Condition of wind turbine Specs.pdfRapport nr. 6758-2 8 The alarm statistic was retrieved from the...

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DV Report Condition of wind turbine

Rapport nr. 6758-2 2

Report no.

:

Manufacture : NEG Micon

Type : NM 900/52

Turbine ID :

Date of commissioning :

Inspection date

: May 30, 2012

Scope of work

: Inspection of Wind Turbine, evaluation of condition

June 7, 2012


Disclaimer This report comprises the results of the inspections carried out on the above mentioned wind turbine The report is based on visual observations and endoscope inspection of gearbox. The conclusions in the report are based on our experience with the components inspected at the time of the wind turbine inspections. The inspections are carried out according to the best practice. It can however not be guaranteed that that all faults on the wind turbine have been found. Danmarks Vindmølleforening (The Danish Wind Turbine Owners Association) can not be held responsible partly or in full for any losses in production or any loss of materials which may occur now or in the future. The recommendations, hints or advice given in this report whether they will be followed or ignored shall not hold Danmarks Vindmølleforening or its employees responsible for any cost, damage or loss that such advice may lead to.


Conclusion

June 7, 2012

No. Text

1 It is recommended to read record and reset the minimum and maximum temperatures at regular intervals, in order to monitor the development in the condition of the components.

2 The safety harness in the tower should be discarded. 3 Although no cracks or damages were found on the blades it is still recommended

to inspect the blades when dismounted. 4 The main bearing should be monitored closely for further development of

standstill marks / pitting and for movement backwards 5 Oil level in the gearbox should be kept at max level 6 It is recommended install an oil level monitoring system on the gearbox. 7 It is recommended to install off-line filter on the gear box. 8 The gear box is in an acceptable condition. 9 It is recommend to equipped the generator with an automatic generator bearings

lubrication system 10 It is recommended to protect the fittings and pipes on the cooler from corrosion. 11 The protection cover over the break disk and shaft is damaged.

The cover should be renewed and positioned in such a way that the break disk does not wear down the protection cover.

12 The gasket between the nacelle and the nacelle hatch needs to be changed. 13 In the rotor end of the nacelle a crack was observed in the nacelle cover. To avoid

that the crack will expand it is recommended to repair the damaged area as soon as possible.


Introduction The Wind Turbine was inspected on May 30th 2012. The wind turbine was in operation at the time of inspection.

Name plate

Date code 2557400-6-5-2000 Serial no. 15016 Model NM 900 / 52 Electrical rating 900 kW / 690 V / 50 Hz N.E.G Micon

Control system Main panel

AX no. 90000300 Un 3x690 V f 50 Hz I 950/230 A IP 54 G/g 900/200 kW Ikmax 20 kA kVAr

System earth TN-C-S NEG Micon Control System

Data from WTG control display:

Wind speed : 2,8 m/s Power : 5,8 kW Generator : 1001 r/min Rotor : 14,8 r/min Hydraulic press. brake : 123 bar Hydraulic press. blades : 139 bar Frequency : 50,0 Hz Power factor cos : 0,89 - Actual voltage : 394-394-394 V


Production : 19.761.628 kWh 91.378 hours Production generator G : 18.610.323 kWh 61.544 hours Production generator g : 1.180.012 kWh 29.833 hours Consumption : -37.962 kWh Grid connected : 103.940 hours Brake off : 102.438 hours Time alarm : 1.448 hours Time without alarm : 102.492 hours Service : 361 hours T1 brake off : 89.314 hours T2 wind OK : 90.314 hours T3 missing time : 42,6 times

Temperatures Actual Maximum Generator G : 38 138 °C Generator g : 52 117 °C Gear oil : 48 64 °C Gear bearing front : 54 73 °C Gear bearing rear : 52 72 °C Ambient : 18 30 °C Nacelle : 19 34 °C Thyristor : 30 40 °C Main panel : 26 49 °C Water after cooler : 29 51 °C Maximum and minimum readings

Max rotor RPM : 23 RPM

Max gen. RPM : 1.540 RPM

Max power 10 min. : 1.016 kW

Max power 1 min. : 1.048 kW

Max power 1 sec. : 1.446 kW

Max wind speed10 min. : 28,8 m/s

Max wind speed 1 min. : 31,3 m/s

Max wind speed 1 sec. : 40,3 m/s

Max oil pressure blades 146 bar

Max oil pressure rotor 139 bar


Parameters (selected) Hydr. Pump blades start/stop/reduce 127/135/145 Bar Hydr. Pump brake start/stop/reduce 110/120/150 Bar Gear cooling pump start/stop 10/5 °C Gear cooling pump bearing stat/stop 80/15

Error 79, Over prod. G long, time : 990 kW 1800 sec Error 80 Over prod. g long, time : 220 kW 1800 sec Error 81, short average prod G : 1035 kW 600 sec Error 82, short average prod g 230 kW 600 sec Error 83, High output G : 1260 kW 0 sec Error 84, High output g 280 kW 0 sec Error 100, Ambient temp. high : 45 °C 60 sec Error 101, Ambient temp. high : -20 °C 60 sec Error 106, generator G temperature : 155 °C 60 sec Error 108, generator g temperature : 155 °C 60 sec Error 112, gear oil temperature : 75 °C 60 sec Error 113, gear oil low temperature : -10 °C 60 sec Error 114, gear bearing 1 temperature : 105 °C 60 sec Error 116, gear bearing 2 temperature : 105 °C 60 sec The alarm statistic and the readings of the TAC 84 vibration monitoring module was read and are enclosed. The readings for maximum temperatures for the gear bearings front and rear are logged at 73 and 72 °C. This is below the alarm level but still rather high. The maximum sump temperature is logged at 64°C which is acceptable. Normally the bearing temperature should preferably not exceed the sump temperature by more than 10°C and never by more than 20°C. It is recommended that the gear oil temperature is kept at maximum 60°C for mineral oils and not over 70°C for synthetic oils. Ageing of the oil happens much more rapid at increased temperatures. Furthermore higher oil temperatures causes the oil film thickness to decrease, this will have a negative effect on the life expectancy of both bearings and gears. The alarm setting for gear bearing temperatures are set at 105°C. It is recommended to read, record and reset the minimum and maximum temperatures at regular intervals, in order to monitor the development in the condition of the components.


The alarm statistic was retrieved from the wind turbine via WTG controller. None of the alarm events is above limit for what is acceptable. Or it is events which is not related to the turbine. . The TAC 84 module holds the maximum vibration level since the last reset. This is recorded at 1,05 m/s2 The limit is set at 1,60 m/s2. The max detected rpm is recorded to 1598 rpm. Which is below the max limit set at 1700. The last 10 errors are recorded, and 1 of the errors are RPM too high and 0 with Vibration too high. The turbine doesn’t seem to have problems with high vibrations. The alarm statistic and the data from the TAC 84 module did not lead to any other remarks Foundation

The foundation was inspected for cracks in concrete, in the joint with the cast in part, sealing, etc. The foundation consists of an armoured concrete footplate, into which a steel part is cast in. Both the outside and the inside part of the foundation seems to be in fair condition.

Tower The tower was inspected for surface treatment, bolt connections, welding’s etc. The tower consists of 2 sections that are bolted together via flanges and galvanized bolts, nuts and washers. No remarks. Ladder and safety equipment was inspected. It is recommended to discard the safety harness, photo 1 due to lack of inspection.


Blades LM Glasfiber LM Glasfiber LM Glasfiber 25.5 A DK 25.5 B DK 25.5 C DK The blades were inspected for cracks and other faults on the surface using a pair of binoculars. No cracks or damages were found on the blades, photo 4. Each blade is fitted with 2 stall strips, all the strips is intact. Although no cracks or damages were found on the blades it is still recommended to inspect the blades when dismounted. No further remarks.

Main shaft and main bearing The main shaft was inspected for rust, wear etc. There was no abnormal amount of grease leak at the bearing housing, photo 3. The main bearing is automatically lubricated, the lubrication chamber on the automatic lubrication system was empty, photo 4. The lubrication chamber must be filled as soon as possible. The main bearing was dismantled and it was observed that 10cm of the filt ring was missing, photo 5. A new filt ring must be installed. Stand still marks and light pitting was observed on the rollers and inner ring, also often called fretting corrosion. Such marks appears as brown lines on the rollers perpendicular to the rolling direction, photo 6 and 7. The appearance of such marks means that the remaining life time for the bearing has been reduced and that a negative process is in progress. The outer bearing ring was inspected with a special tool in the area of the bearing where the bearing load is maximum. No marks of pitting could be observed.

Main bearing seen form the nacelle towards the rotor.

Position in the bearing where maximum load will occur.


The gearbox is not centred in between the gear stag, photo 8 and photo 9. The difference between the distance on the R side and the NR side of the gear stag may have occurred when the gear was installed which is most likely. But it can also indicate that the main bearing is worn and the drive train has begun to slide backwards, this must be avoided do to the risk of damaging the gear box. The main bearing should be monitored closely for further development of standstill marks / pitting and for movement backwards.

Gear box

Winergy I = 67,418 # # 4500095578 / 60067621

No. 4894910-0050 Type PEAS 4320.0 1000 kW n1 22,4 / min n2 15,10 / min VG 320 Oil ~ 170. Weight 6.500kg

According to the log the gear box and the main bearing have been changed in 2005. The oil in the gearbox is Mobil XMP SHC 320, which is a synthetic PAO based gear oil. The oil level was above maximum mark in the sight glass, photo 10. It is recommended to always keep the oil level close to the maximum mark. The gearbox is designed as a three stage gearbox with one planetary stage and two helical parallel stages. Please refer to the appendix for identification of shafts, meshes and bearings. Wear and indentations of the bearings are categorised, please refer to the appendix for these categories. The inspection cover on the top of the helical stage was removed for inspection. Inspection of the planetary stage is only possible if an endoscope is used. Gear mesh Photo Observation Category CategoryRinggear Not accessible Planet wheels Not accessible Sun wheel Not accessible Gear wheel on low speed intermediate shaft

11 A few minor stand still marks are seen on the flanks

K1 P0

Pinion on high speed intermediate shaft

12 Normal wear. K0 P0

Gear wheel on high speed

13 Normal wear. K0 P0


intermediate shaft Pinion on high speed shaft

14 Light pitting in NR end of flanks.. K0 P1

Bearing position

Bearing type Photo Observation Category

NR-High speed shaft

Cylindrical roller bearing

15 No sign of wear is seen L0

A magnet on a flexible shaft was swept over the bottom of the gearbox, photo 16. No particles were found It is recommended to install off-line filter on the gear box. It is recommended install a oil level monitoring system on the gearbox. This is a demand from most insurance companies today. The gear box is in an acceptable condition.

Transmission shaft The transmission shaft between gearbox and generator consist of a hollow shaft with flexible composite elements in both ends, photo 17. No signs of damage or wear was detected.

Generator

ABB Motors M2LG 400LKD 4/6 B3 No. 3421362 200 / 900 kW 1007 / 1511 1/min D+D 690 V 209 / 835 A cos 0,81 / 0,89 50 Hz 3450 kg IC F(B) IP54

The cable connection box for the generator stator was opened for inspection, photo 18. No remarks. Doing test run of the turbine a different noise pattern could be head from the front generator bearing, increased lubrication of the bearing could eliminate the bearing noise. It is recommend to equipped the generator with an automatic generator bearings lubrication system


Yaw system

Motorer 0,75 kW-2,3A-60 Hz-1150 3 stk gear Brevini Type Z11F3EBV101 I =2000-5

The yaw system is a compact system which cannot be inspected visually but doing test run of the turbine and measurement of power consumption, no abnormal sound pattern and power consumption was detected . The yaw system is lubricated by a automatic lubrication system together with the main bearing.

Hub The hub is not inspected do to safety reasons.

Cooling system The radiator is located above the generator outside the nacelle housing. Airflow through the generator is supplied by the naturally wind flow. No leak or wear was found on the hoses but it is recommended to protect the fittings on the radiator from corrosion, photo 19.

Brake system

Simé Type SHD 5.5W-5% Nr. T104

Brake pads, callipers, hydraulic hoses and pipes were inspected for leaks etc. The brake pads and the brake disk was found without abnormal wear. The hydraulic pumping unit for the shaft brake is placed underneath the generator, the oil level was at an acceptable level. The protection cover over the break disk and shaft is damaged, photo 20 The cover should be renewed and positioned in such a way that the break disk does not wear down the protection cover.


Nacelle The nacelle was inspected of surface treatment, bolt connections, weldings, wear on moving parts, cleanliness and accessibility. The gasket between the nacelle and the nacelle hatch needs to be repaired, photo 21. The nacelle was found well cleaned.

Electrical installations Cables etc. were inspected for correct mounting and wear. No remarks. The PFC (Power factor correction) system did not have any leaks or abnormal wear, photo 22.

Functional tests The turbine was tested in operation. No abnormal noise was observed from the gear box Regarding the generator please refer to the chapter “Generator”. The emergency switch and vibration was tested, no remarks.

7, 2012

NEG Micon fejlstatistik, type NM 900/52 Date : May 30. 2012 Report no. : ID :

No. Event text Events Last present Tim

1 Power up 15 26‐04‐2012 21:06 0 12 Grid drop voltage L1 16 16‐04‐2012 12:47 2,6 13 Grid drop voltage L2 19 16‐04‐2012 12:47 3,2

14 Grid drop voltage L3 21 16‐04‐2012 12:47 3,6 49 Vector surge 4 06‐05‐2012 05:00 0,6 60 Low frequency L1 2 10‐05‐2012 12:03 0,1 63 High frequency L1 5 06‐05‐2012 05:22 1 79 Long avg. power gen. G high 2 07‐02‐2011 23:17 2,4 205 Short untwist CCW 28 23‐05‐2012 23:40 8,4 206 Long untwist CW 13 05‐01‐2012 01:39 5,7 207 Long untwist CCW 12 09‐02‐2012 01:41 4,3 226 10 min wind speed high 6 03‐01‐2012 22:28 7,6 228 1 min wind speed high 4 03‐01‐2012 22:28 10,3 251 Generator overspeed 1 1 18‐11‐2009 15:52 0,1 252 Generator overspeed 2 1 18‐11‐2009 15:52 0,1 254 Rotor overspeed 1 18‐11‐2009 15:52 0,1 320 Pump time tip brakes too long 5 29‐03‐2012 07:33 478,2 375 Tip brakes pressure too low 5 06‐05‐2012 05:44 36,4 376 Shaft brake pressure too low 1 06‐05‐2012 05:44 0 380 Platform switch 1 30‐08‐2011 07:13 0 395 Vibration in nacelle 4 26‐04‐2012 21:06 351,8 397 Overspeed guard TAC85 2 15‐12‐2011 07:36 0,1 500 24 VDC supply off 5 10‐05‐2012 12:03 0 506 Main CB off 6 10‐05‐2012 12:03 0 510 CB tripped main panel 1 06‐05‐2012 05:44 102,3 531 Gen. g contactor open 2 15‐01‐2010 11:27 1,8 601 Manual stop keyboard 6 29‐03‐2012 09:56 0,2 621 Service key 26 30‐05‐2012 14:33 61,8 981 Cut‐in phase sequence fault 1 06‐05‐2012 03:21 0 998 Max stop time 8 06‐05‐2012 11:44 884,3 999 Max automatic reset times 2 15‐03‐2012 12:15 406,8

NEG Micon Tac84 Parameterliste, type NM900/52. Date : May 30. 2012 Report number : ID : Nr. Tekst Enhed Observeret

1 Vibration m/s2 0,00 2 Wideband m/s2 0,07 3 RPM rpm 0 4 Centerfrekvens Hz 1,89 5 Bandwith Hz 0,33 6 Vibration limit m/s2 1,60 7 RPM max limit rpm 1700 8 RPM limit vibration sensor error rpm 1400 9 RPM limit rpm sensor error rpm 100

10 Impulses/rev 6 11 Time delay sensor error sec 300 12 Minimumlevel wideband for rpm sensor 0,40

13 Minimum level wideband for vib sensor 0,03 14 Sensor calibration mV/G 447 15 Average time sec 5

16 Peak value vibration (edit for reset) m/s2 1,05 17 Max detected rpm rpm 1598 18 Relay function 7

19 No error 0

20 RPM too high 1 21 Sensor error RPM 4 22 No error 0 23 No error 0 24 No error 0 25 No error 0 26 No error 0 27 No error 0 28 No error 0 29 No error 0

Fejltyper: 0 No error 1 RPM too high 4 Sensor error RPM 2 Vibration too high 8 Sensor error Vibration

Definition of shafts Definition of gearmesh

Definition of bearings R = rotor end NR = non-rotor end

High speed shaft

Low speed shaft

Low speed intermediate shaft

High speed intermediate shaft Planet shafts

High speed intermediate wheel High speed pinion

Low speed intermediate wheel

High speed intermediate pinion Sun wheel

Ring gear

Planet wheels

High speed NR-bearing

Low speed intermediate NR- bearing

High speed intermediate NR- bearing

High speed R-bearing

Low speed intermediate R-bearing Low speed R-bearing Low speed NR-bearingPlanet

bearing R

High speed intermediate R-bearing

Planet bearing NR

Wear on gear mesh are given in categories: Category Typical wear pattern K0 No wear or normal running in wear and polishing of tooth flanks. K1 Micro pitting on 1 – 5 % of the tooth flank typical in a corner or along

the bottom of the tooth flanks. Normally a running in phenomenon, which is not developing further.

K2 Micro pitting on a larger area, typical 50 % of the tooth flank. Normally a running in phenomenon, which is not developing further, but it has to be observed closely.

K3 Small pin holes in the surface, typical in the area with micro pitting. Normally a running in phenomenon, which is not developing further, but it has to be observed closely.

K4 Macro pitting and scaling of larger areas. This will lead to break down and the part has to be exchanged.

Indentation marks on gear mesh is given in categories: Category Typical indentation pattern P0 No indentation marks. P1 Few indentation marks from relatively soft particles. Normal pattern. P2 Many indentation marks on the entire tooth flank from relatively soft

particles. The gearbox has to be observed closely for development of wear.

P3 Many indentation marks on the entire tooth flank from hard particles. Rough surface and/or scuffing. Many wear particles in the gearbox. Repair is necessary.

Wear in bearings are given in categories: Category Typical wear pattern L0 No wear. L1 Dull grey surface of the rollers. Light wear stripes. The bearing has to be

observed closely for development of wear. L2 Heavy wear, scaling of material. The bearing has to be exchanged.

Report no. 6758-2 Green-Ener-Tech Aps May 30th 2012 NM 900/52, ID no. 65016

Photo 1. Safety harness in the turbine.

Photo 2. Blade with stall strips.


Photo 3. Main bearing.

Photo 4. Empty lubrication chamber.


Photo 5. Missing part of filt ring.

Photo 6. Stand still marks on rollers.


Photo 7. Stand still marks and light pitting on inner ring.

Photo 8. Gear stag on R side.


Photo 9. Gear stag on NR side.

Photo 10.Oil level in gearbox.


Photo 11. Gear wheel on low speed intermediate shaft.

Photo 12. Pinion on high speed intermediate shaft.


Photo 13. Gear wheel on high speed intermediate shaft.

Photo 14. Pinion on high speed shaft.


Photo 15. NR-High speed shaft.

Photo 16. No particles were found on flexible magnet.


Photo 17. Transmission shaft between gearbox and generator.

Photo 18. Cable connection box for the generator.


Photo 19. The cooler.

Photo 20. Break disk protection cover.


Photo 21. Gasket between nacelle and nacelle hatch.

Photo 22. PFC system.

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