AP SLPS Installation Guide for G8/G9

AP SLPS Installation Guide For G8/G9

Art. Code D0077 Rev. 16 19/October/2018

Author Jacob Nicholas The information throughout this document is a property of Applied

Philosophy and cannot be used or reproduced without written

permission of the owner Audience Clients Pages 13

AP SLPS Installation Guide For

G8/G9

AP SLPS Installation Guide for G8/G9 D0077 R 16

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Contents

1 Summary Sheet...................................................................................................... 3

2 Terms and Names .................................................................................................. 4

3 SLPS Installation .................................................................................................... 5

4 Recommended Turbine Grounding Verification ...................................................... 11

5 Appendix A: Installation Checklist ......................................................................... 13

This document is not a substitute for the

appropriate safety trainings and turbine access

and maintenance documentation.

Before working on the LPS, ground the Blades

first.

The blade static electricity can be fatal.

The lubricant gel on the SLPS is a chemical.

Protect your skin by using gloves and avoid skin

contact.

Unsafe work at height is a risk to you, to others

and the equipment. Tie-off yourself and your

tools when working in the tower.


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1 Summary Sheet

Applicable Parts D0080, D0081, D0082

Target Equipment Gamesa 2.x MW Platform (G80, G87, G90, G97)

Brief Process Flow 1. Access the nacelle. 2. Lock the rotor and Install the SLPS on Blades A, B and C. 3. Verify correct installation. 4. Inspect Nacelle Grounding cables and clean if required. 5. Exit and return turbine to Service.

Installation Time 1 hour + 1 hour for optional nacelle grounding cleaning.

Skill Level Basic training and ability to access nacelle and lock rotor.

Tools

• Blade grounding cable

• Permamnent marker with sharp tip(e.g. small Sharpie)

• 2 x Channel locks or Vise-Grips

• 2 x 10mm wrench or socket set

• 2 x 13mm wrench (for nacelle grounding cleaning)

• Tool tie-off(s)

• Dremel tool with sanding drum (for nacelle grounding cleaning)

• Smartphone with camera (for verification)

Material • Non-permanent threadlocker (e.g., “Blue Loctite”) • Protective paint (e.g., Zinc-It) (nacelle grounding cleaning)

Task-Specific Risk 1 Proximity to or contact with the Blade LPS.

Risk Mitigation 1 Ground blades using appropriate grounding cables.

Task-Specific Risk 2 Nacelle grounding cleaning requires work while on ladder.

Risk Mitigation 2 Use Personal Protection Equipment, tie-off tools.

Compliance Installation Checklist with photo verification.


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2 Terms and Names

Figure 1: Tower

Figure 2: SLPS on a Candlestick

Figure 3: Blade root

Figure 4: Rotor Cuff

Location of

WT991(A/B/C/D)

Inside the tower

Location of

WT991(A/B)

SLPS Blade Side

SLPS Nacelle Side

Blade Root

Conduction Band

Rotor Cuff

(Gutter Ring)

Arc Receptor


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3 SLPS Installation

1. Lock the rotor with Blade A in top position.

Figure 5: View of Blade in up position

2. Ground the blade using approved and safe techniques as prescribed by the

manufacturer and/or wind farm protocols.

Before working on the LPS, ground the Blades

first.

The blade static electricity can be fatal.

3. Mark the installation date with a permanent marker (e.g. Sharpie) on the SLPS

installation label. Mark the serial number in the checklist

4. Remove lightning system Arc Receptors (i.e., the bronze tips of the “candlestick”

arm, e.g. GP096408 or any other variation) using vise grips or channel locks. If

the tips require excessive force, use two pliers on either end (counteracting each

other) to avoid damaging the white support arm.


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Figure 6:LPS Insulation cylinder(Candlestick) with the bronze Arc Receptors in highlighted

Figure 7 LPS with Arc Receptors Removed

5. Use gloves to handle the SLPS

6. With the arc receptors off, manually open the SLPS mounting bracket legs to

appropriate width to install the SLPS on the Transmission Cylinder studs (the

metal cylinder that the Arc Receptors are screwed on to). The following conditions

should be met after proper installation:

• The loop end of the SLPS must meet the Blade Root Conduction Band (the

discharge band on the blade)

• The tail end must meet the nacelle Rotor Cuff (i.e., “gutter ring”)

• With the blade and candle stick pointing up, the SLPS must be on the

generator side. That is to say the SLPS is to the right of the LPS

(“candlestick”) body when looking at it from inside the nacelle


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Figure 8: SLPS being Installed(photo taken from the Converter side)

Figure 9: SLPS in place. Pay attention to the Blade and Nacelle side drecton

7. Apply small amount of threadlocker(Loctite) and re install the Arc Receptors and

tighten with channels locks or Vise Grips. Use counter-acting force on both ends


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to avoid damaging the white support arm (i.e., the “Candlestick” white support

arm).

Figure 10: Arc Receptor. Use Thread Locker (Loctite) in the hole

Figure 11: The Arc Receptors being secured back in

8. Ensure that the SLPS conductor meets the Rotor Cuff (Gutter ring).


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Figure 12: SLPS meeting the Blade and the Rotor Cuff (Gutter ring)

9. Verify ALL 4 screws and nuts holding the LPS Insulating Arm(Candlestick Arm) to

the Base Plate are tight. (The Base Plate is the metal bracket holding the

“Candlestick” to the Blade bolts). Use 2x 10mm wrenches.

• If any screw is missing, replace with identical replacement and tighten

• If adjustment is needed use the bolts holding the LPS insulating arm to the

Base Plate to raise the support and align

• Position the insulation arm to maximise the contact of the SLPS conductors

with the Blade Root Conduction Band and the nacelle Rotor Cuff particularly

when the blade is up.

Figure 13: Support arm bolts. Verify tightness.

10. Remove grounding cables from the blade Conduction Band and unlock the rotor.


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Figure 14: Installed SLPS

11. Pinwheel the rotor to make sure the SLPS is free, allow a full rotation and verifying

that there are no burrs on the nacelle Rotor Cuff exist that could damage the

SLPS.

• It is recommended to use a file, a Dremel or a drill with a grinding wheel to

remove excessive and sharp burrs on the Rotor Cuff to prevent premature wear of

the SLPS

• Ensure that the SLPS nacelle-side tail is in contact with the Rotor Cuff. If

continuous contact throughout the circle of the rotor is not possible due to

distorted geometry of the Rotor Cuff, align the SLPS such that as much contact as

possible is maintained when the blade is up.

• With the rotor pinwheeling, listen for any cogging of the SLPS and rectify as

needed

12. Take photos of the installation.

13. Fill out the appropriate section of the Compliance Checklist.

14. Repeat for Blades B and C.


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4 Recommended Turbine Grounding Verification

√

If instructed by the Plant Manager or the Support

Engineer in charge of the plant, proceed with

this section

1. Verify that the main nacelle grounding cable, WT991A and WT991B, located under

the gearbox on the Generator side, are installed on clean surfaces.

Figure 15: Location of the grounding connection from near the Generator Coupler

2. Remove the bolts with 13mm socket and clean the surface and the lug with sand

paper and or a Dremel tool with a sanding drum. Ensure that all paint and grease

is remove and you achieve a metal to metal contact between the lug and the

frame. In absence of a Dremel tool, a drill with a grinding wheel could help the

clean up. Avoid excessive sanding and any gouging of or recess in the metal.

3. Re-install the lugs and the bolts and tighten to 20Nm

4. Apply Zinc-it or similar protection

Figure 16: Example of Bad Connection Surfaces


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5. Exit the nacelle and find the midtower grounding tabs where the cables WT991A

and WT991B terminate. (This tab is usually located above the highest deck in

G80-G90 and below the highest deck in G97. )

Figure 17: Example of a Tower grounding tap

6. If the connections appear rusty or otherwise sub standard,

• remove the lugs

• Clean the surface of the tower grounding tab

• Clean the surface of the lugs

• Apply a very thin layer of conductive grease and reconnect the grounding

cables and reinstall the bolts. If one of the designated holes on the tower

tab is obscured by the ladder support, use both sides of the tab with the

remaining holes and double up the lugs

• Coat the area with protective paint (Zinc It)

• Make sure all cables are properly supported and if needed use more zipties

to secure the cables.

AP SLPS Installation Guide For G8/G9

Art. Code D0077 Rev. 16 19/October/2018

Author Jacob Nicholas The information throughout this document is a property of Applied

Philosophy and subject to copyright and reuse restrictions

assigned Confidentiality 6 Pages 13

5 Appendix A: Installation Checklist

Date and Time

Technician Name

Wind Farm

Turbine Number

SLPS Serial Numbers A: B: C:

SLPS Installation

Step Blade A Blade B Blade C

SLPS Installed Factory LPS Arc Receptors reinstalled and tightened on both

ends with Vise-Grips

SLPS tail touching the nacelle Rotor Cuff(Gutter Ring)) SLPS loop touching the blade root conduction band (not above

or below) SLPS loop not touching the Conduction Band Bolt at 90 and 0

Degrees

LPS Insulation (White Support Arm) Screws are tight

Nacelle Grounding Improvements

Step

Nacelle grounding cable WT991A and WT991B (Under the gearbox, generator side) are

clean and retightened with conductive grease

Zinc-It sprayed on to the grounding bolt for WT991A/B after cleaning Mid-tower grounding cables (WT991A, WT991B, WT991C, WT991D (near the highest

tower service platform) are cleaned(sanded) and reinstalled with conductive grease

Zinc-It sprayed on to the grounding bolt for WT991A/B/C/D after cleaning

√

Take a photo of this checklist and each installed

SLPS with a phone and email to

[email protected]

Documents

AP SLPS Installation Guide for G8/G9