Energy generation Availability Base

OFFICIAL Hours LIST FOR ZAFARANA

PUNCH Operational Hours
80 PROJECT KWh.

Wind Turbine Punch List

Gamesa
Customer: NREA Date:
inspector
NREA
Wind Farm: ZAFARANA 80 WTG Nº: 66 inspector
The following are NREA’s proposed general critical points for all the windfarm

NREA PROPOSED CRITICAL POINTS STATUS SIGNED

Touch screen exist and works
Brake battery exist and work
There is no Leakage / sound / disconnected yaw clamps in the turbine
There is no yaw motor defect / leakage
The fans in top and ground cabinets exist and work

If any FG has been tripping in the turbine, the circuit needs to be checked before NREA inspection

No Gear Box leakage can be found in the turbine

If any crack is found in the brake disc, this must be replaced. If not, the brake disc will be delivered
to NREA
There should not be friction between the brake disc and the pads
There should not be leakage at the brake disc
The thickness of the brake disc pads should be in tolerance
There should not be cracks in the rubber of the coupling arms
The thickness of the generator brushes should be in tolerance
No abnormal sound should be found in the generator
No leakage should be found in the Hydraulic Unit

Hydraulic Unit intercooler should work under the specified temperatures and values

No pith cylinder leakage should be found

The following are NREA’s proposed general not critcal points for all the windfarm:

NREA PROPOSED NON CRITICAL POINTS STATUS SIGNED

Air Conditioning working
Ground cables + terminals in a not critical status (example: power cable completely opened and
terminal burned)
Communication battery exist and work
Cables routing in ground cabinet in good condition
The difference of pressures between touch screen and the actual is not bigger than 4bar
Contactors stated to be changed in GL or NREA remarks, need to be changed

Anti-rotation Teflon needs to be change if it is out of range

Hollow Shaft bearing needs to be changed if the hollow shaft clearance is out of range
Pith bearing (supernut) must be without missing bolts and with their right torque

Any point related to blade bearing leakage will be under check and NREA will check it during the
next preventive maintenance

Any point related to main shaft bearing leakage will be under check and NREA will check it during
the next preventive maintenance

All the filters must be in good condition installed in the turbine

All the test (pitch movements, HU tests, etc.) should be in the range
Lighting system should be OK

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 The following are NREA’s remarks for this turbine as presented to Gamesa.

NRE REMARKS STATUS SIGNED

outer blade bearing seals have leakage    
leakage in H.G need to fix not clean    
genrator high sound    
Gnerator filexable    
rc for KM 280    
end stop fro crane is missing    
power cable cracks    
foudation cracks    
air condition not ok    
comm battary not ok    
cable system in tower section    
trap door for tower section not ok    
one plate for ground cabinet is missing    
tray for cable in star-delta cbinet is damdged    
leakage in brake circuit from caliper    
one hose for inter coller need to chane    
temperature sensor so low votage in transformer    
check Generator bearing    

The following points are the Defected faults that 8.2, as the independent expert responsible to inspect the turbine, has delivered on its End of
Warranty Inspection Report of the turbine, as a contractual requirement between Gamesa and NREA; in order to help both parts: NREA and
Gamesa, in the elaboration of a Punch List to be completed in the turbine

8.2 DETECTED FAULTS

PT SYSTEM SUBSYSTEM SHORT DESCRITION STATUS REMARKS SIGNED

The cable ties of the wind vane and anemometer
73 ANEMOMETER CABLE TIES      
are missing. They have to be retrofitted.
SUPPORT The wind anemometer support is bent.
74 ANEMOMETER      
BENT Adjustment is necessary.

CONNECTION The screws of a connection box on the entrance

33 SCREEWS      
BOX platform are loose. They have to be tightened.

66 CONTACTOR RC's A Signal filter is missing. It has to be retrofitted.      

The covers of the generator connection boxes
59 GENERATOR BOX COVER      
are not grounded.
The ventilation sheath of the generator is loose.
58 GENERATOR FLEXIBLE      
It has to be fixed.
GROUND In the master cabinet a communication unit is
7 MOXA      
CABINET loose. It has to be fixed.
GROUND COMM. The UPS of the master cabinet does not work.
6      
CABINET BATTERIES The batteries have to be exchanged.
The insulation of the power cable in the ground
GROUND
3 CRACKS kiosk basement is dry and broken. The power      
CABLES
cables have to be replaced.
The oil hoses between the gear box and the oil
51 INTERCOOLER HOSE      
cooler are cracked. They have to be exchanged.
The sealing element above the oil cooler is dry
52 INTERCOOLER SEALING      
and cracked. It has to be replaced.

There are no grease trays for the used at the

generator’s bearings. Leaking grease is
INSPECTION
54 MAIN SHAFT contaminating the nacelle inside. Trays have to      
COVER
be installed and the contamination has to be
removed.

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 8.2 DETECTED FAULTS

PT SYSTEM SUBSYSTEM SHORT DESCRITION STATUS REMARKS SIGNED

SMP A CMS sensor of the generator is loose. It has to
61 NACELLE      
SENSOR be fixed properly.
Several screws on the outside of the nacelle are
76 NACELLE ROOF      
corroded. Corrosion protection has to be applied.
The soft brake battery does not stay the 30sec
BRAKE
68 NACELLE over the entire test (switch off: FM010). It has to      
BATTERY
be exchanged.

There are cracks around the hinges of the back

door in the nacelle. The door needs a proper
72 NACELLE REAR DOOR fixation during the opened use. The solution that      
is available does not fit to prevent a damage of
the door.

45 NIPPLES CAPS Covers of the greasing nipples are missing      

POWER The insulation on the tower cables is brittle. The
37
CABLES
CRACKS
power cables have to be exchanged.      
The power cables between the switch gear and
POWER
4 SWITH GEAR
CABLES
the transformer have pressure marks at the cable      
feed through. Improvement is necessary.
CABLE In the top cabinets the cable glands are loose
67 TOP CABINET
GLANDS and not sealed. Rework is necessary.      
The fan configuration of the top cabinets is not
64 TOP CABINET FAN conclusive. It is recommended to remove the      
filter mats from the fans.
Several cable glands are loose, leading to stress
35 TURBINE GLAND in the electrical connections. They have to be      
tightened.
Several cable glands have wrong dimensions.
36 TURBINE GLAND
They have to be exchanged.      
Several cable ties are missing in the tower. They
34 TURBINE CABLE TIES
have to be retrofitted.      

Some screws are too short, for example at the

turnbuckles of the safety rope. Two threads need
to be visible where self-locking nuts are
30 TURBINE SCREWS
mounted. One tread need to be visible at high      
strength bolts (HV). They have to be replaced
with longer ones.

LOW
The insulation of the low voltage cables of the
VOLTAGE
69 TURBINE
CABLE
lamp and cooler fan are damaged. They have to      
be exchanged.
INSULATION
VIBRATION VIBRATION The wire of the vibration sensor is not bent. The
62
SENSOR SENSOR pendulum weight could fall away.      
YAW The cable of the yaw sensor (yellow box) is loose
44 YAW COUNTER and endangered to get damaged by the yaw      
SENSOR teeth. It has to be fixed properly.
There is a slightly leakage at the transformer. It
5 has to be sealed and the affected area
has to be cleaned.

A insulation in the left master cabinet is cracked.

8
Rework is necessary

Several cables are damaged and have to be

9
exchanged.

There are cracks on the outside foundation.

Several were marked in 2012. Some of those
10 have grown further. Any decision concerning
repair works need to be verified based on the
foundation design.
11 The second hand rail of the outside stairs is
missing. Fixing the door in open position at

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 8.2 DETECTED FAULTS

PT SYSTEM SUBSYSTEM SHORT DESCRITION STATUS REMARKS SIGNED

the tower wall is unsafe and should be
redesigned
The stairs are not properly mounted and
12 damaging the corrosion protection of the
tower wall. Rework is necessary
The outside stairs are not equipped with
13 grounding cables. A proper grounding has to be
retrofitted.

All warning signs are missing, e.g. "restricted

14
access to unauthorised person".

The outer stairs and the area below are contaminated

by oil. The contamination of the environment has to
15 be prevented.

The type plate in the tower foot is not completely

16 filled out. This has to be done.

17 First aid instruction is missing in the tower and the

ground kiosk
All warning signs and safety stickers have to be in
18 English and local language. They
have to be retrofitted in the local language
There was no conformity of type available, in
which the manufacturer declares that the
19 turbine is erected according to the type approval
and the building permission. A copy of
conformity of type should be lodged on site
The declaration of conformity is not available in
20 the turbines. A copy of the declaration
of conformity should be lodged on site

There is no user manual. The documentation has

21
to be completed.

Service documentation was not complete in the

22 turbine / nor in the service station. The
documentation has to be completed.
A grounding measurement protocol is not
available. Therefore it is not possible to
check whether the resistance for grounding is
23
under the demanded level. It is recommended to
measure every two years. The measurement
should be done during dry summer season
The documentation is not stored in a proper way.
To avoid loss of documents a storage
24 place should be found or installed, which is dry,
where the documentation is easy to find and
does not pose a fire load (as in cabinets).
The winding temperature max. Value of 157.3 is
25 pretty high. It is recommended to
check the generator
The oil collecting barrel in the tower basement is
26 missing. It has to be retrofitted.

There are cracks in the foundation. It is

recommended to mark them and check them.
27 Any decision concerning repair works needs to
be verified based on the foundation design

The grates of the entrance platform are not fixed

28 properly. Rework is necessary.

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 8.2 DETECTED FAULTS

PT SYSTEM SUBSYSTEM SHORT DESCRITION STATUS REMARKS SIGNED

There is a lot of oil in the tower basement, walls
29 and platform and ladder as well.
Cleaning is necessary.
There are cracks in the foundation. Several were
marked. Some of those have grown further or
new ones formed. It is recommended to mark
31
them and check them. Any decision concerning
repair works needs to be verified based on the
foundation design

The platform hatches are too weak. They have to

32
be reinforced or redesigned

There is no type plate of the ladder. The type

plate has to be retrofitted and all information
38 (incl. the last inspection) has to be completed. An
inspection has to be caught up as needed

Bigger gap between the ladder sections.

39
Adjustment is necessary

A bolts from the ladder is loose (2nd section). It

40
has to be tightened.

There is oil on the ladder. The contaminations

41 have to be removed and their reasons
have to be eliminated
The maximum load stickers are missing at every
42 platform. Retrofitting is necessary

The rubber sealing between nacelle and tower

43
(yaw sealing) is cracked. It has to be exchanged

There is a leakage at the hydraulic station due to

46 the eroded sealing and at the oil tray.
The sealing has to be exchanged.
There is oil at the hydraulic block. The
47 contaminated area has to be cleaned in order to
determining leakages
There is a leakage at the front bearing's cover.
48 The torque of the bolting and the bearing has to
be checked.
There are slight scratches from impurities on the
teething of the spur gear stage of the
49
gearbox. The further development has to be
monitored during scheduled maintenance
There are leakages on the gearbox at the air
filter and the main cover. The leakages
50 have to be eliminated and the affected areas
have to be cleaned in order to detect further
leakages

The brake pads are damaged. The pads have to

53
be checked and replaced as needed

Slip ring tracks are uneven. There is a problem

when brushes need to be exchanged.The tracks
55 and the brushes need to be exchanged
according to the limitations given by generator
manfuctuer
56 There is discoloration of the copper bars in the
slip ring unit of the generator. The
maximum temperature of the generator winding
was 157.3°C. check the brushes, the
fixing bolts and the generator sealing and clean
the generator front and rear
compartment from the inside, clean the cooling
rips.

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 8.2 DETECTED FAULTS

PT SYSTEM SUBSYSTEM SHORT DESCRITION STATUS REMARKS SIGNED

The generator is not properly sealed. Sealing at
the connection boxes and cable glands
are insufficient, damaged or not properly
57
installed. Dirt and dust infiltrates into the
generator. The generator has to be sealed and
cleaned from the inside.

60 Different shim material is used.

The wire of the vibration sensor is not bent. The

62
pendulum weight could fall away.

The filter mats at the cabinet are dirty. They have

63
to be exchanged

There is no protection on the crane hook to

protect the tower wall while craning. It has
70
to be retrofitted.

The crane boom has to be fixed to the nacelle

wall to avoid strong wear on the crane
71
axle.

The cooler of the gear oil cooling system is dirty.

75 It has to be cleaned.

Several screws on the outside of the nacelle are

76 corroded. Corrosion protection has to
be applied.

77 The greasing nipples of the blades are leaking

Lightning currents are guided through the blade

bearings. To reduce the risk of defects
78
on the blade bearings lightning currents should
be guided on a different path

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In NREA Zafarana office, on the __h of ___________, 2013:

NREA Inspector Gamesa Inspector

On the __th of _________, 2013, Eng. Hassan Ezzeldin Rifaat as representative of Gamesa and Eng. Osama,, Eng. Mahmoud Elbagory and
Eng. Ahmed Fouad, as representative of NREA, agreed on the Punch List above, as the Punch List to be executed in this particular turbine of
Zafarana 80 Wind Farm; in order to help both: Gamesa an NREA engineers in the site, to agree and follow exclusively the punch list points
mentioned and listed above.

In NREA Cairo office, on the __h of ________, 2013:

NREA Representatives Gamesa Representatives

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