1.

5 MW
Engineering Services (O&M –Mech.)
Tower
Engineering Services (O&M –Mech.)

Tower Height:
82 meters (Tubular)
 Blade Engineering Services (O&M –Mech.)

Pitch circle diameter : 1800 mm

Studs (Blade to Slewing ring) : 54 Studs, Size M33x345, Grade 10.9
Blade Mechanism : Pitch regulated
Rotor Diameter : 82 meters
Slewing Ring : Double row Ball Bearing
Slewing Ring teeth greasing : Moluballoy SF 936 Grease
 Hub
Engineering Services (O&M –Mech.)

Description of Hub :
Bolts (Hub to rotor shaft flange)
Quantity : 54 bolts
Size : M 36 x 255
Grade : 10.9
PCD hub / main shaft: 1290 mm
Stud (Slewing ring to hub)
Quantity : 68 bolts / Slewing ring
Size : M 30 x 210
Grade : 10.9
Gear Box Engineering Services (O&M –Mech.)

Type : PEAS 4409

Stages : Three (One Planetary & two helical)
Make : Winergy
LSS (N1) : 16.2883 rpm
HSS (N2) : 1550 rpm
Weight : 14000 Kg.
Ratio : 1:95.16
Rated Power : 1550 KW
length x width x height : 2800 mm x 2600 mm x 2300 mm
Yaw Drive Engineering Services (O&M –Mech.)

No. of Drives :4
Type of stages : 5 planetary stages
Ratio : 1:2156.9
Gear rim teeth : 141 No.
Pinion teeth : 14 No.
Braking Type : Electromagnetic clutch braking
Yaw motor : 1410 RPM (3 KW)
Output RPM : 0.65 RPM
360 Yawing : 15.3 Minutes
Pitch Drive Engineering Services (O&M –Mech.)

No. of Drives :3
Type of stages : 3 planetary stages
Ratio : 1:104.2
Slewing ring teeth : 139 No.
Pinion teeth : 15 No.
Braking Type : Electromagnetic clutch braking
Pitch motor : 1440 RPM (7.5 KW)
Output RPM : 13.82 RPM
 Generator Engineering Services (O&M –Mech.)

Type : Single Speed Asynchronous Generator

(With Flexi slip control Mechanism)
Pole : 4 Pole Slip ring (Three Phase)
Speed : 1511 rpm
Make : Suzlon
Weight : 7600 Kg.
DE Bearing No : 6328 MC3
NDE Bearing No : 6328 MC3
Arpex Coupling Engineering Services (O&M –Mech.)
Arpex Coupling (Trouble shooting)
Engineering Services (O&M –Mech.)
 Arpex Coupling Engineering Services (O&M –Mech.)

Coupling : In 1.5 MW only ARPEX Coupling is used

Type : ARC06-0410-1009-C (Flexible coupling with H spacer).
Reasons :
fiber joint is used because
1) It absorbs spike in tortional Loads
2) Weight reduction
Less maintenance
The jerks in speed are compensated by generator itself by
converting mechanical load to heat with the help of inbuilt
electrical circuit.
 Arpex Coupling Engineering Services (O&M –Mech.)

Coupling Nomination:
The size identification of the coupling defines the outside
diameter of coupling flange in mm as well as the design of the plate
pack. This identification is complemented by a preceding combination
of letters, which specify the coupling components.

Example: ARS-6 NHN 255-6 (ARC06-0410-1009-C for 1.5 MW)

Coupling with 2 hubs (N) and 1 H spacer (H) size 255 with
hexagon plate pack of series ARS-6 (-6 = hexagon)
 Arpex Coupling (Trouble shooting)
Engineering Services (O&M –Mech.)

Sudden change in noise level and/or suddenly occurring vibrations

Type of error Inspection and remedy
➢Stop drive
➢Remedy reason for change in alignment
Change in alignment (e.g. tighten loose foundation bolts)
➢Check for wear

Broken plate pack, transmission of
torque by close fitting bolts / conical
Bolting
➢Stop drive
➢Disassemble coupling and remove remainder of
plate pack
➢Check coupling components and replace
damaged parts
➢Check alignment and correct it, if necessary
Yaw drive Back lash Engineering Services (O&M –Mech.)

Measure backlash with the

help of feeler gauge between
the Yaw drive Pinion & Gear
Rim.

Specified value of the

backlash is 0.8 to 1.3 mm
 Pitch drive Back lash Engineering Services (O&M –Mech.)

Measure the thickness of the deformed (flat) Lead wire on right

flank and the left flank with the help of Vernier Caliper or Micro meter.
Sum of the value of both flanks should not be more then 0.48 mm.
Specified value of the backlash is 0.36 to 0.48 mm
 Yaw brake gap adjustment Engineering Services (O&M –Mech.)

Remove the motor top cover from yaw motor by

using screwdriver.

Check air gap by using feeler gauge. If it is more

than 0.55 mm or less than 0.4 mm, adjust and
maintain the air gap.

Specified air gap of the pitch brake is 0.4 mm to 0.55 mm

Pitch Brake Gap Adjustment Engineering Services (O&M –Mech.)

Remove the resolver and motor top cover from the

pitch motor by using screwdriver and 2 mm Allen
key.

Check air gap by using feeler gauge.

If it is less than 0.3 mm or more than 0.4 mm we

have to adjust and maintain the air gap between
0.3 mm to 0.45 mm

Specified air gap of the pitch brake is 0.3 mm to 0.4 mm

 Hub Lock Engineering Services (O&M –Mech.)

For manual braking for rotor disc For Hub Lock

 Hub Lock Engineering Services (O&M –Mech.)

➢ Rotate the rotor disc and take the blade No 1 with downward direction.
➢ Change the lever from Electrical operation to Mechanical operation on Hydraulic
aggregate. Refer Fig. 1.
➢ Change the lever from “Neutral" to “Rotor Unlock" condition
➢ Pump the hydraulic aggregate manually using hand lever to stop the rotation
of rotor disc. Refer Fig. 2.
➢ Change the lever from “Rotor Unlock" to “Rotor Lock" condition after stopping
the disc rotation.
➢ Pump the hydraulic aggregate manually using hand lever to do the hub lock.
➢ Remove the hub lock by pumping the hydraulic aggregate manually using hand
lever when the position of lever is in “Rotor Unlock" position after completing
the work.
➢ Change the lever from mechanical operation to electrical operation.
➢ Change the lever from “Rotor Unlock" to “Neutral“.
Rotor Brake Engineering Services (O&M –Mech.)
Rotor Brake (Brake Gap Adjustment)
Engineering Services (O&M –Mech.)

1) Release the oil pressure

2) Adjust the air gap between passive caliper's
brake pad and the disc to 1mm by turning the
adjusting nut (1).
3) Tighten the lock nut (2).
 Rotor Brake (Replacing Brake Pad)
Engineering Services (O&M –Mech.)

The brake pads must be replaced if each pad is worn 5mm. The
thickness of new pads, including steel back plate, is 32mm. This means
that the pads have to be replaced when the whole thickness is 27mm.

1) Release the oil pressure

2) Solve the adjusting screw of the positioning system
3) Remove the return springs (if fitted)
4) Remove the pad holder
5) Push back the piston into the yoke as far as possible
6) Remove the worn pads, and fit the new
7) Re-fit the pad holder
8) Fit the return springs
9) Re-adjust the positioning system (see 2.3)
 Rotor Brake (Trouble shooting)
Engineering Services (O&M –Mech.)

1. The brake applies slowly

Cause Action

Air in the hydraulic system Bleed system

Abnormal throttling in the hydraulic

Check that all valves are in correct position
system, valve in the wrong position

Abnormal throttling in the hydraulic

Clean and check pipes, hoses and valves
system, dirt

Oil in lines between brake and tank has Check that the oil is the recommended grade
too high viscosity and not too cold
 Rotor Brake (Trouble shooting)
Engineering Services (O&M –Mech.)

2. Long braking time or braking distance, insufficient braking force

Cause Action

Load too heavy or speed too high Check the load and speed values

Wash disc with trichlorethylene. Replace pad.

Oil, paint or grease on brake disc or pad
Check that the brake does not leak

All brakes not connected Check valves where applicable

3. Leakage

Worn seals Replace seals. Check sealing surfaces

 Rotor Brake (Trouble shooting)
Engineering Services (O&M –Mech.)

4. Uneven wear on pad

Cause Action

The brake is incorrectly aligned Check the alignment and the bracket

Replace the brake disc and check the shaft

Excessive disc throw or shaft deflection
deflection

5. Abnormally heavy wear on pad

Increased brake utilisation Check that the load, speed and frequency do
values

Check the oil pressure Check the movements of

The brake does not lift properly
pads and pistons
 Pitch drive oil Engineering Services (O&M –Mech.)

Type : Optimol Optigear BM 220/320 (Castrol) or

Mobil gear XMP 220/320 (Exxon Mobil)

Qty. : 5.5 litres per Pitch drive @ 3 Years

• Ensure that the grade and make of the gear oil to be used
is the same as that of the existing oil in the yaw drive

• Drain the oil when it is hot.

• Denote the WTG No. & Pitch drive No. on drain oil can
 Yaw drive oil Engineering Services (O&M –Mech.)

Type : Optimol Optigear BM 220/320 (Castrol) or

Mobil gear XMP 220/320 (Exxon Mobil)

Qty. : 20 litres per Yaw drive @ 3 Years

• Ensure that the grade and make of the gear oil

to be used is the same as that of the existing oil
in the yaw drive

• Drain the oil when it is hot

• Denote the WTG No. & yaw drive No. on drain

oil can
 Main Bearing -(Lubrication)
Engineering Services (O&M –Mech.)

Bearing make : FAG 24092B.MB.R200.300

Grease Type : Arcanol LOAD 400

Quantity : 1.65 Kg /half year
Lincoln luber Timing :
Programmed as
Off Time : 12 Hours
On Time : 1 minute
 Slewing ring (Lubrication)
Engineering Services (O&M –Mech.)

Slewing ring bearing Greasing : Mobilith SHC 460 (Exxon Mobil)

Quantity : 0.675 Kg /slewing ring @ 3 months

Slewing ring teeth Greasing : Molub alloy 936 SF (Castrol)

Lincoln lubber Grease capacity : 6 Kg

Lincoln lubber Timing : Programmed

Off Time : 12 Hours

On Time : 4.4 Minutes

 Gear Rim (Lubrication)
Engineering Services (O&M –Mech.)

Gear rim surface Greasing : Mobilux EP-2 (Exxon Mobil)

Quantity : 6 Kg/Year
Gear rim teeth Greasing : Molub alloy 936 SF Castrol @ 1 month
Lincoln lubber Timing
Programmed
Off Time : 12 Hours
On Time : 148 seconds
 Generator (Lubrication)
Engineering Services (O&M –Mech.)

Elin / SGPL

DE and NDE bearing

- Kluberplex BEM 41-132

- 90 gm/3500 Opr. hrs

 Gear Box Oil Engineering Services (O&M –Mech.)

Type : Optimol Optigear BM 460 (Castrol)

(Environmental temp from 0º to 50º)
: Mobil gear SHC 320 (Exxon Mobil)
(Environmental temp from -20º to 45º)

Qty. : 380 litres

• Ensure that the grade and make of the gear oil to be used is the same
as that of the existing oil in the Gear Box

• Denote the WTG No. & Gear Box No. on drain oil can

• While replacing the oil, the gearbox is flushed with new oil, in this the
gearbox is filled with new oil and machine is run for 01 hour & the
oil is drained off and gear-box is refilled with fresh oil
 Gear Box Oil Engineering Services (O&M –Mech.)

Oil Sample Analysis : First sample – 100 Operating Hours

After that every 3500 Operating Hrs. (6 months)

Quantity : 100 ml

Oil Change : 1) As per Oil Analysis report from H.O.

2) Replace after every 2 Years (For Mineral oil)

Replace after every 3 Years (For Synthetic oil)

Whichever comes first