IT MAN PRV 03 (IT Manutenção Preventiva A) Complementação

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Título do documento: Instrução de Trabalho 
 
IT-MAT-PRV-003 
Manutenção Preventiva Anual (A) - 
Complementação (Manutenção HIGH WIND) 
Revisão: 0A
 
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Revisão Data Item Descrição das Alterações 
0A 22/03/2013 Elaboração da Instrução Operativa - IT-MAN-PRV-003 
 
 
 
 
 
 
 
 
 
 
 
 
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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GE 1.X MW WTG 
High 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:
Task Description and additional information
Task Performed & No 
defects found? Notes, Comments, or Explanations
High Wind Maintenance Checklist
Color of paint pen used for torque checks This maintenance cycle____________________ Last maintenance cycle_____________________
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 050112 SR#:
3. Tower
3.1 Platforms and Hatches 
Visual Inspection: Look for corrosion, damage, correct attachment, 
and hatches for condition.
Visual Inspection: Fall protection anchor points, bolted connections, 
guard rails, and platform hatches
10% Torque Check (2nd tower flange/s)
Yes No
Tool#
M36 bolts = 2800 Nm
M42 bolts = 4500 Nm
3.3 Flange Bolts
Visual Inspection: Tower bolts for corrosion and damage.
10% Torque Check (1st tower flange)
Yes No
Tool#
M36 bolts = 2800 Nm
M42 bolts = 4500 Nm
Ensure cleanliness
Function Test: Proper operation of all hatches.
3.2 Tower Flanges
Visual Inspection: Flange for damage, corrosion, gap, cracks, and 
flange grounding.
3.7 Power Cable Loop
Visual Inspection: The cable bundle has not exceeded more the 3 
turns in either direction, and fiberglass protective wrap. 
3.5 Bus Bar System
Visual Inspection: of the insulation for cleanliness, defects, arcing, 
arcing residue, and excessive heat. 
3.6 Power and Control Cables
Visual Inspection: Cable tray attachment, wire splices, guides, 
clamps, thermal damage and insulation damage.
M36 bolts = 2800 Nm
3.4 Tower Wall
Visual Inspection: corrosion, paint chipping, cracks, welds, tower 
lighting, oil catch basin, and proper safey signage. 
Function Test: Turbine lighting and GFCI sockets.
10% Torque Check (3rd "100m" tower flange/s)
Yes No
Tool#
Visual Inspection: Seams, spacing, condition, damage, and security 
of ladder.
3.12 Ladder Brackets (Ladder to Tower Wall)
Visual Inspection: Bolt movement, connection, proper condition of 
ladder and brakets.
3.13 Nacelle Access Ladder (Yaw Deck to Nacelle)
3.10 Ladder System
Visual Inspection: Look for unusual or unexpected wear present, 
cracks, correct alignment, and safety lables. 
3.11 Ladder Uprights/Rails and Rungs
Visual Inspection: Damage, polyethylene ladder feet, and ladder 
hooks.
3.14 Fall Protection
GE Proprietary And Confidential, No Re-Production Without Written Permission
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4.9 Generator Shear Plate (If Equipped)
Visual Inspection: For signs of friction, movement, paint chips, loose 
hardware
Torque check: The bolted connections of the hardware.
4.10 Tread of the Steps and Gratings
3.14.1 Cable Fall Arrest System
Visual Inspection: Bird caging, kinks, wear, defects, proper tension. 
Cable anchor attachment, condition, and shock absorber. Cable 
stays wear, attachment, and location.
4.6 Port-to-Starboard Mounting Hardware
4.4 Nacelle Enclosure Fastener
Verify the operation of the fasteners.
Maintenance Task: Torque Hardware, complete any recommended 
hoist manufacturer tasks. 
4. Machine Head
3.14.2 Rail Fall Arrest System
Visual Inspection: Gaps, corrosion, wear, defects, rail anchors, proper 
attachment to ladder and anchors. 
3.9.5 Cable Winch / Chain Hoist
Visual Inspection: Damage, condition, lubrication, and mounting.
4.8 Generator Support Frame
Visual inspect all weld locations. See manual for illustration.
10% torque check of the nacelle port to starboard mounting 
hardware.
4.7 Bedplate and Generator Frame
Visual Inspection: Look for cracks, corrosion, and other damage to 
the base frame.
Visual Inspection: look at welds and generator mount for cracks 
corrosion and or damage.
Visual Inspection: Check hardware for tight connection, cleanliness 
Clean all steps and treads. Note any corrosion or defects.
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.
10% Torque Check
2800Nm
4.12.3 Yaw Bearing
Yaw Bearing-to-Bedplate
Yes No
Tool#__________
4.11 Top Box
Visual Inspection Exterior: Damage, excessive wear, corrosion, door 
locks and bolts, and control elements.
Visual Inspection Interior: Overheating, spark marks, thermostat 
settings, cables and cable connection condition, dirt, and door filter 
assemblies. 
4.11.1 Cabinet Electrical Connections
Visual Inspection: Electical connections to the hub, yaw, brake, 
generator, sensors, and all other wiring connections.
4.11.2 Cabinet Doors
Function Test: The doors open, close, and seal properly.
Automatic Greasing Device (If Equipped): Refill auto greaser 
reservoir, check for proper operation, check lines for blockage, or 
damage.
4.12.4 Position Sensor
Visual Inspection: Check Proper attachment, and cleanliness.
Function Test: Check that the sensors read the correct direction of 
yaw.
GE Proprietary And Confidential, No Re-Production Without Written Permission
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4.12.4 Gear Ring and Driving Pinion
4.13 Drive Train
Clean any foreign debris from the grease prior to reappling grease to 
the gear teeth.
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.
Function Test: Auto greaser operation, lines for blockage or damage.
4.13.5 Shrink Disk
Lubrication: Grease main bearing according to current Lubrication 
list. Note: cold weather applications are different.
Automatic Greasing Device (If Equipped): Refill auto greaser 
reservoir, check for proper operation, check lines for blockage, or 
damage.
4.13.2 Main Bearing
Visual Inspection Look for cracks, corrosion, loose, missing hardware, 
and lighting protection system
Function Test: Listen for noise from bearing as rotor turns, and if 
equipped with the lighting protection system, check brush springs 
and holders. 
Empty grease collecting container.
4.12.5 Yaw Position Reset Sensor (If Equipped)
Visual Inspection:Check Proper attachment of sensors and brakets, 
proper gap of sensor and cleanliness.
Visual Inspection: Inspect overall condition.
If Equipped: Ensure the Groove nut has not moved and is secure. 
Consult Engineering if movement has occurred.
4.13.2.1 Main Bearing Groove Nuts
4.14 Gearbox
4.14.1 Bolted Connection of Gearbox – Base Frame
Visual Inspection: Look for corrosion, and movement of previously 
torqued bolts.
10% of the bolts
M30 bolts = 1700 Nm
Shrink Disc
Yes No
Tool#__________
Visual Inspection: Look for leakage, corrosion, abrasion on hoses, 
loose or missing hardware, ground connections, and flaked-off paint. 
Check oil level in accordance with the current procedure.
Open gearbox inspection port at high-speed stage and inspect for 
damage to the gear teeth and roller bearings.
Look at pedestal bearing for elongation, unusual wear, and bolted 
connections.
4.14.3 Gearbox Desiccant/Ventilation Filter
Replace desiccant air filter if 75% or greater color change has 
occurred. Date new filter with paint pen.
4.14.4 Gearbox Operating Condition
10% Torque Check
M36 = 2800Nm
4.14.2 Gearbox Sound Isolation
Visual Inspection: Look for cracks, corrosion, axial displacement, 
abrasion, correct grounding, and cleanliness.
Main Gearbox Support
Yes No
Tool#__________
4.14.6 Oil Cooler
Visual Inspection: Look for leakage, attachment, and condition of oil 
hoses
Clean heat exchanger and fan.
Acoustic Test: Rotate gearbox and listen for excessive noise. Note 
any defects.
4.14.5 Gearbox Oil Filter
Change oil filter, DO NOT over tighten the filter-housing cap. This will 
cause irreparable damage. Change oil filter 3 times the first year and annualy afterwards
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4.16 Secondary Brake System
4.16.1 Brake Pads
Visual Inspection: Look for worn pads and broken or missing parts.
4.16.3 Brake Caliper
Visual Inspection: look for leakage, loose or missing parts, and 
corrosion.
Measure brake pads and enter measurements in “Maintenance 
Inspection Proof.” Space is provided to the right for measurements. 
 Tool #________ Front=________ Back=_________
Adjust brake and set air gap to approximately 1mm as needed.
4.16.4 Wear Sensor / NC Contact
Visual Inspection: Check for damage, corrosion, and worn or missing 
parts. 
Function Test of Wear Sensor: Check for Error Message “Brake Pads 
Worn” and error Message "Brake Pads Worn Warning".
4.19 Generator
100%Torque Check: Stator and Rotor Cable Connections. Torque to 
value indicated on Nameplate of Generator J-Box. Tool#__________
4.17.4 Accumulator
Check Pre-charge pressure of accumulator.
Purge hydraulic system. 
Change hydraulic oil and filter 12 months after commissioning and 
then every 36 months.
4.17.3 Bleed Brakes
Bleed Brake Caliper 
4.17 Hydraulic System
Visual Inspection: Check for damage, corrosion, leaks, and worn or 
missing hardware. 
Check oil level by opening Pressure Relief Valve 21.1. Ensure oil level 
is at max line in sight glass. Add oil as needed
4.17.2 Purging Hydraulic Unit
4.19.4 Generator Carbon Brushes 
Greasing: See Generator Nameplate for amount of grease to be
used in NDE/DE, use current Lubrication List for type. Loosen grease
trap plug.
Automatic Greasing Device (If Equipped): Refill auto greaser 
reservoir, check for proper operation, check lines for blockage, or 
damage.
100% Torque Check: Junction Boxes on Generator. Refer to WDI 
“bolts” for size and torque. Tool#__________
4.19.1 Generator Bearings
Visual Inspection: Look for leakage from seals and empty grease 
overflow collector.
Function Test: Roll generator and listen for unusual noise from 
bearings, rotor, and stator.
4.19.5 Fan
Visual Inspection: For excessive dust build up.
Function Test: Turn fan on and off and listen for unusual noise and 
function.
Visual Inspection: Arcing, proper alignment, proper contact of 
brushes to the slipring, and clean slip ring cabinet of carbon dust
Measure each brush and enter length on “Maintenance Inspection 
Proof.” Replace as needed Tool#__________
Function Test: Verify movement of brush holder springs, micro 
switches, and carbon brushes in the holder. 
GE Proprietary And Confidential, No Re-Production Without Written Permission
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Sect.
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. Hub
Ensure all maintenance documentation is properly filled out and has 
been signed by appropriate personnel.
Ensure all maintenance documentation and records are properly 
stored in accordance to GW-WFO-012 Routine/Planned 
Maintenance Procedure.
5.4 Blade/Pitch Bearing
5.6 Gear Ring and Drive Pinion
Visual Inspection: Look for corrosion, unusual wear, and gear teeth 
pattern. 
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. 
Automatic Greasing Device (If Equipped): Refill auto greaser 
reservoir, replace batteries, check for proper operation, check lines 
for blockage, or damage.
5.5 Pitch Drive and Motors
Drive-to-Mount bolts
Yes No
Tool#__________
Greasing: Refer to current Lubrication list for specific type and 
quantity of grease to use. Grease each pitch bearing.
Automatic Greasing Device (If Equipped): Refill auto greaser 
reservoir, check for proper operation, check lines for blockage, or 
damage.
Notes Section: All tasks where the NO block is marked require a comment
Ensure site is updating maintenance status daily in eMSR
10% Torque Check 
210 Nm = 8.8 screw quality bolts
280 Nm = 10.9 screw quality bolts
Blade-to-Hub Bearing bolts (T-bolts)
Yes No
Tool#__________
10% Torque Check
Refer to the WDI for “bolts” for each type of blade and correct torque 
to be applied.
5.10.2 Rotor Blade Pitch Bearing
5.10 Blades
Records and Reports (Completed by Site Lead or Site Manager)
Ensure all Parts are recorded into E-Services
Ensure all labor hours are recorded in E-Services
Ensure all calibrated tools are recorded with cal dates
Maintenance performed in accordance to revision 17 maintenance 
manual. 
Ensure sites are maintaining and updating a Master Punch list with 
SR #'s in accordance to GW-WFO-012
Maintenance scheduled and performed in accordance to GW-
WFO-012 Planned/Routine Maintenance Procedure
GE Proprietary And Confidential, No Re-Production Without Written Permission
Sect.
Tool #
1
2
3
4
5
6
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11
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17
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20
List of Tools, Serial Numbers, & Calibration Dates
Tool Model Serial Number Calibration Due Date
Notes Section: All tasks where the NO block is marked require a comment
Multimeter
Multimeter
Torque wrench
Slide Caliper
Slide Caliper
Torque wrench
Torque wrench
Megohmmeter
 Maintenance Information
Date WTG Stop Time WTG Start Time Tasks Completed
Maintenance 100% Complete On: Total Man Hours:
Personnel
Date Name Date Name
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