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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 Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No 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 Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No 1 2 3 4 5 6 13 14 15 16 17 18 IF APPLICABLE 19 Yes No Yes No 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 Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No 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 Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No 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 Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No 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 Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No 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 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 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
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