General Turbine Safety

Document no.: 0032-3252 V02 Restricted 1

 General Turbine safety
Turbine safety

Turbine safety

Personal Protective Equipment

Safety Documentation

Safety equipment

Hydraulic safety

Electrical Safety

Locking devices

Generator Safety

Yaw Safety

Blade Safety

Drive train Safety

Nacelle crane Safety

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 Emergency stop buttons
Turbine safety

When EMC buttons are pressed:

• All rotating components come to a stop

• Turbine will stop production and come to

quickest possible stop

• In most cases the brakes are applied

• All motors and contactors are switched

Emergency stop buttons are: off
• Located in the nacelle, hub and tower

• Blades pitch to stop

• Easily accessible in the work areas

• To be pressed in case of danger to • All controller outputs are set to inactive

personnel

• Can be reset by twisting the red switch

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 Location of Emergency stop buttons
Turbine safety

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 Document hierarchy for wind speed reference
Turbine safety

Critical wind speed limits:

Safety
Alerts • Highest priority

Turbine Specific • Determined based on the design limits of

Safety Manuals the Wind Turbine locking devices
• Different for service, construction and
other Wind Turbine related tasks
Work Instructions (WKI) • Depending of the area of work in the Wind
Turbine

Vestas OHS&E Manual • If there is no other defined limit

Note: Wind Speeds Hierarchy ONLY!

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 Wind speeds
Turbine safety

Always check first:

• Safety Alerts
• Turbine specific manuals
• Work instructions

The concept may vary for older wind turbines

Please beware of any given country legislation

Based on average Wind Speed on 10 minutes

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 Emergency escape routes
Turbine safety

• To be used in case of fire or any other work related accident for self or
colleague

• Located in the nacelle, hub and tower

• Emergency decent device and anchor points to be used while using

escape routes in hub and nacelle

• Use fall arrest equipment in case of a danger of fall

• Rescue equipment should be confirmed

before use

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 General Turbine safety
Personal Protective Equipment

Turbine safety

Personal Protective Equipment

Safety Documentation

Safety equipment

Hydraulic safety

Electrical Safety

Locking devices

Generator Safety

Yaw Safety

Blade Safety

Drive train Safety

Nacelle crane Safety

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 PPE in Vestas OHS&E Manual
Personal Protective Equipment

• Eye, Ear, Hand and Respiration Protection

• Safety helmet

• Safety footwear

• Personal Fall Protective Equipment (PFPE)

• Clothing

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 Personal Protective Equipment
Personal Protective Equipment

Protective gloves required

Respiration protection required

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 General Turbine safety
Safety documentation

Turbine safety

Personal Protective Equipment

Safety Documentation

Safety equipment

Hydraulic safety

Electrical Safety

Locking devices

Generator Safety

Yaw Safety

Blade Safety

Drive train Safety

Nacelle crane Safety

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 Vestas OHS&E Manual
Safety documentation

Work rules

Evacuation

Vestas OHS&E
OH&S Manual
Manual

Fall arrest

Signs Personal Protective Equipment

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 Safety Regulations for Operators and Technicians
Safety documentation
Anchoring points
Signs

Safety Regulations for

Operators and Technicians, Escape routes
V90-3.0 MW, Mk 8 and 9

Locks Safety systems

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 Safety Alerts
Safety documentation

Safety Alerts always take top priority!

Safety Alerts (S.A.) overrule any other doc

and remain active/open until:

• The hazard is eliminated Safety Alerts

• The safety issue and its control processes

are incorporated into the normal OHS&E Manual
procedures

• Proper instruction is given Turbine-specific Manuals

…then the S.A. is set to OBSOLETE Service Messages

Work Instructions
(WKI)

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 Safety Alerts
Safety documentation

Example: SA147 Risk related to the use of

Service Lifts and Repair Platforms

Info contained:

• Affected turbines
• Who is affected (Service, Construction…)
• What is the Risk
• What to do to control the hazard
• Expected validity

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 Safety Data Sheet
Safety documentation

SDS contains:

Hazards associated with chemicals, oils,

coolants, lubricants and other consumables

Safe usage

SDS available to all users

Responsible person provides SDS to site

Contact responsible person if new chemical is

to be used

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 General Turbine safety
Safety equipment

Turbine safety

Personal Protective Equipment

Safety Documentation

Safety equipment

Hydraulic safety

Electrical Safety

Locking devices

Generator Safety

Yaw Safety

Blade Safety

Drive train Safety

Nacelle crane Safety

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 Fire equipment
Safety equipment

• CO2 fire extinguisher with quick user guide

• Fire blanket for small fires

• First aid kit on the nacelle wall

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 Checking the pressure guage
Safety equipment

• Mention in the Service Report

• Fire extinguisher should remain in
the turbine

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 Inspection of next service date
Safety equipment

If out of date:
• Mention in the Service Report
• Fire extinguisher should remain in
the turbine

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 Inspection of ResQ Box Seal
Safety equipment

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 Contents of ResQ Box
Safety equipment

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 Inspection of ResQ Vacuum Bag
Safety equipment

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 Fill-out Inspection Journal
Safety equipment

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 Take New Seal and Label
Safety equipment

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 Label and Reseal ResQ Box
Safety equipment

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 Inspection of anchor points
Safety equipment

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 Anchor points in the turbine
Safety equipment

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 Ladder anchor points
Safety equipment

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 Types anchor points
Safety equipment

Examples:

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 Approved anchor points in the Nacelle
Safety equipment

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 Anchor points outside spinner and Tower
Safety equipment

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 Documentation for inspection
Safety equipment

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 Damaged anchor points-Example
Safety equipment

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 Checking Safety Equipment for Turbine Owner
Safety equipment

• H-belt / Belts

• Long Lanyards

• Safety Helmet

• Fall Arrest Equipment

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 General Turbine safety
Hydraulic safety

Turbine safety

Personal Protective Equipment

Safety Documentation

Safety equipment

Hydraulic safety

Electrical Safety

Locking devices

Generator Safety

Yaw Safety

Blade Safety

Drive train Safety

Nacelle crane Safety

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 Protection against hydraulic oil
Hydraulic safety

Avoid consumption Minimise skin contact Avoid inhalation

Hydraulic oil is extremely Long term skin contact with Inhalation of vaporised oil can
dangerous to your health. hydraulic oil can cause chronic cause chronic bronchial
Consumption can cause cancer! eczema. disorders.

Always wash hands after working Use rubber gloves when cleaning Leaking oil under pressure can
with hydraulic oil. Remaining oil or working with flowing oil. Never vaporise. Keep head away from
on hands can contaminate food, keep oil soiled rags in pockets. vaporised oil.
etc.

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 System under pressure
Hydraulic safety

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 Hydraulic PPE
Hydraulic safety

System depressurized before

starting work.

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 Components with Hydraulic hazards
Hydraulic hazards

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 Components with Hydraulic hazards
Hydraulic hazards

Brake calliper and hydraulic connection

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 Components with Hydraulic hazards
Hydraulic hazards

Hydraulic station & hydraulic transfer

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 Components with Hydraulic hazards
Hydraulic Safety

Accumulator pressure

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 Log out tag out
Hydraulic safety

• Check local requirements

• Security against re-connection

• If possible use a lock

• Tags are minimum demands

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 Depressurising the hydraulic system
Hydraulic safety

1.Disconnect the power source and LOTO 2. Identify needle valves, open and LOTO

3.Use test hose to relieve trapped pressure

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 General Turbine safety
Electrical Safety

Turbine safety

Personal Protective Equipment

Safety Documentation

Safety equipment

Hydraulic safety

Electrical Safety

Locking devices

Generator Safety

Yaw Safety

Blade Safety

Drive train Safety

Nacelle crane Safety

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 Components with electrical hazards
Electrical Safety

Switchgear HV Transformer

Cabinets with busbars and

electrical components

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 Components with electrical hazards
Electrical Safety

LCTU

Generator

Slip rings

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 Vestas Standards
Electrical Safety

Follow Vestas Standards

Ask your ECC for support

Vestas Standard for Vestas Standard

Electrical Safety Control of Hazardous Energy

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 Lock Out Tag Out (LOTO)
Electrical Safety

Purpose of LOTO

•Prevent unexpected start up

•Means of warning

•Required by:
• Local regulations
• Work Instructions
• Vestas Standards
• Vestas OHS&E Manual

•Personal safety

•Absence of safety device

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 Lock Out Tag Out (LOTO)
Electrical Safety

Lock out procedure before starting work

•Notify affected employees

•Understand the hazards involved

•Shut down the equipment - normally

•Isolate the equipment from source

•Secure using Lock Out Tag Out

•Release the stored energy

•Verify isolation

Note: Use appropriate PPE

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 Lock Out Tag Out (LOTO)
Electrical Safety

Checks before restoring equipment back

from lock out

•Use PPE to remove non essential equipment

•If equipment is ready for operation

•The work area is safe

•Controls are in Neutral

•Notify affected personnel

•Remove lock out and re energise

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 LOTO Equipment
Electrical Safety

Lock Hasp Lockbox Breaker Lockout

Personal Tag Control Tag Cable Lock out Valve Lock out

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 Use of PPE and tools in electrical safety
Electrical Safety

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 Electrical safety signs used in turbines
Electrical Safety

On capacitor bank panel High voltage To prevent arc detector relay trip

On the door of transformer room

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 Only HV operators (with HV Training)
Electrical Safety

HV training needed

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 General Turbine safety
Locking devices

Turbine safety

Personal Protective Equipment

Safety Documentation

Safety equipment

Hydraulic safety

Electrical Safety

Locking devices

Generator Safety

Yaw Safety

Blade Safety

Drive train Safety

Nacelle crane Safety

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 Rotor lock
Locking devices

V112

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 Different rotor locks
Locking devices

V80

V82

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 Different rotor locks
Locking devices

V90 3MW

Rotor lock released Rotor lock applied

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 Different rotor locks
Locking devices

V52

Bed Plate version I & II

Bed Plate version III & IV

left side right side

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 Rotor locks
Locking devices

Why is the rotor locked ?

• To avoid accidents

When is the rotor locked?

• Before entering the hub

• Working on rotating parts

• Working on hydraulic systems

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 V80 rotor locking system
Locking devices

+
-

Rotor lock

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 V82 rotor lock documentation
Locking devices

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 V90 rotor lock documentation
Locking devices

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 Blade lock or pitch lock
Locking devices

Used when:

• Working on pitch system

• No grid for extended periods

Pitch locks normally:

• Are manual (Some have

automatic pitch locks)

• Can be locked at different

pitch angles

• Are integrated with the pitch

bearing housing

2MW Mk8 example

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 Locking the blades – V90
Locking devices

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 Locking the blades - V80
Locking devices

Pitch lock

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 Locking the blades - V82
Locking devices

Pitch lock in closed position

Pitch lock in open position

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 Locking the blades – V52
Locking devices

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 Locking the blades – V39
Locking devices

• Mount locking block with blade

• Tighten the lock nut

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 Yaw Lock
Locking devices
Yaw motor

Yaw lock - Unlocked Yaw lock - Locked

Safety warning
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 Yaw lock – V82
Locking devices

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 General Turbine safety
Generator Safety

Turbine safety

Personal Protective Equipment

Safety Documentation

Safety equipment

Hydraulic safety

Electrical Safety

Locking devices

Generator Safety

Yaw Safety

Blade Safety

Drive train Safety

Nacelle crane Safety

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 Hazards with Permanent Magnet Generator
Generator Safety

Electrical hazard:

•Induced electricity due to any rotation

Magnetic fields:

•PMG may affect the operation of some medical

devices

•Electronic devices may be affected

•May reach high temperatures

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 Working on Permanent Magnet Generator
Generator Safety

• All motion generates power

• Lock rotor if working on the generator
• Bolt generator if gearbox or coupling is removed

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 Locking out generator breakers
Generator Safety

Q7
Slip rings

Q8
Stator

Safety warning Rotor Lock

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 Dangerous substances - slip ring dust
Generator Safety

Safety warning
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 General Turbine safety
Yaw Safety

Turbine safety

Personal Protective Equipment

Safety Documentation

Safety equipment

Hydraulic safety

Electrical Safety

Locking devices

Generator Safety

Yaw Safety

Blade Safety

Drive train Safety

Nacelle crane Safety

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 Rotating and moving parts
Yaw Safety

Yaw ring Nacelle base Yaw gear Yaw motor

frame

Yaw ring
Safety warning Rotating parts

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 LOTO of Yaw system
Yaw Safety

Q22 Circuit breaker

Bring the turbine to service mode

Wait a few seconds, switch off the turbine

Switch off Q22 circuit breaker

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 General Turbine safety
Blade Safety

Turbine safety

Personal Protective Equipment

Safety Documentation

Safety equipment

Hydraulic safety

Electrical Safety

Locking devices

Generator Safety

Yaw Safety

Blade Safety

Drive train Safety

Nacelle crane Safety

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 Static electricity in blades
Blades Safety

•Connect discharge cable before working on blades and LCTU.

•Do not dismount before it is functional.

•Use approved and certified PPE and tools.

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 Mounting a discharge cable
Blade Safety

Clamp end of discharge Alternative connection

cable point

Current transfer rail

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 Mounting a discharge cable
Blade Safety

Bolt for blade lightening Mounting discharge cable using

band an earth stick

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 Conductive lightening ball head bolt
Blade Safety

Threaded hole on the blade Conductive lightening

lightening band ball head bolt

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 General Turbine safety
Drive train Safety

Turbine safety

Personal Protective Equipment

Safety Documentation

Safety equipment

Hydraulic safety

Electrical Safety

Locking devices

Generator Safety

Yaw Safety

Blade Safety

Drive train Safety

Nacelle crane Safety

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 Main Shaft
Drive train Safety

High risk area!

High torque on the rotating

parts

Safety warning Rotor Lock Rotating parts

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 Gear stay
Drive train Safety

High risk area!

Squeezing danger in torque arm

Safety warning Rotor Lock Rotating parts

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 Gearbox and shaft brake
Drive train Safety

High risk area!

High speed on the rotating

parts

Safety warning Rotor Lock Rotating parts

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 Coupling
Drive train Safety

High risk area!

High speed on the rotating

parts

Safety warning Rotor Lock Rotating parts

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 Slip rings
Drive train Safety

Safety warning Rotor Lock Rotating parts

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 General Turbine safety
Nacelle crane Safety

Turbine safety

Personal Protective Equipment

Safety Documentation

Safety equipment

Hydraulic safety

Electrical Safety

Locking devices

Generator Safety

Yaw Safety

Blade Safety

Drive train Safety

Nacelle crane Safety

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 Nacelle crane introduction
Nacelle crane Safety

• The nacelle crane is intended for vertical lifting only

• Located at the rear of the Nacelle

V80 example

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 Nacelle crane example V82
Nacelle crane Safety

1 of the 2 brakes Lever for trolley brake

Prevent longitudinal travel Prevents traversing travel

Emergency stop (only crane)

Hoist

Control pendant Lower

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 Nacelle crane example V90 3MW
Nacelle crane Safety

1. Emergency stop
2. Hoisting
3. Lowering.

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 Safety precautions operating the crane
Nacelle crane Safety

• Load vertical
• Visual inspection required before use
• Use harness & anchor point
• Check SWL (Safe Working Load)
• Only certified & approved lifting equipment
• Do not touch the chain when in operation
• Ensure communication with tech at the bottom
• Check Wind Speed limits
• Check SA

Seat

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 Securing the crane (Type ABB) - SA120
Nacelle crane Safety

Safety Alert 120

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 Securing the crane (Type ABB) – SWI 0042-8152
Nacelle crane Safety

Using 1 strap

Using 1 sling

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 Nacelle Crane Tech Doc
Nacelle crane Safety

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 General Turbine Safety

The End

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 Change Record

Revision no. 01 Date: See DMS Changes by: OMUVI

Slide: 5, 6 Change: Updates for the Vestas Corporate OH&S Manual.

Vestas Corporate OH&S Manual only used for Wind Speed Limits when they do
not exist in other doc.
Slide: 15 Change: New slide to show an example of a SA, as requested by MOU

Slide: 49 - 54 Change: Updates related to the Vestas Standards for Electrical Safety and Control
of Hazardous Energy

Slide: 56 Change: New slide to cover the requirement of having HV training when doing any
HV work

Slide: 56-62 Change: Removed slides about HV procedures, in line with modification in MOU

Slide: 94-100 Change: Improved and added slides explaining operation of Nacelle Crane

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 Change Record

Revision no. 02 Date: See DMS Changes by: OMUVI

Slide: All Change: “WTG” replaced by “Wind Turbine” and updated to refer to new Vestas
OHS&E Manual 0055-5622 V01
Slide: 5, 6 Change: Text on these 2 slides swapped (and other minor corrections) to match
content to be covered
Slide: 7 Change: Remove text “Use of rescue equipment should be
confirmed before use”

Slide: 8, 9 & 10 Change: “Personal Protection Equipment” changed by “Personal Protective

Equipment” according to definition on Vestas OHS&E Manual
Slide: 30 Change: Speaker Notes corrected to refer to “Safety Regulations for Operators &
Technicians” V80 2MW Mk5
Slide: 38 Change: Updated according to new Vestas OHS&E Manual

Slide: 66 & 68 Change: Speaker Notes corrected and information added

Slide: 67 Change: Previously slide 69. Moved to match order with the other slides

Slide: All Change: Other minor corrections such as:

- Adjustment of pictures size
- Adjustment of text size
- Grammatical errors
- …

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