m/s 10 MINUTE AVERAGE
4.12.1 Yaw Friction System
4.11 Top Box
Value of Reference 
Measurement 
(1st Column)
4.11.5 Safety Chain
Piston No.
Tool#__________
Brake pre-tensioning 100%: Bronze piston = 100Nm + 300o 
GE Proprietary And Confidential, No Re-Production Without Written Permission
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4.12.4 Gear Ring and Driving Pinion
10% Torque Check 
Tool#__________
M20 10.9 screws = 580Nm
Function Test: Check that the sensors read the correct direction of 
yaw.
Visual Inspection: Check Proper attachment, and cleanliness.
Silver Bolts = 2800Nm
Yaw Bearing-to-Top Tower Flange
Yes
4.13 Drive Train
4.13.2 Main Bearing
Yaw Drive-to-Bedplate
Black Bolts = 2800 Nm Perform 100% if not marked +60 
Tool#__________
4.13.1 Connection of Rotor Shaft / Hub
Check Bolted connection of rotor shaft/hub 
Tool#__________
Manual Lubrication: The yaw bearing is lubricated with a centralized 
unit, or distribute the grease evenly thourgh the multiple grease 
buttons. Check current Lubrication List for proper grease.
No
Lubrication: Grease main bearing according to current Lubrication 
list. Note: cold weather applications are different.
Function Test: With the sensors properly adjusted to 5mm, pass a 
steel ruler through each sensor, verify value measured changed.
4.12.4 Position Sensor
10% Torque Check
4.13.3 MainShaft Flange Sensor (ALC) (If Equipped)
M39 = 3500Nm Tool#__________
No
Main Bearing-to-Bedplate
4.13.4 Rotor Position Reset Sensor (If Equipped)
Visual Inspection: Sensors and windings for proper fastening, tight 
electric connections, cable bundles secured, proper sensor 
adjustment.
Visual Inspection: Sensors and windings for proper fastening, tight 
electric connections, and cable bundles secured.
No
4.12.2 Yaw Drive
Function Test: Operate and listen for any unusual noise.
Check oil level. Add oil as needed.
10% torque check 
Function Test: Auto greaser operation, lines for blockage or damage.
Clean excess grease from bearing seal, innner tower wall, and outer 
tower wall. 
Visual inspection: Corrosion, cracks, gap between flanges, integrity of 
the bearing.
4.12.5 Yaw Position Reset Sensor (If Equipped)
Visual Inspection: Check Proper attachment of sensors and brakets, 
proper gap of sensor and cleanliness.
Clean any foreign debris from the grease prior to reappling grease to 
the gear teeth.
1850Nm
Yes
4.12.3 Yaw Bearing
No
Empty grease collecting container.
Visual Inspection: Look for corrosion, damaged coating and unusual 
wear. 
Yes
Visual Inspection: Check for leakage, cleanliness, correct attachment, 
damage, movement of previouly torqued bolts.
Lubrication: Refill automatic greasing device (if installed) OR apply a 
thin coat of grease to the gear ring and driving pinion. Refer to 
Lubrication List for proper grease.
10% Torque Check Yes
M20 12.9 screws = 690Nm
GE Proprietary And Confidential, No Re-Production Without Written Permission
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4.18 Generator to Gearbox Coupling
Visual inspection General condition, damage, leakage, cracks, 
defective disks, rust between the steel disks, and bolt corrosion,
Function Test: The resistance of current from the generator flange to 
gearbox flange.
Perform generator laser alignment reference. 
1.5Serie_xxHz_WDI_generato_GenAlignment.ENxxx.00.doc Tool#__________
4.18.1 Coupling Alignment
10% Torque Check
Visual Inspection Brake Disk: Check for even wear, cracks, disk is able 
to free wheel without touching the brake pads, and pads are parallel 
with disk.
4.14 Gearbox
4.13.6 Rotor Lock, Low-Speed Shaft
4.15 Slipring
Funtion Test: For proper function of the rotor locking device.
Visual Inspection: Look for corrosion, cracks, leakage, and loose or 
missing hardware.
Lubricate the slipring at 3-6-9-12 o'clock positions at a distance of 
150mm.
Replace desiccant air filter if 75% or greater color change has 
occurred. Date new filter with paint pen.
Change oil filter 3 times the first year and annualy afterwards
Take oil sample. Reference 
1.5series_WDI_gearbox_OilSampleHyd.Enxx.00 Oil changes are 
dependent on oil sample results.
4.16.2 Brake Disk and High Speed Rotor Lock
4.16.3.1 Brake Caliper Mount
Yes No
Rotor Lock-to-Gearbox
Visual Inspection: Look for cracks, signs of wear, and loose or missing 
parts.
M24 = 670Nm
Clean the slipring with lint free thread, solvent and a brush.
Visual Inspection: For build up on brushes, loose or missing 
hardware, electrical connections, overheating, spark marks, tight 
connections, and damaged insulation.
4.15.1 Dietrich Slipring (If Equipped)
4.15.2 Stemman Slipring (If Equipped)
Visual Inspection: For build up on brushes, loose or missing 
hardware, electrical connections, overheating, spark marks, tight 
connections, and damaged insulation.
Lubricate the slipring with the appropriate lubricant.
Change oil filter, DO NOT over tighten the filter-housing cap. This will 
cause irreparable damage.
Visual Inspection: Condition of straps, secure attachment, damage, 
electrical connections, and overall condition.
4.15.3 UEA Slipring (If Equipped)
4.14.7 Oil Heater Hose/Pump Type (If Equipped)
4.14.3 Gearbox Desiccant/Ventilation Filter
4.14.5 Gearbox Oil Filter
Visual Inspection: For build up on brushes, loose or missing 
hardware, electrical connections, overheating, spark marks, tight 
connections, brush seating , and damaged insulation.
Function Test: Check operability of the locking device, hand crank 
and release button.
4.16 Secondary Brake System
Tool#__________
Function Test: Measure and record brush lengths.
4.15.4 Mersen Slipring (If Equipped)
Lubricate the slipring with the appropriate lubricant.
Tool#__________
10% Torque Check: Brake-to-Gearbox Refer to WDI “bolts’ for 
correct torque. 
GENERATOR ALIGNMENT TO BE COMPLETED WITH WINDS AT LESS THAN 10m/s 10 MINUTE AVERAGE
GE Proprietary And Confidential, No Re-Production Without Written Permission
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5. Hub
5.5.1 Motor Brushes
Visual Inspection: Look for corrosion, cleanliness, attachment and 
loose or missing hardware. 
Inspect the connection of the pitch bracket to the body of the hub for 
cracks or other damage. Note any defects
Yes No
5.5 Pitch Drive and Motors
Clean blade seals. 
Measure the carbon brushes on accordance with the manual. 
Record the measurements in the “Maintenance Inspection Proof.”
Check bolted connections of: Nose cone, Hub steps, and Railings. 
NOTE: a re-torque is required on all connections where a positive 
identification of torque marks can not be made. Best practice to 
touch-up all existing torque marks! 
Visual Inspection Exterior: Look for corrosion, coating damage, and 
general condition.
All MAINTENANCE ON HUB TO BE COMPLETED IN WINDS LESS THAN 15m/s 10 MINUTE AVERAGE, ONCE WORK IS STARTED CEASE IF 10 
MINUTE AVERAGE IS ABOVE 15m/s OR A GUST OCCURS AT OR GREATER THAN 20m/s FOR 3 SECONDS. WORK CAN CONTINUE LATER IF 
DESIRABLE CONDITIONS RETURN
5.1 Nose Cone General Condition
4.19 Generator
Visual Inspection Cable Connections: Arcing, spark marks, over 
heating, dirt or debris, tight connections, cable spacing, and 
excessive cable bend radius.
Greasing: Refer to current Lubrication list for specific type and 
quantity of grease to use. Grease each pitch bearing.
5.3 Hub General Condition
Function Test: Hub hatch
Check bolted connection of rain shields if equipped.
Greasing: See Generator Nameplate for amount of grease to be
used in NDE/DE, use current Lubrication List for type. For Hitachi
units loosen grease trap plug.
10% Torque Check
Visual Inspection: Connection, torque marks, seals, grease leaks, 
lubrication lines, and corrosion.
Clean drives and mounts.
Tool#__________
Visual Inspection: Look for cracks, corrosion, dirt, loose parts, flaking 
paint, lights and grease.
Pitch Bearing-to-Hub
Check oil level of pitch drive. With sight glass verify proper oil level, 
add oil as needed. (rotate hub & repeat for each axis). Without sight 
glass visually inspect drives for signs of leakage. Report leaks to 
manager immediately.
5.2.2 Access to the Hub (1.6-100)
Visual Inspection: Steps, hingers, door gasket, and manhole cover 
tether.
Function Test: Hub hatch
Tool#__________
10% Torque Check: Damper-to-Base Frame 450 Nm 
Visual Inspection: Look for corrosion, cracks, abrasion, and wear of 
dampers.
4.19.3 Generator to Sound Damper Insulation
Visual Inspection: Look for corrosion, loose or missing hardware, 
cracks, and hatch condition.
5.2.1 Acess to the Hub (non 1.6-100)
Visual Inspection: Look for cracks, corrosion, connection of railing, 
attachment to hub, vent tub, seals, and loose or missing hardware.
Tool#__________5.1.1 Rain Shield (If Equipped)
4.19.2 Generator to Bedplate Attachment
100% Torque Check: Generator-to-Bedplate mounting bolts . Tool#__________
Tool#__________
5.4 Blade/Pitch Bearing
4.19.1 Generator Bearings
Torque Check: The tie off points inside the hub.
GE Proprietary And Confidential, No Re-Production Without Written Permission
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Sect. Notes Section: All tasks where the NO block is marked require a comment
Ensure sites are maintaining and updating a Master Punch list with 
SR #'s in accordance to GW-WFO-012
5.9 Battery System
Ensure all maintenance documentation is properly filled out and has 
been signed by appropriate personnel.
5.10.2 Rotor Blade Pitch Bearing
Ensure all labor hours are recorded in E-Services
5.7.1 Position Sensor at 0° and 90° (non 1.6-100)
Greasing: Apply a thin coat of grease to the pinion and gear teeth on 
bearing. Concentrate on the mesh between -2 degrees to 95, the rest 
is only for protection from corrosion. 
Ensure all maintenance documentation and records are properly 
stored in accordance to GW-WFO-012 Routine/Planned Maintenance 
Procedure.
Ensure all calibrated tools are recorded with cal dates
5.10 Blades
Visual Inspection: Condition of cabinet, loose or missing hardware, 
corrosion, spark marks, and battery terminal conditions.
Ensure all Parts are recorded into E-Services
The rotor blade maintenance is not a constituent of the standard
maintenance by GE Energy. Refer to site contract for specific rotor blade maintenance requirements. 
Function Test: Check the function and range of the 0 and 90 degree 
limit switches using manual operation.
Visual Inspection: Look for corrosion, unusual wear, and gear teeth 
pattern. 
5.8 Hub Cabinets
Visual Inspection: Look for corrosion or unusual damage between 
the rotor blade, the pitch bearing, and the hub.
Visual Inspection: Look for damage, attachment, proper location and 
cleanliness.
Function Test: Complete a battery test.
Records and Reports (Completed by Site Lead or Site Manager)
5.6 Gear Ring and Drive Pinion
Visual Inspection: Attachment of components, attachment of 
cabinets, attachment of doors, cable clamping, and secure 
attachment of terminals and wires.
Tool#__________Visual: Check all mounting hardware, torque if required. 
Function Test:: Check secure attachment of all doors and panels.
Report any obvious defects. 
Maintenance scheduled and performed in accordance to GW-
WFO-012 Planned/Routine Maintenance Procedure
5.7 Pitch Position Sensor
5.7.2 Position Sensor at -8°, 89° and 94° (1.6-100)
Visual Inspection: Look for damage, attachment, proper location and 
cleanliness.
Function Test: Check the function and range of the -8, 89 and 94 
degree limit switches using manual operation.
Ensure site is updating maintenance status daily in eMSR
Maintenance performed in accordance to revision 17 maintenance 
manual. 
Automatic Greasing Device (If Equipped): Refill auto greaser reservoir, 
replace batteries, check for proper operation, check lines for 
blockage, or damage.
GE Proprietary And Confidential, No Re-Production Without Written Permission
Sect.
Tool #
1
2
3
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11
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17
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20
I hereby confirm the correct 
performance of the maintenance in 
accordance with the checklist, manual, 
and all applicable GE Work 
Instructions.
Site Manager or Site Lead Name Date Site Manager or Site Lead Signature
Maintenance 100% Complete On: Total Man Hours:
Personnel
Date Name Date Name
Hydralic Guage
Torque wrench
Torque wrench
Torque wrench
Notes Section: All tasks where the NO block is marked require a comment
Tool Model Serial Number Calibration Due Date
Megohmmeter
WTG Start Time Tasks Completed
 Maintenance Information
Date WTG Stop Time
Hydralic Head
Hydralic Head
Hydralic Head
Hydralic Head
Multimeter
List of Tools, Serial Numbers, & Calibration Dates
Multimeter
Slide Caliper
Slide Caliper