LAGERWEY L100 - Rijksdienst voor Ondernemend … Deel 2b... · ISO limits and fits NEN-ISO 286-2 WdR WdR ISO Transport Nacelle type 2 Gen. 2768-c 16500 ... Lagerwey Wind BV // Anthonie

LAGERWEY L100

American proj.

120m

100m

E

7-5-2014

-

12345678

F

E

D

C

B

A

Scale:size

A3

Init.Description

Initials

Rev Date

Surface roughness ISO 4287

Date Sign

Rev.

© Copyright Lagerwey Wind BV

Module:

Drawing no.:

Weight:

NEN-ISO 1101

mm

Material:

Description:

Surf.treatment:

Document class no.

H

kg

F

L100 2.5-3MW hub height 120m IEC STol.

Welding symbolic ISO 2553

EB

1302ISO

2768-c

of

ISO limits and fits NEN-ISO 286-2

-

Drawn

Gen.

20-000085Approve

A

A

Turbine

A

A

units

unauthorised disclosure, reproduction or use is prohibited. It is subject to change without notice.

First release

M00-C7

1 1

Check

EB

Sheets:

-

1:700

None

C

B

G

D

NEN-ISO7-5-2014

This document is confidential. It contains confidential, proprietary and privileged information and

-

American proj.

1450

320

3545

3641

3373 1540

4906

Mass including transport tooling 16,5 tons

2600

-

12345678

F

E

D

C

B

A

Scale:size

A3

Init.Description

Initials

Rev Date

Surface roughness ISO 4287

Date Sign

Rev.

© Copyright Lagerwey Wind BV

Module:

Drawing no.:

Weight:

NEN-ISO 1101

units

Material:

Description:

kg

04-07-2011

mm

Surf.treatment:

Document class no.

ISO limits and fits NEN-ISO 286-2

WdR

WdR

ISOTransport Nacelle type 2

Gen.

2768-c

16500

Tooling

Drawn

Approve Welding symbolic ISO 2553

Check

A

20-900719

of

A

A

Sheets:

B

1:50

First release

-

M90-C5

1

A

Tol.

NEN-ISO

-

unauthorised disclosure, reproduction or use is prohibited. It is subject to change without notice.

1

C

1302

04-07-2011

D

F

E

H

G

This document is confidential. It contains confidential, proprietary and privileged information and

-

Lagerwey Wind BV // Anthonie Fokkerstraat 2 // 3772 MR Barneveld // The Netherlands //Tel: +31 342 751935 // Fax: +31 342 751939 // [email protected] // www.lagerweywind.nl

© Copyright LagerweyWind BV. This document is confidential. It contains confidential, proprietary and privileged information. No part of this document may be reproduced or published

by print, photocopying, microflim or any other means without written permision from the author. The document is subject to change without notice. 1 - 2

20140507R1 AFVALSTOFFEN EN AFVOER L82-L93-L100

WINDTURBINES.DOC

DATE 2-6-14 MADE BY Wim Robbertsen

Revision Date Initials Short description

0

07-05-2014 WR New layout

1

02-06-2014 WR Added type and quantities of lubricants

Overzicht van afvalstoffen voor de windturbine types L82-L93-L100*

Hoeveelheid bij installeren

verbruik per jaar

Afvoer, altijd door een erkende organisatie, te vinden op de VIHB lijst

Metaalresten 0,0 0,0 nvt

Hout 3,0 m3 0,0 Afvoer geregeld door Lagerwey

Kunststoffen 100 kg 0,0 Afvoer geregeld door Lagerwey

Kabelresten 50 kg 0,0 Afvoer geregeld door Lagerwey

Oliën 0,0 11 Liter Afvoer door Lagerwey service team

Vetten 0,0 12 kg Afvoer door Lagerwey service team

Algemene afvalstoffen 3,0 m3 0,1 m3 Afvoer door Lagerwey service team

Lagerwey Wind BV // Anthonie Fokkerstraat 2 // 3772 MR Barneveld // The Netherlands //Tel: +31 342 751935 // Fax: +31 342 751939 // [email protected] // www.lagerweywind.nl

© Copyright LagerweyWind BV. This document is confidential. It contains confidential, proprietary and privileged information. No part of this document may be reproduced or published

by print, photocopying, microflim or any other means without written permision from the author. The document is subject to change without notice. 2 - 2

Hoeveelheden en locaties van de aanwezige smeermiddelen:

Smeermiddel locatie hoeveelheid Gebruikt voor

Mobil SHC 460 WT vet In krui- en bladlagers 20 Liter voor raceway

Castrol Optipit vet In krui- en bladlagers 8 Liter Voor vertanding

Mobil SHC 632 olie hoofdlager 30 Liter voor raceway

Mobil SHC 460 WT grease hoofdlager 0.5 Liter Voor keerring

Mobil DTE 15M olie Hydrauliek systeem krui- remmen

3 Liter Voor kruirem

Shell Tivela oil S320 oil Krui- tandwielkasten 84 Liter 4 stuks , 21 Liter per stuk

Shell Tivela oil S320 oil Pitch- tandwielkasten 26,1 Liter 3 stuks, 8,7 Liter per stuk

* De hoeveelheden aangegeven in de eerste tabel geven het gemiddelde van de af te voeren smeermiddelen. Afhankelijk van samenstelling zoals die uit testresultaten van de jaarlijkse onderzoeken komen, wordt de vervangingsfrequentie bepaald. Om meerdere redenen wordt die zo laag mogelijk gehouden met een bewaking van de juiste kwaliteit.

1 Generator met hoofdlager 10 Krui- rem

2 Naaf met bladlagers en pitch systemen 11 Luik achterzijde

3 Blad 12 Luik bovenzijde

4 Hoofdframe 13 Anemometer, windsnelheid-en richting meter

5 Toren 14 bliksembeveiliging

6 Gondel/ nacelle 15 bladlager

7 Controller 16 Hydrauliekpomp voor krui-rem

8 Krui-systeem, motor met tandwielkast 17 Service kraan

9 Krui- lager

NORDEX N117

Format: A3

Blatt/sheet: 1/4

Dokumentennummer/ document number:

K0801_041624_IN_R01

Datum/ Date: 22.01.2013

Nordex N 117/3000

Variante Trafo im Turm/ variant internal

transformer

Nabenhöhe/ Hub heigth: 120 m +1,10 m

3,91 m

11

8,0

m

12

0,0

m

17

8,4

m

14,54 m

A=10.715 m²

116,8 m

Diese Darstellung ist nicht maßstabsgerecht

This image is not according scale

Maßstab/scale: 10 m

3,5° + 2 m

+0,0

4,38 m

Format: A3

Blatt/sheet: 2/4

Dokumentennummer/ document number:

K0801_041624_IN_R01

Datum/ Date: 22.01.2013

Nordex N 117/3000

Variante Trafo im Turm/ variant internal

transformer

Nabenhöhe/ Hub heigth: 120 m

117,8 m

Format: A3

Blatt/sheet: 3/4 Dokumentennummer/ document number:

K0801_041624_IN_R01

Datum/ Date: 22.01.2013

Nordex N 117/3000

Variante Trafo außerhalb Turm/ variant

external transformer


3,91 m

11

8,0

m 1

20

,0 m

17

8,4

m

14,54 m

A=10.715 m²

116,8 m

Diese Darstellung ist nicht maßstabserecht


Maßstab/scale: 10 m

3,5° + 2 m

Diese Darstellung ist nicht maßstabserecht


+1,10 m

+0,0

4,38 m

Diese Darstellung ist nicht maßstabsgerecht


Format: A3

Blatt/sheet: 4/4 Dokumentennummer/ document number:

K0801_041624_IN_R01

Datum/ Date: 22.01.2013

Nordex N 117/3000

Variante Trafo außerhalb Turm/ variant

external transformer


117,8 m

2013 by Nordex Energy GmbH

Sales document

Wind turbine class K08 deltaType: N117/3000

Technical description

K0801_041798_EN

Revision 01 / 2013-01-18

- Translation of the original sales document - This document is a translation from German. In case of doubt, the German text shall prevail.

Document is published in electronic form.

Signed original at Nordex Energy GmbH, Department Central Engineering.

2013 by Nordex Energy GmbH

Technical modifications

This document was created with utmost care, taking into account the currently applicable standards.

However, due to continuous development, the figures, functional steps and technical data are subject to change without prior notice.

Copyright

Copyright 2013 by Nordex Energy GmbH.

This document including its presentation and content is the intellectual property of Nordex Energy GmbH.

Any disclosure, duplication or translation of this document or parts thereof in printed, handwritten or electronic form without the explicit approval of Nordex Energy GmbH is explicitly prohibited.

All rights reserved.

Contact details

For questions relating to this documentation please contact:

Nordex Energy GmbH

Langenhorner Chaussee 600

22419 Hamburg

Germany

http://www.nordex-online.com

[email protected]


mailto:[email protected]

Table of Contents Revision 01 / 2013-01-18

K0801_041798_EN Page 3 of 15

1. Set-up................................................................................................................... 4

1.1 Tower .................................................................................................................... 4

1.2 Rotor ..................................................................................................................... 6

1.3 Nacelle .................................................................................................................. 6

1.4 Auxiliary systems .................................................................................................. 8

2. Functional principle.......................................................................................... 10

3. Technical data ................................................................................................... 11

4. Revision index................................................................................................... 15

Revision 01 / 2013-01-18 Sales document

Page 4 of 15 K0801_041798_EN Tower

1. Set-up

The Nordex N117/3000 wind turbine is a speed-variable wind turbine with a rotor diameter of 116.8 m and a nominal power of 3000 kW. This wind turbine is designed for 50 Hz or 60 Hz. The wind turbine is designed for class 2a in accordance with IEC 61400-1.

The wind turbine Nordex N117/3000 is made up of the following main components:

● Rotor, consisting of rotor hub, three rotor blades and the pitch system

● Nacelle with drive train, generator and yaw system

● Tubular tower or hybrid tower with foundation

● Medium-voltage transformer (MV transformer) and medium-voltage switchgear (MV switchgear)

1.1 Tower

The Nordex N117/3000 is erected on tubular steel towers or hybrid towers for different rotor hub heights and wind zones.

The tubular steel tower is a cylindrical tower. The top section is conical. Depending on the hub height, it consists of four to seven tower sections.

Corrosion protection of the tubular steel tower is ensured by a tower surface coating system according to ISO 12944.

A service lift, the vertical ladder with fall protection system as well as resting and working platforms inside the tower allow for a weather-protected ascent to the nacelle.

The Nordex N117/3000 turbine may be erected on a hybrid tower, too. The bottom part of the hybrid tower consists of a concrete tower and the top part of a tubular steel tower with two sections.

The foundation depends on the ground conditions at the intended site. An anchor cage is imbedded in the foundation for anchoring the tower. Tower and anchor cage are screwed together.

In the standard version, the tower base only accommodates the switch cabinet. The switch cabinet contains important components of the electronic controls, turbine PC, frequency converter, main switch, fuses and outputs to the transformer and to the generator.

The frequency converter is equipped with a water cooling system. The water which was heated in the frequency converter is cooled in a water/air heat exchanger. It is located at the outside close to the tower door.

The MV transformer and MV switchgear are located in a separate transformer substation near the wind turbine.

Sales document Revision 01 / 2013-01-18

Tower K0801_041798_EN Page 5 of 15

Fig. 1 Sectional view of the tower base, standard version

1 Soil backfill

2 Tower anchoring

3 Stairs

4 Tower door

5 Ventilation/cooling

6 Power cables

7 2nd Tower platform

8 Switch cabinet

9 1st Tower platform

10 Transformer substation

As an option, the MV transformer and MV switchgear can also be installed in the tower base. In this case, the components are arranged in the tower base on three different levels:

● The MV transformer on the foundation

● The MV switchgear on the 1st tower platform

● The switch cabinet with frequency converter on the 2nd tower platform

In the case of a separate transformer substation, the MV transformer is usually designed as an oil transformer. If the transformer is installed inside the tower, a dry-type transformer is used.


Page 6 of 15 K0801_041798_EN Rotor

1.2 Rotor

The rotor consists of the rotor hub with three pitch bearings and three pitch drives for blade adjustment as well as three rotor blades.

The rotor hub has a modular design. The base frame of the rotor hub is made up of a stiff cast structure. Onto this element pitch bearing and rotor blade are mounted. The rotor hub is covered with the spinner which enables the direct access from the nacelle into the rotor hub.

The rotor blades are made of high-quality glass-reinforced and carbon-fiber reinforced plastics. Each rotor blade is equipped with a highly effective lightning protection system.

In accordance with the guidelines IEC TS 61400-23 and GL IV-1 (2400) the rotor blade is statically and dynamically tested with loads that were even beyond standard design requirements.

The pitch system serves to adjust the pitch angle of the rotor blades set by the control system. For each individual rotor blade, the pitch system comprises an electromagnetic drive with 3-phase motor, planetary gear and drive pinion, as well as a control unit with frequency converter and emergency power supply. Power supply and signal transfer are realized through a slip ring assembly located in the nacelle.

1.3 Nacelle

The nacelle contains essential mechanical and electronic components of the wind turbine. The nacelle is mounted on the tower in rotating bearings.

The rotor shaft is mounted on the rotor bearing in the nacelle. In the rotor bearing a mechanical rotor lock is integrated used to securely lock the rotor.

The gearbox increases the rotor speed until it reaches the speed required for the generator.

The bearings and gearings are continuously lubricated with cooled oil. A 2-stage pump enables the oil circulation. A combined filter element with integrated coarse and fine filter removes solids. The control system monitors the level of contamination of the filter elements (differential pressure measurement). Optionally, an additional offline filtration can be installed (super fine-mesh filter 5 µm).

The gear oil used for lubrication also serves as a gearbox cooling. The temperatures of the gearbox bearings and the oil are continually monitored. When the optimum operating temperature is not reached yet, a thermal bypass shorts the circuit and conducts the gear oil back to the gearbox. If the optimum working temperature of the gear oil is exceeded it is cooled down.

The gearbox cooling is achieved with an oil/water cooler with stepped cooling capacity. The cooler is installed directly at the gearbox. The heated cooling water is recooled together with the cooling water of the generator in a passive cooler on the roof of the nacelle.


Nacelle K0801_041798_EN Page 7 of 15

Fig. 2 Nacelle layout drawing

1 Heat exchanger

2 Switch cabinet 2

3 Switch cabinet 1

4 Hydraulic unit

5 Gearbox

6 Rotor shaft

7 Rotor bearing

8 Yaw drive

9 Gear oil cooler

10 Rotor brake

11 Coupling

12 Generator

13 Cooling water pump

14 Hatch for on-board crane

15 Switch cabinet 3

The generator is a 6-pole double-fed asynchronous machine. An air/water heat exchanger is mounted on the generator. The cooling water is recooled together with the cooling water of the gearbox heat exchanger in a passive cooler on the cabin roof.

1

32

4

6

8

7

9

5

15

14

1312

1110


Page 8 of 15 K0801_041798_EN Auxiliary systems

The mechanical rotor brake supports the aerodynamic braking effect of the rotor blades as soon as the speed falls below a defined value and finally stops the rotor. The aerodynamic braking effect of the rotor is achieved by adjusting the rotor blades perpendicular towards the rotation direction. The rotor brake consists of a brake caliper which acts on the brake disk mounted behind the gearbox.

The yaw drives optimally rotate the nacelle into the wind. The four yaw drives are located on the machine frame in the nacelle. A yaw drive consists of an electric motor, multi-stage planetary gear and drive pinion. The drive pinions mesh with the external teeth of the yaw bearing.

If positioned properly the nacelle is locked by means of a electric brake system. It consists of several brake calipers which are fastened to the machine frame and act on a brake disk. In addition, the electric motors of the yaw drives are equipped with an electrically actuated holding brake.

Fig. 3 Components of the yaw system

1 Machine frame

2 Yaw drives in mesh with yaw bearing teeth

3 Yaw bearing

4 Brake caliper

The hydraulic unit provides the oil pressure for the operation of the rotor brake and the yaw brakes.

1.4 Auxiliary systems

An automatic lubrication unit is provided for each rotor bearing, generator bearing, pitch gearing, pitch races and yaw gearing.

The switch cabinets in the rotor hub, in the nacelle and in the tower base of the wind turbine are equipped with air conditioning units.

2

3

41


Auxiliary systems K0801_041798_EN Page 9 of 15

Gearbox, generator and hydraulic unit are equipped with heaters.

A chain hoist is installed in the nacelle which is used for lifting tools, components and other work materials from the ground into the nacelle. A second, movable overhead crane is used for carrying the materials within the nacelle.



2. Functional principle

The turbine operates automatically. A programmable logic controller (PLC) continuously monitors the operating parameters using various sensors, compares the actual values with the corresponding setpoints and issues the required control signals to the WT components. The operating parameters are defined by Nordex and adapted to the individual site.

When there is no wind the WT remains in idle mode. Only various auxiliary systems, such as heating and gear lubrication, and the PLC, which monitors the data from the wind measuring system, are operational. All other systems are switched off and do not use any power. The rotor idles.

When the cut-in wind speed is reached, the wind turbine changes to the mode 'Ready for operation'. Now all systems are tested, the nacelle aligns to the wind and the rotor blades turn into the wind. When a certain speed is reached, the generator is connected to the grid and the WT produces electricity.

At low wind speeds the WT operates in part-load operation. In the course of this the rotor blades remain fully turned into the wind (pitch angle 0°). The power produced by the WT depends on the wind speed.

When the nominal wind speed is reached, the WT switches over to the nominal load range. If the wind speed continues to increase, the speed control changes the rotor blade angle so that the rotor speed and thus the power output of the WT remain constant.

The yaw system ensures that the nacelle is always optimally aligned to the wind. To this end, two separate wind measuring systems located at the height of the hub measure the wind direction. Only one wind measuring system is required for control system, while the second monitors the first and takes over in case the first system fails. If the measured wind direction varies too greatly from the alignment of the nacelle, the nacelle is yawed into the wind.

The conversion of the wind energy absorbed from the rotor to electrical energy is achieved using a double-fed asynchronous generator with slip ring rotor. Its stator is directly and its rotor via a specially controlled frequency converter connected to the MV transformer. This offers a significant advantage enabling the generator to be operated in a defined speed range near its synchronous speed.

If certain parameters concerning turbine safety are exceeded, the WT will cut out immediately, e.g. if the cut-out wind speed is exceeded. Depending on the cause of the cut-out, various braking programs are triggered. In the case of external causes, such as excessive wind speeds or grid failure, the rotor is softly braked by means of rotor blade adjustment.



3. Technical data

* At installation altitudes above 1000 m, the nominal power can be achieved up to the defined temperature ranges.

Climatic design data of the standard version

Design temperature Standard -20 °C…+50 °C

CCV -40 °C…+50 °CHCV -20 °C…+50 °C

Operating temperature range -20 °C … +40 °C

Operating temperature range CCV -30 °C … +40 °C

Operating temperature range HCV -20 °C … +45 °C

StopStandard -20 °C, restart at .-18 °C

CCV -30 °C, restart at -28 °CHCV -20 °C, restart at .-18 °C

Max. height above MSL 2000 m*

Certificate According to IEC 61400-1

Design

Type3-blade rotor with horizontal axis

Up-wind turbine

Power control Active single blade adjustment

Nominal power 3000 kW

Nominal power starting at wind speeds of(at air density of 1.225 kg/m3)

Approx. 12 m/s

Operating speed range of the rotor 8.0...14.1 rpm

Nominal speed 12.6 rpm

Cut-in wind speed Approx. 3 m/s

Cut-out wind speed 25 m/s

Cut-back-in wind speed 22 m/s

Calculated service life 20 years

Towers

Hub height 91 m 120 m 141 m

Name R91 R120 PH141

Wind class DIBt 3/IEC 2a DIBt 2/IEC 2a DIBt 2/IEC 3a

Number of tower sections 4 7 2 (+ concrete tower)



Rotor

Rotor diameter 116.8 m

Swept area 10715 m2

Nominal power/area 280 W/m2

Rotor shaft inclination angle 5°

Blade cone angle 3.5°

Rotor blade

MaterialGlass-reinforced and carbon-fiberreinforced

plastics

Total length 57.3 m

Total weight per blade Approx. 10.6 t

Rotor shaft/rotor bearing

Type Forged hollow shaft

Material 42CrMo4 or 34CrNiMo6

Bearing type Spherical roller bearing

LubricationContinuous and automatic with lubricating

grease

Rotor bearing housing material EN-GJS-400-18U-LT

Gearbox

Type Multi-stage planetary gear + spur gear

Gear ratio50 Hz: i=92 ± 1%

60 Hz: i=111 ± 1%

Lubrication Forced-feed lubrication

Oil type VG 320

Max. oil temperature 75 °C

Oil change Change, if required

Electrical system

Nominal power PnG 3000 kW

Nominal voltage 3 x AC 660 V ± 10%

Nominal current InG at SnG 3240 A



Nominal apparent power SnG at PnG 3333 kVA

Power factor at PnG

1.00 as default setting0.9 underexcited (inductive) up to

0.9 overexcited (capacitive) possible

Frequency 50 or 60 Hz

NOTE

The nominal power is subject to system-specific tolerances. During nominal power, they are ±100 kW. Practice has shown that negative deviations occur rarely and in most cases are <25 kW. For the precise compliance with external power specifications the nominal power of the single wind turbine may be parameterized accordingly. Alternatively, the wind farm can be parameterized accordingly using the Wind Farm Portal®.

Generator

Degree of protection IP 54 (slip ring box IP 23)

Nominal power 3090 kW

Nominal voltage 660 V

Frequency 50 or 60 Hz

Speed range50 Hz: 700 … 1300 rpm 60 Hz: 840 … 1560 rpm

Poles 6

Weight Approx. 10.6 t

Gearbox cooling and filtration

Type

1. Cooling circuit: Oil circuit with oil/water heat exchanger and thermal bypass2. Cooling circuit: Water/air together with generator cooling

FilterCoarse filter 50 µm

Fine-mesh filter 10 µm

Offline filter (optional) 5 µm

Generator cooling

Type Water circuit with water/air heat exchanger

Cooling water pump50 Hz: 1.3 kW60 Hz: 1.1 kW

Electrical system



Flow rate Approx. 70 l/min

Coolant Water/glycol-based coolant

Converter cooling

TypeWater circuit with water/air heat exchanger

and thermal bypass

Coolant Water/glycol-based coolant

Pitch System

Pitch bearing Double-row four-point contact bearing

Lubrication of the gearing Automatic lubrication unit with grease

Drive3-phase motor incl. spring-actuated brake

and multi-stage planetary gear

Emergency power supply Lead-acid batteries

Hydraulic system

Hydraulic oil VG 32

Oil quantity Approx. 20 l

Thermal protection Integrated PT100

Yaw drive

Motor Asynchronous motor

Gearbox 4-stage planetary gear

Number of drives 4

Lubrication Oil, ISO VG 150

Yaw speed Approx. 0.5 °/s

Generator cooling


K0801_041798_EN Page 15 of 15

4. Revision index

Rev. Date Modification AST Author

01 2013-01-18 New 7592 R. Simon

Nordex Energy GmbH

Langenhorner Chaussee 600

22419 Hamburg

Germany


[email protected]


mailto:[email protected]

K0801_041843_EN Revision 01, 2013-01-22 1 / 32

Transport, access roads and crane

requirements

Nordex N100/3300, N117/3000

Version delta

This document is a translation from German. In case of doubt, the German text shall prevail.

Nordex Energy GmbH, Langenhorner Chaussee 600, 22419 Hamburg, Germany All rights reserved. Observe protection notice ISO 16016.

Transport, access roads and crane requirements

K0801_041843_EN Revision 01, 2013-01-22 2 / 32

Table of contents

1 Basic information .................................................................................................. 3

2 Weights, dimensions and handling instructions ................................................. 4

2.1 Nacelle .................................................................................................................... 4

2.2 Drive train ................................................................................................................ 5

2.3 Rotor hub ................................................................................................................. 5

2.4 Rotor blade .............................................................................................................. 6

2.5 Weights of components on crane hook .................................................................... 7

2.6 Transport frames ..................................................................................................... 8

2.7 Towers N100/3300 ................................................................................................ 10

2.8 N117/3000 towers .................................................................................................. 11

2.9 Anchor cage .......................................................................................................... 12

3 Requirements for the access roads ................................................................... 14

3.1 Loads ..................................................................................................................... 14

3.2 Slopes and vertical radii ......................................................................................... 15

3.2.1 Slopes ................................................................................................................... 15

3.3 Clearance profile on a straight route ...................................................................... 16

3.4 Bends, opportunities to turn, and funnel lanes ....................................................... 16

3.4.1 Bends .................................................................................................................... 16

3.4.2 Opportunity to turn and funnel lanes ...................................................................... 19

3.4.3 Road construction .................................................................................................. 20

3.4.4 Passing places ...................................................................................................... 21

3.4.5 Storage areas and site office ................................................................................. 22

3.4.6 Quality assurance, access roads and crane hardstanding areas ........................... 23

3.5 Public roads ........................................................................................................... 23

4 Crane requirements ............................................................................................. 23

5 Crane hardstanding area ..................................................................................... 24


K0801_041843_EN Revision 01, 2013-01-22 3 / 32

1 Basic information

This document contains the basics for planning of the road construction and infrastructure of wind

farms for the wind turbine class K08 delta (N100 and N117 with the respective hub heights).

Furthermore component dimensions for the design of transport equipment and cranes are

included.

The planning parameters in this document are given as minimum requirements and may vary

depending on the project.

Detailed information on the infrastructure planning is project-specific and must be agreed to with

all persons involved prior to project start.

Each project location must be analyzed and planned correspondingly with regard to its local and

general safety regulations. In this context, the safety of persons and material is given top priority.

Deviations to the below specifications must be agreed to with Nordex beforehand.

We expressly point out that all values must be regarded as standard values only.

Further instructions for transport can be requested from Nordex.

The layout of access roads and hardstanding areas depends on the transportation and

erection method.

- The design must be modified for each individual erection site.

- Depending on the erection site different variants are possible.

- Transport weights may also vary with the erection site.

The exact design of access roads, crane hardstanding areas and assembly areas must

be agreed to

with Nordex prior to starting the erection work!

Improper design or layout of access roads and crane hardstanding areas may cause

considerably higher logistics and erection costs at a later stage.


K0801_041843_EN Revision 01, 2013-01-22 4 / 32

2 Weights, dimensions and handling instructions

2.1 Nacelle

Drive train, rotor hub and further exterior assemblies (obstacle lights, wind sensors, lightning

arrester, etc.) are not assembled for nacelle transport.

The transport frame for the nacelle consists of 4 single supports. They can be used for twist lock

fastening (see chapter 2.6). Otherwise, anti-slip mats must be used for transport.

The nacelle must only be placed on compacted ground or on crane mats.

Fig. 1: Nacelle (view from the left) with transport supports

Fig. 2: Nacelle (front view) with transport supports

The coordinates of the center of gravity of the nacelle are determined without considering the

drive train and the transport support.

12700

40

00

4300

2400

2572


K0801_041843_EN Revision 01, 2013-01-22 5 / 32

2.2 Drive train

Fig. 3: Drive train on transport frame

For the rear section of the gearbox a wooden cladding is planned. This cladding is included in the

overall length.

2.3 Rotor hub

Fig. 4: Rotor hub on transport frame

The rotor hub is delivered on a separable transport frame.

Anti-slip mats must be used for transport.

2784 approx. 6200

29

67

3190

2066

4654

3000

5312

39

70


K0801_041843_EN Revision 01, 2013-01-22 6 / 32

2.4 Rotor blade

Each rotor blade is delivered on two transport frames using a trailer. One of the transport frames

is fastened to the blade root, the other one to the support point.

In addition to center of gravity and support point the drawing shows the defined points where the

webbing slings can be attached. The blade must only be lifted at these points as they are

reinforced in these areas.

Fig. 5: Rotor

blade

Rotor blade LM48.8 NR50 NR58.5

A

Lifting point root

0.8

0.3

0.3

C

Center of gravity

14.5

14.3

15.6

E Lifting point SA 34 32 38

F Support point 35 34 40

G Lifting point SA - 37 43

H Length 48.8 48.8 57.3

I Transport height 2.9…3.9 3.2…4.1 3.1…3.6

J Transport width 2.9…3.1 2.5…3.9 2.5…3.7

Fig. 6 Transport dimensions

Rotor blade

All dimensions in meters [m] SA: Star assembly SBA: Single blade assembly

I

J


K0801_041843_EN Revision 01, 2013-01-22 7 / 32

2.5 Weights of components on crane hook

A) Weights for transport (with transport frame)

Nacelle

Height (without exterior assemblies) 4.00 m

Width 4.30 m

Length 12.70 m

Weight of "empty" nacelle (without rotor shaft, gearbox)

Approx. 60 t

Weight of drive train only (rotor shaft, gearbox)

59.3 -61.3

Rotor hub Ø 100 Ø 117

Weight Approx. 31.5 t Approx. 31.5 t

Dimensions L x W x H 4.65 m x 5.31 m x 3.97 m (overall spinner dimensions)

Rotor blade

Length incl. blade bolts

without blade bolts

49 m

48.7 m

57.6 m

57.3 m

Weight per blade

(varies depending on the manufacturer and the method of transportation)

Max. 11.9 t 11.2 t

Switch cabinet (Bottombox)

Dimensions L x W x H 2.2 m x 1.2 m x 2 m

Weight Approx. 2.9 t

B) Weights for erection (without transport frame)

Nacelle

Height (without exterior assemblies) 4.00 m

Width 4.30 m

Length 12.70 m

Weight of "empty" nacelle (without rotor shaft, gearbox)

Approx. 58.7 t

Weight of drive train only (rotor shaft, gearbox)

56.7 t ... 58.7 t

Weight of complete nacelle (without rotor)

Approx. 115.5 t

Rotor hub Ø 100 Ø 117

Weight Approx. 30 t Approx. 30 t

Rotor blade

Dimensions as specified above, under A)

Weight per blade

(varies depending on the manufacturer)

Max. 11.4 t

10.7 t

Complete rotor Max. 64.2 t Approx. 62.1 t


K0801_041843_EN Revision 01, 2013-01-22 8 / 32

Switch cabinet (Bottombox)

As specified above, under A)

Transformer

With the transformer installed in the tower the transformer substation is omitted.

Individual components per wind turbine:

Transformer Approx. 8.9 t, L x W x H: 2.6 x 1.3 x 2.54 m

Medium-voltage switchgear Max. 1.5 t, L x W x H: 2.0 x 1.0 x 2.0 m

Transformer substation

The transformer substation and wind turbine must not be erected at the same time.

For exact dimensions and weights refer to the manufacturer: Dimensions and weights also vary within a wind farm depending on equipment and project scope.

The following values can be found:

Length 3.3 to 7.0 m

Width 2.5 to 3.0 m

Height 2.7 to 3.9 m

Weight (incl. transformer, etc.) 15 to 31 t

2.6 Transport frames

Transport frame Weight

Nacelle transport frame Approx. 1.25 t

Transport frame – drive train Approx. 2.6 t

Hub transport frame Approx. 1.5 t

Transport frame – rotor blade (root/tip)

Depending on method of transportation

Approx. 150-400 kg/50-600 kg

Transport cross beams – switch cabinet Approx. 100 kg (transport cross beams are expected to remain installed at the switch cabinet)

Nacelle transport frame

Front bearing surface: 400 x 400 mm

Rear bearing surface: 500 x 400 mm

Load per front support: 18 t

Load per rear support: 12 t

The screws for fastening the nacelle are part of the transport supports and must be returned

together with the transport supports to Nordex.


K0801_041843_EN Revision 01, 2013-01-22 9 / 32

Transport frame – drive train

Fig. 7: Transport frame – drive train

The supports for the gearbox supports are removable. The transport frames for the drive train can

be stacked up to 4 for return transport.

The supports for the gearbox supports, including their fastening screws, are part of the transport

frame and must be returned together with the transport frame to Nordex.

A transport frame with a width of < 2.45 m is currently being developed.

Hub transport frame

The transport frame can be stacked and screwed together for return transport.

500

2066

3000

720

75

5

3680

Fig. 8: Hub transport frame

The round wood plate must also be returned if it is not damaged.

4390

2710

13

57

6907 2

22

7


K0801_041843_EN Revision 01, 2013-01-22 10 / 32

2.7 Towers N100/3300

Hub height 75 m 100 m

Tower type Tubular steel tower MT5 Tubular steel tower MTR5

Classification N100/3300

IEC 1a

N100/3300

IEC 1a

Total weight (TaT/TiT) 160.6 / 160.0 308.8/ 310.8

1. Tower section (bottom)

Length m 16.7 12.7

Ø T flange m 4.30 4.30

Ø bottom m 4.00 4.00

Ø top m 4.03 4.29

Weight (TaT/TiT) t 58.4/57.8 71.1/ 73.1

2. Tower section (MID1)

Length m 24.0 12.2

Ø Flange m - -


Ø top m 4.02 4.29

Weight t 54.7 61.1


Length m 18.1

Ø bottom m 4.29

Ø top m 4.27

Weight t 64.2


Length m 24.0

Ø bottom m 4.27

Ø top m 4.27

Weight t 60.2

5. Tower section (TOP)

Length m 31.2 29.8


Ø top m 3.26 3.26

Weight t 47.5 52.5

• Due to the applied transport equipment, the transport height is 7 cm higher than the tower

diameter.

• Each lifting tackle is 15 cm high. Thus the tower sections become longer.

• Changes in the weight of ±8 % must be considered.

• The centers of gravity deviate from the center of tower sections by approx. 5 %.


K0801_041843_EN Revision 01, 2013-01-22 11 / 32

2.8 N117/3000 towers

Hub height 91 m 120 m 141 m

Tower type Tubular steel tower Tubular steel tower MT5 Hybrid tower PH141

Classification N117/3000 N117/3000 N117/3000

Total weight (TaT/TiT) 216.1/ 216.6 466.5/ 466.7 102.1

1. Tower section

Length m 13.8 9.1 23.00

Ø T flange m 4.30 4.30 -

Ø bottom m 4.00 4.07 4.29

Ø top m 4.03 4.30 4.29

Weight (TaT/TiT) t 57.5/ 58.0 69.5 / 69.7 48.5


Length m 18.1 9.3


Ø top m 4.02 4.30

Weight t 54.5 69.9


Length m 24.0 9.3

Ø bottom m 4.02 -

Ø top m 4.02 4.29

Weight t 52.5 68.1


Length m 12.2

Ø bottom m 4.28

Ø top m 4.28

Weight t 68.2


Length m 17.1

Ø bottom m 4.26

Ø top m 4.26

Weight t 69.9


Length m 25

Ø bottom m 4.26

Ø top m 4.25

Weight t 63.7

7. Tower section (TOP)

Length m 32.0 35.00 35.00

Ø bottom m 4.02 4.23 4.29

Ø top m 3.26 3.26 3.26

Weight t 51.2 57.2 53.6

• Due to the applied transport equipment, the transport height is 7 cm higher than the tower

diameter.

• Each lifting tackle is 15 cm high. Thus the tower sections become longer.


K0801_041843_EN Revision 01, 2013-01-22 12 / 32

• Changes in the weight of ±8 % must be considered.

• The centers of gravity deviate from the center of tower sections by approx. 5 %.

2.9 Anchor cage

Nordex delivers modular anchor cages which vary in dimensions and weights. The anchor cages

are always delivered as an assembly set. The anchor cage is assembled on site by the

responsible construction company. Nordex offers against extra payments to deliver the anchor

cages already pre-assembled to the construction site (this is not possible for the anchor cages of

the N100 R100 and N117 R120).

Special permission is required for the transportation of pre-assembled anchor cages. This may

result in lead times of up to 6 weeks depending on the country.

An N100 R75 and N117 R91 anchor cage is made up of the following parts:

WT Name Parts Thicknes

s Dimensions

Maximum Weight

Maximum

N100 R75 N100 R91

Load-spreading plate

2 77 mm Outside ∅ 4500 mm Approx. 3.7 t

Anchor plate 2 70 mm Outside ∅ 4460 mm Approx. 3.1 t

Anchor bolts 160 M42 L = 3071 mm Approx. 5.4 t

Washers, nuts and other small parts Approx. 0.5 t

The complete anchor cage, including transport equipment, weighs approx. 12.6 t.

Fig. 9: Anchor cage with 2x80 bolts Fig. 10: Anchor cage 2x100 bolts (N100 R100)


K0801_041843_EN Revision 01, 2013-01-22 13 / 32

The anchor cage N100 R100 consists of the following parts:


s Dimensions

Maximum Weight

Maximum total

N100 R100

Load-spreading plate

4 160 mm Outside ∅ 4720 mm Approx. 11 t




The complete anchor cage, including transport equipment, weighs approx. 23,7t and is quartered

The anchor cage N117 R120 consists of the following parts:


s Dimensions

Maximum Weight

Maximum total

N117 R120

Load-spreading plate 1

Load-spreading plate 2

4 4

120 mm 120 mm

Outside ∅ 4500 mm

Outside ∅ 4770 mm

Approx. 5.6 t Approx. 8.8 t




These values represent the current status of development and may vary slightly.

The complete anchor cage assembly set, including transport equipment, weighs approx. 30.6 t

and is quartered.

The weights may vary slightly depending on the tower.


K0801_041843_EN Revision 01, 2013-01-22 14 / 32

3 Requirements for the access roads

In general, the ordering party is responsible for the planning of the wind farm infrastructure on the

basis of the requirements stipulated in this document. In order to prevent subsequent problems

during transport and erection work, the planning must be agreed to with Nordex prior to starting

the construction. The infrastructure planning must contain at least the following information:

• WT sites

• Access roads planning, including the longitudinal profile with slopes and vertical radii, cross

profile and bend radii

• Turning and passing places

• Crane hardstanding areas regarding foundation and WT site

To avoid problems during the erection of the wind turbine, the following minimum requirements

for the access roads must be met under normal ground conditions:

3.1 Loads

The access roads for each wind turbine must be capable of supporting the following loads:

Vehicles per wind turbine

- Approx. 50 to 100 concrete and construction vehicles, up to 220 vehicles for hybrid towers

- Approx. 15 to 40 heavy trucks for crane erection (depending on the hub height)

- Approx. 8 to 13 heavy trucks with turbine components

(2 to 7 for tower sections, 3 for rotor blades, 3 for nacelle, rotor hub and drive train, 2 for

switch cabinet (Bottombox), small parts and erection container)

- Maximum truck length 62 m rotor blade transport and 49 m tower transport

- Required clearance height for public roads ≥ 4.50 m,

from construction site access 5.00 m to 6.00 m (depending on the method of transport and

local conditions)

- Different types of construction vehicles

Weight of vehicles

- Max. load per axle: approx. 12 t

- Max. overall weight: approx. 165 t


K0801_041843_EN Revision 01, 2013-01-22 15 / 32

3.2 Slopes and vertical radii

3.2.1 Slopes

If the surfaces meet the descriptions in Chapter 3.5, slopes of approx. 8 % must not be exceeded

at any rate. If there are slopes exceeding 8 %, Nordex must always be consulted.

Against reimbursement of the extra costs, additional tractor units can be used so that slightly

steeper slopes can be handled and under the provision of a suitable surface condition. As the

length of the entire tractor unit becomes larger this must be considered in road construction

planning, especially in terms of bend radii.

Slopes of up to 8 % can only be accomplished when driving forward. In the case the transports

can only manage the slope driving backwards, partly depending on the site-specific conditions,

the maximum inclination must not exceed 1.5 % (without additional tractor units). On these road

sections, the road foundation must be taken into account (see Chapter 3.5) as the traction is

completely shifted to the front axle of the tractor unit. An adapted design and/or the use of other

materials for road construction may be required for the relevant sections.

The lateral tilt must not be greater than 2 %.

Depending on the season and the weather the requirements for slopes may vary so that

additional tractor units or vehicles for braking must be used.

3.2.2 Vertical radii

The radii (vertical) for peaks and valleys must not be lower than R375 m. Over a length of 30.0 m

(largest center distance) the difference in height between two points must not be lower than

0.30 m.

If the required minimum radii can be hardly achieved or not at all due to associated construction

measures an on-site inspection must be carried out to discuss possible alternatives such as other

routes or transport methods.

Fig. 11: Vertical radius

N100 N117

WT type Rmin [m] N100 350 N117 375


K0801_041843_EN Revision 01, 2013-01-22 16 / 32

3.3 Clearance profile on a straight route

For all hub heights

H Clearance height Approx. 4.50-6.00 m (depending on transport method)

W Clearance width 5.00 m (Concrete hybrid towers: 6.00 m)

The clearance on public roads normally has a height of approx. 4.5 m due to bridges. On the

access roads to the construction site a clearance height of 5 m to 6 m* and a clearance width of

at least 5 m must be ensured depending on the project or location. For concrete hybrid towers a

clearance width of at least 6 m must be ensured to enable the transport of prefabricated concrete

elements.

*If it is not possible to adopt the method of transport employed for the route to the construction

site access to the internal access roads due to local conditions (topography, roadway

arrangement, obstacles) components may be reloaded to other means of transport, if required, to

enable the delivery to the crane hardstanding area. The crane capacities needed for such

purposes and the width of the reloading area near or inside the construction site must be agreed

on with Nordex in advance. A corresponding transport, reloading, and storage concept must be

prepared considering the local conditions and the feasibility of measures to be taken.

Fig. 12: Clearance profile

3.4 Bends, opportunities to turn, and funnel lanes

3.4.1 Bends

The following sketches exemplarily illustrate the space required for the rotor blade in a bend:


K0801_041843_EN Revision 01, 2013-01-22 17 / 32

Fig. 13: Minimum required extension 70° bend N100 (left and right turn)




K0801_041843_EN Revision 01, 2013-01-22 18 / 32





K0801_041843_EN Revision 01, 2013-01-22 19 / 32

The continuous lines depict the travel of the truck. The dashed lines mark the areas covered by

the vehicle and the rotor blade. The outer area covered is determined by the length of the rotor

blade protruding at the rear.

The covered area (dashed) must be free of all obstacles, i.e. trees, streetlights, buildings, masts,

etc. This area must be max. 20 cm above the paved level of the accessible road.

The construction of bends to be accessed backwards must enable the respective turbine types to

travel the whole covered radii specified in chapter 3.4. due to the maximum turn angle of the rear-

wheels of less than 70 %. The capacity of the vehicles deployed normally matches the loads that

must be moved. The deployment of additional tractors and/or other vehicles, however, cannot be

excluded due to local conditions. Since in case of pushing other forces act on the vehicle and its

load and the trajectory within the lane cannot be influenced damages to the road surface on

construction site may occur. These damages must be repaired immediately , respectively before

other heavy loads pass through.

The exact values depend on the vehicles used and the individual local situation.

The maximum slope or incline in bend radii/bend areas is < 2 %. A bend with slope/incline shall

be constructed in a manner that the road surface is on an even level to protect the components

from hitting the ground. The area that lay 50 m around the peak is the bend area and must be

constructed as an even surface.

3.4.2 Opportunity to turn and funnel lanes

Depending on the size of project and the access situation double lanes enabling the vehicles to

turn shall be constructed at strategic and central crossroads or preferably at access points to

single turbines.

These double lanes shall enable the vehicles to turn and to leave the construction site forward.

The lanes shall be located at strategic crossroads to avoid reversing over a distance of 500 m

because these movements consume too much time and may negatively affect the traffic on

construction site or the erection process.

The dimensions of the funnel lanes derive from the length of the components (refer to Chapter

2.4) with 5 m to be added to serve as manoeuvring space = width of the lane, the bend radii must

be considered as specified below. The width of the smallest place (front side) is < 4.5 m. If a

funnel lane shall be used as a parking place for more than 1 vehicle the lane must be broadened

by another lane of 4.5 m width per vehicle. In junction areas the turning lanes shall always be

adjacent , not opposite to one another. Depending on the location it should be considered if four

lanes are required or do making sense in junction areas.


K0801_041843_EN Revision 01, 2013-01-22 20 / 32

Fig. 14: Opportunity to turn and funnel lanes

3.4.3 Road construction

In principle, the access roads shall be planned to enable a secure transport for the respective

wind turbine type and to achieve the load-carrying capacities described in chapter 3.1. For that

purpose, the site-specific ground conditions must be taken into account. Planning and execution

shall be adjusted accordingly. The structure described below serves only for illustration and does

not excuse the ordering party from a project-specific design and planning.

Fig. 15: Cross-section of the access road (example)

• Instead of gravel, base and top layer may be made of broken bricks or concrete (free of other

demolition waste).

• All layers and the subsoil must be compacted using proper machinery to allow for heavy loads

• Even road surface

• Proper drainage for all access roads must be ensured (cross slope of 1 to 2 %).

Proper water transport (e.g., in the lateral trenches or under access road junctions) must be

3. Top layer compacted, ballast, 15-25 cm

2. Base layer compacted, gravel, 15-30 cm

1. Bed compacted, 30-100 cm

Geomembrane as separation layer

30-100 cm

Min. 4.5 m

Subsoil


K0801_041843_EN Revision 01, 2013-01-22 21 / 32

ensured in order to permanently prevent undercutting, erosion, cavity formation and

landslides.

• If road sections of the internal access roads are below the level of the surrounding fields,

acres, etc. a suitable measures to drain the roads shall be taken.

• Before starting road construction, a project- and site-specific design/execution plan for the

access roads must be created. In doing so, the detailed requirements specified by the

structural engineer, geotechnical engineer, haulage contractor and by Nordex must be fulfilled.

• Access roads and crane hardstanding areas must be accessible for heavy lorries under every

possible weather condition and over the entire construction period. Occurring damages to the

road surfaces must be repaired by the ordering party within the delivery time of the wind

turbine.

• Crawler cranes may require special transport and travel roads.

Track width of up to 12 m might be necessary.

3.4.4 Passing places

Passing places are parking and passing areas for arriving trucks or already unloaded trucks and

oncoming vehicles. These passing places must ensure an unobstructed accessibility of assembly

areas during the delivery and erection stage and help to maintain smooth traffic flow during the

entire construction phase. The positioning of these areas must individually be agreed upon with

Nordex for each project.

For one-lane main access roads covering a longer distance (from approx. 750 m), passing places

dimensioned L x W (70 m x 4.5 m) must be provided in addition to the already existing main

access road. Thus passing points for oncoming vehicles are made available. This applies to all

vehicles.

NOTICE: In countries where heavy duty and oversize transports are only permitted at

daytime the passing places to main access roads must be dimensioned accordingly larger

(see section below).

Considering site and existing access roads, additional passing places must be provided for

access roads to assembly areas where the access road is used as an entry and exit way (dead

end situation). These additional passing places must be built on one side of the lane and

dimensioned as follows: L x W = < 200 m x 4.5 m (length for N117 R120 = 250 m). This will allow

e.g. ambulance and rescue vehicles to access the site unobstructed during the erection and

delivery stage.

In the case that the existing access road is shorter than the required length of the passing place

the length is to be divided and runs for example along the left and right of the access road. The

extension of an access road behind or past the assembly area is only recommended for one

vehicle length (approx. 50 m).

If the access roads to assembly areas run directly into public roads, these must be cordoned off

250 m in front and behind the junction during the erection and delivery stage. If this cannot be

realized due to local conditions and regulations corresponding above-mentioned passing places

at the access road must be built.

If the incoming and outgoing vehicles do not use the the same access road, i.e. if a circular flow

is possible, passing places might not be necessary.


K0801_041843_EN Revision 01, 2013-01-22 22 / 32

Fig. 16: Examples of a passing place

3.4.5 Storage areas and site office

The following sketch shows a general presentation of a Nordex site office which must be

designed project-specific:

Fig. 17: Nordex site office (example)

The ordering party has provided an area of approx 1200 m² in order to accommodate the

following equipment and accessories:

• Nordex office 20 ft container

• Office for responsible company 20 ft container

• Office for meetings 20 ft container

• Generator with drip tray

• Recycling

• Free space for material on EUR pallets (14 m x 2.5 m)

• Rest room

• Free space for material (fenced: 14 m x 2.5 m)

• 4x 20 ft material container (2x for material / 1x for cables in order to store material in dry and heatable place)

• Parking lots for passenger cars


K0801_041843_EN Revision 01, 2013-01-22 23 / 32

3.4.6 Quality assurance, access roads and crane hardstanding areas

The ordering party is responsible to carry out the following minimum and required quality checks

for the design of access roads and crane hardstanding areas depending on the type and

composition of the earthwork materials. The check results must be submitted to Nordex at the

latest 4 weeks before delivery starts:

Quality checks Minimum

number/comme

nts

Degree of compaction (Dpr) according to DIN 18127 of the access roads

in layers (bed, base layer, top layer)

1 test (every 500

m)

Degree of compaction (Dpr) according to DIN 18127 of the crane

hardstanding areas in layers (bed, base layer, top layer)

4 tests (per crane

hardstanding

area)

Static plate load test according to DIN 18134 of the access roads in

layers (bed, base layer, top layer)

3 tests (every

5000 m²)

Static plate load test according to DIN 18134 of the crane hardstanding

areas in layers (bed, base layer, top layer)

2 tests (per crane

hardstanding

area)

The results of all tests must be documented in full. This must be done in a professional manner

and illustrated with tables and diagrams and submitted to Nordex. The testing points are to be

presented in the diagrams including positions and heights. The soil profile of access roads and

crane hardstanding areas also require neat presentation.

3.5 Public roads

In general, the ordering party is responsible for the access roads from the destination port or the

freeway exit to the construction site. The ordering party is also in charge of planning, obtaining

permission and executing necessary constructive measures.

Here, Nordex can be of support when creating feasibility tests and listing required constructive

measures. Depending on the complexity of the access roads, it may be necessary to perform a

"dummy run" prior to starting the heavy duty transports.

4 Crane requirements

One main crane and, at least, one auxiliary crane are required for the wind turbine erection. The

auxiliary crane must be able to change its position several times before, during and after the wind

turbine erection.

• The required hook height is:

- Hub height + 10 m (e.g. N100 R100: 110 m)

- Exception: N117 R120: Hub height + 20 m (e.g. N117 R120: 140 m)


K0801_041843_EN Revision 01, 2013-01-22 24 / 32

• Main crane radius min. 15 to 30 m (depending on crane type)

• Auxiliary crane radius min. 6 to 12 m (depending on crane type)

Hub height 75 m 91 m 100 m 120 m 141 m Main crane - Maximum hook load - Maximum hook load at hub height

67.0 t 58.0 t

72.3 t 60.0 t

73.7 t 61.0 t

58.0 t 58.0 t

61.0 t 61.0 t

Auxiliary crane Required hook load

35 t

30 t

40 t

30 t

30 t

5 Crane hardstanding area

The crane hardstanding area must be planned and laid out according to the site-specific

conditions and the planned crane positions.

The crane hardstanding area must withstand the soil pressure of the crane outriggers. The soil

pressure depends on the maximum weight of the components and the size of the crane used

(mobile crane, crawler crane) and must be at least 250 kN/m².

The crane hardstanding area must be level across the entire surface:

- Maximum inclination for wind turbines with a hub height up to 100 m: ≤ 1 %

- Maximum inclination for wind turbines with a hub height of 100 m and higher: 0%

The crane hardstanding areas must be planned in such a way that the height difference between hardstanding area and

foundation top edge must not be greater than 1.1 m.

The erection and working area of the crane must be free of obstacles which might impair the

erection and operation of the crane (see following drawings). The length of the rotor blades and

the space for the star assembly must be considered for crane operation.

The transformer substation must not be placed on the crane hardstanding area or the assembly

area of the crane jib.

To prevent dirt from entering the wind turbine, access to foundation and the ground must be

compacted and covered with gravel to ensure a dry and clean surface.

An approx. 2 m wide walkable working area must be provided directly around the foundation.

The nacelle must only be placed on the crane hardstanding area or on the crane mats.

A long erection area is required for assembling the crane jib of lattice cranes. The length amounts

to:

- Hub height + 10 m

- For N117 R120: Hub height +20 m

The auxiliary crane must be free to move parallel to the entire length of the crane jib.

Crane hardstanding areas of 10 x 10 m each must be provided at the third points of the assembly

area (see following drawings).


K0801_041843_EN Revision 01, 2013-01-22 25 / 32

Examples

• Example 1 shows a crane hardstanding area for wind turbines up to 80 m hub height and with

just-in-time delivery. Higher transport costs are generally to be expected for this variant. The

final layout for the specific site must be planned after the site has been inspected.

• Example 1a shows the hardstanding area for wind turbines with tower heights of up to 80 m

and with a storage area for the delivery of turbine components including tower sections and

blades. The final layout for the specific site must be planned after the site has been inspected.

• Example 2 shows a crane hardstanding area for wind turbines up to 100 m tower height and

with just-in-time delivery. Higher transport costs are generally to be expected for this variant.

The final layout for the specific site must be planned after the site has been inspected.

• Example 2a shows the hardstanding area for wind turbines with tower heights of up to 100 m

and with a storage area for the delivery of turbine components including tower sections and

blades. The final layout for the specific site must be planned after the site has been inspected.

• Example 3 shows a crane hardstanding area for a N117, R120 and with just-in-time delivery.

Higher transport costs are generally to be expected for this variant. The final layout for the

specific site must be planned after the site has been inspected.

• Example 3a shows the hardstanding area for a N117, R120 with a storage area for the

delivery of turbine components including tower sections and blades. The final layout for the

specific site must be planned after the site has been inspected.

• Example 4 shows the hardstanding area for wind turbines with concrete hybrid tower (PH 141)

and with optional storage area for the delivery of turbine components including tower sections

and blades. The final layout for the specific site must be planned after the site has been

inspected.

In addition to the examples shown above, a clear assembly area for the rotor (star assembly) is

also required. This area depends on the local conditions and therefore Nordex has to be

consulted before any action is taken. Space for at least 2 Nordex erection containers must be

provided (for power generator and tools).

Further space must be provided for one Nordex material container for temporary material

storage, garbage containers, staff containers, construction vehicles, etc.

The access roads to the wind turbine must always be kept free for ambulance and rescue

vehicles.


K0801_041843_EN Revision 01, 2013-01-22 26 / 32

Example 1: Crane hardstanding area for WT up to 80 m hub height with just-in-time delivery


K0801_041843_EN Revision 01, 2013-01-22 27 / 32

Example 1a: Crane hardstanding area for WTs up to 80 m hub height with storage areas for delivery


K0801_041843_EN Revision 01, 2013-01-22 28 / 32

Example 2: Crane hardstanding area for WT up to 100 m hub height with just-in-time delivery


K0801_041843_EN Revision 01, 2013-01-22 29 / 32

Example 2a: Crane hardstanding area for WTs up to 100 m hub height with storage areas for delivery


K0801_041843_EN Revision 01, 2013-01-22 30 / 32

Example 3: Crane hardstanding area for N117 R120 with just-in-time delivery


K0801_041843_EN Revision 01, 2013-01-22 31 / 32

Example 3a: Crane hardstanding area for N117 R120 with storage area


K0801_041843_EN Revision 01, 2013-01-22 32 / 32

Example 4: Crane hardstanding area for WTs with concrete hybrid tower (PH141) with optional storage

area for delivery

HaskoningDHV Nederland B.V.

Calculations N117

The foundation shape has been determined based on the soil properties, loads and ground water level. Both the

internal forces and external forces have been calculated using Finite Element Method software DIANA, which has

been developed by TNO. Several calculation sheets have been made by Royal HaskoningDHV in order to facilitate

the highly automated design process. The leading input and output sheets of the calculations that lead to a

proximate rebar configuration have been added to this memo. A calculation of the foundations rotational stiffness

shows that it could be critical to reach the value which has been stated in the load document. In the design 28 piles

are required based on bearing capacity. It could however be required to add more piles to full fill the rotational

stiffness criteria or use a higher concrete class for the piles.

Figure 1: Foundation design for N117 wind turbine

Foundation shape Tapered circular

Diameter 17.5 meter

Thickness Center: 2,60 meter

Edge: 1,40 meter

Pedestal height 0,52 meter

Volume

495 m3

Reinforcement

59000 kg (excluding cutting losses) 120 kg/m3

3000 kg (estimated cutting losses)

62000 kg (including estimated cutting losses) 125 kg/m3

Lowering at anchors 175 mm

Blinding layer Minimal thickness: 100 mm

Lowering 150 mm at anchor section includes rebar # 8-150

Soil cover Very limited

Number of piles 28 (inclined outwards 10:1)

Pile type Cast-in place full displacement screw pile with temporary steel casing and grout injection

(Dutch Fundex type or similar)

Table 1: Properties for N117 turbine foundation

LW-AF20130441 14 March 2013

Client confidential - 4 -

K0801_041837_EN Revision 00, 2013-02-07 1 / 5

Lubricants, coolants, transformer oil and

measures against accidental leakage

Nordex N100/3300, N117/3000

Version delta

Nordex Energy GmbH, Langenhorner Chaussee 600, 22419 Hamburg, Germany All rights reserved. Observe protection notice ISO 16016.

Lubricants, coolants, transformer oil and measures against accidental leakage

K0801_041837_EN Revision 00, 2013-02-07 2 / 5

Locations were lubricants and coolants are applied

Lubricants are used in the following assemblies of the wind turbine:

Assembly Name Lubricant type Quantity WHC HSC

1 Cooling systems - Generator - Converter

Varidos FSK45

Varidos FSK 501)

Intercool LCE-502)

Coolant3)

Approx. 150 l Approx. 40 l

1 Xn

2 Generator bearing Klüberplex BEM 41-132 Grease 12 kg 1 4)

3 Gearbox including cooling circuit

Mobilgear XMP 320

Mobilgear SHC XMP 320

Castrol Optigear Synthetic X320

Mineral oil

Synthetic oil

Synthetic oil

Approx. 570 l

1

1

1

-

4 Hydraulic system Shell Tellus S4 VX 32 Mineral oil Approx. 25 l 1 -

5 Rotor bearing Mobil SHC Grease 460WT Grease Approx. 60 kg 2 -

6

Pitch bearing - Gearing and race

Fuchs Gleitmo 585K Grease Approx. 35 kg 2

-

7 Pitch gearbox Mobil SHC 629 Synthetic oil 3 x 11 l 1 -

8 Yaw gearboxes Mobil SHC 629 Synthetic oil 4 x 27 l 1 -

9 Yaw bearing - Gearing and race

Fuchs Gleitmo 585K Grease Approx. 13 kg 2

-

10 Transformer5)

Hyvolt I Transformer oil <1500 kg 1 -

1

2

3

4

5

6

7

8

9

10


K0801_041837_EN Revision 00, 2013-02-07 3 / 5

WHC: Water hazard class

HSC: Hazardous substance class

Xn: Harmful

1) Coolant for Cold climate version (CCV)

2) Coolant only for USA

The hazardousness of chemical substances is classified differently in the

USA.

According to HMIS, this coolant has the classification: 1 / 0 / 0 / B

(HMIS = Hazardous materials identification system)

3) See below "Coolant"

4) "-" EU label not required

5) Only applicable to external transformer, if provided by Nordex

For all lubricants safety datasheets are available according to Directive 91/155/EEC.

Design measures against leakage of lubricants and coolants

• Pitch gearboxes

The pitch gearboxes are located in the rotor hub and turn along with the rotor. A

sealing system effectively prevents the gear oil from escaping. In case of

accidental leakage, the oil remains within the rotor hub and will not escape from

the access hatch due to the shape and inclination of the hub.

• Yaw bearing

The races and gearings of the yaw bearing are lubricated with grease. The

sealing system prevents the grease from escaping. If there is too much grease

in the bearings it escapes inside the hub and remains there.

In case of accidental leakage, the grease remains within the rotor hub and will

not escape from the access hatch due to the shape and inclination of the hub.

• Rotor bearing

Grease regularly emerges from the labyrinth seals of the rotor bearing during

operation and runs directly into two grease drip trays (capacity approx. 10 or

25 l). These are cleaned regularly during maintenance.

• Gearbox

The gearbox has non-abrasive, wear-free sealing systems at both, input and

output shaft. In case of accidental leakage, the oil is collected by the nacelle

housing or by the oil-proof upper tower platform.

• Generator bearing

The generator bearings are lubricated with grease and are equipped with a

highly effective sealing system. This effectively prevents lubricant from


K0801_041837_EN Revision 00, 2013-02-07 4 / 5

escaping. If the sealing system fails the grease remains within the nacelle and is

correctly disposed of during maintenance.

• Hydraulic unit

The hydraulic unit is equipped with a highly effective sealing system which

prevents oil from escaping. If the sealing system is damaged, the oil remains

within the nacelle.

• Yaw gearboxes

The yaw gearboxes are equipped with a sealing system which prevents oil from

escaping. If the sealing system is damaged, the oil remains within the nacelle.

• Yaw bearing

The races of the yaw bearing are lubricated with grease. The sealing system

prevents the grease from escaping. If there is too much grease in the bearing it

escapes to the external gearing.

The external gearing is lubricated with a non-drip adhesive grease.

Underneath the external gearing any escaping grease is collected in the nacelle

housing where it can be removed.

• Nacelle housing

The nacelle housing will collect any escaping fluids which the provided grease

drip trays are not able to collect. The bottom sections of the nacelle housing are

tray-shaped. All pipes are laid above these trays.

• Tower

The top tower platform is designed as an oil-proof drip tray. The drip tray has a

capacity of at least 630 liters.

• Transformer (if provided by Nordex)

External transformer: The transformer is located outside the wind turbine in a

separate transformer substation. Normally the transformer oil is not changed

during the entire service life. In case accidental leakage, the oil is collected in a

drip tray made of oil-impermeable concrete under the transformer. A certificate

of the concrete's impermeability can be requested from Nordex.

Transformer inside tower: The transformer is located on the tower foundation. It

is installed in an separated area. A dry-type transformer is used which operates

without oil.

• Coolant

The cooling system of the generator and the converter work fully independently

from each other. The pressure of the cooling systems is constantly monitored

during operation. A pressure drop is immediately reported via the operation

control.

The coolant is a mixture of an antifreeze liquid and water.


K0801_041837_EN Revision 00, 2013-02-07 5 / 5

Maintenance

The above-mentioned systems, which contain lubricants or coolants, are checked

for leaks during the periodic maintenance works. Any leaks are eliminated. All drip

trays are inspected at regular intervals during maintenance and emptied if

necessary.

Changing the gear oil

During scheduled maintenance an oil sample is taken from the gearbox and

analyzed in a laboratory. The oil is changed if necessary, depending on the result of

the oil sample analysis, or if the maximum operating time is reached.

Waste disposal

All lubricants and coolants must be disposed of by certified specialist waste

management companies from the region upon presentation of proof and in

accordance with local laws and guidelines.

SENVION 3.2M114

7500

2150

4150Outer Dimensions:hight: 2,150 mwidth: 4,150 mlength: 7,500 m

Gross weight: approx. 0,9 mtonsNet weight: approx. 1,0 mTons

alle Angaben in mmevery data in mm

REpower 3.X M

8765

F

E

D

C

B

A

4321

1 2 3 4 5 6 7 8

F

E

D

C

B

A

Weitergabe sowie Vervielfältigungdieses Dokuments, Verwertung undMitteilung seines Inhalts sindverboten, soweit nicht ausdrücklichgestattet. Zuwiderhandlungenverpflichten zu Schadenersatz.Alle Rechte für den Fall derPatent-, Gebrauchsmuster- oderGeschmacksmustereintragungvorbehalten.

The reproduction, distribution andutilization of this document as wellas the communication of itscontents to others without explicidauthorization is prohibited.Offenders will be held liable forthe payment of damages. All rightsreserved in the event of the grantof a patent, utility model or design.

PDM Dok ID

A3

Plot:

Stückzahl proAnlage/ No. ofPieces per Turbine:

.

..

A. Trede05.10.2009

T. Sebon05.10.2009

J. Lütjen05.10.2009

. .1:50

WEC REpowerWEA REpower

nacelle hood - transport documentGondelhaube - Transport Dokument

AD-3.1-GP.MA.02-D

P:\Products\03_01_REpower_3XM\GesamtProjekt\Mass_Abmessg_Transp_Schwerpkt\Doku_Zeichnung\D-3.1-GP.MA.02-D..

1/1

05.10.2009

ToleranceDIN ISO 8015

DIN ISO 2768-mHH

DIN ISO13715

+-

Schutzvermerk DIN ISO 16016

Protection Mark DIN ISO 16016SAP-No.: Pos.-Nr.: (Ers.d. / repl.by:)(Ers.f. / repl.for:)

REpower Systems AG- Entwicklungszentrum -

Hollesenstraße 15D-24768 Rendsburg

Phone: +49 - 4331 - 131390Fax. No: +49 - 4331 - 13139999

Unterbennung / subtitle

DIN-Blatt/DIN-Sheet

Datum/date

be strictly observed!Indicated Specification has to zwingend zu beachten!Angegebene Spezifikation ist

freigegeben/released:

geprüft / checked:

gezeichnet / drawn:

Version / Revision

Workflow Status

Zeichnungsnummer / Drawing Number

Benennung / Title

Werkstoff / Material:

Name/name

Gewicht / Weight:Maßstab / Scale:

EDP NO.

Blatt/Sheet

3910

5047 3632250

13075

1200

450

800

180250 22

0

383

1586

2xM48 at each sideof the main frame

2000

940

2626

1100

4200 10

0

forward transport direction


Outer Dimensions:hight: 3,910 mwidth: 4,200 mlength: 13,075 m

Gross weight: approx. 61,5 mtonsNet weight: approx. 60 mTons

REpower 3.X M

The two transport frames are each equipped with 4Lashing points. In front of the main frame, screwedlashing points can be mounted by a M48 thread. Twotimes in total.Lash point breaking load is about 200 kN, thatequals 100 kN lashing force.

C 16001 05.10.2009 Massen und Abmessungen aktualisiert / weights and dimensions updated J. Lütjen T. Sebon A. Trede

B 13254 02.09.2008 aktuelles WEA design / actual WEC design J. Lütjen T. Sebon A. Trede

Ver./rev.

Änd.Nr.

Datum/date Änderung / modification bearbeitet/

processedgeprüft/checked

Freigabe/released

8765

F

E

D

C

B

A

4321

1 2 3 4 5 6 7 8

F

E

D

C

B

A



PDM Dok ID

A3

Plot:


.

..

A. Trede03.03.2008

Schwerdtfeger03.03.2008

J. Lütjen03.03.2008

. .1:100

WEC REpowerWEA REpower nacelle - transport documentGondel Transport Dokument

CD-3.1-GP.MA.02-B

P:\Products\03_01_REpower_3XM\GesamtProjekt\Mass_Abmessg_Transp_Schwerpkt\Doku_Zeichnung\D-3.1-GP.MA.02-B..

1/2

05.10.2009


DIN ISO 2768-mHH

DIN ISO13715

+-





Phone: +49 - 4331 - 131390Fax. No: +49 - 4331 - 13139999


DIN-Blatt/DIN-Sheet

Datum/date



geprüft / checked:

gezeichnet / drawn:

Version / Revision

Workflow Status


Benennung / Title


Name/name


EDP NO.

Blatt/Sheet

Dokument-Nr./ Document-No.:

V-1.1-FG.OO.OO-A-J

Verfasser / Author

REpower Systems AGAlbert-Betz-Str. 10-24783 OsterronfeldTel.: +49-4331-13139-0Fax: +49-4331-13139-999

Erstellt:Prepared by:

GeprOft:Checked by:

Freigabe:Released by:

Bernd Frost----~

Stephan Schafer

~~

REpower Wind Turbine

Datum / Date:

2011-05-27

Seiten / Pages:

28

Ausfertigung /Issue:

D Original I OriginalD Reg. Exemplar Nr I Reg. Copy No.:_D Kopie (nicht erfasst) I Copy (not registered)

Status:

DEntwurf I DraftDEntwurf zur externen PrUfung I Draft for

external checkD freigegebene Fassung I released Version

Klassifikation / Classification:

D streng vertraulich I strictly confidentialD intern I internal[gI kundenvertraulich I Customer confidentialD offentlich I public

Anderungsdienst / QM document control:

D ja I yesD nein I noD begrenzt bis I limited until:

General Specification for the Design ofOnshore Foundations

Schutzvermerk ISO 16016: Weitergabe sowie Vervielfaltigung dieses Dokuments, Verwertung und Mitteilung seines Inhalts sind verboten, soweit nichtausdrUcklich gestattet. Zuwiderhandlungen verpflichten zu Schadenersatz. AlleRechte fUr den Fall der Patent-, Gebrauchsmuster- oder Geschmacksmustereintragung vorbehalten.

Protection mark ISO 16016: The reproduction, distribution and utilization of thisdocument as well as the communication of its contents to others without explicitauthorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model ordesign.

General Specification for the Design of Onshore Foundations

Dokumenten-Nr. / Document-No.: V-1.1-FG.00.00-A-J Page 2 of 28 Stand / Issue: 2011-05-27

Schutzvermerk ISO 16016 beachten / Protection Mark ISO 16016 to be attended Streng Vertraulich / Strictly Confidental

Der deutsche Text ist maßgebend! / The German Text is Authoritative! Änderungsverzeichnis / Change Index:

Revision Ausgabe-datum / Date of issue

Aus-tausch-seiten / Replaced pages

Änderungen / Modifications

A 2006-03-20 - Erstausgabe / First Issue B 2006-03-23 all C 2007-08-28 all D 2008-01-21 all E 2008-07-14 all F 2008-10-14 all G 2009-12-18 all

H 2010-06-07 p.24, p.26-27

General requirements for 3.XM @ 96.50 to 100 m hh; External Tower Stair Section added

I 2011-01-11 -- Section 4.4 added; Section 5.1 to 5.3 modified; Section 5.7; modified; Section 7.1 modified

J 2011-05-27 -- Section 5 modified; Minimum values for the REpower MM100 added; Section 4.4.1: detailed definition “compacted”

Zugehörige aktuelle Dokumente dieser Unterlage / Other Applicable Documents

Bezeichnung / Designation Dokumenten-Nr. / Document No.

Revisions-Nr. Ausgabedatum / Date of issue

Anlagen / Annex:




Table of Content

1 Introduction..................................................................................................................................4

2 Design Review .............................................................................................................................4

3 Soil Investigations and Geotechnical Data ...............................................................................5

3.1 General requirements....................................................................................................................5 3.2 Geotechnical Investigations for Gravity based Foundations .........................................................6 3.3 Geotechnical Investigations for Pile Foundations..........................................................................7 3.4 Ground Water and Dewatering Requirements ..............................................................................7

4 Foundation Types........................................................................................................................8

4.1 Gravity Foundations ......................................................................................................................8 4.1.1 General Requirements ..................................................................................................................8 4.1.2 Foundation Gapping ......................................................................................................................9 4.1.3 Soil Bearing Pressure for Circular Bases ....................................................................................10 4.1.4 Soil Bearing Pressure for Square Bases .....................................................................................11 4.1.5 Lean Concrete Underneath the Foundation Slab ........................................................................13 4.2 Pile Foundations..........................................................................................................................14 4.3 Pier Foundations .........................................................................................................................14 4.4 Anchor Bolt Foundation ...............................................................................................................15 4.4.1 3.XM @ 96.50m – 100 m Hub Height..........................................................................................17

5 REpower Requirements ............................................................................................................18

5.1 Minimum Requirements for Foundation Design ..........................................................................18 5.1.1 REpower MM82...........................................................................................................................19 5.1.2 REpower MM92...........................................................................................................................19 5.1.3 REpower MM100.........................................................................................................................19 5.1.4 REpower 3.4M104.......................................................................................................................20 5.2 Minimum Shear Reinforcement ...................................................................................................20 5.3 Anchor Reinforcement.................................................................................................................23 5.4 Design of the Pedestal ................................................................................................................24 5.5 Arrangement of Top and Bottom Layer Reinforcement...............................................................24 5.6 Design of Top and Bottom Layer Reinforcement ........................................................................25

6 Foundation Stiffness.................................................................................................................26

7 External Stair .............................................................................................................................27

7.1 External Stair – MM82/MM92 ......................................................................................................27 7.2 External Stair – 3XM, 78-80m Hub Height ..................................................................................28




1 Introduction

The design of foundations for REpower wind turbines has to be carried out based on the REpower load specification. National requirements and standards have also be taken into account. The design of the embedded steel can is carried out by REpower. EUROCODES shall be applied preferably if recognised in that particular country.

2 Design Review

REpower is entitled to do a design-review. However REpower does not accept responsibility as a result of the design review. If the foundation design does not meet REpower’s requirements the design has to be revised. These are the standard documents to be submitted for the design-review:

− Report on Ground Investigation

− General arrangement drawing of the foundation

− Reinforcement Drawings

− Bar Schedule

− Work Instructions

− Design-Report

Technical documentation should be in German and/or English. Other languages can be exceptionally accepted . This information shall be found on the drawings:

− Turbine (e. g. MM82 or 3.XM), hub height, name of the project / site

− Allowable groundwater level for the foundation

− Material properties for concrete and reinforcement steel (yield strength, ultimate strength etc.)

− Demands on the subsoil (allowable bearing pressure etc.)

To advance the projects, consulting-engineers should be able to communicate in English and/or in German.




3 Soil Investigations and Geotechnical Data

3.1 General requirements

Soil investigations should provide all necessary data for a detailed design of a specific foundation structure at a specific location. Soil investigations may be divided into the following parts:

− Geological studies

− Geophysical surveys

− Geotechnical investigations

A geological study should be based on information about the geological history of the area where the wind turbine is to be installed. The purpose of the study is to establish a basis for selection of methods and extent of the site investigation.

A geophysical survey can be used to extend the localised information from single borings and in-situ testing in order to get an understanding of the soil stratification within a given area. Such a survey can provide guidelines for selection of a suitable foundation site within the area, if not already decided. Geophysical surveys are carried out by means of seismic methods.

A geotechnical investigation consists of:

− soil sampling for laboratory testing

− in-situ testing of soil

Soil investigations should be adjusted to the geotechnical design methods used. The field and laboratory investigations should establish the detailed soil stratigraphy across the site, thus providing the following types of geotechnical data for all important soil layers:

− data for classification and description of the soil, such as

unit weight of sample

unit weight of solid particle

water content

liquid and plastic limits

grain size distribution

− parameters required for a detailed and complete foundation design, such as

permeability tests

consolidation tests

− static tests for determination of characteristic shear strength parameters such as friction angle φ for sand and undrained shear strength cu for clay (triaxial tests and direct simple shear tests)

− cyclic tests for determination of strength and stiffness parameters (triaxial tests, direct simple shear tests and resonant column tests)




Sampling can be carried out with and without drilling. The cone penetration test (CPT) and various vane tests form the most commonly used in-situ testing methods. Results from such in-situ tests can be used to interpret parameters such as the undrained shear strength of clay. The extent to which the various types of in-situ tests and laboratory tests are required depends much on the foundation type in question, for example, whether it is a piled foundation or a gravity-based foundation. This geotechnical report should contain sufficient information about the site and its soils, e.g. in terms of soil strength and deformation properties, to allow for design of the foundation with respect to:

− bearing capacity

− stability against sliding

− settlements

− foundation stiffness

− need for and possibility of drainage

− static and dynamic coefficients of compressibility

− sensitivity to dynamic loading

− highest possible groundwater table

− seismic activity

The geotechnical report is further required to contain identification of soil type at foundation level.

3.2 Geotechnical Investigations for Gravity based Foundations

Regarding gravity-based foundations, an extensive investigation of the shallow soil deposits should be undertaken. This investigation should cover soil deposits up to a depth, which is deeper than the depth of any possible critical shear surface. Further, all soil layers influenced by the structure in terms of settlement should be thoroughly investigated. This also has to be done for all soil layers contributing to the foundation stiffness. The foundation stiffness is of importance for the design of the structure supported by the foundation. The depth to be covered by the thorough investigation should at least equal the largest base dimension of the structure. The extent of shallow borings with sampling should be determined on the basis of the type and size of structure as well as on general knowledge about the soil conditions in the area considered for installation. Emphasis should be given to the upper layers and potentially weaker layers further down. It is recommended that the sampling interval is not in excess of 1.0-1.5 m. Shallow CPTs distributed across the installation area should be carried out in addition to the borings. The number of CPTs depend on the soil conditions and on the type and size of structure. If the soil conditions are very irregular across the foundation site, the number of CPTs will have to be increased. The shallow CPTs should provide continuous graphs from the soil surface up to the maximum depth of interest. Special tests such as plate loading tests, pressuremeter tests and shear wave velocity measurements should be considered where relevant.




3.3 Geotechnical Investigations for Pile Foundations

For lateral pile analysis, shallow cone penetration tests should be carried out from the surface to 20-30m depth. In addition, shallow borings with sampling should be considered for better determination of characteristics of the individual layers identified by the cone penetration tests. It is recommended that the sampling interval is not in excess of 1.0-1.5m. As regards axial pile analysis, at least one down-the-hole CPT boring should be carried out to give a continuous CPT profile. Moreover, one nearby boring with sampling should be carried out for the axial pile capacity analysis. The minimum depth should be the anticipated penetration of the pile plus a zone of influence sufficient for evaluation of the risk of punch-through failure. The sampling interval should be determined from the CPT results, but is recommended not to exceed 3 m. Special attention should be paid when potential end bearing layers or other dense layers are found. Here, additional CPTs and sampling should be carried out in order to determine the thickness and lateral extension of such layers within the area considered for the foundation.

3.4 Ground Water and Dewatering Requirements

The geotechnical engineer of record has to determine the maximum ground water level on site. The encountered ground water level has to be clearly stated together with the ground profile.

During the construction phase of the proposed foundation, it might be necessary to dewater the construction site temporarily. REpower won’t accept foundation designs considering a permanent dewatering during the operational life-span of the WTG. For the structural foundation design, buoyancy and hydrostatic effects have to be considered, if applicable. Lowering the groundwater level by wells and ducts may not be taken into account for the design of the overall stability. If the natural ground water level is higher than the base, buoyancy has to be considered even if there is area drainage.




4 Foundation Types

4.1 Gravity Foundations 4.1.1 General Requirements

For economical reasons, gravity foundations should preferably be designed with a circular base. Octagonal or polygonal (n ≥ 8) bases are also acceptable. To simplify the analysis of polygonal bases, a circular base with an equal area may be modelled as well. To improve the stiffness of the foundation it is recommended to arrange a layer of ballast on top of the foundation slab.

The design shall include the following key elements:

− Overall stability assessments taking into account the ground water level

− Reinforced concrete design

− Fatigue analysis for the reinforcement and the concrete

Depending on the design of the embedded steel can provided by REpower, the foundation should be engineered as follows:

For US projects only: Due to patent reasons the version 1 general arrangement of the above figure is not allowed to be used in connection with an embedded steel can the USA.




4.1.2 Foundation Gapping

No inactive area at the base of a gravity foundation is admissible for the tower moment specified by REpower. No safety factors have to be applied. It has to be proven that the excentricity of the total vertical load (turbine, foundation slab, pedestal, ballast etc.) due to the tower moment is

e < R / 4 for circular bases

e < a / 6 for square bases with tower moment parallel to edges

e < a / 8.485 for square bases with tower moment in 45° direction to edges

For unscaled ultimate loads (γF = 1.0) not more than 50% of the base may be without compression. No safety factors have to be applied. It has to be proven that the resultant of all forces (tower moment, turbine, foundation slab, pedestal, ballast) is within a circle

e < 0.59 * R for circular bases

e < a / 3 for square bases




4.1.3 Soil Bearing Pressure for Circular Bases

The bearing pressure beneath a circular base has to be calculated as follows

− Ultimate bearing pressure at the edge of the foundation for characteristic loads

⏐Fz ⏐ = resultant of all vertical forces ( turbine, tower, foundation, ballast etc.)

e = M / ⏐Fz ⏐ excentricity

K = coefficient according to the graph below

σmax = K * ⏐Fz ⏐ / (π* R2) soil pressure at the edge

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

0.10

0.15

0.20

0.25

0.30

0.35

0.40

0.45

0.50

0.55

0.60

e/r

K

− Ultimate averaged bearing pressure for characteristic loads as shown in the sketch

α = 2 * arccos(e / R) (included angle of sector circle)

Aeff = R2 * (α - sin α) (area with constant pressure)

σm = ⏐Fz ⏐ / Aeff




4.1.4 Soil Bearing Pressure for Square Bases

The bearing pressure beneath a square base has to be calculated as follows:

− Ultimate bearing pressure at the edge of the foundation for the characteristic loads

⏐Fz ⏐ = resultant of all vertical forces ( turbine, tower, foundation, ballast etc.)

e = M / ⏐Fz ⏐ excentricity

K = coefficient according to the graph below

σmax = K * ⏐Fz ⏐ / a² soil pressure at the edge of the foundation

foundations w ith a square base

0.00

1 .00

2 .00

3 .00

4 .00

5 .00

6 .00

0.00

0.02

0.04

0.06

0.08

0.10

0.12

0.14

0.16

0.18

0.20

0.22

0.24

0.26

0.28

0.30

0.32

0.34

0.36

e /a

K

para lle l 45°




− Ultimate averaged bearing pressure for characteristic loads as shown in the sketch (90° direction):

Aeff = a2 - 2 * a * e area with constant pressure


− Ultimate averaged bearing pressure for the characteristic loads as shown in the sketch (45° direc-tion):

Aeff = (a – e* 20.50)2 area with constant pressure





4.1.5 Lean Concrete Underneath the Foundation Slab

If the ground conditions do not allow to set up a gravity foundation directly on the natural soil, poor soil may be exchanged by lean concrete or engineering backfill. The backfill has to be arranged in a conical way:

For US projects only: Due to patent reasons no reinforced sub bases or lean concrete layers are allowed to be used on site in the USA. The embedded steel can has to be placed on a non-reinforced sub base layer. It is required to use a minimum of 100mm lean concrete to support the levelling legs of the embedded steel can.




4.2 Pile Foundations

If the ground conditions do not permit gravity foundations, piled foundations are required. The piles have to absorb the axial forces due to the tower moment and dead loads as well as the horizontal forces due to torsion and lateral forces. It is recommended to use raked piles. REpower exclusively accepts reinforced concrete piles. Steel piles and wooden piles are not admissible. Reinforcement cages for the piles may not be welded, even spot welding is not admissible because the performance of the pile regarding to fatigue would decrease dramatically.

4.3 Pier Foundations

A pier foundation is neither a gravity foundation nor a piled foundation. A pier foundation can be referred to as a caisson, a mono-pile with a large diameter. The proprietary name is “Patrick & Henderson” foundation.

For pier foundations the centre of rotation is located at a lower height indication compared with gravity foundations or piled foundations. If the point of rotation is placed too low, the pier foundation acts like an extension of the tower, which affects the natural eigenfrequencies of the tower-foundation system. The engineer of record has to assure, that the tower-foundation system does not become softer than the minimum dynamic rotational stiffness specified by REpower!

Among other things the design of a pier foundation has to include the following elements:

− Verification of the rotational and lateral stiffness at a reference height indication as specified by REpower. If the centre of rotation is at a lower height indication than specified by REpower, the complete system (nacelle, tower and foundation) has to be taken into consideration.

− Overall stability

− Structural design of the foundation body

− Fatigue analysis for the reinforcement and/or anchor bars as well as for the concrete

For pier foundations (caisson, Patrick & Henderson, and similar) excavating using explosives is prohibited. Where necessary, a hydraulic excavator or other applicable devices shall be used instead. Especially for P&H-Foundations the excavation method may not degrade the texture of the in-situ soil/rock. The engineer of record has to propose a suitable method for excavation works.




4.4 Anchor Bolt Foundation

A tubular steel tower of a REpower wind turbine may be designed to be connected to the foundation with an anchor cage. The proposed anchor cage consists of an embedment ring as well as an inner and outer ring of holding down bolts fixed to the embedment ring with threads. The bolts will be pre-stressed after erection of the bottom tower segment.

REpower accepts the following two principle positions of the embedment ring. The following figure does not represent a complete structural drawing. It only shows basic parts of a proposed foundation design.

Option A: The embedment ring is placed below the bottom reinforcement. In that case no anchor reinforcement around the holding down bolts is needed.

Option B: The embedment ring is placed above the bottom reinforcement. In that case anchor reinforcement around the holding down bolts is required. The anchor reinforcement has to be in accordance with the stated design approach in section 5.3 on page 23. A sufficient anchor length on the tension site of the anchor reinforcement has to be assured.

The number of bolts, the mean diameter of the inner & outer bolt ring as well as the proposed bolt diameter can be found on the tubular steel tower drawing.




The following general requirements have to be taken into account:

− A suitable long term corrosion protection of the bolts has to be assured. The bolts have to be pro-tected against corrosion for the proposed design life of 20yrs.

− Concrete is sensible to creeping and shrinkage effects. The foundation engineer generally speci-fies the pre-tension force of the bolts. The pre-tension force shall be checked periodically after ini-tial pre-tension of the bolts. The foundation engineer has to clearly state after what time frame the pre-tension force has to be adjusted.

− It has to be assured that water, grout or concrete does not come into contact with the holding down bolts. Typically a high temperature (HT) tube is used to prevent contact between concrete, grout and water. A heat shrinkage tube seals the HT tube at both ends. See figure below:

1. HT tube avoiding contact between concrete and bolt

2. Heat shrinkage tube for sealing

3. Threaded bolt end

1

2 3




4.4.1 3.XM @ 96.50m – 100 m Hub Height

REpower’s wind turbine 3.XM @ 96.5 m – 100 m hub height shall be arranged with a pre-stressed concrete pedestal. The bolt cage as well as the template for the erection of the bolt cage is provided by REpower. Therefore the design of each foundation shall be based on REpower’s standard foundation design which will be provided on demand. Only country-specific inevitable modifications are permitted. The general arrangement shall comply with the sketch below:




5 REpower Requirements

To assure a proper foundation design REpower specifies the following minimum requirements. These requirements are structural requirements as well as geometrical and requirements regarding the proposed concrete class. Nevertheless for the foundation design local codes and standards have to be considered.

5.1 Minimum Requirements for Foundation Design

Each of the following sections do contain a table stating the minimum requirements, that have to be considered for the foundation design:

− Hub Height [m]: Range or single value for the hub height.

− Wind Class: Proposed wind class of a specific location.

− Concrete Volume [m3]: Minimum values for concrete volume. The column differentiates between gravity foundations without buoyancy and pile foundations with buoyancy effects. For squared foun-dations values have to be increased by 10%.

− Reinforcements Steel [t]: Minimum values for reinforcement steel. The column differentiates be-tween gravity foundations without buoyancy and pile foundations with buoyancy effects. For squared foundations values have to be increased by 10%.

− Slab Thickness h [mm]: That column states the minimum thickness of the foundation slab itself. The given values are valid for foundations with an embedded steel can as well as if an anchor cage is supposed to be used for the tower – foundation connection. The blinding layer may not be taken into account.




− Concrete Class: In that column the minimum concrete class around the embedded flange is stated. The concrete class is based on Eurocode 2 nomenclature. If the Eurocode 2 is not applica-ble in an particular country, the chosen concrete compressive strength fck shall be equivalent.

5.1.1 REpower MM82

Concrete Volume [m3] Reinforcement Steel [t] Slab Thickness h Hub

Height

[m]

Wind Class Gravity Found.

without buoyancy Pile Found. with

buoyancy Gravity Found.


buoyancy [mm]

ConcreteClass

59 IEC1a, 2a & IEC S-Class 213 186 23.5 27.5 1,500 C35/45

69 IEC1a, 2a & IEC S-Class 244 212 27.0 31.0 1,650 C35/45

69 IEC CCV 265 229 30.0 33.5 1,750 C35/45

78-80 IEC2a, IEC S-Class 291 250 33.5 36.0 1,900 C35/45

80 IEC CCV 297 263 34.0 30.0 2,000 C35/45

100 IEC 3a 350 293 40.0 42.0 2,200 C35/45

5.1.2 REpower MM92


Height

[m]





buoyancy [mm]

ConcreteClass

68.5 IEC2a 241 209 27.0 30.5 1,700 C35/45

78-80 IEC2a 286 244 33.0 35.0 1,950 C35/45

80 IEC CCV 299 265 34.0 35.0 2,000 C35/45

98-100 IEC2a & 3a 355 293 41.0 41.5 2,250 C35/45

5.1.3 REpower MM100


Height

[m]





buoyancy [mm]

ConcreteClass

78-80 IEC2a 290 250 33.0 35.0 2,000




5.1.4 REpower 3.4M104 Concrete Volume [m3] Reinforcement Steel [t] Slab Thickness

h Hub Height

[m]





buoyancy [mm]

ConcreteClass

78-80 IEC2a 353 299 42.0 42.0 2,300 C35/45

93 IEC1b 433 433 46.5 46.5 2,500 C35/45

96.5-100 IEC2a 450 450 47.5 47.5 2,500 (*)

(*) Anchor cage design: C50/60 below the tower base flange; C30/37 around the embedded ring flange at the bottom of the anchor cage.

5.2 Minimum Shear Reinforcement

REpower specifies a minimum shear reinforcement depending on the shear forces in the foundation slab. Furthermore local codes and standards have to be considered. Regardless of REpower’s requirement, the adequacy of the shear reinforcement has to be proven by the designer. Shear reinforcement shall embrace the bottom layer of reinforcement as well as the top layer of reinforcement.




(Concrete: C30/37) VEd [KN/m] (γ incl.)

d ↓ 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000

[cm] [cm²/m²

] [cm²/m²

] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²]

100 0.00 3.41 5.11 6.81 8.52 11.26 15.52 19.78 24.04 28.30 32.56 36.82 41.08 45.34 49.60 110 0.00 3.10 4.65 6.20 7.74 9.29 12.81 16.68 20.56 24.43 28.30 32.17 36.05 39.92 43.79 120 0.00 2.84 4.26 5.68 7.10 8.52 10.55 14.10 17.65 21.20 24.75 28.30 31.85 35.40 38.95 130 0.00 2.62 3.93 5.24 6.55 7.86 9.17 11.92 15.20 18.47 21.75 25.02 28.30 31.58 34.85 140 0.00 2.43 3.65 4.87 6.08 7.30 8.52 10.05 13.09 16.13 19.17 22.22 25.26 28.30 31.34 150 0.00 2.27 3.41 4.54 5.68 6.81 7.95 9.09 11.26 14.10 16.94 19.78 22.62 25.46 28.30 160 0.00 2.13 3.19 4.26 5.32 6.39 7.45 8.52 9.67 12.33 14.99 17.65 20.31 22.98 25.64 170 0.00 2.00 3.01 4.01 5.01 6.01 7.02 8.02 9.02 10.76 13.27 15.77 18.28 20.78 23.29 180 0.00 1.89 2.84 3.79 4.73 5.68 6.63 7.57 8.52 9.47 11.74 14.10 16.47 18.84 21.20 190 0.00 1.79 2.69 3.59 4.48 5.38 6.28 7.17 8.07 8.97 10.37 12.61 14.85 17.09 19.33 200 0.00 1.70 2.56 3.41 4.26 5.11 5.96 6.81 7.67 8.52 9.37 11.26 13.39 15.52 17.65 210 0.00 1.62 2.43 3.25 4.06 4.87 5.68 6.49 7.30 8.11 8.92 10.05 12.08 14.10 16.13 220 0.00 0.00 2.32 3.10 3.87 4.65 5.42 6.20 6.97 7.74 8.52 9.29 10.88 12.81 14.75 230 0.00 0.00 2.22 2.96 3.70 4.44 5.19 5.93 6.67 7.41 8.15 8.89 9.78 11.63 13.49 240 0.00 0.00 2.13 2.84 3.55 4.26 4.97 5.68 6.39 7.10 7.81 8.52 9.23 10.55 12.33 250 0.00 0.00 2.04 2.73 3.41 4.09 4.77 5.45 6.13 6.81 7.50 8.18 8.86 9.56 11.26


d ↓ 320

0

3400 3600 3800 4000 4200 4400 4600 4800 5000 5200 5400 5600 5800 6000

[cm] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²]

100 53.86 58.12 62.38 66.63 70.89 75.15 79.41 83.67 87.93 92.19 96.45 100.71 104.97 109.23 113.49110 47.66 51.53 55.41 59.28 63.15 67.02 70.89 74.77 78.64 82.51 86.38 90.25 94.13 98.00 101.87120 42.50 46.05 49.60 53.15 56.70 60.25 63.79 67.34 70.89 74.44 77.99 81.54 85.09 88.64 92.19 130 38.13 41.41 44.68 47.96 51.24 54.51 57.79 61.06 64.34 67.62 70.89 74.17 77.45 80.72 84.00 140 34.39 37.43 40.47 43.51 46.55 49.60 52.64 55.68 58.72 61.77 64.81 67.85 70.89 73.94 76.98 150 31.14 33.98 36.82 39.66 42.50 45.34 48.18 51.02 53.86 56.70 59.54 62.38 65.21 68.05 70.89 160 28.30 30.96 33.63 36.29 38.95 41.61 44.27 46.94 49.60 52.26 54.92 57.58 60.25 62.91 65.57 170 25.80 28.30 30.81 33.31 35.82 38.32 40.83 43.33 45.84 48.34 50.85 53.36 55.86 58.37 60.87 180 23.57 25.93 28.30 30.67 33.03 35.40 37.77 40.13 42.50 44.86 47.23 49.60 51.96 54.33 56.70 190 21.58 23.82 26.06 28.30 30.54 32.78 35.03 37.27 39.51 41.75 43.99 46.23 48.48 50.72 52.96 200 19.78 21.91 24.04 26.17 28.30 30.43 32.56 34.69 36.82 38.95 41.08 43.21 45.34 47.47 49.60 210 18.16 20.19 22.22 24.24 26.27 28.30 30.33 32.36 34.39 36.41 38.44 40.47 42.50 44.53 46.55 220 16.68 18.62 20.56 22.49 24.43 26.36 28.30 30.24 32.17 34.11 36.05 37.98 39.92 41.85 43.79 230 15.34 17.19 19.04 20.89 22.75 24.60 26.45 28.30 30.15 32.00 33.86 35.71 37.56 39.41 41.26 240 14.10 15.88 17.65 19.43 21.20 22.98 24.75 26.53 28.30 30.08 31.85 33.63 35.40 37.17 38.95 250 12.97 14.67 16.38 18.08 19.78 21.49 23.19 24.89 26.60 28.30 30.00 31.71 33.41 35.12 36.82

Example: VEd = 3000 KN/m d = 180 cm as,req = 21.20 cm²/m²





d ↓ 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000

[cm] [cm²/m²

] [cm²/m²

] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²]

100 0.00 3.41 5.11 6.81 8.52 10.51 14.77 19.03 23.29 27.55 31.81 36.07 40.33 44.58 48.84 110 0.00 3.10 4.65 6.20 7.74 9.29 12.06 15.93 19.80 23.68 27.55 31.42 35.29 39.16 43.04 120 0.00 2.84 4.26 5.68 7.10 8.52 9.94 13.35 16.90 20.45 24.00 27.55 31.10 34.65 38.20 130 0.00 2.62 3.93 5.24 6.55 7.86 9.17 11.17 14.44 17.72 20.99 24.27 27.55 30.82 34.10 140 0.00 0.00 3.65 4.87 6.08 7.30 8.52 9.74 12.34 15.38 18.42 21.46 24.51 27.55 30.59 150 0.00 0.00 3.41 4.54 5.68 6.81 7.95 9.09 10.51 13.35 16.19 19.03 21.87 24.71 27.55 160 0.00 0.00 3.19 4.26 5.32 6.39 7.45 8.52 9.58 11.58 14.24 16.90 19.56 22.22 24.89 170 0.00 0.00 3.01 4.01 5.01 6.01 7.02 8.02 9.02 10.02 12.51 15.02 17.53 20.03 22.54 180 0.00 0.00 2.84 3.79 4.73 5.68 6.63 7.57 8.52 9.47 10.98 13.35 15.72 18.08 20.45 190 0.00 0.00 2.69 3.59 4.48 5.38 6.28 7.17 8.07 8.97 9.86 11.86 14.10 16.34 18.58 200 0.00 0.00 2.56 3.41 4.26 5.11 5.96 6.81 7.67 8.52 9.37 10.51 12.64 14.77 16.90 210 0.00 0.00 2.43 3.25 4.06 4.87 5.68 6.49 7.30 8.11 8.92 9.74 11.32 13.35 15.38 220 0.00 0.00 2.32 3.10 3.87 4.65 5.42 6.20 6.97 7.74 8.52 9.29 10.12 12.06 14.00 230 0.00 0.00 2.22 2.96 3.70 4.44 5.19 5.93 6.67 7.41 8.15 8.89 9.63 10.88 12.73 240 0.00 0.00 2.13 2.84 3.55 4.26 4.97 5.68 6.39 7.10 7.81 8.52 9.23 9.94 11.58 250 0.00 0.00 2.04 2.73 3.41 4.09 4.77 5.45 6.13 6.81 7.50 8.18 8.86 9.54 10.51


d ↓ 3200 3400 3600 3800 4000 4200 4400 4600 4800 5000 5200 5400 5600 5800 6000[cm] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²] [cm²/m²]

100 53.10 57.36 61.62 65.88 70.14 74.40 78.66 82.92 87.18 91.44 95.70 99.95 104.21 108.47 112.73110 46.91 50.78 54.65 58.52 62.40 66.27 70.14 74.01 77.88 81.76 85.63 89.50 93.37 97.24 101.12120 41.75 45.29 48.84 52.39 55.94 59.49 63.04 66.59 70.14 73.69 77.24 80.79 84.34 87.89 91.44 130 37.38 40.65 43.93 47.21 50.48 53.76 57.03 60.31 63.59 66.86 70.14 73.42 76.69 79.97 83.25 140 33.63 36.67 39.72 42.76 45.80 48.84 51.89 54.93 57.97 61.01 64.06 67.10 70.14 73.18 76.22 150 30.39 33.23 36.07 38.91 41.75 44.58 47.42 50.26 53.10 55.94 58.78 61.62 64.46 67.30 70.14 160 27.55 30.21 32.87 35.53 38.20 40.86 43.52 46.18 48.84 51.51 54.17 56.83 59.49 62.15 64.82 170 25.04 27.55 30.05 32.56 35.06 37.57 40.07 42.58 45.09 47.59 50.10 52.60 55.11 57.61 60.12 180 22.81 25.18 27.55 29.91 32.28 34.65 37.01 39.38 41.75 44.11 46.48 48.84 51.21 53.58 55.94 190 20.82 23.06 25.31 27.55 29.79 32.03 34.27 36.51 38.76 41.00 43.24 45.48 47.72 49.96 52.21 200 19.03 21.16 23.29 25.42 27.55 29.68 31.81 33.94 36.07 38.20 40.33 42.45 44.58 46.71 48.84 210 17.41 19.43 21.46 23.49 25.52 27.55 29.58 31.60 33.63 35.66 37.69 39.72 41.75 43.77 45.80 220 15.93 17.87 19.80 21.74 23.68 25.61 27.55 29.48 31.42 33.36 35.29 37.23 39.16 41.10 43.04 230 14.58 16.44 18.29 20.14 21.99 23.84 25.70 27.55 29.40 31.25 33.10 34.95 36.81 38.66 40.51 240 13.35 15.12 16.90 18.67 20.45 22.22 24.00 25.77 27.55 29.32 31.10 32.87 34.65 36.42 38.20 250 12.21 13.92 15.62 17.33 19.03 20.73 22.44 24.14 25.84 27.55 29.25 30.95 32.66 34.36 36.07

Example: VEd = 3000 KN/m d = 180 cm as,req = 20.45 cm²/m²




5.3 Anchor Reinforcement

The embedded steel can is tied back to the foundation slab by anchor reinforcement. Bars within a section of 70 cm may only be taken into account. Regardless of REpower’s requirement, the adequacy of the anchor reinforcement subjected to fatigue as well as to ultimate loads has to by proven by the designer.

REpower requirement:

− Mres = resultant tower moment incl. safety factor

− ⏐ Fz⏐ = vertical load of the tower reduced by safety factor γ = 0.90

− D = Diameter of the tower

− F = 4 * Mres / D - ⏐ Fz⏐ force to be covered by anchor reinforcement around the circumference




5.4 Design of the Pedestal

To avoid cracking of the pedestal REpower specifies a minimum reinforcement according to the sketch below:

5.5 Arrangement of Top and Bottom Layer Reinforcement

The top and the bottom layer of reinforcement should preferably be arranged in an unseparated way. If the required length of the bars is not available, the overlap joint should be designed according to the sketch below. Overlap joints have to be placed staggered. Placing them in one line is not permissible. It should be avoided to arrange overlaps in the area of high bending moments in the foundation slab. Regardless of REpower’s requirement, the adequacy of the arrangement of reinforcement subjected to fatigue as well as ultimate loads has to by proven by the designer.

Where overlap joints can’t be avoided the overlap length shall be not less than 45 times the diameter of the reinforcement bars.

Welded or manually connected rebars do have a significantly reduced fatigue strength. Therefore no manual connection of rebars are permitted.




5.6 Design of Top and Bottom Layer Reinforcement

The top and the bottom layer of reinforcement has to be designed by means of the finite-element-method taking into account the stiffness of the soil. The curve of moments has to be enveloped by the resistance. Averaging the curve of moments is not admissible.




6 Foundation Stiffness

REpower specifies minimum dynamic foundation stiffness (kϕ,dyn and kxy,dyn) in order to ensure that the overall system natural frequency stays above the main excitation loads. This requirement enables REpower to demonstrate that fatigue life will be acceptable since the foundation stiffness has been assumed in the turbine fatigue simulations. Furthermore REpower specifies statical foundation stiffness (kϕ,stat) to ensure stability and to limit moments from second order theory.

θϕ

ϕMk dyn

dyn,

,=

yxFk dynyx

dynyx ,,,

,, Δ=

θϕ

ϕMk stat

stat,

,=

− kϕ,dyn : dynamic rotational stiffness of the foundation

− kxy,dyn : dynamic horizontal stiffness of the foundation

− kϕ,stat : statical rotational stiffness of the foundation

− θ: rotation at reference height

− Δx,y: horizontal displacement at reference height

− Mϕ,dyn : resultant dynamic moment at reference height

− Mϕ,stat : resultant statical moment at reference height

− Fxy,dyn : resultant horizontal force at reference height

For circular gravity bases dynamic foundation stiffness is calculated using a rigid footing on elastic half-space formulation:

2

23

,, )1()1()21(*

34

νννν

ϕ −⋅+−−

⋅=rEK dynsdyn

r: radius of the base ES,dyn: dynamic module of compressibility ν: Poisson’s ratio

For squared gravity bases dynamic foundation stiffness is calculated using a rigid footing on elastic half-space formulation:

2

23

,, )1()1()21(**2*

νννν

ϕ −⋅+−−

=aEK dynsdyn

a: half side length ES,dyn: dynamic module of compressibility ν: Poisson’s ratio

In the estimation of foundation stiffness at the design stage, sufficient allowance should be made for ground variability across the site. Regardless of this requirement, the rotational stiffness of the foundation shall be proven by the designer using adequate equations.




7 External Stair

Each turbine can be entered by an external tower stair. As a rigid support a proper stair base support has to be provided. The rigid stair base support shall be set up on site. The needed dimensions of the support area are depicted in this section. The support area has to be made of a concrete slab, flagstones or any other suitable support material. The stair base can be levelled within ±50mm up and downwards.

7.1 External Stair – MM82/MM92

Depending on the turbine configuration the distance Lx varies. The information regarding the turbine configuration will be provided be the project management. The stair base support has to be provided in front of the proposed tower door.

Distance Lx [mm]

ETS (External Transformator) ITS (Internal Transformator)

2700 3800

The height hbase depends on the hub height of the turbine. The following listing states the height of the stair base depending on the configuration and hub height of a specific turbine in relation to the top of the embedment can.

hbase for ETS [mm] hbase for ITS [mm]

MM-Series, Hub height = 59m 710 720

MM-Series, Hub height > 59m 610 660




7.2 External Stair – 3XM, 78-80m Hub Height

For this specific turbine the height hbase in relation to the top of the embedment can is given below:

− 3XM – 80m hub height: hbase = 800mm

The distance Lx and the distance Ly for the 80m hub height is given below:

− Distance Lx = 1600mm

− Distance Ly = 4500mm

Wind turbine

REpower 3.XM

Lubricants and measures

against leaks caused by accidents

Document no. (version):

D-3.1-GP.00.01-A-EN (D)

Author

REpower Systems SE Albert-Betz-Str. 1 D-24783 Osterrönfeld Phone: +49-4331-13139-0 Fax: +49-4331-13139-999

Original document: German

Prepared: Gunnar Sienknecht

Reviewed: Jan Lütjen

Approved: Rainer Rieckenberg

Translated: Service provider

Date:

2013-02-22

Pages:

8

Document type:

Original � Reg. copy no.:___ � Copy (unregistered) Status:

� Draft � Draft for external review Approved version

Classification:

� Strictly confidential � Internal Customer confidential � Public

Updating service:

Yes � No � Limited until: _________ � = <ALT> 0168, � = <ALT> 0254

Protective note ISO 16016: The reproduction, distribution and utilization of this document, as well as the communication of its contents to others without explicit authorization, is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the granting of a patent, utility model, or registered design.

Wind turbine REpower 3.XM Lubricants and measures against leaks caused by accidents

Change history:

Ver

sio

n

Issu

e d

ate

Rep

lace

d

pag

es

Changes

A 2008-01-31 First edition B 2009-04-14 All New identification for 3.XM

New lubrication grease for generator bearing lubrication C 2012-10-16 All Types of grease / separation of German/English / content revision D 2013-02-22 All Water hazard class adjusted

Related documents:

Name Document no.

Please ask the REpower Systems SE Document Management department for the most current versions of the respective related documents. The German description will apply in case of doubt.

Document no.: D-3.1-GP.00.01-A-EN Version D Page 2 Last updated: 2013-02-22 – Observe protective note ISO 16016 –


Lubricants and measures against leaks caused by accidents

3.XM

Table of contents:

1 List of lubricants ........................................................................................................ 4

2 Design measures to prevent lubricant from escaping ........................................... 6 2.1 Blade pitch gearbox......................................................................................... 6 2.2 Blade adjustment bearing................................................................................ 6 2.3 Rotor bearing................................................................................................... 6 2.4 Gearbox........................................................................................................... 6 2.5 Generator bearing ........................................................................................... 7 2.6 Hydraulic system ............................................................................................. 7 2.7 Yaw gearbox.................................................................................................... 7 2.8 Yaw bearing..................................................................................................... 7

3 Maintenance and oil change ..................................................................................... 7 3.1 Maintenance .................................................................................................... 7 3.2 Oil change ....................................................................................................... 8 3.3 Disposal........................................................................................................... 8



1 List of lubricants

10, 121 4, 12

6, 7 8, 9 2

5

No. Location Type Brand Quantity WHC* HSC*

1 Gearbox

Synthetic oil

Mobil SHC XMP 320 or

Castrol Optigear SYN A320

≈580 l

1

2

-

-

2 Yaw gearbox

Synthetic oil


Mobil SHC Gear 150

≈20 l

≈20 l

1

2

-

-

3 Hydraulic system

Hydraulic oil

Fuchs ECO-HYD S plus (NCV)

Shell Tellus Arctic 32 (CCV)

≈20 l

≈20 l

1

2

-

-

4 Main bearing

Lubrication grease

Fuchs Lubritech Stabyl EOS E2 ≈135 kg

1

-

5 Generator bearing

Lubrication grease

Klüberplex BEM 41-132 ≈11 kg 1 -



6 Yaw – bearing

Lubrication grease

Fuchs Lubritech Gleitmo 585K ≈17 kg 2 -

7 Yaw – gearing

Lubrication grease

OKS 495 or

Fuchs Lubritech Gleitmo 585K

≈1 kg

≈1 kg

1

2

-

-

8 Rotor blade – bearing

Lubrication grease

Fuchs Lubritech Gleitmo 585K ≈3x10 kg

+15 kg

2 -

9 Blade bearing

– gearing

Lubrication grease

OKS 495 or


≈3x1 kg

≈3x1 kg

1

2

-

-

10 Blade pitch gearbox

Synthetic oil


Mobil SHC Gear 150

3×7.5 l

3×7.5 l

1

2

-

-

11 Blade pitch gearb.

seal

Lubrication grease

Fuchs Lubritech Stabyl EOS E2 <1 kg

1

-

12 Rotor lock,

door hinges, etc.

Lubrication grease


1

-

* - WHC = water hazard class (- = not applicable because insoluble solid substance)

** - HSC = hazardous substances class (- = not applicable)

Safety data sheets in accordance with directive 91/155/EEC are available for all lubricants



2 Design measures to prevent lubricant from escaping

The following design measures can prevent leakage as a cause for escaping lubricant:

2.1 Blade pitch gearbox The blade pitch gearboxes are arranged along the cast element of the rotor hub and rotate with the rotor. A double sealing system effectively prevents the discharge of the gear oil. If there is leakage, the oil remains inside the rotor hub, the spinner or the rotor blades. The corresponding sump capacity is adequate for the relatively low oil quantity.

2.2 Blade adjustment bearing The tracks of the bearings are lubricated with lubrication grease. The sealing system effectively prevents the discharge of the lubrication grease Used lubrication grease expelled from the tracks will be collected in lubrication grease collection bottles that are mounted on the inner bearing ring. The grease collection bottles are emptied during maintenance. If the bottles are too full and lubrication grease is discharged, the sealing system ensures the lubrication grease remains inside the rotor hub enclosure. If the external sealing system of the blade bearing fails, the discharged lubrication grease will be collected by the rotor blade rain deflector. The rain deflector and the deflector on the rotor hub enclosure form an effective labyrinth, both against penetrating rainwater and against discharged lubrication greases from the pitch bearing. The blade bearing gearing is lubricated with an adherent lubrication grease. This adherent lubrication grease is highly viscous and non-drip. Clumpy flaking of the adhesive lubricant from the gearing is not possible. In addition, the blade bearing gearing is covered to prevent access. Any leakage will remain inside this cover.

2.3 Rotor bearing During operation, lubrication grease escapes from the labyrinth seals of the rotor bearing. This lubrication grease will be collected directly below the bearing, in a lubrication grease pan integrated in the main frame. Aluminum sheet inserts provide the necessary sealing of the integrated grease pan. The grease pan is regularly emptied during maintenance and the discharged lubrication grease is disposed of properly.

2.4 Gearbox The gearbox features non-abrasive, i.e. wear-free, sealing systems on the drive shaft and output shaft. If leakages occur on the gearbox, the discharged will be immediately collected in an oil pan that is integrated in the nacelle. In addition, the top platform of the tower is designed to function as an oil pan. To this end, the platform is welded oil-tight with an 80 mm high, circular edge. The threaded joint holes are sealed. This effectively prevents the oil from continuing to enter the tower interior.



2.5 Generator bearing The lubricated generator bearings are equipped with a non-contact sealing system based on the labyrinth principle. This sealing system effectively prevents uncontrolled discharge of the lubricant. Used, excess lubrication grease will be collected in the designated containers. The collection containers will be emptied during maintenance.

2.6 Hydraulic system The hydraulic unit is located in the nacelle. An oil pan is positioned directly below the unit for any lingering leaks or discharged hydraulic oil.

2.7 Yaw gearbox The oil-filled gearboxes for the yaw system feature a complex sealing system on the input and output shafts. The drives are located within the nacelle enclosure. If oil escapes as the result of damage, this oil will be collected by a circular coaming mounted on the nacelle enclosure.

2.8 Yaw bearing The tracks of the bearing are lubricated with lubrication grease. The selected sealing system ensures that excess lubrication grease is discharged outward toward the gearing. The yaw bearing gearing is lubricated with an adherent lubrication grease. This lubrication grease is highly viscous and non-drip. Clumpy flaking of the lubrication grease from the gearing is not possible. To collect lubrication grease discharged from the yaw bearing sealing system, a continuous coaming ring is mounted below the yaw bearing gearing. These lubrication grease collection channels will be regularly emptied during maintenanc.

3 Maintenance and oil change

3.1 Maintenance The lubrication grease collection pans are checked at regular intervals during maintenance and emptied as required (see "Disposal" section). Required quantities of lubrications grease and hydraulic oil are lifted into the nacelle using a chain hoist.




3.2 Oil change Lubricants are not stocked on site at the wind turbine. Oil is not refilled. During the scheduled maintenance an oil sample is taken from the gearbox and inspected in a laboratory. An oil change is only carried out if necessary depending on the result of the oil sample inspection. The oil change is carried out by a service company. For draining and refilling the oil, a hose is attached between the tanker and the gearbox.

3.3 Disposal Lubricant is disposed of by approved, specialist firms in the region using a tracking form procedure.

SENVION 3.4M104

1

P

O

N

M

L

K

J

I

H

G

F

E

D

C

B

A

H

G

F

E

D

C

B

A

P

O

N

K

M

L

J

I

2 3 4 5 6 7 8 9 10 11 12

1 2 3 4 5 6 7 8 9 1110 12



Dokumentstatus


DIN ISO 2768-mHDIN ISO13715

+-


Protection Mark DIN ISO 16016

SAP-No.:

(Ers.d. / repl.by:)(Ers.f. / repl.for:)

REpower Systems AG- TechCenter -

Albert-Betz-Straße 1D - 24783 Osterrönfeld

Phone: +49 - 4331 - 131390Fax. No: +49 - 4331 - 13139999


DIN-Blatt/DIN-Sheet

Datum/date



geprüft / checked:

gezeichnet / drawn:

Version / Revision

Matchcode


Benennung / Title


Name/name


Blatt/Sheet

Plot:EDP NO.

TL/Typ000RK5

A1..

A.Trede30.07.2007

K.Schwerdtfeger30.07.2007

30.07.2007

.1:250

WEC REpowerWEA REpowermain view HH 100 mGesamtansicht NH 100 m

10000030957. 1/1

J.Lütjen

11.07.2011Z-3.1-GP.AN.04-A_10000030957_RK5_000_D

. .

DZ-3.1-GP.AN.04-A

50

104 m

100

m

ground surfaceO.K. Erdreich

152

m

4,23 m

2,3

m

6,33 m

Maße nur für die bildliche DarstellungDimensions are for illustration purposes only

D

mit Rotorblatt RE 50.8with rotor blade RE 50.8

D 20396 11.07.2011 A10-Bemaßung hizugefügt / dimensioning added J.Lütjen S.Meierdierks A.Trede

C 16986 10.03.2010 Bemaßung hizugefügt / dimensioning added J.Lütjen S.Meierdierks A.Trede

B 15062 15.05.2009 Design aktualisiert / updated J.Lütjen S.Meierdierks A.Trede

Ver./rev.

Änd.Nr.



Freigabe/released

GE-RDMC-O-03-VB_DINA1h

7500

2150

4150Outer Dimensions:hight: 2,150 mwidth: 4,150 mlength: 7,500 m

Gross weight: approx. 0,9 mtonsNet weight: approx. 1,0 mTons


REpower 3.X M

8765

F

E

D

C

B

A

4321

1 2 3 4 5 6 7 8

F

E

D

C

B

A



PDM Dok ID

A3

Plot:


.

..

A. Trede05.10.2009

T. Sebon05.10.2009

J. Lütjen05.10.2009

. .1:50

WEC REpowerWEA REpower

nacelle hood - transport documentGondelhaube - Transport Dokument

AD-3.1-GP.MA.02-D

P:\Products\03_01_REpower_3XM\GesamtProjekt\Mass_Abmessg_Transp_Schwerpkt\Doku_Zeichnung\D-3.1-GP.MA.02-D..

1/1

05.10.2009


DIN ISO 2768-mHH

DIN ISO13715

+-





Phone: +49 - 4331 - 131390Fax. No: +49 - 4331 - 13139999


DIN-Blatt/DIN-Sheet

Datum/date



geprüft / checked:

gezeichnet / drawn:

Version / Revision

Workflow Status


Benennung / Title


Name/name


EDP NO.

Blatt/Sheet

3910

5047 3632250

13075

1200

450

800

180250 22

0

383

1586

2xM48 at each sideof the main frame

2000

940

2626

1100

4200 10

0

forward transport direction


Outer Dimensions:hight: 3,910 mwidth: 4,200 mlength: 13,075 m

Gross weight: approx. 61,5 mtonsNet weight: approx. 60 mTons

REpower 3.X M

The two transport frames are each equipped with 4Lashing points. In front of the main frame, screwedlashing points can be mounted by a M48 thread. Twotimes in total.Lash point breaking load is about 200 kN, thatequals 100 kN lashing force.

C 16001 05.10.2009 Massen und Abmessungen aktualisiert / weights and dimensions updated J. Lütjen T. Sebon A. Trede

B 13254 02.09.2008 aktuelles WEA design / actual WEC design J. Lütjen T. Sebon A. Trede

Ver./rev.

Änd.Nr.



Freigabe/released

8765

F

E

D

C

B

A

4321

1 2 3 4 5 6 7 8

F

E

D

C

B

A



PDM Dok ID

A3

Plot:


.

..

A. Trede03.03.2008

Schwerdtfeger03.03.2008

J. Lütjen03.03.2008

. .1:100

WEC REpowerWEA REpower nacelle - transport documentGondel Transport Dokument

CD-3.1-GP.MA.02-B

P:\Products\03_01_REpower_3XM\GesamtProjekt\Mass_Abmessg_Transp_Schwerpkt\Doku_Zeichnung\D-3.1-GP.MA.02-B..

1/2

05.10.2009


DIN ISO 2768-mHH

DIN ISO13715

+-





Phone: +49 - 4331 - 131390Fax. No: +49 - 4331 - 13139999


DIN-Blatt/DIN-Sheet

Datum/date



geprüft / checked:

gezeichnet / drawn:

Version / Revision

Workflow Status


Benennung / Title


Name/name


EDP NO.

Blatt/Sheet

Wind turbine

REpower 3.XM

Lubricants and measures

against leaks caused by accidents

Document no. (version):

D-3.1-GP.00.01-A-EN (D)

Author

REpower Systems SE Albert-Betz-Str. 1 D-24783 Osterrönfeld Phone: +49-4331-13139-0 Fax: +49-4331-13139-999

Original document: German

Prepared: Gunnar Sienknecht

Reviewed: Jan Lütjen

Approved: Rainer Rieckenberg

Translated: Service provider

Date:

2013-02-22

Pages:

8

Document type:

Original � Reg. copy no.:___ � Copy (unregistered) Status:

� Draft � Draft for external review Approved version

Classification:

� Strictly confidential � Internal Customer confidential � Public

Updating service:

Yes � No � Limited until: _________ � = <ALT> 0168, � = <ALT> 0254

Protective note ISO 16016: The reproduction, distribution and utilization of this document, as well as the communication of its contents to others without explicit authorization, is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the granting of a patent, utility model, or registered design.


Change history:

Ver

sio

n

Issu

e d

ate

Rep

lace

d

pag

es

Changes

A 2008-01-31 First edition B 2009-04-14 All New identification for 3.XM

New lubrication grease for generator bearing lubrication C 2012-10-16 All Types of grease / separation of German/English / content revision D 2013-02-22 All Water hazard class adjusted

Related documents:

Name Document no.

Please ask the REpower Systems SE Document Management department for the most current versions of the respective related documents. The German description will apply in case of doubt.



Lubricants and measures against leaks caused by accidents

3.XM

Table of contents:

1 List of lubricants ........................................................................................................ 4

2 Design measures to prevent lubricant from escaping ........................................... 6 2.1 Blade pitch gearbox......................................................................................... 6 2.2 Blade adjustment bearing................................................................................ 6 2.3 Rotor bearing................................................................................................... 6 2.4 Gearbox........................................................................................................... 6 2.5 Generator bearing ........................................................................................... 7 2.6 Hydraulic system ............................................................................................. 7 2.7 Yaw gearbox.................................................................................................... 7 2.8 Yaw bearing..................................................................................................... 7

3 Maintenance and oil change ..................................................................................... 7 3.1 Maintenance .................................................................................................... 7 3.2 Oil change ....................................................................................................... 8 3.3 Disposal........................................................................................................... 8



1 List of lubricants

10, 121 4, 12

6, 7 8, 9 2

5

No. Location Type Brand Quantity WHC* HSC*

1 Gearbox

Synthetic oil


Castrol Optigear SYN A320

≈580 l

1

2

-

-

2 Yaw gearbox

Synthetic oil


Mobil SHC Gear 150

≈20 l

≈20 l

1

2

-

-

3 Hydraulic system

Hydraulic oil

Fuchs ECO-HYD S plus (NCV)

Shell Tellus Arctic 32 (CCV)

≈20 l

≈20 l

1

2

-

-

4 Main bearing

Lubrication grease

Fuchs Lubritech Stabyl EOS E2 ≈135 kg

1

-

5 Generator bearing

Lubrication grease

Klüberplex BEM 41-132 ≈11 kg 1 -



6 Yaw – bearing

Lubrication grease

Fuchs Lubritech Gleitmo 585K ≈17 kg 2 -

7 Yaw – gearing

Lubrication grease

OKS 495 or


≈1 kg

≈1 kg

1

2

-

-

8 Rotor blade – bearing

Lubrication grease

Fuchs Lubritech Gleitmo 585K ≈3x10 kg

+15 kg

2 -

9 Blade bearing

– gearing

Lubrication grease

OKS 495 or


≈3x1 kg

≈3x1 kg

1

2

-

-

10 Blade pitch gearbox

Synthetic oil


Mobil SHC Gear 150

3×7.5 l

3×7.5 l

1

2

-

-

11 Blade pitch gearb.

seal

Lubrication grease


1

-

12 Rotor lock,

door hinges, etc.

Lubrication grease


1

-

* - WHC = water hazard class (- = not applicable because insoluble solid substance)

** - HSC = hazardous substances class (- = not applicable)

Safety data sheets in accordance with directive 91/155/EEC are available for all lubricants



2 Design measures to prevent lubricant from escaping

The following design measures can prevent leakage as a cause for escaping lubricant:

2.1 Blade pitch gearbox The blade pitch gearboxes are arranged along the cast element of the rotor hub and rotate with the rotor. A double sealing system effectively prevents the discharge of the gear oil. If there is leakage, the oil remains inside the rotor hub, the spinner or the rotor blades. The corresponding sump capacity is adequate for the relatively low oil quantity.

2.2 Blade adjustment bearing The tracks of the bearings are lubricated with lubrication grease. The sealing system effectively prevents the discharge of the lubrication grease Used lubrication grease expelled from the tracks will be collected in lubrication grease collection bottles that are mounted on the inner bearing ring. The grease collection bottles are emptied during maintenance. If the bottles are too full and lubrication grease is discharged, the sealing system ensures the lubrication grease remains inside the rotor hub enclosure. If the external sealing system of the blade bearing fails, the discharged lubrication grease will be collected by the rotor blade rain deflector. The rain deflector and the deflector on the rotor hub enclosure form an effective labyrinth, both against penetrating rainwater and against discharged lubrication greases from the pitch bearing. The blade bearing gearing is lubricated with an adherent lubrication grease. This adherent lubrication grease is highly viscous and non-drip. Clumpy flaking of the adhesive lubricant from the gearing is not possible. In addition, the blade bearing gearing is covered to prevent access. Any leakage will remain inside this cover.

2.3 Rotor bearing During operation, lubrication grease escapes from the labyrinth seals of the rotor bearing. This lubrication grease will be collected directly below the bearing, in a lubrication grease pan integrated in the main frame. Aluminum sheet inserts provide the necessary sealing of the integrated grease pan. The grease pan is regularly emptied during maintenance and the discharged lubrication grease is disposed of properly.

2.4 Gearbox The gearbox features non-abrasive, i.e. wear-free, sealing systems on the drive shaft and output shaft. If leakages occur on the gearbox, the discharged will be immediately collected in an oil pan that is integrated in the nacelle. In addition, the top platform of the tower is designed to function as an oil pan. To this end, the platform is welded oil-tight with an 80 mm high, circular edge. The threaded joint holes are sealed. This effectively prevents the oil from continuing to enter the tower interior.



2.5 Generator bearing The lubricated generator bearings are equipped with a non-contact sealing system based on the labyrinth principle. This sealing system effectively prevents uncontrolled discharge of the lubricant. Used, excess lubrication grease will be collected in the designated containers. The collection containers will be emptied during maintenance.

2.6 Hydraulic system The hydraulic unit is located in the nacelle. An oil pan is positioned directly below the unit for any lingering leaks or discharged hydraulic oil.

2.7 Yaw gearbox The oil-filled gearboxes for the yaw system feature a complex sealing system on the input and output shafts. The drives are located within the nacelle enclosure. If oil escapes as the result of damage, this oil will be collected by a circular coaming mounted on the nacelle enclosure.

2.8 Yaw bearing The tracks of the bearing are lubricated with lubrication grease. The selected sealing system ensures that excess lubrication grease is discharged outward toward the gearing. The yaw bearing gearing is lubricated with an adherent lubrication grease. This lubrication grease is highly viscous and non-drip. Clumpy flaking of the lubrication grease from the gearing is not possible. To collect lubrication grease discharged from the yaw bearing sealing system, a continuous coaming ring is mounted below the yaw bearing gearing. These lubrication grease collection channels will be regularly emptied during maintenanc.

3 Maintenance and oil change

3.1 Maintenance The lubrication grease collection pans are checked at regular intervals during maintenance and emptied as required (see "Disposal" section). Required quantities of lubrications grease and hydraulic oil are lifted into the nacelle using a chain hoist.




3.2 Oil change Lubricants are not stocked on site at the wind turbine. Oil is not refilled. During the scheduled maintenance an oil sample is taken from the gearbox and inspected in a laboratory. An oil change is only carried out if necessary depending on the result of the oil sample inspection. The oil change is carried out by a service company. For draining and refilling the oil, a hose is attached between the tanker and the gearbox.

3.3 Disposal Lubricant is disposed of by approved, specialist firms in the region using a tracking form procedure.

SIEMENS SWT3.2-113

Hub height

Rotor diameter

Total height

Scale:

Sheet S

ize:

1 / 1

Page N

r.:

This docum

ent must not be copied or m

ade available to anythird party w

ithout our written perm

ission.T

he contents must be used only as agreed w

ith us.B

reach of the above will cause legal action.

Siem

ens Wind P

ower A

/S

Siem

ens Wind Pow

er A/S

ISO

Restricted

A3

1:750S

WT-3.2-113 115 H

H

Borupvej 16 D

K-7330 BrandeTel. +45 9942 2222

Meter

Total height*171,5

Hub height

115R

otor diameter

113* Incl. 200 m

m elevated foundation and grouting

The tower bottom

flange diameter w

ill be between

4.5m and 4.8m

depending on the final tower

design.

Prelim

inary

Generic flat foundation design, SWT-3.0-113, 115m NH, IEC2B

Dokument-ID: E R WP EN-40-0000-7046-02André Frank / 2013.01.23

Restricted

Siemens Wind Power A/S © 2011. Alle Rechte vorbehalten.

SWT-3.0-113, 115,0m_EFD_IEC2B_Rev 1_en.doc 1 / 2

SWT-3.2-113, 115 m hubheight, IEC2B Generic foundation design without buoyancy Use only for the cost inquiry! Subject to change! Basic data

size note value unit Concrete (C30/35, C45/55) Ca. 614 [m³] Steel (BST500S) Ca. 67940 [kg] Density, surcharge: Min. 18,0 [kN / m³] Groundwater Under foundation base Foundation shape round Outer diameter 19,5 [m] Plate down- grade (1 : 5,2) 10,9 [°]

Sketch

flat foundation

GOK

0,00; 0,10

3,00; 0,10

3,00; -0,40

9,75; -1,70

9,75; -3,10

10,25; -3,30

13,55; 0,0010,75; 0,0010,75; 0,00

-3,10

-4,00

-3,00

-2,00

-1,00

0,00

1,00

2,00

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Soil requirements

size comment value unit Edge pressure App. 275 [kN / m²] Mean pressure App. 197 [kN / m²] Base friction angle (against gliding) App. 15 [°] Es,dyn app. 120 [MN / m²] Misalligment after 20 years 0,25 [°] Reference is made to: DIBt 2004 Richtlinie für Windkraftanlagen

Source for foundation loads: SWT-30-113, 115.0m Tubular, Foundation loads for preliminary use only rev00 - 20130121.pdf

Generic flat foundation design, SWT-3.2-113, 115m NH, IEC2B

Dokument-ID: E R WP EN-40-0000-7046-02André Frank / 2013.01.23

Strictly confidental

Siemens Wind Power A/S © 2011. Alle Rechte vorbehalten.

SWT-3.0-113, 115,0m_EFD_IEC2B_Rev 1_en.doc 2 / 2

Bill of quantities 1 – Site equipment Amount Unit

1.1 Site equipment Delivery and removal of equipment, incl. safeguards during civil works 1 pcs

1.2 Dewatering system According to geotechnical report 1 pcs

2 – Earthwork

2.1 Top soil App. 30cm, exposing, casting at site and later on leveling according foundation 173 [ m² ]

2.2 Excavation Excavating, storing at side, later on backfilling around the foundation. 1478 [ m³ ]

2.2a Excavation (as before) Displacing within the area, no dump fees 1478 [ m³ ]

2.3 Fine level Building into 330 [ m² ]

2.4 Soil improvement According geotechnical report 1 pcs

3 - Foundation

3.1 Subbase App. 10cm, C20/25, building into, incl. film as underlayer. 330 [ m² ]

3.2 Formwork As lost formwork. 95 [ m² ]

3.3 Foundation concrete C30/37 or C45/55, building into according soil conditions, in certain circumstances with several layers. 614 [ m³ ]

3.4 Foundation basket Delivered as single elements, carrying into excavation by crane, assembling, leveling and safeguarding. 1 pcs

3.5 Reinforcement steel BST 500S / D=10 - 28 mm, supplying, cutting, bending and laying. 67940 [ kg ]

3.6 Cable ducts (eg. Kabuflex) d=125mm, supplying and building into according cable duct system. (power cables and communication) 200 rm

3.7 Cable ducts d=40mm, supplying and building into according cable duct system. (earthing and drainage) 20 rm

3.8 Mortar grouting Between foundation socket and bottom flange, immediately after tower erection., Material: C90/105 z.B. Pagel V1/160 1 pcs

3.9 Gravel path App.. 2,00m width, from crane floor space to tower door 1 pcs

3.9 Finishing work Finishing soil surface after tower erection. 1 pcs

4 - Others

4.1 Prooving cubes Manufacturing and testing general

Substances Hazardous to Water, SWT-3.2-113, Wieringermeer

Document ID: E W ON CSM COE-40-NL00078/80-7248-002014.05.12Restricted

Siemens corporate proprietary information

Siemens Wind Power A/S © All Rights Reserved 2014

1 / 1SWT-3.2-113 Specification Hazardous Substances, Wieringermeer rev 0.doc

Substances Hazardous to Water SWT-3.2-113 Windpark Wieringermeer Siemens has designed the wind turbines SWT-3.2-113 in such a way as to avoid any environmental impact due to a leakage of a fluid in the turbine. This document describes the provisions made in the design of these wind turbines to inhibit any leakage of a substance hazardous to water and to prevent any negative impact on the environment if a leakage were to occur. Hydraulic system The hydraulic system is used for the pitch control of the rotor blades and brake. Its components are placed both in the nacelle and the hub; the main pump unit with the hydraulic oil reservoir is installed in the nacelle. The volume of the reservoir in the main system is 130 liter. The tank has a low-level indicator with a threshold of 80 liters, so that the turbine is stopped when 50 liter (130-80) oil is missing. If there is damage in the reservoir up to 130 l can be leaked from the pump system in the nacelle; if there is damage on any of the remaining parts of the system, up to 50 liters (130-80) can be leaked. In case of a leak in the hydraulic system in the nacelle, the hydraulic oil is collected in the lower part of the canopy. The capacity of the collection system in the canopy is more than 300 liter; this volume fully covers the needs for collection of all liquids in the nacelle. The hydraulic system in the hub contains at 90 liter (max. capacity of the pitch accumulators). The oil is mainly contained in the three pitch accumulators and pitch cylinders. The capacity is evenly divided between the three independent pitch systems (one per blade, each containing 30 liter). Due to the fact that the pitch system is designed with three independent systems, the maximum oil amount that can be leaked at a single incident is 80 liters (130-80+30), which represents the total volumetric oil content in one of the pitch systems and the oil supplied from the main pump system before the low level sensor stops the turbine. Oil collecting in the hub is utilized by the use of oil absorbing material with a minimum capacity of 80 liters and this volume fully covers the needs for collection of all liquids in the hub. Yaw system Each wind turbine has eight yaw gears (ten as an option). Each of the eight yaw gears contains 8.6 l of gear oil. In case of an oil leak in the yaw gear, the oil is collected in the lower part of the canopy. The capacity of the collection system in the canopy is more than 300 liter; this volume fully covers the needs for collection of all liquids in the nacelle. Transformer (optional) Wind turbines equipped with a power transformer inside the tower hold an aluminum tank that is mounted below the rack supporting the transformer. The tank is able to contain all potentially leaking oil from the transformer, being more than 1000 liter. The top edges of the tank are furnished with a collar that seals tightly to the bottom side of the rack.

MIDEL® 7131

Greater Environmental Protection

June 2013 Page 1 of 2


Companies are under increasing

pressure to ensure their activities cause

as little damage as possible to the

environment. A call for change is evident

from the introduction of strict governing

standards and legislation designed to

encourage best practice and punish the

neglect of our communities.

Companies with progressive thinking

have realised that as well as helping to

save the planet, they can also benefit

from the positive PR and cost advantages

associated using ‘greener options’.

MIDEL 7131 has been proven to be non-

toxic and readily biodegradable, and as

such is an environmentally friendly

alternative to mineral oil and silicone

liquid. MIDEL 7131’s classification as

non-water hazardous by UBA further

supports this assertion.

Biodegradation

Biodegradation is the process by which

organic substances degrade and become

harmlessly absorbed by the environment.

The biodegradation of MIDEL 7131 has

been assessed by an accredited

laboratory using a standard test method

developed by the Organization for

Economic Cooperation and Development

(OECD), a worldwide standard-setting

body.

Method

Tests for biodegradation use micro-

organisms, of the type present in

wastewater treatment plants. These

organisms are put into glass jars with the

test compound for 28 days.

Measurements are taken of the oxygen

consumed, or carbon dioxide produced,

to determine the biodegradation

percentage.

Results

Figure 1 demonstrates that MIDEL 7131

achieved 10% degradation by day 3 and

10 days later it was 71% degraded. On

the 28th day MIDEL 7131 reached 89%

degradation, putting it comfortably in the

Readily Biodegradable OECD and the

Fully Biodegradable IEC 61039

categories.

MIDEL 7131 will not biodegrade in a

transformer. This is due to the fact that

the conditions within the transformer are

too hot and dry to sustain microbial life.

Comparative independent studies

examining the biodegradation of mineral

oil and silicone liquid show a stark

contrast to the environmentally friendly

MIDEL 7131.

In Figure 2, the graph clearly

demonstrates that neither of MIDEL

7131’s counterparts managed to achieve

even a 10% level of degradation at the

end of the 28 day test period. Therefore

MIDEL 7131’s excellent biodegradable

properties make it the sensible solution

for use in a transformer.

Figure 1 - Biodegradation of MIDEL 7131

0

10

20

30

40

50

60

70

80

90

100

0.0 5.0 10.0 15.0 20.0 25.0 30.0

Time (Days)

% B

iod

eg

rad

ati

on

10 Days

10%

71%

OECD 301 F Manometric Respirometry

Figure 2 - Biodegradation of Mineral Oil and Silicone Liquid

0

10

20

30

40

50

60

70

80

90

100

0.0 5.0 10.0 15.0 20.0 25.0 30.0

Time (Days)

% B

iod

eg

rad

ati

on

Mineral Oil

Silicone Liquid

OECD 301 D Closed Bottle Test

MIDEL® 7131


June 2013 Page 2 of 2

UBA Water Hazard Classification

Germany’s central environmental

authority, Umwelt Bundes Amt (UBA),

evaluates chemicals and provides them

with ratings, either as non-water

hazardous (nwg) or one of three hazard

levels.

The UBA classification is based on the

biodegradability of the chemical

combined with the potential effect on

aquatic life. The classification for various

transformer fluids is shown in the Table 1.

MIDEL 7131 is classified as non-water

hazardous, while silicone liquid and

mineral oils do present some hazard and

therefore require extra containment

measures incurring further costs.

Effect on Aquatic Life

In addition to the importance of

biodegradability, it is favourable if a

transformer fluid does not represent a

hazard to the ecosystem. In extreme

concentration levels of 1000mg/l it has

been demonstrated that MIDEL 7131 will

have no ill effects on aquatic life in the

event of a spillage into a watercourse.

Wastewater

Biological sewage treatment plants use

'activated' or microbially active sludge to

break down organic matter within

sewage. Contaminating chemicals can

destroy these micro-organisms and a

total cessation of the sewage treatment

process may result. This is a very costly

and time consuming problem for the

sewage treatment industry.

Tests carried out by the global chemical

company, BASF; demonstrate that

MIDEL 7131 has no effect on the

respiratory inhibition of activated sludge

even at very high concentrations of up to

1000mg/l. The conclusion is that MIDEL

7131 does not represent a risk to

biological treatment plants.

Advantages of Using Biodegradable

MIDEL 7131

Local regulations and insurance

companies usually determine the

containment requirements for

transformers. Over the years it has

become more common for insurance

companies to identify reduced

containment requirements for

transformers containing safer alternatives

to mineral oils.

Table 1 - Common Test Parameters and Guidance Limits

Fluid CAS Number UBA Classification

MIDEL 7131 68424-31-7 nwg

Silicone Liquid 63148-62-9 1

Mineral Oils Variety 1

VESTAS V112

VESTAS V117

DN]\7

DEr NonsKE VEnrrASDEsrcN EvILUATToN CoxroRMrry SI^ITEMENT

Vestas VllT-3.3 MW

DE-230902-B-1 2013-12-04Conformity Statement number Date of issue

Manufacturer:Vestas Wind Systems A/S

Hedeager 448200 Aarhus N

Conformity evaluation has been carried out according to IEC 61400-22t 2010 "Wind Turbines -Part22zConformity Testing and Certilication". This conformity statement attests compliance with IEC 61400-1ed. 3: 2005 incl. Al and IEC 61400-22 concerning the design except for outstanding issues listed in Appendix 2

Any change in the design is to be approved by DNV. Without approval the Statement loses its validity.

Evaluation reports:Technical Report: PD-2309-18CGY6P-14 Rev. I

ÍVind Turbíne speciJìcøtion and outstanding issues :IEC WT class: IEC IIA. For further information see Appendices I and 2 of this Certificate

Date: 2013-12-04 Date:2013-12-04

PRODReg no 7031

Management RepresentativeDet Norske Veritas, Danmark A/S

Project ManagerDet Norske Veritas, Danmark A/S

Dnr NonsKE VERTTAS, DANMARK A/S

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 disclaims all warranties except as expressly granted by written agreement and is not responsible for unauthorized uses, for which it may pursue legal remedies against responsible parties.

DerNonsrs VeRrresDnNuem A/SDE-230902-B-lCoN¡oRrr¿trv SrRreN4pNr

APPENDIX 1 . WIND TURBINE TYPE SPECIFICATION

General:IEC WT class acc. to IEC 61400-1 ed. 3: 2005 incl. A1:Rotor diameter:Rated power:Rated wind speed Vr:Hub height(s):Operating wind speed raîge V¡¡-Veu1:

Design life time:

Wind conditions:V,.¡(hub height):Vuo. (hub height):I¡s¡¿ICC. to IEC 61400-1 ed.3:2005 incl. AlMean flow inclination:

Electrical network conditions:Normal supply voltage and range:

Normal supply frequency and range:

Other environmental conditions (where taken into account):Air density:Normal and extreme temperature ranges:

Relative humidity

Solar radiation:Salinity:Description of lightning protection system:

IEC IIAll7 m3300 kwll.2mls91.5 m3 -25 mls20 years

42.5 mls8.5 m/s0.1680

3x650V/10.5-35kVS}Hzor 60Hz

l.225kglm3Normal: _10 "C to +40 "CExtreme: -20oC to +50 "C100% (max 40%o of time) and 90o/o

(rest of life time)1000 V//m2ISO 9223: Airborne salinity 53

Designed acc. to IEC 61400-24,Protection Level I and IEC 61312-1

Main components:Blade type:Gear box type:Generator type:Tower type:Service lift:Crane:

Airfoil shells bonded to a supporting beam

Winergy, PZAE 3530.1Siemens, JGWA-5 60LM-064Tubular steelAvanti Shark or Power Lift Sherpa-SD

Star 071/95 Liftket, max 800 kg

Dnr NonsKE VERITAS, DANMARK A/S Page2 of3

D¡rNonsrsVezurRsDnNvem A/SDE-230902-B-rCoN¡oRrr¿rrv SrerpvnNr

APPENDIX2 . OUTSTANDING ISSUES

a Final documentation on 60 Hz issues needs to be received and reviewed

Dnr NonsKE VERITAS, DANMARK A/S Page 3 of3