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REPORT BY :- MITESH SINGH

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MECHANICAL HUB ASSEMBLY MECHANICAL ASSEMBLY:Whole the mechanical assembly covers two type of assembly 1) Rotor hub assembly 2) Nacelle assembly

1) ROTOR HUB ASSEMBLY:It contains following assembly which are given below a) Blade adaptor assembly b) Hub assembly c) Axle pin assembly d) Hub assembly to the rotor disc e) Stator jib preparation f) Mounting of stator disc on jib carrier g) Spinner assembly A) BLADE ADAPTOR ASSEMBLY:Blade adaptor assembly contains some important part which is given below. 1. Pitch bearing 2. Pitch motor drive 3. Blade adaptor body 4. High strain sensor 1) PITCH BEARING:Pitch bearing is used for wind turbine rotor hub, the pitch bearing comprising cylindrical inner bearing ring connectable to a rotor blade of the wind turbine rotor, a cylindrical outer bearing ring connected to the hub of the wind turbine rotor . SPECIFICATION:MANUFACTURER :-KAYDON Made :-Made In India Running Torque :- 1172 N-m (it may change ) Weight :-395 kg Greasing point :-13Nos (7 nos. in lower portion,6 nos. in upper portion)& 3Nos. extensions lubrications tins 2) PITCH DRIVE:Pitch drive system for a wind turbine is provided which comprises a regulation the pitch of a rotor blade of the wind turbine during normal operation. SPECIFICATION:Manufacturer :-Transmittal Bonfiglioli Ratio :-1/63-2 Oil (lubrication):- Shell TIVELA SC 320

3 3) BLADE ADAPTOR BODY:¾ It contains a flange for the blade. ¾ Arrangement is given for fixing pitch bearing and pitch gear drive a groove for “O” ring ¾ Two holes for High sensitive strain sensor. 4) HIGH SENSITIVE STRAIN SENSOR:A method for limiting loads in a wind turbine by using measured loads or wind speed to increase the minimum pitch angle for extended periods. The method will allowed turbine to capturing more energy by operation in high wind speeds and or utilizing larger rotors without additional loss of fatigue life. WHOLE ASSEMBLY OF BLADE ADAPTOR:¾ Carry the blade adaptor casing from the place where it already approved by Q.A. mount the casing on stand and clean it with diesel & cotton waste ¾ Fix the “O”ring in the groove of pitch drive housing in blade adaptor casing ¾ Fastened studs of M24*190,10.9tzn 48 No.to maintaining the height of studs 145 mm with the Use of Molykote (Heavy duty grease) ¾ Take pitch bearing, which already lubricated by Mobil SHC 460 and fix it into the stud at torque 790N-m. ¾ Check backlash which has the value in between 0.15 to 0.3mm allowable, this testing carried out where the teeth of gear thickness is more than others.

B) HUB ASSEMBLY:Hub assembly’s main component is given below. 1)Front or outer race and inner race 2)Centering ring 3)Rubber sealing 4)Sealing ring 5)Temperature sensor frame 6)Angle encoder 7)Pulsor sensor frame PULSAR SENSOR FRAME:Pulsar sensor frame is used to mount pulsor sensors. In each blade adaptor one pulsar sensor is there. Mainly pulsar sensor comprises with Blade pitch in & out. HUB ASSEMBLY ACCEPTANCE PARAMETERS:S.No

Description

Required Dimension in mm

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Front bearing assembly inside Diameter 340 mm Rear bearing assembly inside

339.867-339.903

Observed Dimension in mm 339.87/89

739.832-739.912

739.89/90

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4

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Diameter 740 mm Sealing Ring assembly inside Diameter 760 mm

760.000-760.125

760.08/09

HUB ASSEMBLY ¾ Mount the hub assembly on the stand. ¾ Clean the front as well as rear portion with rust cleaner. ¾ Retapping procedure is carried out on the threaded hole by the use of thread taps. ¾ On L,R&G flange sealing is carryout with rubber ring and finally two end of it is joint by Lucite 638. ¾ Before the assembly of outer race, inner race and centering plate these part are frozen up to -45˚c because there some shrinkage are formed in these three so they can easily inserted In the front and rear side. ¾ After fixing front & rear race we put a seal ring having a size of 760*720*20,before sealing ring putting on the outer race applying Loctite 638 .On the surface of outer race and then fix it with M8*10 in 8 Nos. with washer ¾ Fastened angle encoder frame & temp. Sensor frame and three extensions tins on front as well as rear for lubricating purpose. ¾ Now cover the rear portion of hub with the help of polyethylene and after that stand it. ¾ Three blade adaptor assemblies is going to fix with hub assembly one by one. ¾ With the help of M24*170 30Nos. bolts at torque 790N-m blade adaptor is fix with hub flange aligned using a 1.5mm feeler gauge. ¾ Pitch motor mounted on all the three blade adaptor. ¾ Three pulsor frames fitted on blade adaptor from the one slot which in hub with reference to that from counters clock wise it locates 9&10 position. ¾ Fastened the double spoke with (M16*135)at rear side and for front side we are using three sizes of bolts M16*70 for cable mounting (Z-clamp) 3Nos. M16*80 for single spoke mountings in 6-Nos. M16*60 for (Bearing cover) ¾ Frame for temperature sensor fitted by 2nos. M8*16 mm hardware at the upper side and lower side of the hub. ¾ On Z Clamp (for cable guide) by M12* 35 8.8 & Sensor holding plate are fitted to their position with square plate for mounting the load distribution box.

C) AXLE PIN:It contains, 1) Taper collar (Big & Small) 2) Taper thrust bearing (Big &Small) 3) Bearing cover 4) V-shaped ring 5) Locking plate 6) Locking nut AXLE PIN ASSEMBLY:¾ First of all clean axle pin with diesel by the use of cotton waste. ¾ Insert the taper collar first & then taper bearing (having specification BT1-8034/HB1 UK 443 )at rear side which have heated up to 110˚C by the use of induction heater.

5 ¾ Lubrication carried out of taper bearing with SHC-460. ¾ Insert the hub assembly into the axle pin with careful by the use of crane. ¾ After completion of hub assembly to the axle pin, insert the small taper roller bearing (32044X) at front side which is heated up to 70˚C. ¾ Then after thrust collar with same procedure and then fix bearing cover(contains shaft sealing ring 270*240*15)already fix in bearing cover with the help of Loctite 574,vshaped ring ¾ One fixture is there with the use of it holds the shaft nut and people rotate the whole assembly in three complete rotation this method used to lock shaft nut in axle pin. AXLE PIN SPECIFICATION:S.No

Description

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Front bearing assembly outside Diameter 220 mm Rear bearing assembly Outside Diameter 600 mm

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Required Dimension in mm 220.004-220.33

Observed Dimension in mm 220.006/015

599.978-600.022

599.98/99

D) PREPARATION HUB ASSEMBLY TO ROTOR DISC:¾ Mount the rotor disc on the stand and place the hub assembly with careful and fastened it by the M24x160 with torque 790 N-m. ¾ On rotor disc all the ten boxes to be mounted (3-relay,3-capicitor,3-pitch drive,1-rotor sub distributor) on the opposite side of hub mounting. ¾ Drilling tapping to be done for air gap switches. ¾ Electrical wiring & similarly testing carried out. pitch-in, pitch-out testing to be done by electrical person individually. ¾ Pole shoe painted with spray paint named DRY LUBE (MOLY) which has property of temp. Resistant 399˚c &extreme pressure and lubricating. ¾ Brake disk fitted to rotor disc by using M12x50 on the torque of 100N-m. ¾ By the use of dial gauge peak pole is measured. MAIN COMPONENT OF STATOR JIB:1) Hydraulic brake 2Nos.(Brake body part and brake pads and, having specification of Max pressure 140bar,oil type-46PG, working temperature -10to60˚c.) 2) Hydraulic motor & its resting steel post 3) Polyamide clamp 4) Bush and steel spindle for rotor lock 5) Hose pipes for the connection to motor to brake (400mpa) 6) Insulation paper

E) STATOR JIB PREPARATION:¾ Cleaning and re-tapping of stator carrier. ¾ At 10’o’ clock position one arrangement is there for manual lock called rotor lock, they inserted bush in between slot and shaft spindle to reduce wear and tear.

6 ¾ Isolation films installs at all 12’o’clock positions. ¾ At 2’o’clock and 8’o’clock hydraulics break mounted with M16*210 stud and given a torque of 230Nm.At 6’o’clock positions 3 phase induction motor rated 0.37 KW is fitted to tray by M12*30, for hydraulic brake. ¾ Speed sensor clamp mounted in between 10 o’clock and 12’o clock arm by two M8*20 bolts ¾ At 4’o’ clock position main polyamide(power cable) mounted for main supply. ¾ Testing of hydraulic brake is carried from the panel manually at 140 bar which can adjusted as per required. ¾ Mount the stator on jib carefully by the use of with the torque of 790 N-m ¾ Mount the rotor hub assembly on the stator jib assembly. AIR GAP TESTING PROCEDURE ¾ After mounting of rotor disc on the stator jib assembly checking of air gap take high peak pole as a reference between rotor and stator is carried out by the use of feeler gauge. ¾ According to reading little bit air gap setting carried out, with the use of fixtures at all positions. ¾ Take reading at all 6th positions and then take sum of total values divide it into 6 part Pos.6=2.5 Pos.8=2.6 Pos4=-2.3

Pos.10=2.7 Pos.2=2.5 Pos.12=2.6

Calculation given below: #Total values-2.3+2.5+2.5+2.6+2.6+2.7=15.2mm 15.2/6=2.5333mm (2.5x5)+2.7=15.2mm ¾ This max. value put at 6th position because of when it is in practice 6th position is at lower side due to weight of assembly affected at lower side so it’s value always kept higher than others. AXIAL PLAY TESTING PROCEDURE:¾ To check axial play tied up with all three blade adaptor, in initial position. ¾ Then after dial gauge mount on the blade adaptor and give some pressure, set it zero. ¾ After setting over of dial gauge the whole assembly hooked up with crane & notes the reading of dial gauge that how much it was hooked? ¾ After seeing reading it indicates the total axial play. ¾ It should be within 0.1 mm.

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G) SPINNER CASING ASSEMBLY:¾ Spinner casing assembled in three segment also top dome (nose cone) is in three parts. ¾ All three segments are assembled and outer surface is checked. It is fastened with M12 hardware. And the loose part is fitted. ¾ The Blade sealing brushes are fitted to the blade openings of the spinner cap for protection from dust. All joints are sealed with Carlo flex/farm flux adhesive (silicon paste). ¾ The three parts of the top dome of the Spinner cap are assembled and the joints are sealed with the silicone paste.M12 x 35mm are used.

F) TESTING IN ROTOR ASSEMBLY:¾ Various tests are done in the rotor head assembly. Before going for any test connection are properly checked. Following are some test described. 1)_ZERO DEGREE TESTING:¾ Clinometers (Spirit level gauge) reading is calibrated by placing on the lock nut of axle pin. ¾ Then the support channel for blade is mounted on the 5th hole (reference hole) on the blade adopter. ¾ Now the Clinometers is place in the support and the adopter is adjusted upto 0˚ ¾ It is mechanically now set on zero degree. But in the mean time electrical zero degree is not achieved. ¾ To get the electrical zero degree CLS is adjusted. The SW7 screw (inner screw) is loosen and SW19 (outer screw) is tighten by applying 100Nm torque. ¾ Tighten the screw SW7 on which CLS shows the Zero degree. ¾ Now it is both mechanically and electrically set to zero. 2) 3.07 DEGREE SETTING AND PITCH IN/OUT TEST:¾ Adjust the distance between the sensor and the 3 deg. Mark to 1.0 to 1.5 mm and checked with filler gauge. ¾ Set alpha minimum to -3 degree. Slowly pitch blade adopter forward. ¾ The -2 degree limit switch reacts at a -2 degree +/- 1 degree blade angle and the capacitors move the blade adopter back to 97deg ¾ Press pitch blade out of ES-95 along +, the blade adopter moves to 56 degree & check that the sensor reacts at 58 to 54 degree. ¾ Again position the blade adopter to 92 deg move to set alpha minimum to 0 degree. Use blade in until blade out appears then the blade out the blade back to approx 92 degree. Overall it should be between 53 º - 59 º. ¾ Pitch the blade to approximately 56º& switch off the MSC. See that all blades are pitched out to 90-92 degree position. See to it that the capacitor voltage does not fall below 60V & 160V BALANCING OF ROTOR: ¾ Rotor head is placed on balancing chamber and spinner casing equally marks at twelve positions. Weights of rotor are measured at all positions and add weights at determined

8 position. Now go for next run until the permissible difference between max. And min. values in the final run are +/-1 Kg. PROCEDURE: ¾ The complete generator assembly is lifted and kept on the balancing unit in such a way that 12’ O clock arm of stator jib should come exactly on load cell. For this purpose generator assembly is divided into 12 or 6 rotor positions each displaced by 30º or 60º (1145 mm/115 cm from each other). ¾ Measure 550 mm from (FRP joint or Pole no.-5) to right side towards 12’ O clock position and mark it position no.-1. Measure 1145 mm from position no-1 towards right side and mark it position no-2. Similarly mark 12 positions, each mark are displaced from each other by 30º (Mark 6 positions, if rotor webs having only six weight plate mounting holes). ¾ Connect the calibrator unit with load cell cable. Rotate the generator assembly in such a way that marked position -1 come over load cell. Set the calibrator to 00 for position-1. Now bring position -2 over load cell and note the reading of calibrator display in protocol in KG. Similarly, take readings of all 12 or 6 positions. Then the minimum weight and maximum weight and added and putted in the minimum weight position. ¾ The same process is repeated until the weight difference becomes