0001-2437 Use of Lifting Unit For Upending and Vertical Lift of Single Tower Section

Use of lifting unit for upending
and vertical lift of single tower

section
Document no.: 0001-2437 V13
Class: RESTRICTED
Type: T09
Date: 2019-02-28
VESTAS PROPRIETARY NOTICE: This document contains valuable confidential information of Vestas Wind Systems A/S. It is protected by copyright law as an unpublished work. Vestas reserves all patent, copyright, trade secret, and
other proprietary rights to it. The information in this document may not be used, reproduced, or disclosed except if and to the extent rights are expressly granted by Vestas in writing and subject to applicable conditions. Vestas
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Use of lifting unit for upending and vertical lift of single tower section
Document no.: 0001-2437 V13 · Class: RESTRICTED · Type: T09 Page 2 of 29
Wind turbine type
Read the full document before you start to do work.

Send questions or concerns about the document to Vestas Wind Systems A/S.
Wind turbine type Mk version
All MW wind turbines All Mk versions
Change description
Description of changes
Updated section 3 Abbreviations and technical terms, page 4, section 5 Purpose, page 5,
section 7.1 Kit set in lifting units, page 6, section 7.2 List of tools in all toolkits, page 7, section
7.6 Specific tools for the kit set VT20024896, page 12, section 7.7 Tower lifting unit
VT20024896, page 12, and section 13.1.1 To lubricate the lifting units, page 25.
Table of Contents
1 Safety ........................................................................................................................... 4
2 Educational requirements of service technician .................................................... 4
3 Abbreviations and technical terms .......................................................................... 4
4 Referenced documentation....................................................................................... 5
4.1 Safety documents......................................................................................................... 5
4.2 Reference documents .................................................................................................. 5
5 Purpose ....................................................................................................................... 5
6 Note.............................................................................................................................. 6
7 Tools ............................................................................................................................ 6
7.1 Kit set in lifting units ...................................................................................................... 6
7.2 List of tools in all toolkits ............................................................................................... 7
7.3 Lifting capacity of VT200880 ........................................................................................ 7
7.4 Specific tools for the kit set VT20003722 ....................................................................11
7.5 Specific tools for the kit set VT20008420 ....................................................................11
7.6 Specific tools for the kit set VT20024896 ................................................................... 12
7.7 Tower lifting unit VT20024896 .................................................................................... 12
8 Spare parts ................................................................................................................ 13
9 Consumables ............................................................................................................ 13
10 Weights...................................................................................................................... 13
11 Estimated time use................................................................................................... 13
12 Procedure.................................................................................................................. 14
12.1 To prepare the lifting units before use ........................................................................ 14
12.1.1 To clean the lifting unit ................................................................................................ 14
12.1.2 To replace the bolt bushings and the axles ............................................................... 15
12.1.2.1 To replace the bolt bushings....................................................................................... 16
12.1.2.2 To replace the axle...................................................................................................... 18
12.1.3 Lifting configuration .................................................................................................... 19
12.1.3.1 To lift with a single hook.............................................................................................. 19
12.1.3.2 To prepare the crane with double hook (T-hook)........................................................ 20
12.1.4 To install the lifting unit on the tower flange................................................................ 20
12.1.5 To release the lifting units from the tower flange ........................................................ 23
13 Service and maintenance ........................................................................................ 25
13.1 Daily maintenance ...................................................................................................... 25
13.1.1 To lubricate the lifting units ......................................................................................... 25
13.2 Replacement of tower bolts ........................................................................................ 28
13.3 Annual service inspection........................................................................................... 28
13.4 Repair ......................................................................................................................... 29
14 Certification............................................................................................................... 29
1 Safety 0011465016
All work relating to a Vestas wind turbine, including work methods and practices, employee
training and protective measures, and use of tools and equipment, shall be in accordance with
the requirements of the applicable governmental and private occupational safety and health
codes and standards. Employers engaged in such work are also required to be familiar with and
comply with the wind turbine-specific ‘Safety regulations for operators and technicians’ manual
for the relevant wind turbine type. Vestas shall not be responsible for any liabilities arising from
failure to comply with such requirements. Vestas reserves the right to inspect such work to
ascertain such compliance.
The service technician must read and understand the PPE sheets for each of the chemicals used
or work done in this instruction. The PPE sheets describe the correct personal protective
equipment to wear for the specific work. If in doubt about the PPE requirements for the work,
contact the site responsible or the line manager and confirm the correct procedure before starting
the work.
For chemicals that are not specified with accurate name and item no., contact the local site-
responsible person for information about PPE and other safety instructions related to the use of
the chemical.
2 Educational requirements of service technician 0011358855
At least 2 of the service technicians who do work in a wind turbine must be able to prove that they
have a valid GWO basic safety training certificate.
At least 1 service technician must hold the wind turbine-specific training course certificate for the
wind turbine in question.
Some tasks require one or more advanced training modules or job-specific training, as described
in the Vestas ‘Technical training programme’. The person who plans a specific task must make
sure that the service technicians involved have the proper know-how for the completion of that
task.
3 Abbreviations and technical terms 0011403086
Table 3.1: Abbreviations
Abbreviation Explanation
BCD Bolt circle diameter
CCW Counterclockwise
CW Clockwise
ECC Energy control coordinator
ERP Enterprise resource planning
GWO The Global Wind Organisation
PPE Personal protective equipment
RA Risk assessment
SBU Sales business unit
SDS Safety data sheet
SPRA Standardised procedure risk assessment
Abbreviation Explanation
UHMPE Ultra high molecular density poly ethylene
WLL Working load limit
Table 3.2: Explanation of terms
Term Explanation
None
4 Referenced documentation
4.1 Safety documents 0011403085
Table 4.1: Safety documents
Document no. Title

Various Safety regulations for operators and technicians
0001-2707 RA for 0001-2437 Use of tower lifting unit
0004-4159 Standardised procedure risk assessment (SPRA)
0014-0410 Personal protective equipment sheets
4.2 Reference documents 0011403084
Table 4.2: Reference documents
Document no. Title

Various Installation and decommissioning manuals for the tower
0057-8563 User manual
920098 Torque wrench settings
960501 Bolt connections
Unless it is specified differently, see 920098 ‘Torque wrench settings’ for information
about bolt types and bolt lubrication, and see 960501 ‘Bolt connections’ for
information about torque values.
5 Purpose 0011403223
The purpose of this document is to give the procedure for how to assemble, configure, and use
the lifting units for tower installation and tower disassembly.
Below listed items with different WLLs are available for this procedure:
• VT200880
• VT20003722
• VT20008420
• VT20024896
6 Note 0011362898
This section is not relevant to this procedure.
7 Tools 0021400905
For standard service tools, see 0065-3482 ‘Standard service tools’.
Some tools in this tools list can vary in shape and technical specification from region
to region due to local requirements.
If in doubt, contact your local tools warehouse for tools applicable to your region.
This note may not be applicable for any special tools used in this procedure.
7.1 Kit set in lifting units 0011403220
Table 7.1: Kit set
Item no. Quantity Description

VT200880* 2 WLL 39900 kg each
ERP: TOWER LIFTING UNIT
VT20003722† 2 WLL 60000 kg each
ERP: TOWER LIFTING UNIT WLL60T
VT20008420‡ 2 WLL 60000 kg each
ERP: TOWER LIFTING UNIT 60T 10MTR
VT20024896§ 2 WLL 55000 kg each
ERP: TOWER LIFTING UNIT KIT
*)
VT200880 includes a lifting unit with grommet sling, replaceable bushings, axles, bolts,
washers, and nuts for lifting of towers with M30, M36, M42, M48, M56, and M64 bolt holes.
†)VT20003722 includes a lifting unit with UHMPE rope (8500 mm), replaceable bushings, axles,
bolts, washers, and nuts for lifting of towers with M30, M36, M42, M48, M56, and M64 bolt holes.
‡)VT20008420 includes a lifting unit with UHMPE rope (10000 mm), replaceable bushings, axles,
§)VT20024896 includes a lifting unit with UHMPE rope (7500 mm), replaceable bushings, axles,
All kit sets in table Kit set, page 6 contain the items in table List of the tools in all
toolkits, page 7.
7.2 List of tools in all toolkits 0011403221
Table 7.2: List of the tools in all toolkits

VT730060 1 Round sling 6000 mm, WLL 3000 kg (extension sling)
ERP: SLING RNEN 6M 3T
2 46 mm fixed ring spanner (M30 bolt)
1 Set of metric Allen keys
Specific tools for the toolkit VT200880
Table 7.3: List of the tools for the toolkit VT200880

VT730768 2 10000 mm steel wire, WLL 40000 kg
ERP: WIRE GROMMET SLING 10M
Additional tools for single hook crane for VT200880
VT206183 2 4000 mm grommet slings, WLL 49000 kg
ERP: GROMMET Ø54MM WLL49 T 4,0 M
VT206181 1 Triangle plate, WLL 85000 kg
ERP: TRIANGLE PLATE WLL 85
VT206182 2 Shackle, WLL 42500 kg
ERP: SHACKLE BOW BLT 42,5t
VT730585 1 Shackle, WLL 85000 kg
ERP: SHACKLE BOW BLT 85t
VT200880: The tower lifting units must be used in sets of 2 to lift a tower section.
The tower lifting units have replaceable bolt bushings for M30, M36, M42, M48, M56,
or M64 bolts. The bolt bushings are installed in the double eccentric housings to
adapt to the variable distance between bolt holes.
An axle in the centre of the tool transfers the load to the tool when you lift the towers
from a horizontal position.
See section 7.3 Lifting capacity of VT200880, page 7 for charts with lifting
configurations for the different bolt/pin sizes.
7.3 Lifting capacity of VT200880 0011403219

Figure 7.1: Capacity per lifting unit set with the M30 bolts
Figure 7.2: Capacity per lifting unit set with the M36 bolts
Figure 7.3: Capacity per lifting unit set with the M42-M64 bolts
Figure 7.4: Example of the BCD on a tower L-flange
1 L line
7.4 Specific tools for the kit set VT20003722 0011403218
Table 7.4: List of items for the kit set VT20003722

VT20004841 2 8500 mm Dyneema sling, WLL 60000 kg
VT20004841 must not be used for tower flange BCD larger than 5200 mm.
Table 7.5: List of items for the kit set VT20008420

VT20003722 / VT20008420: These units must be used in sets of two for lifting a tower
section. The M30 bolts are only allowed to lift 30000 kg for each unit and 60000 kg for
a set. The WLL for the remaining bolts, M36, 42, 48, 56, and 64 is 60000 kg each and
120000 kg for a set.
The units are equipped with replaceable bolt bushings for M30, 36, 42, 48, 56, or 64
bolts. The bolt bushings are installed in the double eccentric housings to be able to
adapt to variable distance between bolt holes.
An axle in the centre of the tool transfers the load to the tool when you lift the towers
from a horizontal position.
Table 7.6: List of item for the kit set VT20024896

7.7 Tower lifting unit VT20024896 0015520442
Figure 7.5: VT20024896

To lift the top end of the tower section, the lifitng units must be used in sets of 2.
The lifting units are equipped with replaceable bolt bushings for M30, M36, M42, M48, M56, or
M64 bolts.
The bolt bushings are installed on the double-eccentric housings to adapt to the variable distance
between bolt holes.
8 Spare parts 0011449219
Table 8.1: Spare parts

None
9 Consumables 0011403216
Table 9.1: Consumables

149181 As needed ERP: GREASE TRIBOL 3020-1
149139 As needed ERP: GREASE SKF LGWM 1/0,4
10 Weights 0011403215
The weight of the full tool kit for the lifting unit is about 250 kg.
11 Estimated time use 0011449216
This section is not relevant to this procedure.

12 Procedure
12.1 To prepare the lifting units before use 0011427375
Risk of suspended load failure! SPRA ID No. 19.01

• It is strictly prohibited to stay or work below a suspended load or in a drop zone.
The only exception to this rule is when you do approved work in a Vestas-defined
protective zone.
• A lifting plan must be made and communicated to all personnel before the lifting
operation.
• Lifting operations are not allowed when the wind speed is higher than the maximum
value in accordance with the wind speed guidelines for the task. See the lifting
plan.
• Only trained and qualified service technicians and crane operators are allowed to
do the lifting operation.
• Make sure that an examination and test of the crane is done in accordance with
local requirements.
• Use only certified lifting equipment and fully examine the lifting equipment before it
is used.
• All hoists and lifting equipment must be formally examined before it is used.
• Obey the correct slinging arrangement and lifting procedures.
• Use the lifting equipment that is approved for the specific task.
• Use guiding ropes when situations are made dangerous by the rotation or
uncontrolled movement of a load.
• Obey the precautions to avoid entanglement when you attach or detach the load.
Risk of damage to lifting tool!

• Always keep the lifting slings and lifting units clean.
• Check the tools for defects before each lifting operation and check for signs of wear
and tear which can prevent correct functionality of the tool, especially the tilting/
turning function of the tool.
• Ensure that the tools are correctly greased.
12.1.1 To clean the lifting unit 0011403242
Do not store the lifting units directly on the ground surface as mud and dirt can damage the
bearings in the lifting units.
• Put the lifting units on the pallet or on some equipment which can protect the lifting units and
the lifting slings from the dirt.
12.1.2 To replace the bolt bushings and the axles 0011403241
Figure 12.1: Tower lifting unit
1 Outer eccentric 2 Inner eccentric

Figure 12.2: Tower lifting unit, side view
1 Axle
12.1.2.1 To replace the bolt bushings 0011403240
1 Loosen the locking screw for the bolt

bushing (1) (the diameter of the hole is
stamped on the bolt bushings).
2 Push the locking screw away from the centre

of the bolt bushing (1) and pull the bushing
out.
3 Install the new bolt bushing. Align the locking

pawl (1) on the bushing and the mating hole
in the eccentric.
4 Push the locking screw towards the bolt

bushing bolt and tighten it.
12.1.2.2 To replace the axle 0011403239
1 Loosen the locking screw for the axle (1) (the

axle diameter is stamped on the axle).
2 Turn the axle (1) CCW until it reaches the

locking groove (2). Make sure that the
locking screw is aligned and pull the axle (1)
out.
3 Engage the new axle.
4 Turn the axle (1) CW until it reaches the

locking groove (2). Make sure that the
locking screw is aligned.
5 Tighten the locking screw.
12.1.3 Lifting configuration
12.1.3.1 To lift with a single hook 0011403238
1 Attach the 2 WLL 49000 kg grommet slings

(item no. VT206183) onto the single crane
hook (1).
2 Attach the WLL 49000 kg grommet slings

(item no. VT206183) onto the WLL 85000 kg
triangle plate (1) (item no. VT206181) with 1
WLL 85000 kg shackle (item no. VT730585).
3 Attach the 2 lifting units onto the 2 remaining holes of the triangle plate with WLL 42500 kg
shackles (item no. VT206182).
4 Secure the shackles with locking pins.
12.1.3.2 To prepare the crane with double hook (T-hook) 0011403237
1 Attach the lifting sling (1) directly to the

double crane hook (2).
12.1.4 To install the lifting unit on the tower flange 0011403236
Risk of suspended load failure! SPRA ID No. 19.01

• It is strictly prohibited to stay or work below a suspended load or in a drop zone.
The only exception to this rule is when you do approved work in a Vestas-defined
protective zone.
• A lifting plan must be made and communicated to all personnel before the lifting
operation.
• Lifting operations are not allowed when the wind speed is higher than the maximum
value in accordance with the wind speed guidelines for the task. See the lifting
plan.
• Only trained and qualified service technicians and crane operators are allowed to
do the lifting operation.
• Make sure that an examination and test of the crane is done in accordance with
local requirements.
• Use only certified lifting equipment and fully examine the lifting equipment before it
is used.
• All hoists and lifting equipment must be formally examined before it is used.
• Obey the correct slinging arrangement and lifting procedures.
• Use the lifting equipment that is approved for the specific task.
• Use guiding ropes when situations are made dangerous by the rotation or
uncontrolled movement of a load.
• Obey the precautions to avoid entanglement when you attach or detach the load.
1 Torque the bolts that are attached with the

lifting unit. Use scaffold or a man basket (1) if
you cannot access the bolts from the ground
level.
2 Attach a round sling (item no. VT730060) to extend the wire sling of one of the lifting units.
3 Attach the extended lifting unit to the crane hook.
4 Attach the other lifting unit directly to the crane hook.
5 Guide the crane operator until the extended lifting unit is at the tower flange and aligned with
the centre of the tower section.
6 Guide the extended lifting unit (1) in position

on the L-flange (2).
7 Install the lifting unit in the inner flange holes on the top flanges of T-flanges.
8 Put the lifting unit (2) in place on the T-flange

tower (1) so that the axle is engaged in the
bolt hole closest to the horizontal centre line
of the tower.
9 Turn the eccentrics to align the bolt bushings with the bolt holes of the flange.
10 Install the bolts with the washers and the nuts.
The chamfer on the washers must face the bolt head and the nut.
11 Torque the bolts manually to approximately 400 Nm .
12 Guide the crane operator until the other lifting unit is at the tower flange and horizontally
aligned with the one that is already installed.
13 Install the second lifting unit in the same procedure as the first one.
14 Guide the crane operator to lower the hook above the centre of the tower flange.
15 Remove the extension lifting unit (1) from the

crane hook (2) and connect both the wire
slings (3) directly to the crane hook (2).
Let the extension lifting unit (1) stay on the wire sling (3). It must be used again
for the removal of the lifting units.
12.1.5 To release the lifting units from the tower flange 0011403235
1 Release one of the lifting units from the crane hook.
2 Extend the released lifting unit with the applicable round sling.
3 Attach the lifting unit (2) to the crane hook

(1).
4 Guide the crane operator to put the crane hook in position straight above the lifting unit
which is not extended.
5 Remove the nuts (2) and the washers from

the lifting unit (1).
6 Guide the crane operator to move the crane up until the bolts are clear of the flange.
7 Install the washers and nuts (2) to the lifting

unit (1).
8 Guide the crane operator to put the hook in

position straight above the remaining lifting
unit.
9 Do the steps 1–8 again to remove the

remaining lifting units in the same way that
you removed the first lifting unit.
13 Service and maintenance
13.1 Daily maintenance 0011403234
• The lifting units and lifting slings must be kept clean.
• The lifting units and lifting slings must be stored in a dry location when they are not in use.
• The lifting units must be lubricated through the grease nipples at every 10 lifts.
13.1.1 To lubricate the lifting units 0011403273
Risk of exposure to hazardous substances and mixtures, Tribol 3020-1 grease!

SPRA ID No. 2.02
• Prolonged skin contact can cause itching or skin diseases.
• Do not eat, drink, or smoke during lubrication of lifting units.
• Wear gloves.
• Remove excessive grease from the lifting units after lubrication.
1 Lubricate the bushing on all the lifting units (2) through the bushing grease nipples (1) until
the new grease flows from the lifting unit.
Lubrication of the bushing is not necessary on the toolkit VT20024896.

Lubrication of the eccentrics is necessary according to the annual service
requirements.
Figure 13.1: VT20024896
1 Lifting unit (item no. VT20024896) 2 Grease nipple for eccentric lubrication
2 Remove the excess grease from the lifting sling unit.

Figure 13.2: Location of the grease nipples on the lifting unit
1 Lifting unit (item nos. VT200880, 2 Grease nipple for eccentric lubrication
VT20003722, and VT20008420)
3 Grease nipple for bushing lubrication
Figure 13.3: Location of the grease nipples on the lifting unit
1 Lifting unit (item no. VT20024896) 2 Grease nipple for eccentric lubrication
3 Grease nipple for bushing lubrication
13.2 Replacement of tower bolts 0011403272
The tower bolts. with the washers and the nuts, must be replaced once a year at the annual
service inspection.
The tower bolts must also be replaced in case of damage seen during visual inspection or if
required by local rules or regulations.
13.3 Annual service inspection 0011403270
The lifting units must be sent to Vestas Wind Systems A/S for service inspection at the interval of
12 months. Certification of the lifting slings must be done along with the annual service
inspection. See section 14 Certification, page 29.
13.4 Repair 0011403269
If any damage is found on the lifting units, the complete lifting unit must be identified as defective
and sent back to Vestas Wind Systems A/S for repair. Do not try to repair the lifting unit on-site.
14 Certification 0011403271
The lifting units must be certified at an interval of 12 months by an approved certification authority
or more frequently, if it is necessary.

0001-2437 Use of Lifting Unit For Upending and Vertical Lift of Single Tower Section

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0001-2437 Use of Lifting Unit For Upending and Vertical Lift of Single Tower Section

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Use of lifting unit for upending

and vertical lift of single tower

Wind turbine type

Read the full document before you start to do work.

Wind turbine type Mk version

All MW wind turbines All Mk versions

2 Educational requirements of service technician 0011358855

3 Abbreviations and technical terms 0011403086

Table 3.1: Abbreviations

Table 3.2: Explanation of terms

4.1 Safety documents 0011403085

Table 4.1: Safety documents

Document no. Title

4.2 Reference documents 0011403084

Table 4.2: Reference documents

Document no. Title

This section is not relevant to this procedure.

For standard service tools, see 0065-3482 ‘Standard service tools’.

7.1 Kit set in lifting units 0011403220

Table 7.1: Kit set

Item no. Quantity Description

7.2 List of tools in all toolkits 0011403221

Table 7.2: List of the tools in all toolkits

Item no. Quantity Description

Specific tools for the toolkit VT200880

Table 7.3: List of the tools for the toolkit VT200880

Item no. Quantity Description

7.3 Lifting capacity of VT200880 0011403219

Figure 7.4: Example of the BCD on a tower L-flange

7.4 Specific tools for the kit set VT20003722 0011403218

Table 7.4: List of items for the kit set VT20003722

Item no. Quantity Description

7.5 Specific tools for the kit set VT20008420 0011403217

Table 7.5: List of items for the kit set VT20008420

Item no. Quantity Description

7.6 Specific tools for the kit set VT20024896 0021919749

Table 7.6: List of item for the kit set VT20024896

Item no. Quantity Description

7.7 Tower lifting unit VT20024896 0015520442

Figure 7.5: VT20024896

8 Spare parts 0011449219

Table 8.1: Spare parts

Item no. Quantity Description

Table 9.1: Consumables

Item no. Quantity Description

11 Estimated time use 0011449216

This section is not relevant to this procedure.

12.1 To prepare the lifting units before use 0011427375

Risk of suspended load failure! SPRA ID No. 19.01

Risk of damage to lifting tool!

12.1.1 To clean the lifting unit 0011403242

12.1.2 To replace the bolt bushings and the axles 0011403241

Figure 12.1: Tower lifting unit

1 Outer eccentric 2 Inner eccentric

Figure 12.2: Tower lifting unit, side view

12.1.2.1 To replace the bolt bushings 0011403240

1 Loosen the locking screw for the bolt

2 Push the locking screw away from the centre

3 Install the new bolt bushing. Align the locking

4 Push the locking screw towards the bolt

12.1.2.2 To replace the axle 0011403239

1 Loosen the locking screw for the axle (1) (the

2 Turn the axle (1) CCW until it reaches the