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REPORT BY :- MITESH SINGH

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MECHANICAL HUB ASSEMBLY MECHANICAL ASSEMBLY:- Whole the mechanical assembly covers two type of assembly 1) Rotor hub assembly 2) Nacelle assembly 1) ROTOR HUB ASSEMBLY:- It contains following assembly which are given below a) Blade adaptor assembly b) Hub assembly c) Axle pin assembly d) Hub assembly to the rotor disc e) Stator jib preparation f) Mounting of stator disc on jib carrier g) Spinner assembly A) BLADE ADAPTOR ASSEMBLY:- Blade adaptor assembly contains some important part which is given below.

1. Pitch bearing 2. Pitch motor drive 3. Blade adaptor body 4. High strain sensor

1) PITCH BEARING:- Pitch bearing is used for wind turbine rotor hub, the pitch bearing comprising cylindrical inner bearing ring connectable to a rotor blade of the wind turbine rotor, a cylindrical outer bearing ring connected to the hub of the wind turbine rotor . SPECIFICATION:- MANUFACTURER :-KAYDON Made :-Made In India Running Torque :- 1172 N-m (it may change ) Weight :-395 kg Greasing point :-13Nos (7 nos. in lower portion,6 nos. in upper portion)& 3Nos. extensions lubrications tins 2) PITCH DRIVE:- Pitch drive system for a wind turbine is provided which comprises a regulation the pitch of a rotor blade of the wind turbine during normal operation. SPECIFICATION:- Manufacturer :-Transmittal Bonfiglioli Ratio :-1/63-2 Oil (lubrication):- Shell TIVELA SC 320

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3) BLADE ADAPTOR BODY:- It contains a flange for the blade. Arrangement is given for fixing pitch bearing and pitch gear drive

a groove for “O” ring Two holes for High sensitive strain sensor.

4) HIGH SENSITIVE STRAIN SENSOR:- A method for limiting loads in a wind turbine by using measured loads or wind speed to increase the minimum pitch angle for extended periods. The method will allowed turbine to capturing more energy by operation in high wind speeds and or utilizing larger rotors without additional loss of fatigue life. WHOLE ASSEMBLY OF BLADE ADAPTOR:-

Carry the blade adaptor casing from the place where it already approved by Q.A. mount the casing on stand and clean it with diesel & cotton waste

Fix the “O”ring in the groove of pitch drive housing in blade adaptor casing Fastened studs of M24*190,10.9tzn 48 No.to maintaining the height of studs 145 mm

with the Use of Molykote (Heavy duty grease) Take pitch bearing, which already lubricated by Mobil SHC 460 and fix it into the stud at

torque 790N-m. Check backlash which has the value in between 0.15 to 0.3mm allowable, this testing

carried out where the teeth of gear thickness is more than others.

B) HUB ASSEMBLY:- Hub assembly’s main component is given below. 1)Front or outer race and inner race 2)Centering ring 3)Rubber sealing 4)Sealing ring 5)Temperature sensor frame 6)Angle encoder 7)Pulsor sensor frame PULSAR SENSOR FRAME:- Pulsar sensor frame is used to mount pulsor sensors. In each blade adaptor one pulsar sensor is there. Mainly pulsar sensor comprises with Blade pitch in & out. HUB ASSEMBLY ACCEPTANCE PARAMETERS:-

S.No Description Required Dimension in mm

Observed Dimension in

mm 1 Front bearing assembly inside

Diameter 340 mm 339.867-339.903 339.87/89

2 Rear bearing assembly inside 739.832-739.912 739.89/90

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Diameter 740 mm 3 Sealing Ring assembly inside

Diameter 760 mm 760.000-760.125 760.08/09

HUB ASSEMBLY

Mount the hub assembly on the stand. Clean the front as well as rear portion with rust cleaner. Retapping procedure is carried out on the threaded hole by the use of thread taps. On L,R&G flange sealing is carryout with rubber ring and finally two end of it is joint by

Lucite 638. Before the assembly of outer race, inner race and centering plate these part are frozen up

to -45˚c because there some shrinkage are formed in these three so they can easily inserted In the front and rear side.

After fixing front & rear race we put a seal ring having a size of 760*720*20,before sealing ring putting on the outer race applying Loctite 638 .On the surface of outer race and then fix it with M8*10 in 8 Nos. with washer

Fastened angle encoder frame & temp. Sensor frame and three extensions tins on front as well as rear for lubricating purpose.

Now cover the rear portion of hub with the help of polyethylene and after that stand it. Three blade adaptor assemblies is going to fix with hub assembly one by one. With the help of M24*170 30Nos. bolts at torque 790N-m blade adaptor is fix with hub

flange aligned using a 1.5mm feeler gauge. Pitch motor mounted on all the three blade adaptor. Three pulsor frames fitted on blade adaptor from the one slot which in hub with reference

to that from counters clock wise it locates 9&10 position. Fastened the double spoke with (M16*135)at rear side and for front side we are using

three sizes of bolts M16*70 for cable mounting (Z-clamp) 3Nos. M16*80 for single spoke mountings in 6-Nos. M16*60 for (Bearing cover)

Frame for temperature sensor fitted by 2nos. M8*16 mm hardware at the upper side and lower side of the hub.

On Z Clamp (for cable guide) by M12* 35 8.8 & Sensor holding plate are fitted to their position with square plate for mounting the load distribution box.

C) AXLE PIN:- It contains, 1) Taper collar (Big & Small) 2) Taper thrust bearing (Big &Small) 3) Bearing cover 4) V-shaped ring 5) Locking plate 6) Locking nut AXLE PIN ASSEMBLY:-

First of all clean axle pin with diesel by the use of cotton waste. Insert the taper collar first & then taper bearing (having specification BT1-8034/HB1 UK

443 )at rear side which have heated up to 110˚C by the use of induction heater.

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Lubrication carried out of taper bearing with SHC-460. Insert the hub assembly into the axle pin with careful by the use of crane. After completion of hub assembly to the axle pin, insert the small taper roller bearing

(32044X) at front side which is heated up to 70˚C. Then after thrust collar with same procedure and then fix bearing cover(contains shaft

sealing ring 270*240*15)already fix in bearing cover with the help of Loctite 574,v-shaped ring

One fixture is there with the use of it holds the shaft nut and people rotate the whole assembly in three complete rotation this method used to lock shaft nut in axle pin.

AXLE PIN SPECIFICATION:-

S.No Description Required Dimension in

mm

Observed Dimension in

mm 1 Front bearing assembly outside

Diameter 220 mm 220.004-220.33 220.006/015

2 Rear bearing assembly Outside Diameter 600 mm

599.978-600.022 599.98/99

D) PREPARATION HUB ASSEMBLY TO ROTOR DISC:-

Mount the rotor disc on the stand and place the hub assembly with careful and fastened it by the M24x160 with torque 790 N-m.

On rotor disc all the ten boxes to be mounted (3-relay,3-capicitor,3-pitch drive,1-rotor sub distributor) on the opposite side of hub mounting.

Drilling tapping to be done for air gap switches. Electrical wiring & similarly testing carried out. pitch-in, pitch-out testing to be done by

electrical person individually. Pole shoe painted with spray paint named DRY LUBE (MOLY) which has property of

temp. Resistant 399˚c &extreme pressure and lubricating. Brake disk fitted to rotor disc by using M12x50 on the torque of 100N-m. By the use of dial gauge peak pole is measured.

MAIN COMPONENT OF STATOR JIB:- 1) Hydraulic brake 2Nos.(Brake body part and brake pads and, having specification of Max pressure 140bar,oil type-46PG, working temperature -10to60˚c.) 2) Hydraulic motor & its resting steel post 3) Polyamide clamp 4) Bush and steel spindle for rotor lock 5) Hose pipes for the connection to motor to brake (400mpa) 6) Insulation paper E) STATOR JIB PREPARATION:-

Cleaning and re-tapping of stator carrier. At 10’o’ clock position one arrangement is there for manual lock called rotor lock, they

inserted bush in between slot and shaft spindle to reduce wear and tear.

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Isolation films installs at all 12’o’clock positions. At 2’o’clock and 8’o’clock hydraulics break mounted with M16*210 stud and given a

torque of 230Nm.At 6’o’clock positions 3 phase induction motor rated 0.37 KW is fitted to tray by M12*30, for hydraulic brake.

Speed sensor clamp mounted in between 10 o’clock and 12’o clock arm by two M8*20 bolts

At 4’o’ clock position main polyamide(power cable) mounted for main supply. Testing of hydraulic brake is carried from the panel manually at 140 bar which can

adjusted as per required. Mount the stator on jib carefully by the use of with the torque of 790 N-m Mount the rotor hub assembly on the stator jib assembly.

AIR GAP TESTING PROCEDURE

After mounting of rotor disc on the stator jib assembly checking of air gap take high peak pole as a reference between rotor and stator is carried out by the use of feeler gauge.

According to reading little bit air gap setting carried out, with the use of fixtures at all positions.

Take reading at all 6th positions and then take sum of total values divide it into 6 part

Calculation given below: #Total values-2.3+2.5+2.5+2.6+2.6+2.7=15.2mm 15.2/6=2.5333mm (2.5x5)+2.7=15.2mm

This max. value put at 6th position because of when it is in practice 6th position is at lower side due to weight of assembly affected at lower side so it’s value always kept higher than others.

AXIAL PLAY TESTING PROCEDURE:-

To check axial play tied up with all three blade adaptor, in initial position. Then after dial gauge mount on the blade adaptor and give some pressure, set it zero. After setting over of dial gauge the whole assembly hooked up with crane & notes the

reading of dial gauge that how much it was hooked? After seeing reading it indicates the total axial play. It should be within 0.1 mm.

Pos.6=2.5

Pos.2=2.5 Pos.12=2.6

Pos4=-2.3

Pos.10=2.7

Pos.8=2.6

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G) SPINNER CASING ASSEMBLY:- Spinner casing assembled in three segment also top dome (nose cone) is in three parts. All three segments are assembled and outer surface is checked. It is fastened with M12

hardware. And the loose part is fitted. The Blade sealing brushes are fitted to the blade openings of the spinner cap for

protection from dust. All joints are sealed with Carlo flex/farm flux adhesive (silicon paste).

The three parts of the top dome of the Spinner cap are assembled and the joints are sealed with the silicone paste.M12 x 35mm are used.

F) TESTING IN ROTOR ASSEMBLY:-

Various tests are done in the rotor head assembly. Before going for any test connection are properly checked. Following are some test described.

1)_ZERO DEGREE TESTING:-

Clinometers (Spirit level gauge) reading is calibrated by placing on the lock nut of axle pin.

Then the support channel for blade is mounted on the 5th hole (reference hole) on the blade adopter.

Now the Clinometers is place in the support and the adopter is adjusted upto 0˚ It is mechanically now set on zero degree. But in the mean time electrical zero degree is

not achieved. To get the electrical zero degree CLS is adjusted. The SW7 screw (inner screw) is loosen

and SW19 (outer screw) is tighten by applying 100Nm torque. Tighten the screw SW7 on which CLS shows the Zero degree. Now it is both mechanically and electrically set to zero.

2) 3.07 DEGREE SETTING AND PITCH IN/OUT TEST:-

Adjust the distance between the sensor and the 3 deg. Mark to 1.0 to 1.5 mm and checked with filler gauge.

Set alpha minimum to -3 degree. Slowly pitch blade adopter forward. The -2 degree limit switch reacts at a -2 degree +/- 1 degree blade angle and the

capacitors move the blade adopter back to 97deg Press pitch blade out of ES-95 along +, the blade adopter moves to 56 degree & check

that the sensor reacts at 58 to 54 degree. Again position the blade adopter to 92 deg move to set alpha minimum to 0 degree. Use

blade in until blade out appears then the blade out the blade back to approx 92 degree. Overall it should be between 53 º - 59 º.

Pitch the blade to approximately 56º& switch off the MSC. See that all blades are pitched out to 90-92 degree position. See to it that the capacitor voltage does not fall below 60V & 160V

BALANCING OF ROTOR:

Rotor head is placed on balancing chamber and spinner casing equally marks at twelve positions. Weights of rotor are measured at all positions and add weights at determined

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position. Now go for next run until the permissible difference between max. And min. values in the final run are +/-1 Kg.

PROCEDURE:

The complete generator assembly is lifted and kept on the balancing unit in such a way that 12’ O clock arm of stator jib should come exactly on load cell. For this purpose generator assembly is divided into 12 or 6 rotor positions each displaced by 30º or 60º (1145 mm/115 cm from each other).

Measure 550 mm from (FRP joint or Pole no.-5) to right side towards 12’ O clock position and mark it position no.-1. Measure 1145 mm from position no-1 towards right side and mark it position no-2. Similarly mark 12 positions, each mark are displaced from each other by 30º (Mark 6 positions, if rotor webs having only six weight plate mounting holes).

Connect the calibrator unit with load cell cable. Rotate the generator assembly in such a way that marked position -1 come over load cell. Set the calibrator to 00 for position-1. Now bring position -2 over load cell and note the reading of calibrator display in protocol in KG. Similarly, take readings of all 12 or 6 positions. Then the minimum weight and maximum weight and added and putted in the minimum weight position.

The same process is repeated until the weight difference becomes </=1 Kg. Here we use weights of 1kg, 2kg, 5kg, and 10kg for balancing operation. After balancing air gap switch settings are done from electrical end.

. NACELLE ASSEMBLY This is the stationary assembly of WEC that is mounted on tower. In Nacelle assembly we do the different preparation step such as follow: 1) MAIN CARRIER PREPARATION

At first the main carrier is cleaned and every hole should be checked& cleaned with AC 90.

Then the main carrier is mounted upon the middle gallery and fitted to it by M16*60 10.9 bolts (16 no’s) where 10 are taper and 6 are plane ones. Torque: 230Nm.

The azimuth bearing is cleaned and checked for any damages. Also rust protection coating (HD) is applied.

Azimuthally bearing is then assembled to the lower portion of the main carrier by Molykote coated M24*155 10.9 bolt (60 no’s), torque of 800Nm given.

Two 45 elbow and 90 each extension for greasing nipple fitted to the azimuthally bearing.

2) GALLERY FITTING TO MAIN PLATFORM:-

Now the left and the right gallery fitted to the side of the middle gallery by 12 no’s of M12*50 HV bolt each. Torque: 100Nm.

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YAW GEARBOX ASSEMBLY:- The four yaw gear drive left side front, left side rear, right side front and right side rear is

cleaned with AC 90 and applied Molykote is placed on respective position. Also oil level to be checked and refilled if required.(It should be ¾ ) The backlash checking is done by the filler gauge between each yaw gear and

azimuthally bearing which should be between 0.4-0.6 mm. Yaw gears adjusted if required.

After this the yaw gear is fitted to the main carrier by M16*60 10.9 bolt (20 no’s each) Molykote applied.Torque:230Nm.

YAW MOTOR ASSEMBLY:-

Now the 3phase induction yaw motor (3.3Kw) for respective yaw gear is placed and assembled by M10*25 8.8 grade 4Nos.

Now lotus clamp is fitted left side and right side rear yaw motor each for mounting yaw pulsor.

PROTECTOR ANGLE, ANGLE SUPPORT AND DEPOSITION MOUNTING Protector angle, angle support and deposition for the cast iron main carrier mounted.M12*30(to main carrier) and M12*35(inter assembly) 8.8 grade bolts (11 no’s) are used. LADDER MOUNTING

1. Now the nacelle ladder, step ladder and hood ladder mounted to the main carrier 2. M12 x 30mm 8.8 grade 4 Nos. For Nacelle Ladder 3. M12 x 40mm 8.8 grade 2 Nos. For Step Ladder 4. M12 x 30mm 8.8 grade 4 Nos. For Hood Ladder 5. Lightening protection (sliding contactor M24), cable strain relief on the nacelle and

handhold (right and left) on the cast iron main carrier mounted. NCC, EXCITATION CABINET AND RECTIFIER Now the NCC, excitation cabinet and rectifier cabinet mounted on respective places. UPPER CASING ASSEMBLY:

The upper casing is cleaned first. The guiding rails, sliding block and three handles on the nacelle upper facing mounted. Also the winch mounted in the upper casing.

UPPER CASING TO NACELLE ASSEMBLY: After completing the Upper casing (hood) assembly, the same is lifted, positioned and fitted to the main carrier (M 12*50) and hood ladder. LEFT AND RIGHT CASING MOUNTING Then the nacelle left and right casing mounted to the main carrier by M12*50 bolt and fitted to the upper casing by M12*35 bolt (21 each side)

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ELECTRICAL CONNECTIONS AND TESTINGS: Many tests (Nearly about 107) are done in the nacelle assembly. Most of them are the continuity test and the connection test. Following are some of the important test that is carried out in nacelle assembly. FUNCTION OF VIBRATIN SENSOR: When the machine is in operation during the heavy wind conditions, the machine tends to vibrate more. If the vibration of the machine increases, which leads to the fall of ball from its holder will make sensor give signal to the main control box, making the machine stop. NACELE CASING OVALITY CHECK: After fitting the left & Right Casing, a laser Distance measuring instrument and accordingly the position of casing is fixed with the platform and fastened with it checks the radius of Nacelle casing.(2090 mm)After fitting of Casings, The gaps between the casings are seal with the application of Silicone. CABLE TWIST LIMIT SWITCH: Limit switch consists of a gear plate, which meshes with the yaw bearing teeth. When the wind direction is identified and the machine is made to rotate in air direction the limit switch will count the angular movement. If the Machine completes 3 revolutions in one direction, then the limit switch will come in action, which passes the signal to the control box and hence the direction of revolution is changed to opposite. The above facility is provided in order to limit the twist of cables, so as to stop any damage to machine electrical assembly. Winch Motor, Supporting Handle, First aid box, support for twist limit Switch etc. are fitted. GENERATOR ASEMBLY There are two type of assemblies made in “GENERATOR”. 1) Stator Preparation 2) Rotor disc Preparation 1) STATOR DISC PREPARATION: It is the stationary part of the generator and windings are placed over here. Stator ring preparation can be divided into following sub division A) Stacking B) Winding C) Binding D) Connections E) High voltage test F) Impregnation of resin G) Baking H) Powder coating

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FIG. GENERATOR FLOW DIAGRAM FOR STATOR

A) STACKING AND STAMPING:- 1)_STACKING:- The process of arranging the end plates (3mm thickness) segment plates (0.65mm thickness) is called stacking. The segment plates are arranged in lapping manner (in between the layers), for uniform distribution of magnetic field. 2) STAMPING:- The phenomenon of tightening the segment plates to the segment height of 370mm with M8X392 bolts on 3mm thick end plates

IMPEGRATION TANK

BAKING OVEN (3hrs @ 200˚C)

POWDER COATING (@190˚C)

STATOR WINDING

LUGGING & HARNESS FITTING, CONECTION

H-V TEST OF ROTOR AND STATOR

STATOR WINDING

STAMPING

F-93

RUST CLEANING

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3) MATERIALS REQUIRED:- Stator ring:-

Material is of MS, height of the ring is 390mm, on the ID of the ring 20mm of portion on both sides is not applied with red-oxide paint for welding purpose. Inner diameter of the ring is 3742mm.

Segment plates:- CRNGO silicon steel plates of 0.65mm thickness. CRNGO - Cold rolled non-grain oriented, Eddy current losses (Permeability) is low to the silicon steel.

Total no of segment plates per stator ring – 11400 Total no. of segments in one layer is ------ 20 Total no of segment plates per segment – 571 Thickness – 0.64mm Width – 120mm End plates (Mild steel / Carbon steel) – 3mm thickness – M8X392 stud bolts with nuts – 54nos, tightening torque – 30NM. ID after stacking is 3500mm

4) WELDING:- In between the each stud 50mm length marking is done with the help of template on both the side of stack. Process of welding is MIG (Metal Inert Gas) welding, filler rod is of MS/CS material and the shielding gas is CO2 (Carbon Dioxide). Then the welded areas has to be cleaned and visually inspection is to done. 5) LACQUERING

The main objective of this process is to provide the anti corrosion layer to segment plates. This is process has to be done where segment plates is there, and then applied with

insulation varnish F93. F93 is mixture of two components A: B (3:1) by weight.

A -Red Oxide. B -Hardener.

After curing ensure the slots for no lumps formation, else clean the lumps with sand paper. Paint should be uniform.

B) WINDING OF STATOR RING:- 1) PRE WINDING PROCESS:

In this step slots are inspected for lumps and uniformity of anti corrosion paint layer and after numbering is given to the slots to start the winding and to providing the temperature controllers (i.e PTC-140, PT-100). The reference point to start the marking is the hole in between the starting and end connection terminals on stator ring (3Hours hole on the). The numbering is given in clock wise direction when the connection side is in upwards.

2) WINDING:

In winding of stator ring wave winding is implemented in two systems, each system has the capacity of 400KW. In this winding process the dual coated enamel copper wires are

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placed into the slots which are created by stacking. Each slot contains 4 bunches of 36 conductors i.e. in total 144 number of conductors in one slot.

For stator winding following materials are required,

Enameled copper wire Ø 2.24 mm, Dual coated Supplier:-

1. Pearl insulation ltd. 2. Precision wires. 3. LS cables.

Insulation papers (Nomex) of class-Fit is made Up of 3 layers - Nomex, Minor (polyester foil) and Nomex.

1. Slot insulation - 0.48 mm thickness 2. Slot closer - 0.48 mm thickness 3. Phase insulation (A-type, C-type and straight) - 0.25 thickness, Double layers are

used. Platinum thermister controller (PTC 140): 24 Nos. (It’s for tripping purpose acts as a

switch). During winding process PTC 140 (white and blue) sensor is inserted in Between 2nd & 3rd

turn in the fixed slots. (12-used, 12-spare) For system-1 231-232; 235-236; 239-240 For system-2 243-244; 247-248; 251-252 Platinum thermister sensor (PT100): 04 Nos. (It’s for measuring the temp) This PT 100 sensor (red and white) is inserted in between 2nd and 3rd turn in slot 227 for

system-1 and in 228 for system-2. Two more PT 100 is placed in same slot for spare purpose. So total 4nos PT 100 is used.

At the starting and ending of winding insulation sleeves are used. C) BINDING

Binding is done with binding string (Fibre plastic string) to bring the winding into the required dimensions.

Winding height at connection side – 150mm Winding height at non- connection side – 135mm Winding width - 90mm Slot to slot gap is ensured. Hydraulic press is used to press the winding at stator jib

connection places to clearance between the jib and winding. Over insulation is removed by cutting.

D) CONNECTIONS:-

To starting and ending connections on every cable enamel layer is removed over the length of 40mm, lugs are connected by Brazing process and these are covered by heat shrink tubes.

The starting terminals are connected as star connection into two systems. System – 1:- 1, 3, & 5 terminals (odd numbering terminals). System – 2:- 2, 4, & 6 terminals (even numbering terminals Tightening torque of the M16 hardware is of 90NM.

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E) TESTING:- Stator ring and winding are to be cleaned of dust and dirt. To carry out other visual

checks like overhung of winding (shape and size), insulation position, connections, holes on steel part etc.

High voltage test is to be taken after completion of binding process. Phase to body. Test voltage – 2.5 kV Test current – 100 mA (Max) Phase to phase. Test voltage – 2.5 Kv Test current – 40 mA (Max)

F) IMPREGNATION:-

The stator is placed in the impregnation tank and a vacuum of 35milli bar for 15 minutes is brought into the vessel.

Vacuum is held for 15 minutes. Resin flooding is done for 15-20 minutes. 30-35 kg of unsaturated polyesterimide resin is

used. Viscosity: 85-95 stokes at 23˚C. Gel time: 24-64 minutes at 180˚C. This process normally takes 3-3.5 hours.

G) BAKING:-

After the impregnation process the stator is the put into the baking oven at 200˚C. This process is carried out nearly for 4 hour. Temperature readings of body and winding are plotted in graph.

H) POWDER COATING:-

Powder coating of stator and rotor is carried out at 160 ºC to 190 ºC. Resicoats powder is used for stator, approx. 9 Kg.

Gun distance should be 3cm to 20 cm. Coating thickness: 100 to 150 micron. (Measured with elcometer) Powder spray: R4-ES-HLF16R GREY Total powder coating time for stator: 30 min. The powder should spray uniformly on the winding part first and then on body. Here the stator body is earthed as powder is electronegative one.

DELIVERY TEST:

• After powder coating it is waiting for 2 hours for cooling. • Then Neutral point and clamp board is checked. PTC AND PT100 checked for

continuity whether it is in order or not. • And then powder coating check is done by MIBK liq. A drop of it is kept on

stator for 30 sec to ensure that whether the coating is properly coated.

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2)ROTOR PREPARATION: It is the rotating part of the generator on which the pole shoes are mounted. Flow of rotor manufacturing sequence is given below. A) Rotor disc cleaning B) Pole shoe mounting C) Connection and tapping D) High voltage testing E) Resin impregnation F) Baking G) Powder coating and re-heating H) Finishing and dispatch A) ROTOR DISC CLEANING: Rotor disc kept on the swiveling fixture. Clean the rotor disc and visually check it for any cracks, damage or welding defects. B) POLE SHOE MOUNTING

POLE SHOE SPECIFICATINS:- 1. No of pole shoes 60. 2. Stamping material – CRNGO Silicon steel 1mm thickness, 3. Enamel strip size – 7.5 X 3.45, 4. Bobbin is of H-Class material 5. Pole shoe weight – 72Kg PROCEDURE:

Insulation paper i.e. 75 mm*410mm and of thickness 0.35mm is to be pasted on disc.

60 number of Pole shoes mounted with connection side facing upwards and washer and nut fitting on the threaded stud at hub side & main carrier side and it is tighten with the torque of 120 Nm.

Size of pole shoe conductor: 7.5mm thickness x 3.45mm width, Total no of turns-136 nos.

No. of layers: 10 with 14 number of winding in each layer with last one having 10 number of winding.

4 nos. hardware used for pole shoe mounting: M12 x 100mm (30mm inside the shoe and 70mm projected outside of pole shoe), tightening torque is 120NM

Gap between two pole shoe: 3mm to 6mm C) CONNECTION:

Now, pole winding beginning and end to be cut to the required Length. After that, enameled insulation removed up to required length for connection. Pole winding connected with ferrule by crimping and soldering is done (soldering material: SN97 Cu3).

Two types of temperature sensors used in rotor. PT 100 for temperature sensing placed in pole shoe no. 59 and 2. One is used to sense

temperature of rotor, another is for Spare.

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PTC 140 used as over temperature switch to cut off which is placed on pole shoe no. 60 and one is used and another is for Spare.

D) TESTINGS:-

Pole shoe sequence test: 14 V DC supply given to the pole shoe winding and then pole shoe sequence meter is moved around all poles to check pole sequence.

High Voltage Test (H.V TEST): 5.2 KV applied for 1 minute between the phase winding and body of pole shoe.

Insulation/Megger Test is to test the resistance of insulation material (i.e, Enamel layer), the value should be above 200MΩ.

Resistance of PTC 140: around 40 to 100 ohm Resistance of PT 100: around 100 ohm.

E) IMPREGNATION:- The rotor is then impregnated with polyesterimide resin for 3 hours in an impregnation tank under a vacuum of 35 milli bar. F) BAKING:- After the impregnation process the Rotor is put into the baking oven to heat at 205˚C. This process is carried out nearly for 4 hour 5 minutes. G) POWDER COATING:-

After the baking process when the Rotor is still hot resicoat powder is coated on the Rotor.

Carried out nearly for 45 minutes at 160-190˚C. Here the Rotor body is earthed as powder is electronegative one. After powder coating is over the rotor is again reheated for 1 hour to cure it properly.

F) REFINISHING AND DELIVERY:- Visual inspection and finishing operation are carried out. All the threaded holes are cleaned by re-tapping. Numbering is given to pole shoes Grinding or polishing is done on the pole shoes where the paint thickness is more. Then it is ready to be delivered to the mechanical assembly (packing and dispatch).

ELECTICAL ASSEMBLY: Electrical assembly mains contains with three sections: - 1) Harness preparation 2) P.C.B preparation 3) Cabinet preparation 1. HARNESS PREPARATION Harness is like one finished product which used in electrical connection, contains no. of cables. We are using currently 19 type of harness. A) Filter cabinet B) Excitation cabinet C) Rectifier cabinet

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D) Pitch box E) Relay box F) N.C.C (Nacelle Control Cabinet) G) R.S.D (Rotor Sub Distributor) H) Control cabinet I) Yaw Inverter J) Hub sub distribution K) Stator sub distribution L) Load control box M) Compact limit switch N) Power cabinet O) Optional light P) Pitch motor cabinet Q) 5x10 mm² 5x16 mm² Tower cable 18x2.5 mm² 1) HARNESS PREPARATION STEP:-

• Measuring of cable according to requirement. • Cutting of cable is done. • Ferruling of cable which are necessary for identification • Stripping of cable • Lugging (Crimping)

If Heat sink cable is there then, 1) Sleeving 2) Plugging 3) Inserting

• Separating 1) Checking 2) Dispatch 2) LUG:- It works as a intermediate junction between two conductors. TYPES OF LUG: 1) Pin lug:-

S.no Size ( in mm2) color 1 0.34 Green 2 0.50 Orange 3 0.75 White 4 1.00 Yellow 5 1.5 Red 6 2.5 Blue 7 4.0 Grey

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8 6.0 Black 9 10.00 Ivory 10 16.00 Green 11 25 Brown

2) Cable socket lug:-

3) Receptacle lug:- 4) Connector butt:- For all the three above sizes, S.No Cable Size ( in mm2) Lug Color 1 1 to 1.5 Red 2 2.5 Blue 3 4.0 to 6.0 Yellow 5) Fort lug:- 6) Twin lug:- Sr.No Cable Size ( in mm2) Lug Color

1 0.75 Grey 2 1.00 Yellow 3 1.50 Black 4 2.50 Blue 5 4.00 Grey 6 10.00 Red

7) Cable socket pipe lug 8) Cable socket crimping 9) Signal contact pin or socket 10) Power contact pin or socket 11) Optical small plug or long plug 12) Pilot pin or pilot socket 3) TYPES OF CABLE: A) Single core cable B) Multi core cable C) YOZ cable (All are black cables) D) YJZ cable ( Black/Green cable) E) Optical cable F) Fuse cable G) Flat cable I) Hybrid Cable (multi core + optical cable)

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J) Silflex Cable (used in high temp. region) MATERIALS USED DURING HARNESS PROCESS 1) Cable 2) Lugs 3) Insert 4) Hood 5) Extension 6) Skin top P.C.B PREPARATION:- P.C.B

Based on production Based on function T.H.T (Details given in table below) S.M.T Why P.C.B required ? P.C.B means (Printed Circuit Board) to drive to controllers. 1) T.H.T (Through hole technology )

• According to resistor mounting it is defines whether this P.C.B is T.H.T type or S.M.T type.

• In T.H.T type P.C.B has to maintain I.P.C standard of resistor lead length through holes should be 1.5 mm max. to achieve this criteria we used “component cutting & bending m/c.

T.H.T PREPARATION STEPS:-

HARD BOARD BAKING (Before starting P.C.B production, it is kept for 4hrs in oven @60˚C temp, to

remove totally moisture from in it.

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WAVE SOLDERING:- • It is the m/c from E.R.S.A make by which one kind of soldering process is carried out. • Before starting wave soldering it requires 3hrs to get ready in terms of fully melt soldering

material, which used in wave soldering. • After achieving 260°C soldering m/t is ready to solder bath. • Soldering material 67% Sn & 33% Pb. Procedure:- • First of all fix the P.C.B properly in the frame& then insert inside the m/c manually to the

sensor, when sensor sense the frame it goes inside automatically. • Then after solenoid valve activated so compressed air passing through very small holes,

which is less 20 micron with flux liquid that’s why it come out with foam , which touch the bottom side of P.C.B and making flux layer.

• After flux bath P.C.B passed through step by step through three heaters which having temperature of 400˚, 400˚, 260˚C that’s why it known as preheating section. So before soldering start preheating of P.C.B is done this way.

• After passing through two heaters now it time for short wave heating which sets on 262˚C to the solder bath.

• After successfully passing from these three heaters there are two motors at the side of molten solder pool. When it senses the P.C.B coming from last heater it activated itself then soldering is started at bottom side of P.C.B.

• Soldering is done only that place where soldering masking is there, it maintains the quality, quantity and off course mass production.

• Defect of P.C.B 1) Pin Hole:- Improper setting of P.C.B in the frame. 2) Dry Hole:- 3) Bridges:- Less distance between two filament. 4) Blow Hole:-

COMPONENT STUFFING (In this section the various component according to their work instruction

installed in P.C.B board like mounting of capacitors, resistors etc)

WAVE SOLDERING

SPRAY OF LIQUID ACRYLIC (requires 20 min to dry)

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Air trapped in soldering. LIST OF P.C.B:- SR.NO.

DESCRIPTION TYPE OF

P.C.B

QUATITY ASSEMBLY

1 P.C.B Opt. dist. Rotor type CAN V1.2 E112

THT 1 RSD

2 P.C.B Battery charger V2.3 THT 3 PB 3 P.C.B Rectifier driver board V3.1 THT 2 RC 4 P.C.B Opt. dist cont. type CAN V2.2a THT 1 NCC 5 P.C.B Filter yaw invertors V1.0 THT 1 YI 6 P.C.B ICA V1.1 THT 2 YI 7 P.C.B current meas. Adaptor 50a V1.0 THT 2 YI 8 P.C.B Current meas. Adaptor 3x50A V1.0 THT 2 YI 9 P.C.B earth fault detection V1.0 THT 1 NCC 10 P.C.B 300KW inverter supply V1.5 THT 4 YI+PC 11 P.C.B C-adaptor V1.0 THT 1 EC 12 P.C.B Capacitor board V1.1 THT 6 CB 13 P.C.B Chopper pitch V1.2 THT 3 PB 14 P.C.B Display I/O V1.1 THT 1 CC 15 P.C.B Excitation filter V1.1 THT 1 EC 16 P.C.B Sine-wave generator V1.0 THT 1 CC 17 P.C.B DC-link-interface V1.2 THT 3 PB 18 P.C.B Ic-symmetry V1.0 THT 6 PB 19 P.C.B Single blade control V1.1 SMT 3 LCB 20 P.C.B I/O board V1.5 SMT 3 CC+NCC 21 P.C.B Driver inverter 100A module V1.2 SMT 2 YI 22 P.C.B SCADA-interface V1.1 SMT 1 CC 23 P.C.B Power board pitch V2.2 SMT 3 PB 24 P.C.B CAN optical distribution V2.0 SMT 2 CC+NCC 25 P.C.B FACTS-power control V1.3 SMT 1 CC 26 P.C.B C167 core V1.1 SMT 2 27 P.C.B Control board pitch V1.5 SMT 3 PB 28 P.C.B Control board rectifier V1.6 SMT 1 RC 29 P.C.B Control board excitation V1.2 SMT 1 EC 30 P.C.B Motor control V1.3 SMT 2 YI 31 P.C.B C167 core V1.1 SMT 2 32 P.C.B Anemometer interface V2.2 SMT 1 NCC 33 P.C.B Display control V1.3 SMT 1 CC 34 P.C.B Single IGBT-driver CM800 V1.0 SMT 3 PC 35 P.C.B IGBT-driver CM800 V1.1 SMT 9 PC 36 P.C.B Inverter control V2.5 SMT 3 PC 37 P.C.B Noise sensor V1.0 SMT 3 PC

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38 P.C.B C167core V1.1 SMT 6 PC 1) OPTICAL DISTRIBUTION PCB:- The main function of rotor sub distribution is to convert the optical signal into electrical or vice versa. It transmits & receives optical signal to the pitch box, convert it into electrical signal and then transmit to slip ring. 2) BATTERY CHARGER: _ It is used to charge the battery cells at 175V DC, as per the signal received from pitch control board. It has regular based on constant voltage variable current charging. 3) RECTIFIER BOARD:- There are two rectifier boards in rectifier box. One for each system. These are directly mounted on the Thyristor. • It drives the switching of Thyristor so it is known as rectifier driver board • It’s received the signal form rectifier control board and gives gate pulse to the Thyristor for

rectification. 3) OPTICAL DISRIBUTION:- Optical distribution PCB converts the optical signal in to electrical or visa versa. It receive signal optical signal from CAN PCB and transmit it to electrical signal or receive electrical signal from data bus and convert it into optical 4) FILTER YAW INVERTER PCB:- • It filters out the output AC power supply to the yaw motor through 12 numbers of chokes. • Six chokes works for system one and other six for system two. • The function of these chokes is similar to decoupling chokes and smoothing of supply

incoming and outgoing. 5) INTERMEDIATE CURRENT ADAPTOR PCB:- This PCB is mounted on the IGBT to measure the incoming DC bus bar voltage across the IGBT. It is also connected with the motor control PCB. 6) CURRENT MEASUREMENT PCB:- • There are four PCB mounted on yaw inverter, where two PCB measure three phase current

and other two PCB measure Unbalance current flow. • Current of each system is measured separately. There are six LEM modules located inside

the yaw inverter box. • There are two more LEM modules in yaw inverter to detect the earth fault. The ratings of all

these LEM modules are same (50A). 7) EARTH FAULT PCB: • Earth fault monitoring PCB is located beside the anemometer PCB.

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• Earth fault monitoring PCB is directly connected with the CBCT (core balance current transformer).

• It compares the current of both the system. If there is any difference in the current in CBCT it sends the signal through this PCB to the I/O board PCB to stop the machine.

8) 300 KW INVERTER SUPPLY PCB (V 1.5): • This PCB is used to provide the power supply to all the PCB in power cabinets. • Input supply to this PCB is 230V AC and output is 40V, 30HZ. • The output is in two parts, AC1 and AC2. • AC1 is given to the inverter control PCB and AC2 is divided on the inverter control and

supplied to the drivers and the DC link interface. • The Processor 1 will switch the voltage to DC link interface via relay. 9) C –ADAPTER PCB • It is used for controlling output voltage when sudden changes occur in the output voltage

level. • It is meant for dropping the extra voltage. Thus it is used to stabilize the output. 10) CHOPPER PCB (V1.2a): • It is used to stabilize the DC output received from half controlled rectifier and give it to main

drive circuitry of IGBTs. It also maintains the constant voltage level. 11) I/O board (V 1.5): • It is the main PCB of CC. It communicates with all the boxes of WEC and controls their

functions. 12) EXCITATION FILTER PCB: • This PCB is used to filter the output DC excitation for the rotor. 13) SINE WAVE GENERATOR: • It is used to nullify the effect of AC harmonics .Sine wave generator generates sine waves

and sends them to a sensor in the power cabinet. • Now in the power cabinet it produces some waves in air, which nullifies the effect of other

waves and fields in the machine, which may harm the human beings working on the machine.

14) PCB-DC LINK INTERFACE (V 1.2): • This PCB is used to maintain the positive and negative voltage at constant level (approx.

+300V and -300V). • It also measures UGR and UZW voltage via optical wave-guide. It discharges the capacitor

in case of switching off the WEC. 15) PCB IC-Symmetry (V1.0) • Maintain the symmetry in the DC voltage level.

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16) I/O BOARD (V 1.5): • It is the main PCB of CC. It communicates with all the boxes of WEC and controls their

functions. 17) DRIVER INVERTER PCB:- • Driver board PCB is mounted over the IGBT’s. There are two driver board PCB. There are

fourteen IGBT in yaw inverter cabinet. • Driver board is optically connected with motor control card and it gives gate pulse to IGBT

(insulated gate bipolar transistor). • It converts electrical signal to optical signal and then it’ll start firing, if firing is negative left

side yawing and if firing is positive right side yawing takes place. 18) SCADA (Supervisory control and data acquisition) PCB (V 1.1): • It is the intermediate PCB of SCADA computer and WEC. It is connected with the I/O board. • This PCB communicates with the I/O board and sends all the status of machine to the

SCADA computer. • It can transmit data through copper cable OR optical cable as per requirement. This PCB

helps in remote monitoring of the WECs. 19) PITCH POWER SUPPLY PCB (V2.2): • Pitch power provides supply to all the component of pitch box. It is mounted on DC bus bar

and directly connected with IGBTs. • It gives firing signal to IGBTs to drive the motors. • It also provide path for DC supply to IGBTs, which comes from half controlled rectifier and

chopper PCB. 20) CAN OPTICAL DISTRIBUTION PCB v1.1: This PCB communicates with NCC CAN PCB, I/O board, and display PCB. 21) FACT (Flexible AC Transmission) power control PCB (V 1.3): It continuously measures grid parameter like voltage, current and frequency. Functions: • Voltage and current measurement. • Phase angle measurement. • Auto transformer operation. • Grid safety circuit. • Optical communication with inverter control PCB. 22) PITCH CONTROL PCB (V1.5): • It is used for controlling the pitch in/ pitch out of blade. It also monitors the sensors and takes

action accordingly. • It gives the signal to battery charger card for charge the capacitor/battery.

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• It gives signal to pitch power board to drive the pitch motor. It also gives access to user to monitor and perform operations manually.

• Sensors connected in pitch control PCB : Temperature: battery, motor, bearing, rotor • Switches: air gap switch, over speed switch, compact limit switch • Pulsor: 3.07 deg. Sensing pulsor, 56 deg. Sensing pulsor, speed pulsor 23) RECTIFIER CONTROL BOARD:- • The rectifier control board is in the rectifier box. • It communicates with CAN PCB of the NCC and gives signal to rectifier driver board for

firing the Thyristor. 24) CONTROL BOARD EXCITATION PCB:- • Excitation box is optically connected with NCC. The function of excitation control board is

to control the excitation voltage with respect to RPM. • It also measures the amount of excitation supply for rotor. This PCB give gate pulse to IGBT. • Some of the other functions of this PCB are listed below: • Excitation Voltage measurement • Earth fault monitoring • Excitation current measurement • Heat sink temperature 25) MOTOR CONTROL PCB:- • Yaw inverter box contains two motor controls PCB. Each card control one pair of yaw

motors. • Card one and two communicates optically with each other. • Card no.1 located on the left side and directs the function of card no.2.So it is also known as

master card, it also gives supply to capacitor for charging purpose. • This PCB Optically communicates with nacelle control cabinet, driver board PCB and

current measuring PCB. 26) ANMOMETER INTERFACE PCB:- • This PCB is used for interfacing the wind measuring device with the nacelle control cabinet. • Anemometer interface is located below the CAN optical and optical distribution PCB • It is connected with the anemometer (Cup Type anemometer. It receives signals from

anemometer in terms of pulse and then it measure speed of wind • Wind vane give signal in terms of voltage as per change a direction. One portion of the PCB

is connected with can optical distribution. This data can be seen in I/O board II. 27) DISPLAY I/O, GRAPHICS, CONTROL PCB (V 1.3) • These PCBs are used for display of the information and current operating status of the WEC. • It is used to transfer information from CAN PCB to power control PCB. It also shows the

different parameters like wind speed, power, operating hours, total KWH etc. • The display is activated by pressing one of the function keys (F1-F5) and switches itself off

automatic after few seconds.

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28) IGBT Driver PCB • The gate signal from inverter control is optical signal. So IGBT driver PCB converts it into

electrical signal. • The drivers also having a heat sink temperature switch connection and IGBT internal

temperature connection. 29) INVERTER CONTROL PCB (V 1.5): This PCB is used control the different parameter. Acoustic sensor is also inbuilt in the PCB. SECTION 1:- • Fuse and temperature monitoring • Drive step up chopper • Drive all relay (grid contactor, fan contactor) • Temperature measurement of IGBT module • Measurement of UGR and UZW • Monitoring of chopper • Control of converter power SECTION 2:- • Synchronizing to zero crossing • Measurement of current (L1, L2, L3 IGR) • Driving of IGBT (L1, L2, L3) • Cross short circuit monitoring - 2) CABINET PREPARATION: In electrical assembly it contains numbers of control boxes according to their use & application.

1. R.S.D 2. Relay box 3. Capacitor box 4. L.S.B 5. H.S.D 6. S.S.D 7. N.C.C 8. Power cabinet 9. Control cabinet 10. Yaw inverter 11. Filter cabinet 12. Excitation cabinet 13. Rectifier cabinet

1) R.S.D (Rotor sub-distribution box) 1Nos:- • Works as the main junction to the other controllers, and gives information from slip ring

body to others. • This contains some mechanical and electrical part in it. a) Golden resistor

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b) Over voltage arrestor c) Contactors d) Over speed mechanism e) Harness details a) GOLDEN RESISTOR:- This resistor of 68 ohm used for discharge of charge from capacitor using in PCB. b) OVER VOLTAGE ARRESTOR:- This arrestor are use to protect the excitation winding from the over excitation voltage. It will ground supply when excitation voltage becomes more than 680 Variable Direct Current c) CONTACTORS:- We use two different contactors, K-01 Having supply of 230VAC 50Hz , it having M.S.C (Main security circuit) circuit which connected with Air gap switch, Cable Twist Switch, Vibration Switch. e) HARNESS DETAILS:-

Cable code Cable size Cable preparation

W-10 42X1 Pitch box ‘a’ W-20 “ Pitch box ‘B’ W-30 “ Pitch box ‘C’

W-01 D.C I/P

Excitation from slip ring body to R.S.D

W-02 A.C I/P

Supply Lt pitch to slip ring casing to R.S.D

W-03 Control rotor to slip ring casing to R.S.D W-04 Spinner lamp switch W-09 Supply to hub sub-distributor box W-07 Level switch W-48 Pump centralized W-49 Valve centralized

C.L.S system centralized

lubrication W-14 Rotor Temperature

002-W-01 D.C O/P

Excitation to rotor

002-W-02 Sill-flex cab.

Rotor pole shoe temperature

W-12 Air gap switch A1 W-22 Air gap switch B1 W-32 Air gap switch C1 W-13 Air gap switch A2 W-23 Air gap switch B2

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W-33 Air gap switch C2 W-17 Optical cable for pitch box A W-27 Optical cable for pitch box W-37 Optical cable for pitch box

2) RELAY BOX 3Nos:- Relay box having no. of components like Resistor, Contactors, and Diode. R.C element. It contains 7 Nos of A.C Contactors & 6 nos. D.C contactors. Sr. No

Components/cable code

Supply rating Functions

1 K-02 2 K-03

It gives the supply to the armature of 48 D.C supply.

3 K-04 4 K-05

For field break

CAPACITORMODE (2,3,4,5) is works pitch out

condition in Emergency mode 175V

5 K-01 Given the supply of 230V & 45A

6 K-15 Works as the timer 7 K-16 It is D.C type contactors

having voltage of 45V & 16A

Connected with each other in series connection used for

capacitor/battery test

8 K-07 9 K-08

Having a supply of A.C 230V & 35 Amp. For armature only.

10 K-09 11 K-10

Having a supply of A.C 230V & 20 Amp. For field brake

only.

(7,8,9,10) is works pitch in condition controlled from pitch

box by giving 300VDC

12 K-11 For interlocking means (pitch mode on-capci. off, capacitor

mode on-pitch mode off) 13 K-12

Having a supply of A.C 230V & 20 Amp This Contactor Will give the

Charging supply to the capacitor (Charging Contactor)

14 K-06 48VDC,20A To by pass blade angle 90º&95º(emergency cond)

15 J-02 For angle encoder (C.L.S) 16 J-01 For pitch motor 17 W-01 For pitch in-out , having

supply of 230VAC from pitch box

18 W-03(4X2.5 cable)

For capacitor box

19 R01 13 ohm .200 watt Resistance is used in charging and discharging of the

capacitor 20 RC Element

(Resistor capacitor series)

For protection of AC contactor coil

29

21 F-2 (Fuse) Over voltage charge 22 F-3 To measure 75V 23 F5 +175 VDC pressure charge 24 F8 Measuring limit switch 97 25 F9

3.15A,600V

Measuring limit switch 90 26 F-1

Supply provide from armature

to field 27 F-07 To protect the contactor 28 V01 Blocking

diode This diode is used to in DC

contactor coil protection. In pitch and capacitor mode

K11

1. K11 will act like interlocking contactor i.e. it will on in pitch mode and off in capacitor mode

2. When K11 is ON contactor K07, K08, K09, K10 will ON (work in pitch mode). 3. When K11 will OFF contactor K02, K03, K04, K05 will ON (work in capacitor mode). 4. K06 will activate and K11 will ON, motor will act in pitch mode.

Diode:- IN 6293 A 1 ohm

Black cable Red cable Purpose:-To protect D.C contactors coil (Resisting diode series) 3) CAPACITOR BOX 3 Nos.:- Purpose:- • To provide supply in emergency conditions to pitch motors. • Total capacity 2x37=74 , capacitance 350 faraday each The total output supply to pitch motor

is 175V DC.It gives supply to pitch motors in case of grid failure to pitch out the blades. And there is another tapping, it is having output of 75V DC which energizes the coil of the DC contactors in the relay Cabin.

• Two P.C.B of T.H.T type in each capacitor • When temperature goes down then KTY 81 sensor connects the 230V DC supply to 820 ohm

resistor to maintain temperature.

K07 K08 K09 K10 K02 K03 K04 K05

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COMPACT LIMIT SWITCH It monitors the actual position of the blade, and gives feedback to the pitch box Component. • Angle encoder: - gives its signal to pitch box • 4 Limit switches - they give signal to relay box • Heating resistor: - to reduce the humidity and maintain the temperature of the cabinet WORKING OF COMPACT LIMIT SWITCH • -2˚ Extreme pitch in, In pitch mode. (Safety Purpose). • 90˚ Extreme pitch out, In capacitor mode (In grid failure) • 95˚ During Pitch out controller failure. (Blade out of limit in Pitch mode) • 97˚ when –2 activate (Emergency Mode) • 4) Pitch Box 3Nos

• Function :– Pitch in – pitch out of a blade • I/p – from RSD (AC) • O/p – to pitch motor through relay box (DC) • CLS (encoder) is connected to the pitch box to give feedback about the blade angle • Only one out of three box is having a signal from rpm sensor which is placed at slip ring

to measure the rotor rpm • Load control box which is connected to strain gauge sensor gives feedback to the pitch

box • Pitch box is also connected to capacitor box to pitch out the blade in case of emergency

power cut off • Pitch box’s control board gets signals from different sensors like – encoder, RPM sensor,

air gap sensor, pulsor sensor and temperature sensor of blade, nacelle, rotor, battery, motor

Over Speed Mechanism

• If W.E.C controllers fail to shut m/c at very high rotation to avoid this situation this mechanism is given, it operates when m/c rotational speed goes to upto 39r.p.m.

• Due to “centrifugal forces” this mechanism operates a spring, loaded by a dead weight which operates the electrical switch

5) L.C.B (Load control box ) 3Nos.- Purpose:-

• To detect the load which is coming from high speed wind on blade? • It having a supply of 15 VDC from pitch box for each L.C.B • It works in which format given below

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• To sense the load strains sensors are available there, which works on whiten bridge. • It requires the supply of 15VDC from pitch box to perform operation. 6) H.S.D (Hub sub-distributor ) 1Nos.:- Purpose: It deals with mainly hub related activity, which is as per given below. W01 W02,W03,W04 W05,W06 W07,W08 W09 6) S.S.D( Stator sub-distributor )1Nos.:- Location: On the stator jib’s 12’o’clock position. Purpose :It deals with the controlling of stator temp,hydraulic motor, rotor lock sensor, manual lock switch, torque monitoring sensor,R.P.M sensor etc.

L.C.B

Optical o/p

Optical dist.

R.S.D (230 VAC)

H.S.D

Bearing temperature

C.L.S gauge supply

0 deg calibration sensor

Spinner lamp supply

Pitch box

32

W15 W2,3,4 W30 W33 W17 7) N.C.C (Nacelle Control cabinet ) 1Nos.

Rectifier =017

Excitation controller =018

Stator Sub-distribution =014

Slip ring unit =051

Yaw inverter cabinet =102

NACELLE CONTROL CABINET

Control cabinet =052 Anemometer =052

Control cabinet navigation light =115

W03 =051

W27 =015 W31

W01 =014 W02

W35 =015

W76

W81

W82

W85.1 =015

W85.2

W01 =007

W02 =007

W47 =007 W22, =004

W22 ,=015 W22 =015

W39 =015

N.C.C (230 VAC)

Stator temp. Hydraulic motor Rotor locks sens. Torque monitoring sensor at 6 nos. stator jib position

Manual lock switch

S.S.D

R.P.M sensor

33

Supply Distribution of NCC: S.No Main Distribution Cable Details Connection Details

1 J01 3 phase main supply from control

cabinet 2 J02 control cable from control cabinet 3 J03 Power cable to RSD though SRB 4 J04 Control cable to RSD though SRB 5 J05 To stator sub distribution

6 J09 CAN optical (CC)

Fuse connections for M.C.B’s

7 F01 1 Phase Supply for PCB’s

8 F02 Supply of 1-¢ for rotor sub distribution

9 F 03 Rectifier cabinet supply

10 F04 MCB in main security circuit

11 F06 Service Socket

12 F07 For nacelle inside lighting

13 F08 For CEE socket

14 F10 Over voltage arrester

15 F11

16 F12

17 F13

Over voltage arrester

18 F17 Supply for heater and cooling fan

Motor Protection switches:

19 Q01 hydraulic motor supply-1.1A

20 Q02 3 phase R.S.D supply through slip ring body

21 Q03 3 phase supply For Excitation 25A

22 Q04 3 Phase supply for winch motor-2.6A

23 Q06.1 3 Phase for Nacelle cooling fan

34

24 Q06.2 3 Phase for Nacelle cooling fan

25 Q06.3 3 Phase for Nacelle cooling fan

26 Q07,Q08,Q09,Q10 yaw motor protection switch-14A Through Yaw Inverter

27 Q11 3 phase supply for yaw inverter (22to32A)

28 Q11.1 Left side yawing-14A (Nacelle Mode)

29 Q11.2 Right sideyawing-14A (Nacelle Mode)

Contactors:

30 K01 Main supply Emergency Stop Contactor

31 K02.1,K02.2,K03.1,K03.2 Yaw Motor supply

32 K04 Nacelle cooling fan

33 K06 Hydraulic motor supply

34 K07 Rotor lock limit switch

35 K08 Automatic/Manual for maintenance purpose

36 K09 Single blade adjustment

37 K26 Yaw inverter supply

38 K27.1

39 K27.2

Cable twist limit switch

S.No Sub Distribution Cable Details Connection Details

1 W85.1,W85.2 Yaw Inverter

2 W35 Rectifier 3 W31 Excitation 4 W41, W42 Acceleration sensor 5 W19 Lamp hand 6 W81 Yaw inverter control

7 W76 Yaw inverter supply 8 W27 Excitation supply 9 W15 Switch nacelle lighting

10 W16 Emergency lighting

35

12 W17 Nacelle lighting

13 W03 Winch motor

14 W25 PT-100 outside nacelle temperature 15 W43, W44 Core Balance Current Transformer

16 W09 Vibration monitoring

17 W10 Supply Rectifier unit 18 W23 Cable twisting switch

19 W21 External tower lighting

20 W72 Smoke detector nacelle 21 W73 Smoke detector main carrier

22 W04,W05,W06,W07 Yaw Motor

23 W131,W132,W133 Nacelle fan

24 W22 Anemometer

NCC Sensor details

S.No Sensor Name Details Sensor Function Details 1 KTY81 Nacelle inside temperature sensor

2 KTY81 Nacelle outside temperature sensor

3 B02 Transversal oscillation sensor

4 B01 Longitudinal oscillation sensor

5 Pt100 Outside tower temperature measuring

Cable twist switch:- When yawing of m/c in is going on , if m/c three times complete rotation in particular direction it activates automatically. • 1135˚ 9.85 V left direction • 0˚ 5V Normal • 1135˚ 0.15V Right 8) POWER CABINET 3Nos :- • Three power cabinets located at tower bottom each of 300 KW. • It is used to convert variable DC power coming from the Rectifier Cabinet (Via DC

Distribution Box) into constant AC power as per grid requirement Component details given below:

S.No PCB Description Version Qty 1 300 KW Inverter Supply PCB V 1.5 1 2 Inverter Control PCB V 2.5 1 3 Power Supply Board 1

36

4 DC Link Interface V 1.2 1 5 IC-Symmetry PCB V1.0 1 6 Single IGBT Driver PCB CM 1000/ CM 800 V 1.1 1 7 Dual IGBT Driver PCB For cm 1000 V 1.0 3 8 Chopper Circuit PCB V 1.2a 1 9 Noise Sensor V 1.0 1

We can easily understand from given flow diagram

9) CONTROL CABINET Control cabinet is located at the bottom of the tower. It consists of different PCBs to monitor the entire WEC and take action according to the situation. Control.

DEVICE ID RATING APPLICATION CAN Optical distribution (Control Area Network)

A03.1,V-2.0, R-00 Optical data collection and distribution

I/O board (input-output board)

A021,V-1.5, R-01 Controlling temp. monitoring, tower cooling fan, Heater fan,

Optical data communication, Door switches

FACTS power control (Flexible AC Transmission

System)

A011,V-1.3, R-00 Controlling and measuring: Voltage, Phase, siquency and

Frequency, Auto X-mer operation, Grid safety circuit, Optical

communication with Inverter control and Display control.

Rectifier O/P 125-670VDC

Grid choke

3Phase Inverter

D.C link Step up Chopper

M.C.C.B Contactors Decoupling

choke

3 Phase 400 VAC O/P

POWER CABINET

37

SCADA (Supervisory Control and Data Accuntation)

A28,V-1.1,R-00 It is intermediate P.C.B Of SCADA computer& with this P.C.B

communication with I/o board& sends all status of m/c to/the

SCADA computer. Display I/O,Display control &

Display graphic) A02,V-1.1,R-00 Output information

Sine wave generator 118,A-01, V-1.0,R-00

A.C harmonics

F04 25A Protection switch for service socket F05 D16,3 Pole Supply cee socket

F07,F08 D1O,1 Pole Navigation light U.P.S F09 D1O, 2

Pole/230V Tower light ,shine wave gen.,

supply& extra lamp F10,F11,F12 D1O,1 Pole 3 phase supply for Power cabinet

cooling fan F16 D1O,1 Pole Supply for I/O board, CAN optical,

SCADA, Display & Customer interface.

F17 D1O,1 Pole 1 Phase supply to power cabinet (P.C.B 300 kw power supply)

F20 D10,2Pole/400V Supply for FACTS Power control F32 D16,1 Pole 1 Phase supply to heater fan

&Dehumidification power cabinet1,2,3

F36 D16,3 Pole Tower cooling fan F21,F22,F23 B10,1 Pole Voltage measurement

F19 3.15A,250V Supply activation grid contectors F28 24V,300mA

SCADA P.C.B protection, data

modulation F01,F02,F03 35A Main incoming supply (fuse

disconnector ) F24,F25,F26,F27 275V Over voltage arrestor

Q01 2.8A to 4A Protection switch for tower cooling fan

K01 90 AMP ,3RT-1044 Supply for control cabinet & nacelle cabinet supply

K05 90 AMP , 3RT-1044 Over voltage compensation K02.1 20 AMP , 3RT-1016 Tower cooling fan K06 20 AMP , 3RT-1016 1 Phase supply to heater fan &

dehumidification power cabinet 1,2,3

K10 16 AMP , 3RT-1015 Grid safety circuit T01

(3 Phase auto transformer) R-15300VA, 230V/200V

Over voltage compensation

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P01 400V/5A KW/H O/P supply meter E01 230V Cabinet heater fan A07 15W,230V Cabinet internal light & socket A06 Telephone J02 Junction for control cabinet to

N.C.C J05 optical connection between control

cabinet to N.C.C J13 Chopper cabinet1 G02 12V,7.2AmpH SCADA back up voltge J10 Testing socket

X04,X06,X13,X02,X01, X03 Terminal series for distribution R05 KTY-81 Control cabinet temperature R06 KTY-81 Tower temperature S01 Main switch S02 Quick start S03 Error reset S04 Quick stop S05 Blade out (-) S06 Blade in (+) S07 Plant start/stop S08 Maintenance S09

SWITCH 400V,20V,20A,1Pos,8

220 Automatic/manual S10 2Pos,8210 Yawing left/right S11 Horn top/tower external light H01 Maintenance on indicator H02 Manual on indicator H03 Buzzer (Horn)

W20/L1 W21/L2 W22/L3

1x16 mm²fuse type

cable W23/N 1x10mm² blue cable

1x10mm² G/Y cable W24/PE

Main incoming 3 Phase supply

(Via Power cabinet – Grid)

W41.1 W41.2

W41.3

Cable hybrid 19x1 mm²+4xPof(sap-41887)Or Cable

control20x1mm²(sap-599) opti-2Y2P(sap-

6064) Cable

Power cabinet 1,2,3 (J01& Invertor control board

P.C.B)

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10) YAW INVERTER:- Purpose: It is used to make yawing smooth, by giving constant 3 phase A.C supply to the yaw motor.

• There are two systems in the yaw inverter, namely MASTER and SLAVE Master is Called System 1 its control the motor No 1&3. Slave is called System 2 It’s Control motor No.2 & 4.

• There are two systems in the yaw inverter, namely MASTER and SLAVE Master is Called System 1 its control the motor No 1&3. Slave is called System 2 It’s Control motor No.2 & 4.

COMPONENT DESCRIPTION DETAILS:-

S.No COMPONENT RATING FUNCTION QTY 1

Fuse semiconductor 400V,100A From the protection of Incoming supply. 1 nos.

2 Incoming choke L01 0.1mH,25A To filter input AC supply. 1 nos.

3 contactor K02, smooth staring , 1 No.

4 Resistor (R01,R02) 100w,27ohm Smooth charging of

capacitors (Voltage drop) 2 nos.

5 contactor Ko1, Main contactor, 1 No.

6 Three phase bridge rectifier V01 1200V,85A

For the rectification from AC to DC 1 nos.

7 Capacitor C04,C05 400V,14000microF, Smooth the supply voltage To

feed a Constant Supply to IGBT

2 nos.

8 Capacitor with resistor 22kohm

To control charging of capacitor 2 nos.

9 IGBT (V10 to V16;

V 20 to V26) 1200V,100A

12 IGBT for Inverting DC to AC controlled supply

purpose and 2 IGBT for chopper

14 nos.

10 Inductor L11 to L16, L21 to L26 1 phase, 0.03 mH, 20A

Filtering purpose 12 nos.

11 Outgoing choke L17,L27 3x0.1mH, 25A

To filter the output controlled supply 2 nos.

12 contactor K04,K05 250v, 35 A yawing 2 Nos. 13

Snubber capacitor C06, C09 1.5microF

When increase voltage to fed IGBT so that work as resistor and maintain voltage supply.

2 nos.

14 Heater fan E05 250v,200w Heating purpose when

moisture in box. 1 nos.

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Connection flow diagram

11) FILTER CABINET:- Purpose:- Filter cabinet is used to remove A.C harmonics. • This cabinet is located in nacelle. One rectifier box with two filter cabinet are connected in

parallel. • The filter cabinet does the filtration of AC current through generator. It removes the

harmonics present in the output of the generator before it is fed to the rectifier for rectification.

• In this cabinet there is an L- C- R circuit The capacitor is a bank of 3 capacitors connected in delta and parallel to the inductor.

• There are two systems so there are two filter cabinets individually for each system.

N.C.C (415V) K02

CHOKE FUSE RECT. 600VDC

C1

C2

DRIVER CKT. MOTOR CON. P.C.B

SYS.P.C.B (2n)

CHOKE FOR EACH SYSTEM

SMALL CHOKES (2X3n)

I.G.B.T (12n)

N.C.C (K04/K05 MOTOR

G

RECTIFIER

F1 F1

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COMPONENT DESCRIPTION OF FILTER CABINET Sr.No COMPONENT RATING FUNCTION Qty 1 L01 choke 3 – Φ (3x0.1mH),100A Smoothing purpose 1no.

2 R01-R03 resistor 3 – Φ (3x0.77ohm),(3x0.5kw) For load 3nos.

3 C01-C04 capacitor

(3x96.3) μF, 565V . delta connected capacitor

Aluminum body used for filtering purpose.

4nos.

4 Fuse link 100A,HRC 16mm² cable used for tripping device

1nos.

12) EXCITATION CABINET:- • Purpose:- Excitation box convert AC supply coming from the grid during starting into DC

with the help of a three phase controlled rectifier. • Excitation box is located in the nacelle. The function of this box is to provide excitation

Supply to the rotor pole shoe. • This box has two inputs and one output. But at any instant only one input is given to the

control box. • At the time of starting of the machine it gets the input from the grid and after the machine

comes to running condition it gets the input from the rectifier cabinet. • After starting when the rectifier power becomes more than that of the grid the diode becomes

forward biased and it draws DC supply directly from rectifier box. • The IGBT inside the box converts the uncontrolled DC into variable DC by getting the gate

pulse from the excitation control board PCB. • Excitation supply varies between150-600V DC as depending on the wind. 13) RECTIFIER CABINET:- COMPONENT DESCRIPTION OF RECTIFIER CABINET

S.NO COMPONENT RATING FUNCTION QTY

1 Main fuse 1000A, 690V AC From the protection of generation supply. 1nos.

2 LEM module 1:1000 For current measurement at

input side of rectifier 6nos.

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3 Heat sink

This sink is used for heat dissipation of the box. Both the rectifier driver board pcbs are mounted on it. When current passes through these pcbs, It's got heated and this absorbed by that sink and hear is dissipated.

1nos.

4 Thyristor 570A,1800V Used for converting AC to DC.

6nos.

5 Capacitor 10μF, 930V Driver board function 2nos.

6 Fuse 100A,690V Protection of outgoing excitation supply 1nos.

7 Cooling fan 230V,50 Hz, 1.31A, 300W

Cooling fan is directly mounted on heat sink for cooling. This fan starts only when heat sink exceeds 50 degrees.

1nos.

8 Heater fan 230V,250W,50 Hz

This fan is used for maintaining the temperature inside the box .It starts only when inside temperature goes below 10 degrees.

1nos.

Testing:- • 750 V Tripping • 500A Current test 1 Hrs • 650 V 25 min for each system • S.C.B (Silicon Control Board)

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Generator (var A.C Out)

Rectifier (D.C variable)

System1 System 2

R Y B

Filter cabinet

HRC HRC HRC

Copper bus bar

L.E.M

DIODE

Driver Board (gate pulse)

Excitation Box

Junction Board

Control Cabinet

Thyristor (2nos. S.C.R 1800V.570A

N.C.C

D.C dist. Board

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DESIGNATION OF CABINET AND COMPONENT 001=HUB 002=ROTOR 003=STATOR 004=NACELLE 005=CONTROL CABINET 006=POWER CABINET 007=TOWER 008=X’-MER STATION 010=BATTERY BOX 011=RELAY BOX 012=PITCH BOX 013= RSD BOX 014=SSD BOX 015 NACELLE CONTROL CABINET. 017=RECTIFIER BOX 018=EXCITATION CABINET 019=OVER VOLTAGE GENERATOR BOX 028=COMPACT LIMIT SWITCH 035=HSD BOX 047=CONTROL CABINET HEATER 045=DC DISTRIBUTATION BOX 051=SLIP RING BODY 052=WIND MEASURING DEVICE. 053=PITCH MOTOR 066=FILTER BOX 075=LOAD CONTROL BOX 076=CAPACITOR BOX 102=YAW INVERTER BOX 118=SINE WAVE GENERATOR

45

INCOMING QA-ELECTRICAL:-

Incoming QA Electrical is the department which deals with inspection and testing of electrical components. It also provides the technical support for the indigesnisation of components, inspection of modification to improve the quality & performance of component. ACTIVITIES OF QA INCOMING ELECTRICAL:- 1. Initial assessment of the supplier identified by materials dept. for the manufacturing capability, quality system to maintain the consistence in the quality. 2. Inspection and testing of the components used for electrical assembly, generator manufacturing, projects and service as per specification and QAP. 3. Corrective action and preventive action on the non conformity observed during the production or service. 4. Technical support for the indigenisation of components. 5. Initiation of modification to improve the quality and performance of components. 6. Inspection and testing of component at subcontractor’s plant for the components directly supplied to site. 7. SAP QM module Data Planning and change over planning related to design changes. 8. Facilitation of calibration for instruments, test and measuring equipment. Results of inspection

1. Acceptance reports. 2. Rejection reports. 3. Defects reports.

CATAGORIES/CLASS OF MATERIAL:- Materials are divided into 3 categories. Those are as follows: A class material: - it includes the component like pitch motor, yaw motor, pole shoe etc. the materials used here of high standards. 100% inspection is done for these elements. B class material: - These are the materials in which inspection are done at the sample basis. Some of the examples of B class materials are copper wire, resin etc. C class material: - These are the materials where quality measures are not as high as in A class material. Inspection is done as sample basis in these kinds of materials. INSPECTION CARRIED OUT Component Category 1. Fabrication items 2. Hardware items. 3. Control Cable and Cable Accessories 4. Switch Gear Components. 5. Wound Components. 6. Rotating Components. 7. Electronics Components.

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8. Segment Plate. 9. Enameled Copper Wire. 10. Pole Shoe. 11. Insulating Material. 12. Coil Form. 13. Power Transformer. 14. Power Cable Copper and Aluminum. PROCESS FLOW OF TESTING SUPPLIER VENDOR ` MATERIAL INWARD GOODS RECEIVE NOTES (G.R.N) QUALITY ASSURANCE INSPECTION TESTING AND INSPECTION OF RECEIVED COMPONENTS ACCEPT/REJECT/AUD REJECTED MATERIALS ACCEPTED MATERIALS BACK TO VENDOR STORES

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TESTINNGS:- 1. COPPER WIRE TESTING:- • Copper wire the most important material used in generator. It is there fore tested for its

various properties like enamel strength, temperature tolerance capacity, break down voltage etc. The various tests are as follows.

1. Abrasion test:-

• This test measures the resistance to abrasion of copper winding wire of 2.24mm cross section dia.

• It ensures the mechanical property of the enamel used. • 5 no. of samples of 400mm are taken and tested in the enamel remover

along 0 deg, 120deg, and 240deg, • The level of acceptance is min > OR= 15.4 N • Avg > OR=18.2 N

2. Peel test of copper wire:

• This test is conducted for the measuring mechanical strength of enamel. • Testing and confirming standard – IEC 60317-13. • 5 no of 600mm long copper wire is placed in peel tester and 10 mm enamel

coating is removed away from the holding end. Load of 60 N is applied and tester is started.

• No. of revolution is noted down from the counter display and multiplied with wire diameter.

• If result is >=110 sample is accepted (Required minimum no. of revolution are 49).

3. Resistant to abrasion test:

• This test is conducted for mechanical properties. • Enamel at one end of 400mm long copper wire is removed and placed in the

unidirectional scrap tester. • Needle of 0.230mm dia is placed on the surface of wire and 13.2 N loads is

applied and tester started. • Required values: min. > or = 15.4N and avg. > or = 18.2N (multiplying factor

x load). • The same test is conducted at 120 deg. & 240 deg.

4. Spring ness test: • To check the spring back action (mechanical property) of wire. • Acceptance level is < =5 d

5. Cut through test: • This test is meant to check the thermal property of the enamel.

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• Two specimen of wire of 300mm are taken and enamel from one end about 20mm is removed and inserted in pre-heated testing device at320 deg. Celsius so that they cross each other at right angles for 3 minute.

• Hot block of 71 N is applied. and 100v +/-10v voltage passed through conductors for 2 minutes.

• If enamel resists the result is ok.

6. Breakdown voltage test: • This test is done to ensure Die-electric strength of enamel. • Two 400mm length of copper wire is taken and enamel is removed at one end. • Wires are twisted three times and108 N loads are applied. And put it in BDV

tester and test is done at 15KV at 500 V/sec. • If value obtained is > = 5 KV than material is accepted.

7. Resistance measurement using micro ohm meter: • This test is done to measure the resistance value of the copper wire • The acceptance level is Min – 004213 and Max. - 004468.

8. Elongation test: • Test measures the elasticity of the material. • 1 m length of copper wire is taken and 200mm to 250 mm wire is fixed in

between the jaws. • Tester is stated and allows stretching the wire at the rate of 5 mm/s +/- 20%. • When the wire breaks, reading is taken. Acceptance level is minimum 33%.

THERMAL CLASSIFICATION OF INSULATING MATERIALS: Thermal class is the class which defines the limiting temperature of the different materials. Following table shows the different class and materials. It is used to define what kind of material should be used in which place. CLASS LIMITING

TEMP. ºC MATERIAL

Y 90 Cotton silk, paper of similar organic materials neither impregnated nor immersed in any oil rubber, polyvinyl

chloride. A 105 Impregnated paper, silk, cotton, (fibrous material) polyimide

resin. E 120 Enameled wire insulation on basis of polyvinyl formed

polyurethane, and epoxy resins, molding power plastics etc. B 130 Inorganic materials, (mica, fiber glass, asbestos) impregnated

with varnish or other compound. F 155 Polyester, epoxies, varnishes, and other varnishes with high

heat resistant. H 180 Composite material on mica, fiberglass and asbestos bases

impregnated with silicon rubber.

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C 25 Mica ceramic, glass Teflon.

INCOMING QA-MECHANICAL

Incoming QA Mechanical is the department which deals with inspection and testing of mechanical components. It also provides the technical support for the indigesnisation of components, inspection of modification to improve the quality & performance of component. ACTIVITIES OF QA INCOMING MECHANICAL:- 1. Initial assessment of the supplier identified by materials dept. for the manufacturing capability, quality system to maintain the consistence in the quality. 2. Inspection and testing of the components used for mechanical assembly. 3 Technical supports for the indigenisation of components 4 SAP QM module data planning and design changes. 5 Initiation of modification to improve quality and performance of the components. 6 Facilitations of calibration for instruments test and measuring activity. 7 Facilitations of QA activity of construction of new plant CATAGORIES/CLASS OF MATERIAL:- Materials are divided into 3 categories. Those are as follows A class material: - 100% inspection is done for these elements. Parts included in this type are stator ring, disc rotor, stator jib carrier, axel pin, rotor hub, main carrier, blade adopter etc. B class material: - These are the materials in which inspection are done at the sample basis. Some of the examples of B class materials are bearing, drives etc. C class material: - These are the materials where quality measures are not as high as in A class material. Inspection is done on sample basis in these kinds of materials. Ex- Accessories like cable pin, hardwires etc.

A class material: - STATOR RING:- • Six parts are fabricated to form a stator ring. Fillet winding is used for wielding purpose. • Inside dia is critical. Micrometer is used for measuring. • Inside dia: - 3742.5mm +/- 0.5 mm • Shell height:- 390mm +/- 5mm DISC ROTOR:- • Disc rotor has both inside and outside critical dia. • For outside dia first circumference is measured with the help of tape. Then dia is calculated. • O.D should be 3193.1+/- 0.5 mm. • Out side height should be 370mm+0.5mm • Inside dia is measured by inside caliper .Inside dia should be 950mm+0.09mm and inside

height is 381.7mm+/-0.2mm. • Twelve no of rotor lock hole is present there. Which is also measured. • Width: - 62.2mm+/-0.2 mm

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• Depth: - 45 mm STATOR JIB CARRIER:- • Stator jib has a inside critical dia of 810mm+0.09mm • Inner side holes have 35mm+5mm dia. Height is 385mm. ROTOR HUB: - Following parts are measured in the rotor hub. • Front bearing assembling

1. ID-340 mm 2. Tolerance- 339.867 to 339.903

• Rear bearing Assembly: 1. ID:- 740(Tolerance 739.832 to 739.9143) 2. It is measured through inside micrometer 3. Flange OD: - 1300mm +/- 0.2 mm

MAIN CARRIER: - It consists of yaw motor assembling boar. • Upper ID:- 270mm+50 micron • Lower ID:- 230 mm+50 micron • Inside dia of stator carrier • Assemble= 930+.23mm • Depth= 10 to 14 mm. BLADE ADAPTER:- • Inside dia: - 1304mm + 1mm • Pitch drive ID:- 150mm+ 40mm;

B class material& C class material HARDNESS CHECKING:- • Hardness of the hardware is checked with the help of Rockwell hardness tester. Here we

have two grade of hardness one is 8.8 and another is 10.9 • E.g. hardness for 10.9 grade = between 32 to 39 HRC. BEARING CHECKING:-

• Bearing surface checking is to be done at incoming QA. Bearing is cleaned with Lind free cloth and checked for the defects by visually. 1500 grade paper is used for removes minor defects. After checking, apply LHMF 300/5 SKF bearing oil.

• Following are the defects which are generally found in bearing. 1. Scratch marks on bearing surface 2. Pitting marks 3. Corrosion and rust spots 4. Nick marks 5. Depression and damage of rollers 6. Manufacturing defects on bearing parts

51

7. Presence of foreign materials 8. Misalignment and cage damage 9. Inadequate lubrication

• During visual checking following things were also noticed. 1. Dimension deviations 2. Difference in roller dimensions 3. Difference in drawing

BLADE BLADE MANUFACTURING PROCESS Process Flow of Blade manufacturing: 1) Mould cleaning 2) Laying up of fabrics 3) Vacuum application 4) Resin Infusion 5) Application of heat (curing) 6) Cooling to De-moldings temperature 7) Mould releasing after cooling 8) Joining of web to suction shell 9) Joining of glue cap, balancing chamber and tail-tip to Pressure shell 10) Full joining 11) Heating 12) Deburring or Pre finishing. 13) V-Profile fixing, D-Profile fixing 14) Sawing and Drilling 15) Stud bolt fixing 16) Spoiler fixing and Discharge ring fixing 17) Painting 18) Balancing of blades 19) Dispatch All these processes are performed sequentially The different blade components are as follows: 1) Rotor shell (pressure shell and suction shell) 2) Spar boom (pressure and suction shell) 3) Spoiler 4) Preform 5) Glue cap 6) Shell web 7) Spoiler glue cap 8) Spoiler web 9) Balancing chamber 10) Tip

52

11) Flange 12) V, D, Flat profile 13) Discharge ring 14) Discharge box 15) Studs and bolts FIBERS The type of fibres used here is glass fibre which acts as a reinforcement material. E-glass, C-glass and S-glass are normal grades of the fibres. The main function of the fibre is:-

• To carry load (70% to 90%). • To provide stiffness, strength, thermal stability and other structural properties in the

composites. Fabrics used in the blade production:

• G represents gel age. • R represents roving. • 0 represents no thread. • 1 represents normal thread. • 2 represent strong thread.

According to the different type of orientation, pattern of stitch and weaving different types of glass fibres are used in production. RESIN A glass fibre alone exhibits weak strength so resin is used to bind the fibres and give shape. The main function of the resin is:

• Matrix material binds the fiber together and transfers the load. • Isolates the fibers. • Provides good surface finish. • Protection against the chemical attacks and mechanical wear.

Balsa wood has to be checked for moisture content and its moisture presence should be between 5 to 14%.. Manufacturing Processes of Different Parts: The manufacturing process of different parts of the blade is as follows: 1. PREFORM MAKING:

1. Perform is the combination of glass fibre layer, which are used as a single unit and placed at the root side of the blade to provide it sufficient strength. The process of manufacturing:

2. Clean the mould with cotton material used for sweeping or wiping. 3. Then apply Frekote NC-55 as a mould releasing agent. 4. Cut the layers according to the design and lay it on the mould, use hot iron press to

straighten it. 5. Vacuum of 1 bar of 70˚C for 1 hour.]

Temporary vaccum after placing the first 20 layers.

53

• Release vaccum slowly and perform from the mould.

• Switch off the heater and perform is ready for shell making.

2. SPAR BOOM MAKING: It is the backbone of the rotor blade giving entire strength to it entire longitudinal direction. It is of two types pressure shell and suction shell. Made up of 22 layers of unidirectional fabrics R1/0-1188 M70 and R1/0-2340 M70.

• Layer width 420mm. • Component width 535mm.

PROCESS • Mould cleaning by cleaning agent and NC-55 as releasing agent. • Peel ply adhered to the mould according to design. • Staggering R2300 to /R2900 layer 2 to 8 with cutting angle 45˚ both side end. • Foam edges from R1800 to R19600 rhombic slit (10 mm) foam TE side. • Balsa wood from R19600 to R25670 and R 18555 to R25670 LE side. • Silicon rubber profile 15*10 mm at TE side.

NOTE: The only difference in spar cap pressure and suction face is 10 mm foam which is present in suction shell at R1800-R19600. 3. WEB It is called as shear web which protects the blade from buckling due to high torsion. It works as an I-beam. It is placed between the blade suction and pressure shell. Made up of glass reinforced, PVC foam with balsa sandwiched. Web LE- R2700 to R24450. Web TE- R2700 to R20100. 4. SPOILER The purpose of the spoiler in the rotor blade is to increase the surface area of the blade. This extra part provides additional drag that enhance in lifting of blade.

1. Spoiler suction shell- R2254 to R11500. 2. Spoiler pressure shell- R2254 to R11500. 3. Spoiler web- R2300 to R5500. 4. Spoiler glue cap- R2254 to R9400.

5. BONDING CAP OR GLUING CAP This component helps in joining together the rotor blade two shell at both the edges that is leading and trailing edge.

1. Leading Edge Cap: R1150 to R26450. 2. Trailing Edge Cap: R1150 to R10500.

6. BALANCING CHAMBER

54

It is a container with three chamber of three volume fixed at a radial position R16250 to R17750 on pressure shell of blade.

• This chamber is used to fill the weight difference of the set of blade to make it nearly equal.

• The balancing chamber is attached to the pressure shell. • It comprises of hollow section, which is used during the balancing of the all the three

blades of the particular turbine. • If the weight of all the blades is not same then the weight is added in this section equal to

the difference of the weight of the heaviest of the three blades and the blade itself. 7. BLANK PRERPARATION Mould Preparation:-

• Cleaning of the mould and applying mould releasing agent NC-55. • Preparation of the suction shell and pressure shell according to the design in respective

mould by using perform. • Applying vaccum then resin infusion followed by heating and cooling of shell. • Putting the leading edge and trailing edge web in its position and joining of the shell with

the help of gluing or bonding cap. 8. ROTOR BLADE ASSEMBLY

• After the joining of the two shells together the raw blade is called as blank which is brought to the assembly section where various parts are assembled together to form rotor blade.

• The total time duration time required for assembly section is 50-56 hours to complete.Whole activities can be divided in to three stages:-

ASSEMBLY 1 FLASH CUTTING (DEBURING)

• During shell joining process the excess glue will be pressed out which form as flash. Along with the glue the other accessories like spoke puller and covering tapes will be present.

• The flash is removed in a closed chamber so that during the operation dust powder do not escapes outside.

• The hand held cutting machine used to trim the excess flash present in the shell joining portions.

SAWING AND DRILLING • Sawing done before drilling so as to get plane or even root surface. Holes for M22 size

bolts and 45mm diameter studs are made. • Type G resin and Type 38G paste is applied inside the circumference of the stud holes for

bonding. • The bolts are inserted on the slotted holes and the studs are inserted into their slots and

finally the bolts are screwed tightly with the studs. FLANGE FIXING

• Flange is also called as compression plate.

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• It is of 4mm thickness and fitted at the circumference of the blade root. • It protects the FRP from the environment impact and also a connective part of the blade

with the hub face in between the flange in the adaptor. ASSEMBLY 2

• V-profile fixing. • Discharge ring fixing.

ASSEMBLY 3 Spoiler fixing BLADE BALANCING

• The blades are being produced in different moulds and huge manpower is needed for producing blade.

• So blade production is not accurate. The weight of the blade varies from each other. • If it is left unsolved then numerous problems like longitudinal oscillation and vibration

will come into picture. So to avoid these kind of problems we need mass balancing (moment balancing) in the blades.

• This process is carried out in the following ways: • Three blades forming one set manufactured from same mould are taken. • Then each blade is placed onto two load shells placed at R1150 and R16000.Then mass at

that position is noted down for each. • Then moment (massХdistance) at both the position is calculated and added to get the net

moment for each blade. • Then taking the blade with the highest moment as reference the other two blades are

balanced. • The balancing chamber (R16250-R17750) made up of fabrics having three chambers

partitioned by balsa (9.5mm) is where the extra mass (resin lead ball hardener) is placed. • The exact amount of mixture and the compartment where the mass to be placed is

calculated by a software. • The acceptable variation after the mass balancing is ±12 Kg-m.

EW ANGLE (EINSTA WINKLE) It is a setting angle that is provided to the blade at the time of manufacturing otherwise later it creates the problem of oscillation. As our blade is curvier in nature after R-1500 so we need to maintain that same curve or profile in all the blades so that we will not face any oscillation problem. For this reason we check the angle at the root of the blade with the R-1500 position to check the EINSTA WINKLE angle. We measure it among 2 blades and within 1 blade also.

Procedure 1. The spirit leveler is placed at two position of the blade i.e. at R2000 and R10000, reading

noted. 2. Now the difference between the two readings calculated which should be between

tolerances of ±0.4˚. 3. Now for each three blade the above difference is calculated and seen whether it’s in the

range otherwise the blade is rejected.

56

4. The value obtained above for each blade is now compared with each other with tolerance of ±0.4˚.

5. If there is any variation between blades then accordingly the blade is replaced with other blade.

BLADE QA 1. This department deals with the quality of the outgoing blades. The main function of the

blade QA department are as follows: 2. To check raw materials at the incoming stage. 3. To find defects in the parts manufactured and steps to be taken to rectify it.

Precaution for the material handling. • Visual inspections are carried out to check the blades. In this part we check the critical

dimensions and quality checking of the parts is being done.The visual inspections are carried out with the help of:

• Traveling Camera • Light Inspection