HomeMy WebLinkAbout3 D EWSI LIFTING INSTRUCTIONS TurbineTowerLIFTING INSTURCTIONS
COMBINED TURBINE-TOWER ASSEMBLY
The following is the recommended procedure for assembly of the tower and turbine prior to
erection of the combined tower and turbine components.
The following tools are required:
1. Socket Wrenches, 3/8” 1/2” and 3/4” drive up to 2”
2. Torque Wrenches, 250 ft-lbs and 600 ft-lbs
3. 5/8 and 1” drift pin
4. 2 ton cable puller or chain fall
5. Various hand tools
Procedure:
1. Raise the tower onto secure blocking placed 16-20 feet from the tower top until the
flanges of the tower top are about 9 feet above the ground. Ensure blocking is stable in all
directions.
2. Carefully lift the wind turbine drive train using fabric slings. Once the drive-train is
suspended, fully disengage the yaw locking pin allowing the tower top to be rotated. It is
also necessary to orient the wind turbine horizontal with the generator junction box
upwards. Use a cable puller or “come-along” attached to the centre gearbox lifting eye
and lifting hook to adjust orientation to allow easy fit up to the tower top. Do not use the
lifting eyes on the drive-train for main lifting. See diagram 1.
Diagram 1.COMBINED TURBINE-TOWER ASSEMBLY CONT’D
3. Route the blade cables through the tower to the base. See diagram 2.
Diagram 2.
4. Install the drive-train to the tower top. The nuts are to be downward. Leave loose until all
are in place. The use of a lining bar may be required to enable bolt insertion.
Diagram 3.
5. Torque the nuts to 600ft/lbs. it may be necessary to remove some brace bolts to allow fit
of the torque wrench socket depending on the type.
6. Engage the yaw lock securely. Then release the come along and sling tension gradually
and test security and stability of the complete tower/drive-train assembly on the blocking.
Adjust as necessary.
7. Release the yaw lock and rotate the drive-train so that the hub is downward. Relock the
yaw.
8. Complete the installation of anemometer see Diagram 4.
Diagram 4.
9. Remove the blades from the shipping crate and attach to the hub with the bolts and
washers provided. Support the blade until the bolts are securely tightened. Ensure that the
holes in the blade inserts are clean. Apply a 1”x 1/4” strip of Medium Strength thread
locking compound to each bolt on insertion. Leave bolts loose but with oval washers
fully seated in hub slots until blade pitching is complete. Ensure no bolts are cross
threaded upon insertion. See Diagram 5.
10. Pitch (rotate) each blade clockwise, looking at the tip, about its long axis such that the
washers are as fully rotated as possible to one end of the hub slots. In other words: Push
with the bolts slightly loose so that the trailing edge of the blade is pushed down towards
the ground until the pitching washers rest against the side of their slots Tighten the bolts
fully snug with a ½ drive 15/16 socket. Install all three blades in this fashion before
torquing the bolts.
Diagram 5.
11. Using a calibrated torque wrench tighten the bolts in sequence beginning with the
uppermost bolt. Label this bolt #1. Then torque in sequence as shown below to 180ft/lbs
and then to 240ft/lbs. See Diagram 6
12. Install tip brake plates to each blade end. Connect the tip brake wires at the hub
and place cable ties to eliminate any long loops in cable. See Diagram 7. for an
example of a properly installed plate.
Diagram 6.
Diagram 7.
13. Consult with the crane operator to determine the best method of lifting the turbine
using the crane onsite. Below is the most popular method used for lifting the
complete tower and turbine assembly. It is also advisable to have a consultation
with the crane company at the time of booking the service in order to prevent
delays onsite on the day of lift. See Diagrams 8, 9 & 10.
RECOMMENDED SLING POSITIONS DURING LIFT. NOTE SMALL SLING IS
USED AS A CHOKER TO BRING TWO MAIN SLINGS TOWARDS CENTER OF
TOWER.
READY FOR LIFT
Diagram 8.
Diagram 9.
A 6-8 foot spreader
bars may be necessary
to prevent damage to
generator junction box
and its associated
cables during lift.
Diagram 10.
LIFT CONTINUING Diagram 11.
14. Place one install team member at each foundation anchor bolt location to guide
the lifted tower onto the leveled anchor bolt bottom. Minor adjustments to tower
leg or bolt orientation may be necessary o make holes in tower flanges fit over
bolts. See Diagrams 12. & 13.
Diagram 12.
Diagram 13.
15. Once all tower legs oriented properly over anchor bolts and secured with nuts and
washers provided. Tighten any bolts on legs and cross braces that were loosened
in order to make tower fit anchor bolts properly. Climb tower to release crane
sling from top of tower.
COMPLETED LIFT Diagram 14.
16. Grout the base of the tower legs using the grouting specifications and instructions on the drawing shown as Diagram 15. Failure to grout the tower as specified can lead to structural fatigue of tower components. See Diagram 16 for an example of a properly completed grouting of a tower base. Diagram 15