300 HOURS MAINTENANCE

INSTRUCTION
E48, E53
(CS48)
Instruction Number : s_ind-me-08-eng-eng-12-001 Rev000
Compiled by- Central Technical Team
Released By- Central Technical Leads
Date of Release : 05.05.2012

ENERCON INDIA LIMITED,

A9- ENERCON Tower,
Veera Inductrial Estate,
Veera Desai Road,
Andheri (West)
Mumbai-400053
Phone- 022-66924848

Page 1 of 21 s_ind-me-08-eng-eng-12-001 Rev000

300 Hour Maintenance:

The 300h maintenance is the first health check (maintenance) of WEC after commissioning. The purpose of
this maintenance is to conduct a thorough check of sitting of mechanical and electrical components after
300hr operation from grid commissioning of WEC.

*During this maintenance all the mentioned checks to be performed without any fail and the deviation report
with pictures to be published to OMS and TSS team.

Safety instructions:

Improper conduct in or around the wind turbine may result in material damage or personal injury. In order to
avoid this, take note of and comply with all safety instructions mentioned in this document. Depending on the
degree of risk, safety instructions are marked with the following symbols:

Before maintenance inform the EWCC about the maintenance.

Page 2 of 21 s_ind-me-08-eng-eng-12-001 Rev000

Checking reports:

Mark the maintenance activities as follows on the checking report:

Bolt Connection:
Tighten all bolt/screw connections to the required torque as Per Torque Table.
Important: Use calibrated Torque wrench only.
Record any deviations, Torque wrench number and next due date of calibration under
‘Miscellaneous/Remarks with checking report in the Life time file.

Every bolt/ screw (M16 and above) after checking in 300hrs maintenance should
be marked with red marker as shown.

Complete WEC Visual check

Visually inspect whether there are any deficiency like :

a) Corrosion in components and hardware
b) Mechanical damage (e.g. cracks, deformation, flaking, cable insulation damage)
c) Leaks (of oil, water, grease)
d) Missing of components
e) Presence of Soil / foreign objects
If deviation found then write down in checking report. Inform TSS.

Take note of the documents applicable to the respective maintenance items as stated in the
latest document reference list!
Warning signs:
1
While carrying out maintenance, check that all warning signs (as per document s-me-02-ger-
eng-05-001) are present and clearly visible in the entire WEC.

Foundation and Grouting:

2 a) Visually check the foundation as stated in the annual foundation inspection checking list (s-
m-01-eng-04-002/ Annexure-1).
b) In case of grouting chip out, measure the gap between flange and grouting.

If gap observed, record in checking report. Inform TSS.

Basic Settings:
Check turbine-specific settings in the “Basic settings” menu on the control cabinet I/O board and
3 compare to the turbine data sticker.
Check in IO Board of Control Cabinet and Nacelle Control Cabinet as per Basic Setting List
given in Annexure-4. Fill in measurement sheet s_ind-e-03-eng-eng-12-002 Rev000.
If the observed values are not as per Basic setting List, correct it and record as per Annexure-4

Page 3 of 21 s_ind-me-08-eng-eng-12-001 Rev000

 Latest Software setting in WEC:
4
Check there is latest software updated in WEC as per Annexure-3

Grid Voltage:
a) Measure the grid voltage 230V (± 8V).
5
b) Compare the voltage with that indicated on the display.
c) If it is different, adjust the grid voltage in FACTS Power Control.

PE/Earthing Connection tightness inside Tower:

Verify the tightness of PE earthing connection and washer orientation in following joints
a) Tower earthing connection to PE Bus bar
b) DC distribution box earthing connection in PE Bus Bar
c) Power Cabinet earthing connection in PE Bus Bar
d) Control Cabinet PE and Neutral Cable connection in PE Bus Bar
e) UPS earthing connection with Podium Platform
6 f) Podium platform earthing with PE- Bus Bar
g) Transformer Body to Tower Body connection
h) LA cable connection from Transformer to GI strip
i) PE1, PE2 cable connection in PE Bus bar to GI strip
j) Transformer Neutral Earthing point-1 & 2 to GI strip
k) Tower Body earthing in foundation to GI strip
l) Check the concrete tower segment to segment joint earthing strip availability on both
side of tower and its connection.
Apply Cold Galvanized spray on joint part or bi-metallic part in earthing connection
Earthing connection tightness in Tower External Earth chamber and earth
pit:
Verify the tightness of earthing connection and washer orientation in following joints

a) Earth chamber connection of GI strip

7 b) LA earthing cable connection in Transformer structure and HT Bushing Surge arrester
c) Transformer Neutral cable connection in Neutral Bus bar
d) Check all Earth Pit connection and Earth pit identification
Note:- All exposed joints/ welded part of GI strips to be painted with bituminous paints
Apply Cold Galvanized spray on joint part or bi-metallic part in earthing connection
Fan operation
Tower Fan ( to turn on from special function of IO-Board CC from K09 relay),
Power Cabinet Fan ( to turn on from special function of Inverter Control Board)
8
a) Check for any abnormal vibration or noise during operation
b) Also check the direction of rotation of fan blade as per arrow marking on fan body

Tower fan Hose (according to equipment):

Check the air hose on the tower fan:
a) Check tightness of tower fan mounting hardware
9 b) Check tightness of ratchet belt & proper sitting of hose
c) Damage of hose pipe (if Damage is more than 5mm Replace /Repair hose with new one)
d) Check hose support chain, tightness of D shackle, sharp edge.

Note - If sag in hose observed, shorten the air hose.

Page 4 of 21 s_ind-me-08-eng-eng-12-001 Rev000

 Motor protection switch and tripping circuit setting:
10
a) Check the 005.Q01ampere setting of Tower Ventilations fan as per instruction
(s_ind-e-02-eng-eng-10-003 Rev000)
b) Check the MCB 006.Q02 ampere setting of Power cabinet fan as 2.2A

Power Cabinet check:

WARNING
• Before working in Power Cabinet for any check trip the NZM, cut off the mains supply
from CC
• Before checking tightness of NZM connections, ISOLATE the WEC from Transformer
Isolator.
• Ensure all LED of DC Link Interface PCB should be off before working with any
connections of DC supply
11 • Always wear antistatic glooves while working on IGBT connections
a) Check the tightness of DC cable, IGBT connection and Transformer 3 phase cable
connection.
b) Check all PCB connector identification
c) Check the functioning of Hygrostat with a calibrated hygrometer. Also manually actuating
it by reducing the humidity knob setting less than ambient setting i.e. 40%. Check it for
heater fan getting on or not. Reset hygrostat after checking.
After checking of Power Cabinet connection, turn on the supply from Transformer Isolator

12 NZM Setting
Check the MCCB 006.Q01 (NZM) setting as per instruction (s_ind-e-02-eng-eng-10-004Rev000)

Tower
Bolt Connection Checking:
13
Check tightness of all bolt connections in Tower and Foundation as per Torque Table

Precast Concrete Tower:

14
Check the precast concrete tower as stated in the instructions (s-me-02-eng-04-012).
In the case of defects or damage, complete the precast concrete tower inspection report and
cross off on the checking report. Inform TSS and OMS team with report and photographs.

Steel Tower and Steel Section on Concrete Tower:

Check the entire tower against following points :
a) Flange gap ( Limit:- 0.1mm filler gauge insertion depth not more than 30mm in three
consecutive bolts). Fill in measurement sheet (s_ind-m-03-eng-eng-12-001 Rev000)
b) Water ingress from flange area
15 c) Welding crack/ corrosion at vertical and circumferential seams of Tower section
d) Corrosion in Tower body
e) Paint peel out
Note:- Incase of flange gap observed above the mentioned limit in point 12.a, inform to OMS
& Central technical Lead immediately.
Note-in the event of Cracks, damage caused by vandalism, during installation or similar, then
send a detailed report with photos to OMS and Central technical team.

16 Safety Ladder:

Page 5 of 21 s_ind-me-08-eng-eng-12-001 Rev000

 Service the safety ladder in accordance with the manufacturer’s instructions (LMB) (s-me-03-
eng-04-012/ s-e-03-eng-04-001).
Note down all rectified deficiencies in the follow-up work inspection report.
Check foot rest properly fixed or not and correct accordingly.

Platforms and assembly parts:

Visually check the podium platforms and assembly parts
17 Visual check the Tower section platform and clit welding joints
Check that the platform hatches close properly.
Check if hatch door rubber stoppers are in place.

Tower Cable guide and fastening:

Visually check the cable guide brackets and torquing up as per torque table.
Check that the cable polyamide clamps fit tightly
Check the U-Clamp’s plastic inserts are present.

Action - Immediately provide missing plastic inserts!

Check all Power and DC cables as below :-
a) Tightness of connection & proper sleeve in DC distribution box
18 b) Edge protection at sharp edges
c) Cable Sag at tower flange up to 80-100mm .
Action - If deviation found then provide insulation sheet
d) Cable Sag at deflection pulley up to 150-200mm at top section of tower against cable
twist
e) Optical breakout cable routing against sharp bending and over tightness and coupling
connecter support at top section
f) Cable guide handle tightness.
In case of any deviation found correct and record in checking report.

Nacelle orientation to North:

Untwist the tower cables completely.
Manually move the nacelle until the north direction stickers on the tower / nacelle joint are on top
of each other.
a) Check the nacelle position in the “yaw data” menu for the nacelle control cabinet I/O
board 2 (nominal value: 0° ± 5°).
b) If north direction stickers are missing, proceed as follows:
c) Use a compass to align the wind turbine to the north (keep a distance of 100m to the
19 tower).
d) Check the nacelle position in the ”yaw data” menu for the nacelle control cabinet I/O
board 2 (nominal value: 0° ± 5°).
e) Place north direction stickers on the tower/nacelle joint!

IMPORTANT
If the nacelle position and the north direction sticker differ, determine the cause and if
necessary, reset the cable twist limit switch.

Page 6 of 21 s_ind-me-08-eng-eng-12-001 Rev000

 20 Vibration Sensor:
Check the vibration ball sensor functioning as per instruction.( s_ind-me-01-eng-eng-07-002)

Machine House

• While applying rotor lock ensure no body part come near rotating area
• While locking the rotor take care that the lock pin do not damage the rotor
• Enter into rotor only after confirming rotor lock completely set.
Non confirming above point may cause fatal injury/ accident
Bolt Connection Checking:
21
Check tightness of all bolt connections in machine house as per Torque Table

Material lifting (rope winch) winch:

Check in total length of rope for any damages (If found damage replace rope)
Visually check the following components:
a) Mounting hardware tightness /cracks at welded joints and the proper alignment of winch
arm and boom.
b) Check the stopper positions(If Boom is touching to Nacelle FRP then inform Area lead
and record, Action to be taken immediately)
22 c) Winch rope guiding handle is available? If not available then record.
d) Winch hook to rope crimping. (if not correct then restrict the use of winch also inform
Area lead)

Protection check as per

e) Actuate the lower limit switch of winch and check the tripping in un-roll direction of winch
drum
f) Actuate the upper limit switch of winch and check the tripping in wounding direction of
drum
g) Activate the winch emergency stop button during winch operation to check proper
functioning of emergency button.
PE earthing connection tightness at Nacelle
a) NCC Cabinet earthing to main carrier
b) Yaw Inverter earthing with Nacelle Platform
c) Hazard lamp box earthing with Nacelle Platform
d) Rectifier cabinet earthing with PE bus bar
e) Filter Cabinet Earthing with PE bus bar
23 f) Stator Jib earthing with PE bus bar
g) Platform earthing with PE bus bar
h) Anemometer stand and railing handle earthing with PE bus bar
i) Sliding contact earthing with main carrier. Check operation as per instruction (i_ind-me-
01-eng-eng-07-002 Rev000)
j) Nacelle fan earthling with Nacelle platform

Note:- All earthing point should be metal to metal contact. Bi-metallic contact should be
protected with cold galvanized spray

Rotor lock:
Visually check the entire rotor lock and check whether it works properly. Refer Instruction(s_Ind-
24 me-01-eng-eng-06-001)
a) Check the rotor lock guide plate as per instruction.
b) Check the stopper bolt modification done
c) Check the pulser setting (Limit : 4mm pulsar setting = 2-3 mm gap) Record in checking
report after checking/adjusting

Page 7 of 21 s_ind-me-08-eng-eng-12-001 Rev000

 Caution: Ensure the hydraulic brake is active and any part of the body should be away from the
rotating part.

Hydraulic unit:
a) Functional check: ON/OFF the hydraulic motor and check the duration for activation of
brake (Limit :The hydraulic brake should apply within 10 seconds. If not ok then remove
the air entrapped in the lines or clear leakages if any)
25 b) Check for any leakages hydraulic unit
c) Check for any leakages all hydraulic hoses.
d) Check oil level is ok? The level should be at the central position of the inspection
window/Level shown on tank. {If found less then top up the oil upto the level (Renolin
PG46)}.

Motor circuit breakers:

Check the settings for the motor circuit breakers in the nacelle control cabinet:

a) Q01 In = 1.1 A; (Power supply hydraulic motor rotor brake)

b) Q02 In = 25 A; (Power supply rotor sub-distribution system)
26 c) Q03 In = 25 A; (Power supply excitation controller)
d) Q04 In = 2.8 A; (Power supply winch)
e) Q04 In = 6.0 A (According to equipment: single-phase Planeta winch)
f) Q06.1 – 3 In = 3.4 A; (Power supply nacelle fans 1-3)
g) Q07 – -Q10 In = 6.7A (Yaw motors 1-4, 3,3kW motor)
h) Q11.1 – 2 In = 14A (Yaw – contactor operation; 3,3kW motor)
i) Q11 In = 28A (Power supply power unit yaw inverter, 3kW motor)
Motor circuit breakers and auxiliary contacts:
Check the auxiliary contacts for all motor circuit breakers in the nacelle control cabinet and the
fault / warning messages on the I/O board after tripping test:

a) Q01 I/O board 1 “act. I/O status”: 90:6

b) Q02 I/O board 1 “act. I/O status”: 90:9
c) Q03 I/O board 1 “act. I/O status”: 90:10
27 d) Q04 I/O board 1 "act. I/O warning”: 90:7
e) Q06.1 – 3 I/O board 1 "act. I/O warning”: 90:81 – 90:83
f) Q07 I/O board 2 “act. I/O status”: 90:51
g) Q08 I/O board 2 “act. I/O status”: 90:53
h) Q09 I/O board 2 “act. I/O status”: 90:52
i) Q10 I/O board 2 “act. I/O status”: 90:54
j) Q11.1 – 2 I/O board 2 “act. I/O status”: 90:61 – 90:62
k) Q11 I/O board 2 “act. I/O status”: 90:63
Fire extinguishers and first aid kits:
Check whether the Pressure level of Fire Extinguisher is in green zone and due date.
If date found over-due and pressure in green zone then put new inspection date of six month
validity.
28
Check the First aid kit’s contents and expiring date. If expired, then replace.

Record the findings in checking report under the column of ‘Miscellaneous / Remarks’
Fire extinguisher next due date: DD/MM/YYYY.

Assembly parts:
Install stabilizing angle plates as per instruction s_ind-m-02-eng-eng-10-002 Rev 001.
29 Visually check all assembly parts, such as:
a) Holder angle on casing
b) Nacelle platform
c) Nacelle Control cabinet
d) Cabinet brackets
Page 8 of 21 s_ind-me-08-eng-eng-12-001 Rev000
 Lights / sockets / earth leakage circuit breaker:
Check the lighting system (illumination) of Entire WEC is in working condition. Such as:
a) Tower Lights
b) Nacelle lamps
c) Spinner lamps,
30 d) Emergency lamps, etc.

Replace the non glowing lamps.

e) Check supply in CEE socket outside NCC for 1 phase and 3 phase supply
f) Check F08 for functionality by testing it with trip button
Nacelle Cooling fans:
31 Visually check all fans and their assembly parts.
Install the fan holders as per instruction (s_ind-m-01-eng-eng-07-002 Rev002).
Check fan rotational direction as per mark given on the fan body.

Anemometer and support:

Visually check the anemometer and support stand
32 Check the alignment of Anemometer support stand with digital spirit level as per instruction
(s_ind-me-01-eng-eng-08-003 Rev000).
(Tolerance is applicable of +1o from vertical.)

Anemometer/ Wind Vane Setting:

a) Use tape to fix the wind vane in such a way that there is a voltage of 5.00V ± 0.1V between
terminals -X17:5B (wind direction) and -X17:6A (GND) in the nacelle control cabinet, and
between terminals –X03:1 (wind direction) and –X06:3 (GND) of the anemometer interface.
b) The wind direction displayed under “wind direction” in the “general data” menu on the
nacelle control cabinet I/O board 2 is < ±1.0°.
33
Note:- If setting found disturbed then align the anemometer so that the wind vane is positioned
exactly parallel to the WEC axle pin.
In order to check the position, keep as large a distance as possible to the anemometer. After the
inspection, remove the tape!
The wind speed displayed under “wind speed” in the “general data” menu on the nacelle control
cabinet I/O board 2 is plausible.

Mounting and earthing tightness of Cabinet hardware

a) Check the Rectifier Cabinet, Excitation cabinet, Filter Cabinet, Aviation Box, Yaw
Inverter, etc are mounted over Nylon washer
b) Check the caste resin mounting of Excitation Cabinet for any crack
34 c) Check the mounting of Cable Twist Limit switch pinion wheel for proper engagement with
Yaw gear rim
d) Check all controller doors are properly earthed
Clear all the points if found any deficiency.
Nacelle Ventilation System:
Visually check the following components:
a) Tarpaulin covers in rotor
35 b) Generator to GRP armaflex sealing
c) Main carrier cable hole sealing with armaflex
d) Main carrier hatch door rubber beading
e) Yaw Inverter cable entrance beading
Check sealing as stated in the instructions (s-me-01-ger-eng-05-016). In case of any
deficiency, clear it.

Page 9 of 21 s_ind-me-08-eng-eng-12-001 Rev000

 Casing and Hatches:
Visually check the entire casing/ hood.
36 Visually check the following component.
a) Hatches
b) Locks
c) Connection ropes

Cables:
a) Visually check all cables and wires in Nacelle Machine house
37 b) Check cables for edge protection at sharp edge and tightness of lug and hood
connecters in Control boxes
If edge protection is not there, provide it.
Main carrier, axle pin:
Visually check the following components for any damages, crack
and corrosion:
a) Main carrier
38 b) Axle pin
Mark identification line between axle pin-> stator Jib-> main carrier
with red color permanent marker as shown

Yaw gear System:

Visually check the following components for any crack, oil leakage, corrosion & hardware
damage:
a) Yaw gear rim teeth
b) Yaw bearing
39 c) Yaw gear box and pinion
Note: In case of crack component observed, immediately inform Area Lead/ Central.
• Top up oil gear level as per mentioned in Gearbox name plate if required.
• Grease the yaw control teeth with Mobil gear OGL 461 in case of dry teeth observed
• Listen for abnormal noises during yawing

Yaw control:
a) Check and set the 2mm Yaw pulsar gap setting of B01.1, B01.2, B01.3, B01.4, B01.5
and B01.6 between Motor shaft and pulsar in range of 0.7mm-1.0mm.
b) Check movement of nacelle in left and right direction from NCC Yaw control switch.

40 c) Check the Yaw Inverter Operational On/ Off from Yaw parameter in NCC IO-board-2.
d) Check the brake functioning on/off from K03 relay of special function of IO-board-2 NCC
e) Check for smooth yawing in Yaw Inverter mode for 1 turn in any one direction.
f) Check the motor current balance in both master and slave system in Yaw Inverter

Clear the deficiencies in Yaw Control if any

Oil pans, grease collecting ring:

Visually check the following components:
41 a) Yaw Pinion grease collecting pans
b) Gear Rim Grease collecting ring
If necessary, clean the grease pans and collecting ring.

Generator:
42

Page 10 of 21 s_ind-me-08-eng-eng-12-001 Rev000

 Switch off the main switch on the nacelle control cabinet.
Check the entire generator for:
a) Discoloration
b) Insulation damage
c) Damage to the pole shoes, neutral points, coil assemblies
Check the air gap for:
a) Scratches
b) Foreign objects
Follow the generator inspection report, complete it in the case of deficiencies and cross off on
the checking report.
Torque Verification:
Verify the torque at generator neutral and output terminal as per instruction (s_ind-me-01-eng-
eng-10-001).
Generator Air Gap:

Measure the generator air gap as per instructions (s-me-03-ger-eng-04-006).

In the case of defects or damage, complete the generator air gap measurement report and cross
off on the checking report!
Protective nets / protection grids generator:
43 Visually check the protective nets / protection grids. Replace if found damage.

Rotor Head
Bolt Connection Checking:
44
Check tightness of all bolt connections in rotor head as per Torque Table

Rotor Mounted Boxes casting and cable routing:

Check the following components for crack, tightness of mounting hardware, damages:

a) Connections of each rotor box

b) Earthing connection of each rotor box cover.
45 c) Locks on control cabinets
d) Access tarpaulins
e) Brushes in rotor cable guide hole
f) Cables, connecters and wires in rotor boxes
Correct the deficiencies if any.
Spinner supports:
46 Check front and rear spinner supports for crack, tightness of mounting hardware, etc.
In case of crack spinner support, replace arms.

Rotor hub and blade adapter:

Check the following components for damage, corrosion, crack, etc:
47
a) Rotor hub
b) Blade adapter
V rings and bearing seal rings:
Visually check the sealing rings and V rings for any grease or oil leakages
a) Front main bearing
48 b) Rear main bearing

Note:-
• If leakages observed then inform immediately with photographs to Area Lead and
Central and record in Life Time File.

Page 11 of 21 s_ind-me-08-eng-eng-12-001 Rev000

 • Apply MoS2 grease at V ring of front bearing.
• Mark the identification line between shaft nut and bearing cap with Permanent Red
Marker.
Sealing of Rotor and GRP gaps
Check the sealing of spinner GRP to GRP joints openings to prevent against water ingress.
a) Nose cone to spinner sealing
b) V-Lid
49 c) Blade skirts
d) Spoiler extension cover plates

If GRP joints are not properly sealed, then seal it with pyrmaflex paste.

Pitch gear Box and Pitch Bearing:

Check the pitch gear and bearing system for any damage, crack, corrosion, grease/ oil leakage.
a) Pitch gear box
b) Knock test the Pitch bearing to adaptor assembly hardware.
c) Check the Pitch adapter seal ring for any grease leakage
d) Pitch bearing ball insertion cap grease leakage from inside the blade adapter
50
Note:-
• If necessary, top up gear box oil level (RenolinUniSynCLP220).
• After topping up oil, replace the copper washer (where present).
• In case of crack or damage of gear box, replace it with new one
• In case of grease leakage from seal ring, replace it.
• Pitch bearing ball insertion cap looseness should be tightened.
Slip Ring Unit:
Before checking the slip ring unit, carry out the following switching operations on the nacelle
51 control cabinet:
a) Switch off the main switch.
b) Press the emergency stop button.
c) Visually check the entire assembly of slip ring unit.
d) Check and remove if grab screw is available in front bearing jacking hole in axle pin
e) Align the jacking holes of SRB flange with axle pin holes as per Instruction.
Central lubrication system:
Check the working of entire lubrication system as per instruction (s-me-01-ger-eng-05-017).
52 Check all main lines and secondary lines for:
- No leaks
- Proper tightness of joints
Check the grease reservoir for leaks.
Carry the repair work as per instruction (s_ind-me-01-eng-eng11-001 Rev000)
Fill the Check list of Centralised Lubrication System (s_ind-me-03-eng-eng-12-001 Rev000)

Lightening Protection System:

53
Lock the rotor so that blade A (B, C) stops at 12 o’clock.
Check the lightning protection system for burn marks and damage:
a) Lightning rods
b) Discharge color
c) Lightning protection ring
Check the settings of the lightning protection system:
• Use the “Blade A /B/ C (blade) buttons on the nacelle control cabinet to manually pitch
the blade forward.

Page 12 of 21 s_ind-me-08-eng-eng-12-001 Rev000

 • The distance between the blade and the lightning rod must be between 1mm at the
narrowest point and maximum up to 10mm at other part of the pitch in area.
• Ensure that the lightning rods do not touch the blade’s lightning protection Al ring.
• The lightning rod tip points to the discharge ring centre on the blade.
• The distance between the lightning rod and the stator ring (12 o’clock position) may only
be between 10mm and 15mm (max.).
• The lightning rod has to be centered exactly to the middle of stator discharge path.
• Rotate and check and ensure that the lightning rods do not touch the stator ring.
Refer instruction number s_ind-me-01-eng-eng-09-001

Discharge Box
54 After opening the Discharge Box connection from adapter side measure the resistance of each
blade discharge box. It should come in range of 50kΩ + 5kΩ

55 Shaft nut monitoring Switch:

Install the shaft nut monitoring switch as per instruction (s_ind-me-01-eng-eng-09-002).

Rotor blades:
• Visually check the rotor blades for damage with binocular.
56
• Check that the sealing brushes are correctly and securely positioned.

In case of deficiencies complete the rotor blades inspection report and cross off on the checking
report.( s-me-03-ger-eng-06-002)

Bolt Connection Checking:

57
Check tightness of all bolt connections in rotor blade as per Torque Table

Pitch control:
• Pitch blade A to the 95° limit switch.
• Check that the blade stops at a 95°± 1° angle.
• Reset the wind turbine control system.
• Pitch the blade in to approx. 1°.
• Listen for abnormal noises!
• The discharge rod does not come in contact with the discharge ring.
• Slowly pitch the blade to the -2° limit switch from pitch control box A.
• Check that the limit switch reacts at an angle of -2° ± 1° and that the blade pitches out to
58 an angle of 97° ± 1°.
• Reset the wind turbine control system.
• Pitch the blade in to approx. 70°.
• Actuate the mechanical overspeed switch:
• Check that the mechanism and the switch itself function smoothly.
• Check that the blade is pitched out in capacitor mode and stops at approx. 92°.
• Status 41:1 (blade B = 41:2; blade C = 41:3) is displayed in the pitch control box.
• Reset the switch.
• Reset the wind turbine control system.
• Repeat the tests for blades B and C.

After Maintenance
Painting and cleaning:
59 Use a vacuum cleaner to clean the stator windings.
- Check for damage and foreign objects.
Paint and clean.

Page 13 of 21 s_ind-me-08-eng-eng-12-001 Rev000

 Running test of WEC after maintenance from top:

Before taking the running test, clear all the tools, materials and tackles from the
rotating area and kepp it in a safer distance.
60 Turn the nacelle automatically into the wind.
Listen to the wind turbine in idle mode.
Use the quick start button on the nacelle control cabinet to initiate a quick start and listen to the
wind turbine in normal mode.
Press the quick start button again to stop the wind turbine.

Transformer Mounting Structure Torquing

Transformer structure:

WARNING
Before starting work in Tower mounted Transformer structure, ensure that WEC is stopped and
isolated from supply line from VCB. Use earth rod in all three phases and ground in earth pit.

61 a) Check the torque of all hardware connections of transformer mounted DP structure.

b) Try to align the mismatched clit point with help of chain block/ ratchet belt
c) Check all transformer cable connection for its tightness in LT terminal box.
d) Check all PG clamps tightness and binding of ACSR in Tower Mounted structure
e) Check earthing connections of transformer body and Lightening arrestor.
f) Check PRV, MOG and temperature sensors are connected properly in Control Cabinet
as per instruction (s_ind-e-01-eng-eng-11-004 Rev00).

PE/ Earthing connection tightness in Tower External Earth chamber and

earth pit:
Verify the tightness of PE earthing connection and washer orientation in following joints

a) Earth chamber connection of GI strip

62 b) LA earthing cable connection in Transformer structure and HT Bushing Surge arrester
c) Transformer Neutral cable connection in Neutral Bus bar
d) Check all exposed joints/ welded path of GI strip are painted with bituminous paint from
outside the contact area
e) Check all Earth Pit connection and Earth pit identification

Apply Cold Galvanized spray on unpainted joint part or bi-metallic part in earthing connection

Earth Resistance Measurement:

The earth resistance of earth pit can be measured in two way:
• With Megger and 2 electrode system by isolating each earth pit
• With Clamp on earth tester without isolating the earth pit

Note:- The following earth resistance reading in LTF

1. Lightning Arrester (LA1/ LA2)
2. Transformer Neutral (TN1/ TN2)
63 3. Potential Earthing (PE1/ PE2)
4. Tower Body Earthing (TBE)
5. Transformer Earthing (TE)
Measured Value Result
0Ω to 3Ω Result is within limit
Repeat the measurement, use charcoal and
3Ω to 10Ω
salt water solution
> 10 Ω Inform Area Lead & Central Team

Fill the earth resistance value in measurement sheet (s-ind-e-03-eng-eng-12-02 Rev000)

Page 14 of 21 s_ind-me-08-eng-eng-12-001 Rev000

 Start the wind turbine:
Reset the WEC control system!
- Switch off the main switch on the control cabinet and switch on again after a few seconds.
Start the wind turbine from the control panel on the control cabinet:
- Set the manual/automatic switch to “Automatic”.
- Set the start/stop switch to "Start". (Status message: 0:1 Turbine starting)
64 Wait until the WEC automatically restarts normal operation after about three minutes.
- Listen for abnormal noises.
- Status message: 0:0 Turbine in operation.
Set the maintenance switch to “Off”.
Lock all cabinets.
Lock the wind turbine on leaving.

Documentation
File a report copy in the wind turbine folder (LTF) after maintenance.
65 All checking reports .

Page 15 of 21 s_ind-me-08-eng-eng-12-001 Rev000

Annexure 1: Torque Table 01

Tower (Steel and Concrete Towers)

Torque (Lubricated with
Bolt Connection Bolts
MoS2)
Tower – U Bracket M16 – 8.8 147 Nm
U Bracket - Ladder M12 – 8.8 71 Nm
M12 - 8.8 71 Nm
Ladder – Ladder *1*2 Or Or
M12 A2*1 Only Lightly hand Tightened!*2
*1 – Not Lubricated with MoS2
*2 – Only lightly hand tightened with self locking nuts to allow compensation for tower
movement
Steel Tower
Torque (Lubricated with
Bolt Connection Bolts
MoS2)
M36 – HSFG
Steel Tower Flange 2800 Nm
(HV)
Foundation (Inside and Outside) M36 – 8.8 1970 Nm
Machine House
Torque (Lubricated with
Bolt Connection Bolts
MoS2)
Tower - ball bearing slew ring M24 – 10.9 790 Nm
Winch M12 – 8.8 61 Nm
Main carrier - yaw gear M16 -10.9 230 Nm
Ball bearing slew ring rim – main
M24 -10.9 790 Nm
carrier
Main carrier - stator support star -
M24 -10.9 790 Nm
axle pin
Brake disc- generator rotor M12 -10.9 90 Nm
Brake caliper - stator support star M16 -10.9 230 Nm
Guide plates M16 – 8.8 160 Nm

Page 16 of 21 s_ind-me-08-eng-eng-12-001 Rev000

Annexure 1 : Torque Table -02

Rotor Area

Torque (Lubricated
Bolt Connection Bolts
with MoS2)
M12 – 10.9 90 Nm
Supports rotor - spinner fastener And And
M16 – 8.8 160 Nm
Stator support star - stator support
M24 – 10.9 790 Nm
ring
Generator rotor - rotor hub M24 – 10.9 790 Nm
Rotor hub - blade flange bearing M24 – 10.9 790 Nm
Rotor blade - blade adapter M22 – 10.9 570 Nm
Pitch drives M16 – 10.9 230 Nm
Rotor hub - bearing cover M16 – 8.8 160 Nm
SRU fastening bolts M16 – 8.8 160 Nm
Transformer Structure
Concrete Tower to DP Frame M20 A2 281 Nm
OR OR OR
Steel Tower to DP Frame M24 – 8.8 540 Nm
M16 – 8.8 160 Nm
Transformer Frame to Platform
M12 – 8.8 120 Nm
Bolt/screw connections:
After the 300h maintenance use Loctite 290 to secure all bolt/screw connections between
different materials (e.g. metal – GRP) in the rotor area.

Page 17 of 21 s_ind-me-08-eng-eng-12-001 Rev000

 Annexure 2 : List of reference Documents
Reference Documents:
Check
Reference Document Name Instruction Number
Point
® Checking Report s-me-03-ger-eng-04-003
1 Warning Signs s-me-02-ger-eng-05-001
Annual Inspection Foundation s-m-01-eng-04-002
2
Foundations s-m-03-eng-04-001
Optimum Setting of MCBs for Various s_ind-e-02-eng-eng-10-003 Rev000
10
Ventilation System – CS48 WEC
Optimum Setting of Various Power s_ind-e-02-eng-eng-10-004Rev000
12
Switches – 300kW Power Cabinet
Annual Inspection Of precast concrete
11 s-me-02-eng-04-012
tower
Flange Gap Check Instruction s_ind-m-02-eng-eng-12-002 Rev000
14/15
Steel tower paint repairs s-me-07-ger-eng-06-001 Rev001
Follow-up work inspection report safety s-me-03-eng-04-012
ladder
16
Inspection report safety ladder during s-e-03-eng-04-001
commissioning
Vibration ball checking and switch s_ind-me-01-eng-eng-07-002
20
actuation
Rope Winch Inspection s-me-01-ger-eng-05-006
22
Winch rope guiding equipment s-ta-i-03-013

23 Checking of sliding contact functioning i_ind-me-01-eng-eng-07-002

24 Rotor lock guide plate s_Ind-me-01-eng-eng-06-001

29 Adjustment of stabilizing angles s_ind-m-02-eng-eng-10-002
31 Holders for Nacelle fan s_ind-m-01-eng-eng-07-002
Nacelle Sealing s-me-01-ger-eng-05-016
35 Sealing E-48 wind turbines with new fan s-me-01-ger-eng-05-008
systems
Inspection report generator air gap s-me-03-ger-eng-04-006
42
Generator Terminals Verification s_ind-me-01-eng-eng-10-001
51 Slip Ring Jack hole Alignment s_ind-me-02-eng-eng-09-001
Central Lubrication system structure and s-me-01-ger-eng-05-017
52 operation
Stabilizing Central Lubrication System s_ind-me-01-eng-eng11-001
53 Adjust lightening protection system s_ind-me-01-eng-eng-09-001
55 Installation of Shaft nut monitoring switch s_ind-me-01-eng-eng-09-002
56 Rotor blade inspection report s-me-03-ger-eng-06-002
59 Paint repairs s-me-07-ger-eng-06-001
Page 18 of 21 s_ind-me-08-eng-eng-12-001 Rev000
Annexure 3 : Program Overview List

PCBs Program. Version

Pitch A/B/C 2.37
CC IO 1.94
NCC IO1 1.65
NCC IO2 1.70
Yaw Inverter 1 1.46
Yaw Inverter 2 1.46
Rectifier 2.21
Rectifier Control V2.X 3.02
Excitation 1.19
Anemometer Interface 1.49
Display 1.32
Inverter Control-1 V1.X 1.37
Inverter Control-2 V1.X 1.21
Inverter Control-1 V2.X 2.01
Inverter Control-2 V2.X 2.00
FACTS Power Control 1.73
Power Control 4.57
Load Control 3.34

Page 19 of 21 s_ind-me-08-eng-eng-12-001 Rev000

Annexure 4 : Basic Setting List

Settings in PCB Display 
Mains Parameter 
Nom. Voltage  230 
Min. Voltage  190 
Max. Voltage  270 
Limitation Voltage  265 
Nom. Freq.  50 
Min. Freq.  46 
Max. Freq.  54 
Start Delay  00:00:00 
Frequency Limitation parameter 
Frequency Limitation  Off 
Mode  Static 
Ref. power  P‐rated 
Fre. Limitation  53Hz 
Operation Adjust 
Noise Optimisation  Off 
Settings in PCB IO Board C.C. 
Basic Setting 
Rated Power  800kW 
Site Height above sealevel  Location Height as per Micro‐siting 
Rated reactive Power Q(rated)  0 kVAr 
max. power (SCADA)  950kW 
blade version  E53/1 
Generator version  G53/8/G1 
stat comp operation  Off 
fci‐reactive‐power‐control  Off 
SCADA farm control  Off 
dp/dt‐ control  Off 
storm control  As per inst. s_ind‐me‐02‐eng‐eng‐08‐001 Rev002 
min. start wind speed  2m/sec 
max. start wind speed  6m/sec 
storm wind (3min average)  28m/sec 

storm wind (15sec average)  30m/sec 
Pitch parameter 
nominal speed (power opt)  29.8 
nominal speed (noise opt)  29.5 
ini. In nom. Speed  0.0rpm 
over speed  35rpm 
min. blade angle   +1o 
min. start blade angle  +5o 
max. blade angle  +92o 
adjust min blade angle  600kW 

Page 20 of 21 s_ind-me-08-eng-eng-12-001 Rev000

load control parameter 
initialized load control  2 
feeding parameter 
P‐max (power opt)  840 
P‐max (noise opt)  840 
static reactive power  0 kVAr 
Start at 10.5rpm= 5kW 
Power Curve 
End at 29.0= 840kW 
Start at 7rpm= 20V 
Voltage Curve 
End at 24rpm= 630V 
excitation gain‐1  1180 
excitation gain‐2  2600 
Settings in IO Board‐1 of NCC 
Basic Setting 
E48/S/56/5K/01 for 56m Steel Tower 
Tower Version  E48/BF/74/20/01 for 74m Concrete Tower 
E53/S/72/3K/01 for 72m Steel Tower 
labko ice detector  not installed 
Cooling parameter 
Cooling Fan on  100 
Cooling Fan Off  90 
Settings in IO Board‐2 of NCC
wind parameter 

wind direction adj : Lambda  5 

Corr.  30o 

wind direction adj (blade angle)  0.6 °/ ° 

Page 21 of 21 s_ind-me-08-eng-eng-12-001 Rev000