Blacklaw 2.3Cs service checklist

• Site conducted

  Select

• Conducted on

  Date

• Prepared by

• Location
  Address

• Turbine number & serial number

Calibrated Tooling

• Note: See service manual before carrying out checkpoints.

• Calibrated tools required, please add calibration ID:

• 50 NM torque wrench

• 200 NM torque wrench

• 400 NM torque wrench

• 600 NM torque wrench

• 800 NM torque wrench

• insulation resistance tester

• ELMA clamp metter

• Multimeter

• Generator allignment kit

• Manometer

• Prove dead meter

• Prove dead tester

• O2 meter

• Cordless impact driver 1/2 "

• Ratchet 1/2" & 1/4 "

• Socket extension bar length 6" 3/4" drive

• Socket adaptor 1/2 " & 3/4 " drive

• 36mm 3/4" socket

• 19mm open ended socket 1/2"

• 1/2" socket set 10mm - 30mm

• 1/4" socket set 3mm - 13mm

• cordless screw gun

• Cordless impact gun 1/2"

• Combination spanner 13mm, 17mm, 19mm, 24mm, 30mm, 36mm, 41mm, 55mm

• Adjustable spanner 8" & 10"

• Small & large pipe grips

• wire cutters

• Allen keys 2mm - 12mm

• Allen socket 19mm 1/2"

• Screwdriver set

• Torx driver set

• Cabinet key

• Cleaning rags

• Paper overalls

• Nitrile gloves

• Cleaning spray

• Autogreaser

• manual one shot greaser

• Funel

• Hydraulic sample pipe

• Lamp

• Scraper

• Tape measure

• Smoke gas

• Tie wraps

• Vacuum cleaner

• Head torch

• Hammer

• lock off kit

• sling/shackle for yaw lock

• A2 cabinet UPS battery replacement (every 3rd year)

  Yes

  No

  N/A

• A1/A2/A8 & A8.1 cabinet- Filter - Replace.<br>(A1 CVT25,26 &27) (A21 CVT28 & ABB).

  Yes

  No

  N/A

• A1 or Power unit- Varistor & Varistor fuses – Visual check

  Yes

  No

  N/A

• Emergency lighting in Tower & Nacelle.<br>Test.

  Yes

  No

  N/A

• A8 cabinet – Ground connections – Visual check.

  Yes

  No

  N/A

• A8 cabinet – 690v Cables – Visual check

  Yes

  No

  N/A

• A2 cabinet- Emergency Stop – Test.

  Yes

  No

  N/A

• A1/A2 Cabinet – Smoke detector – Test.

  Yes

  No

  N/A

• A8/A8.1 Elspec filter cabinet- Smoke detector – Test.

  Yes

  No

  N/A

• GFCI Relay – Test by pushing test button.

  Yes

  No

  N/A

• A1/A2/A8 & A8.1 cabinet- heating element - Test.

  Yes

  No

  N/A

• A1/A2 cabinet- ventilator - Test

  Yes

  No

  N/A

• A4 cabinet- Emergency Stop – Test.

  Yes

  No

  N/A

• A4 cabinet- Emergency Stop – Test.

  Yes

  No

  N/A

• A3 cabinet- smoke detector test

  Yes

  No

  N/A

• A4 cabinet – Contactors – Visual inspection. (remove covers & look for signs of heat damage)

  Yes

  No

  N/A

• A4 cabinet- Filter element – Replace.

  Yes

  No

  N/A

• A4 cabinet – Main Power connections – Visual inspection (remove covers & look for signs of heat damage)

  Yes

  No

  N/A

• Elspec – Measure capacity in Capacitors (step 1 to 8 for results) 1

• Elspec – Measure capacity in Capacitors (step 1 to 8 for results) 2

• Elspec – Measure capacity in Capacitors (step 1 to 8 for results)

• 3

• Elspec – Measure capacity in Capacitors (step 1 to 8 for results) 4

• Elspec – Measure capacity in Capacitors (step 1 to 8 for results) 5

• Elspec – Measure capacity in Capacitors (step 1 to 8 for results) 6

• Elspec – Measure capacity in Capacitors (step 1 to 8 for results) 7

• Elspec – Measure capacity in Capacitors (step 1 to 8 for results) 8

• 690V cables between nacelle and A4 - Visual inspection

  Yes

  No

  N/A

• Cable saddles - Visual inspection (Ensure all mounting points are tight.)

  Yes

  No

  N/A

• Cable snowflake - Visual inspection (Check for wear, loose bolts or connections between snowflake & frame)

  Yes

  No

  N/A

• Snowflake frame – Visual inspection (Ensure mount is set to correct height and all bolts are tight.)

  Yes

  No

  N/A

• A4 cabinet to tower mounting bolts – Check all bolts are tight.

  Yes

  No

  N/A

• Blades – General Visual check for cracks and unusual sounds during operation. If any cracks or unusual sounds are found, they must be reported to site management.

  Yes

  No

  N/A

• Door in tower – Lock & Seals – Check.

  Yes

  No

  N/A

• Door in tower – Filter element option – Replace.

  Yes

  No

  N/A

• Grouting at foundation – check for water ingress and cracks – report any cracks to site management.

  Yes

  No

  N/A

• Tower Bottom – Check for leaks.

  Yes

  No

  N/A

• Tower dehumidifier – Check & replace filter.

  Yes

  No

  N/A

• Tower – check for corrosion, damage or flaked paint etc.

  Yes

  No

  N/A

• Tower welds – Visual inspection for any cracks.

  Yes

  No

  N/A

• Tower welded brackets – Visual inspection

  Yes

  No

  N/A

• Tower 690V cable splices at tower joints – Visual inspection.

  Yes

  No

  N/A

• Tower Flanges – lightning protection – Visual inspection

  Yes

  No

  N/A

• Tower 690V cable ladders – Visual Inspection-Check for evidence of movement caused by loose mounting bolts

  Yes

  No

  N/A

• Cable twist check ensure contactor drops out (yaw turbine)

  Yes

  No

  N/A

• Assist Tech 1

  Yes

  No

  N/A

• Gearbox – oil – sample – taken immediately after stopping turbine before replacing in & off-line filters. Sample No.

• Hydraulic station oil Sample. Sample No.

• In line filter magnet – Visual Check and photo.

  Media

• Gear oil Inline filter change

  Yes

  No

  N/A

• Gearbox offline filter – Replace.

  Yes

  No

  N/A

• Hydraulic Station air Filter – Replace

  Yes

  No

  N/A

• Hydraulic Station oil level – Check

  Yes

  No

  N/A

• Hydraulic Station pressure Filter –Replace.

  Yes

  No

  N/A

• Hydraulic Station return Filter –Replace.

  Yes

  No

  N/A

• Hydraulic station oil level sensor-Check

  Yes

  No

  N/A

• Hydraulic Station Accumulator 60 –Test 165 bar +/- 5bar. Replace if below 110 bar. :Before adjustment :After adjustment : Serial No.

• Hydraulic Station accumulator 54 –Test 70 bar +/- 5bar. Replace if below 50 bar. :Before adjustment :After adjustment : Serial No.

• Hydraulic Station accumulator 40 –Test 70 bar +/- 5bar. Replace if below 50 bar. :Before adjustment :After adjustment : Serial No.

• Hydraulic station pressure Transducer 17 –Test

  Yes

  No

  N/A

• Hydraulic Station – Relief valve 10 –Test 270 bar +/- 5bar. :Before adjustment :After adjustment

• Hydraulic Station pressure transducer 57 –Test

  Yes

  No

  N/A

• Hydraulic Station – relief valve 38 –Test.

  Yes

  No

  N/A

• Hydraulic Station – Valve pos 43 & 45 –Test

  Yes

  No

  N/A

• Hydraulic Station – Idle circuit & valve 51 –Test

  Yes

  No

  N/A

• Hand terminal – Idle circuit & valve 48 –Test

  Yes

  No

  N/A

• Hydraulic system – hoses, filters, fittings – Check for leaks.

  Yes

  No

  N/A

• Gearbox – Pressure Transducer – Test.

  Yes

  No

  N/A

• Gearbox – Idle pump - Check flow.

  Yes

  No

  N/A

• Blades – General – Inspection.<br>(assist Tech 2)<br>

  Yes

  No

  N/A

• Nacelle emergency hatch – Visual and functional check. Lubricate the studs with anti-corrosion compound and the rubber seals on the emergency escape hatch with silicone grease.

  Yes

  No

  N/A

• Nacelle emergency Stops – functional Test.

  Yes

  No

  N/A

• Gearbox – Oil level sight glass- Check

  Yes

  No

  N/A

• Gearbox – Oil level sensor - Test

  Yes

  No

  N/A

• Gearbox – Oil pump, filter, fitting, hoses- Check for leaks.

  Yes

  No

  N/A

• Gearbox oil connections. Visual Check.

  Yes

  No

  N/A

• Generator - cable brackets – Visual inspection

  Yes

  No

  N/A

• Gearbox pressure transducer – Test.

  Yes

  No

  N/A

• Nacelle - Vibration sensors & TCM module – Test.

  Yes

  No

  N/A

• Yaw Deck – Cable twist switch – Test (have turbine yawing to confirm it stops turbine yawing)

  Yes

  No

  N/A

• Blades – General Visual check for cracks and unusual sounds during operation. If any cracks or unusual sounds are found, they must be reported to site management.

  Yes

  No

  N/A

• Vortex generators on blades – Visual check for damage and missing items

  Yes

  No

  N/A

• Blades stall strips – inspect for condition and note number missing.

  Yes

  No

  N/A

• Assist Tech 1.

  Yes

  No

  N/A

• Blade A – drain cups – Empty/ Replace

  Yes

  No

  N/A

• Blade A – Inside root end- Visual check for damage. If damage is found site management must be informed.

  Yes

  No

  N/A

• Blade A – VCU System- Test and lubricate with sterile oil.

  Yes

  No

  N/A

• Blade A – Lightening card- Check

  Yes

  No

  N/A

• Blade A – Central lubrication system- All hoses and fittings – Check for leaks

  Yes

  No

  N/A

• Blade A – check hub hatch latches

  Yes

  No

  N/A

• Blade A- Blade Bearing seal/ring – Check and wipe clean.

  Yes

  No

  N/A

• Blade A – Check & adjust encoders

  Yes

  No

  N/A

• Blade A – accumulator 1- Test pre- charge pressure (100 bar+/- 5bar) Replace if lower than 70 bar. :Before adjustment :After adjustment : Serial No.

• Blade A – Accumulator 2- Test pre- charge pressure (100 bar+/- 5bar) Replace if lower than 70 bar. :Before adjustment :After adjustment : Serial No.

• Blade A – Accumulator 3- Test pre- charge pressure (100 bar+/- 5bar) Replace if lower than 70 bar. :Before adjustment :After adjustment : Serial No.

• Blade A – Accumulator 4- Test pre- charge pressure (100 bar+/- 5bar) Replace if lower than 70 bar. :Before adjustment :After adjustment : Serial No.

• Blade A – Accumulator- Test all test nipples for leaks ( use leak foam)

• Blade B – Accumulator 1- Test pre- charge pressure (100 bar+/- 5bar) Replace if lower than 70 bar. :Before adjustment :After adjustment : Serial No.

• Blade B – Accumulator 2- Test pre-<br>charge pressure (100 bar+/- 5bar) <br>Replace if lower than 70 bar. <br><br>:Before adjustment <br><br>:After adjustment <br><br>: Serial No.

  Yes

  No

  N/A

• Blade B – Accumulator 3- Test pre-<br>charge pressure (100 bar+/- 5bar) <br>Replace if lower than 70 bar. <br><br>:Before adjustment <br><br>:After adjustment <br><br>: Serial No.

  Yes

  No

  N/A

• Blade B – Accumulator 4- Test pre-<br>charge pressure (100 bar+/- 5bar) <br>Replace if lower than 70 bar. <br><br>:Before adjustment <br><br>:After adjustment <br><br>: Serial No.

  Yes

  No

  N/A

• Blade B – Accumulator- Test all test <br>nipples for leaks ( use leak foam)

  Yes

  No

  N/A

• Blade C – Accumulator 1- Test pre-<br>charge pressure (100 bar+/- 5bar) <br>Replace if lower than 70 bar. <br><br>:Before adjustment <br><br>:After adjustment <br><br>: Serial No.

  Yes

  No

  N/A

• Blade C – Accumulator 2- Test pre-<br>charge pressure (100 bar+/- 5bar) <br>Replace if lower than 70 bar. <br><br>:Before adjustment <br><br>:After adjustment <br><br>: Serial No

  Yes

  No

  N/A

• Blade C – Accumulator 3- Test pre- charge pressure (100 bar+/- 5bar) Replace if lower than 70 bar. :Before adjustment :After adjustment : Serial No.

• Blade C – Accumulator 4- Test pre- charge pressure (100 bar+/- 5bar) Replace if lower than 70 bar. :Before adjustment :After adjustment : Serial No.

• Blade C – Accumulator- Test all test <br>nipples for leaks ( use leak foam)

  Yes

  No

  N/A

• A6 cabinet- Filter - Replace.

  Yes

  No

  N/A

• Blade A, B & C - lightning connectors blade / hub – <br>Check.

  Yes

  No

  N/A

• Blade A - carbon sliding shoes in check measurement

  Yes

  No

  N/A

• Blade B - carbon sliding shoes in check measurement

  Yes

  No

  N/A

• Blade A - carbon sliding shoes in check measurement

  Yes

  No

  N/A

• Blade A, B & C – Check hub hatches

  Yes

  No

  N/A

• Hub – Cables & hoses – Visually inspect for cracks and damage.

  Yes

  No

  N/A

• A6 cabinet – Heating Element – Clean & remove any loose objects. Check the front and back cover, make sure all 4 corners are locked.

  Yes

  No

  N/A

• Hub – Remove all lose objects & Clean.

  Yes

  No

  N/A

• Blades A, B & C – Pressure transducer 107 – Test

  Yes

  No

  N/A

• Blade A – Valve 103 & 120 – Test

  Yes

  No

  N/A

• Blade A – Valve 109 & 119 –Test

  Yes

  No

  N/A

• Blade A – Valve 116 –Test

  Yes

  No

  N/A

• Blade B – Valve 103 & 120 –Test

  Yes

  No

  N/A

• Blade B – Valve 109 & 119 –Test

  Yes

  No

  N/A

• Blade B – Valve 116 –Test

  Yes

  No

  N/A

• Blade C – Valve 103 & 120 –Test

  Yes

  No

  N/A

• Blade C – Valve 109 & 119 –Test

  Yes

  No

  N/A

• Blade C – Valve 1116 –Test

  Yes

  No

  N/A

• Blade A – Check pitch angle and re calibrate if needed - gap from 0 mark in mm

• Blade B – Check pitch angle and re calibrate if needed - gap from 0 mark in mm

• Blade C – Check pitch angle and re calibrate if needed - gap from 0 mark in mm

• Hub – Blade Bearing Lubrication system – Refill. - Quantity of grease refilled (kg)

  Yes

  No

  N/A

Cluster 3 Technician 2

• Main Bearing – Lubrication system – Re-fill.- quantity of grease refilled (kg)

• Main bearing – Waste trays – Empty

  Yes

  No

  N/A

• Main bearing lubrication system - reset pulse counter

  Yes

  No

  N/A

• Main bearing – Labyrinth seals – Lubricate.

  Yes

  No

  N/A

• Generator terminal box – 690v copper cables – Visually inspect – Do not remove cover

  Yes

  No

  N/A

• Generator– Lubrication system – Refill.- quantity of grease refilled (kg)

• Generator – Lubricating system – All hoses and fittings – visual check for leaks

  Yes

  No

  N/A

• Generator – Waste trays – Empty

  Yes

  No

  N/A

• Generator lubrication system - reset pulse counter

  Yes

  No

  N/A

• Yaw– Lubrication system – Re-fill. quantity of grease refilled (kg)

  Yes

  No

  N/A

• Yaw – Central lubricating system – All hoses and fittings – Visual check for leaks

  Yes

  No

  N/A

• yaw- Central lubricating system pulse counter reset

  Yes

  No

  N/A

• yaw - axial sliding pads - check for movement in pad

  Yes

  No

  N/A

• Yaw Gear- oil level - Check

  Yes

  No

  N/A

• Yaw Deck – emergency stop- Test

  Yes

  No

  N/A

• Carbon sliding shoes – Main shaft / nacelle – Check

  Yes

  No

  N/A

• Carbon sliding shoes – bedplate / tower – Check.

  Yes

  No

  N/A

• Weather stand - visual check

  Yes

  No

  N/A

• Lightning cards in the nacelle (wind vane & Flight beacon). Check. Replace if suspected strike.

  Yes

  No

  N/A

• Lightning cards – if replaced return to your service department

  Yes

  No

  N/A

• Nacelle lightning protection (gearbox suspension, generator & tower flange) - Visual inspection

  Yes

  No

  N/A

• Gearbox – Oil flange connections – Visual inspection of bolts.

  Yes

  No

  N/A

• Nacelle – Dehumidifier check

  Yes

  No

  N/A

• Nacelle hatches – Seals – spray with sillicone spray - replace if damaged

  Yes

  No

  N/A

• Gearbox – Oil pump – check all hoses and connections

  Yes

  No

  N/A

• Sump under main bearing – yaw teeth & Drives – Check for correct greasing & wear.

  Yes

  No

  N/A

• Sump under main bearing - rubber collar sealing at tower nacelle - checks and lubricate system.

  Yes

  No

  N/A

• Sump under main bearing brass brush lightning protection - visual check

  Yes

  No

  N/A

• Sump under main bearing – emergency Stop – test

  Yes

  No

  N/A

• Sump under main bearing - clean sump room

  Yes

  No

  N/A

• Gearbox oil radiator - check for cracks and corrosion

  Yes

  No

  N/A

• Gear oil radiator cooling fins - clean and check

  Yes

  No

  N/A

• Yaw position indicator- check & test.

  Yes

  No

  N/A

• Yaw - clean

  Yes

  No

  N/A

• Yaw System – Yaw motor 1 – Current test. : L1 Amps : L2 Amps : L3 Amps

• Yaw System – Yaw motor 2 – Current test. : L1 Amps : L2 Amps : L3 Amps

• Yaw System – Yaw motor 3 – Current test. : L1 Amps : L2 Amps : L3 Amps

• Yaw System – Yaw motor 4 – Current test. : L1 Amps : L2 Amps : L3 Amps

• Yaw System – Yaw motor 5 – Current test. : L1 Amps : L2 Amps : L3 Amps

• Yaw System – Yaw motor 6 – Current test. : L1 Amps : L2 Amps : L3 Amps

• Yaw System – Yaw motor 7 – Current test. : L1 Amps : L2 Amps : L3 Amps

• Yaw System – Yaw motor 8 – Current test. : L1 Amps : L2 Amps : L3 Amps

• Yaw System – Yaw Brakes – torque test.

  Yes

  No

  N/A

• Nacelle bed plate to tower – Carbon sliding shoes – Check.

  Yes

  No

  N/A

• Generator heating element – Test. Measure Amp:

• Gearbox inspectiuon sheet - fil in checklist

  Yes

  No

  N/A

• Generator alignment – Axial deviation(635+/- 1mm) – Check before adjustment: after adjustment:

• Generator alignment – Vertical angle deviation – Check before adjustment: after adjustment:

• Generator alignment – vertical parallel deviation – check before adjustment: after adjustment:

• Generator alignment – horizontal deviation – check before adjustment: after adjustment:

• Generator Aalignment – horizontal parallel deviation – Check before adjustment: after adjustment:

• H/S Brake – Brake disc – inspect for cracks & discolouration.

  Yes

  No

  N/A

• Brake calliper & Caliper plate– Visual -number of loose bolts

• H/S Brake – Callipers – inspect for leaks

  Yes

  No

  N/A

• Generator feet – generator (PUR rubber) – Tighten all bolts.<br><br>No of lose bolts:

  Yes

  No

  N/A

• H/S Brake – right hand side Calliper – Measure pad thickness. : Rotor side mm : Gen side mm

• H/S Brake – left hand side calliper – Measure pad thickness. : Rotor side mm : Gen side mm

• H/S Brake – right hand side calliper – Measure pad Air gap. : Rotor side mm : Gen side mm

• H/S Brake – left hand side calliper – Measure pad Air gap. : Rotor side mm : Gen side mm

• Generator drip pans – Empty.

  Yes

  No

  N/A

• HCU - check

  Yes

  No

  N/A

Cluster 4 Technician 2

• Main shaft/ Nacelle bed plate – carbon sliding shoes – Check

  Select Yes No N/A

  • Yes
  • No
  • N/A

• A3 cabinet filter - replace

  Yes

  No

  N/A

• A3 cabinet – Heating element – Test.

  Yes

  No

  N/A

• A3 Ventilator – Test

  Yes

  No

  N/A

• A9 cabinet – Filter – replace.

  Yes

  No

  N/A

• A9 cabinet – Heating element – Test.

  Yes

  No

  N/A

• A9 Ventilator – Test.

  Yes

  No

  N/A

• Yaw - clean

  Yes

  No

  N/A

• Assist Technician 1

  Yes

  No

  N/A

• Generator re-alignment – Axial deviation(635+/- 1mm) – Check After adjustment

• Generator re-alignment – Vertical angle deviation – Check After adjustment:

• Generator re-alignment – Vertical parallel deviation – Check After adjustment:

• Generator re-alignment – horizontal deviation – Check After adjustment:

• Generator re-alignment – horizontal parallel deviation – Check After adjustment:

• Cleaning

  Yes

  No

  N/A

Cluster 6 Technician 2

• Under gearbox, gearbox oil pump, oil filter, fitting and hoses - visual check

  Yes

  No

  N/A

• Generator – Power cables – inspect for cracks & surface changes.

  Yes

  No

  N/A

• Cleaning

  Yes

  No

  N/A