Rotor Assembly and Lift

8 Rotor lifting

8.1 Simple diagrammatic drawing of rotor lifting process

Place the blade

vertically (tailing

edge upwards)

Ground motor-

driven pitch

changing; pitch

bearing changes

to -90

Screw all the

bolts in blade

-90 assembly

of blade

Install the tooth

belt(6552mm)in

stead of

5130mm

Pitch bearing

changes to

0,for there are

about 11 bolts

near the pitch

motor bracket

we cant put the spanner on

these bolts

Change the

2#,3# blade to

90 and the 1#

blade to -90

Lock the

2#,3#blade,and

replace their

tooth belts to

5130mm

Install rain

blocking ring;

install front end

cover of dome

hoisting of

rotor(2 blades

90,1 blade -

90 )

Disassembly

lifting tools

1# blade:change to 90,lock the

blade,and exchange the tooth belt to

5130mm,then unlock all the blades

Unlock

the

blade

block

Check the belt

frequency

34

Pic34 Diagrammatic Drawing of rotor installation Process of Rotor

8.2 Ground assembly of blade

8.2.1 18 19 20

Preparationsstandard component refer to table18,lifting spreader refer to table19,tools

list refer to table20

18

Table18 Standard Parts Needed in Assembling Blade

No.

name

specification

quantity

Remark

1 Stud bolt M36625-10.9 276pcs

For 3 blades 2 Hex nut M36-10(GB/T 6170-2000) 276pcs

3 Washer 36-300HV (GB/T 97.1-2002) 276pcs

19

Table19 Lifting tools Needed in Assembling Blade

No.

name

specification

quantity

Remark

1

Round sling 18t10m 1pcs For 1# blade

2

Protector of

edge of the

blade

4pcs

3

Protector of

blade tip

3pcs

4

Guide rope

Guide rope(50m)

Short guide rope(100m)

Long guide rope(300m)

2 rolls

2 rolls

2 rolls

5

Hoisting

beam of blade

15T*10m 1pcs

6

eye & eye

webbing sling

8t10m 2pcs

7

Bow shackle G209-S-BW12t-1 1/4'' 5pcs

8

Rotating

ring

VLBG 8t M36 2pcs

20

Table20 tools Needed in Assembling Blade

No.

name

specification

quantity

Remark

1

spanner 55mm 2pcs

2

Adjustable

spanner

45055mm 2pcs

3

hairbrush 2 pcs

4

socket 55mm (long) 1 pcs

5

Hydraulic

wrench

4514N.m

Maximum value 4514Nm 1set

6

sleeper p.s.

7

Solid

lubrication

grease

MOLYKOTE G-Rapid Plus p.s.

8

Washing

liquid

p.s.

9

Lashing belt 3pcs

10 Manual chain

block 5t3m 2pcs

8.2.2 Blade assembly (or named fitting up)

8.2.2.1 Preparation hub

1 90

Determine the area for assembling blade and hub according to site conditions, then

place 90 hub support of rotor to corresponding position with crane and the ground for

placing bracket is required to be compacted and smooth.

1#

Note:for easy to install the slip ring support,the 1# blade must be use as the

trail blade,so when fixing the hub on the assembly support,pay attention to this

point.

1#1#

How to recognise which pitch box is 1#?As the pic below shown,there is a cable

bridge(in red block) on the left side of the cabinet,so its 1# pitch box,and the

blade is 1# blade.

2904M30100-8.8

300N.m

3435

Place the pitch system of hub and transportation tools onto 90 hub support of rotor

with crane and connect them firmly with four bolts M30100-8.8, with the tightening torque

value of 300N.M. Pitch system and bracket can be lifted off the ground by crane and the

orientation of pitch bearing can be adjusted by rotating the hub, thus preventing the blade

from interfering with other objects during fitting up. (refer to Pic34,35).

3

Disassemble lifting tools in pitch system of hub.

4-90

000

Operation pitch system of hub. Change the position of pitch bearing near to -90

(There is a red line scale 0on the pitch bearing flange. The 0 red line is on the horizontal

direction. We need to pitch to change the red 0line near to support of pitch motor.)

a)

Supporting area of hub is required to be solid and smooth.

b)

According to position and yard conditions, adjust the orientation of blade

installation opening of hub dome when the pitch system of hub is lifted off

ground, which will be convenient for assembly of blade and prevent

interference with other objects during assembling blade, meanwhile, make

the orientation of one blade opening fit main wind direction to the greatest

extent and ensure that no barrier is in blade assembly area.

c)

Pay attention to the protection of components when assembling and

disassembling them, avoiding knocking against interior components in pitch

system of hub.

34 90 35

Pic 34 90hub assembly support Pic 35 hub position

8.2.2.2 Blade preparation

1)

First, check whether the thunder record card and variable pitch limit stop are

installed; if not, they should be installed before the fitting up of blade.

2) 36

Install the sensor block.refer to pic36.

3) 280mm1mm

37

38

Screw stud bolt into blade flange which reveals a length of 280mm1mm. The stud

is required to be screwed into manually when it is implanted into blade, strictly

forbidding clamping stud head by motor-driven and hydraulic wrench or pipe

wrench. (refer to Pic37,38)

(MOLYKOTE G-Rapid Plus

Note: the thread of flange part which is screwed into blade is not coated with

solid lubricating grease (MOLYKOTE G-Rapid Plus).

4) 39

Paint the stud bolt with solid lubricating grease (refer to Pic39) and put the required

bolts, washers and nuts near hub for use.

5) 2#3# 300m

1# 100m

Sleeve in the protective belt for rip of blade from rip of blade and tie two guidance

rope.(1#blade:100m;2# and 3#blade:300m).

36 37

Pic36 install the sensor block Pic37 Screwing into Stud Bolt

38 39

Pic38 Measuring the Extending Length of Stud Pic39 Painting Solid Lubricating Grease

8.2.2.3 Blade fitting up

1) 8T*10m

Hoist with 2 cranes, which use two 8T*10m eye&eye slings at lifting position of

blade,direct the crane and maintain lifting tonnage of crane just when the lifting

power can lift the blade.unloading the blade on the ground,then use the beam

to lift the blade to disassemble transport holder of blade, tie a guiding rope to

root parts of blade to coordinate with guiding rope at the rip of blade and

allocate specially-assigned person to pull guiding rope to control the direction of

blade. Direct the stable hoisting of crane to reach pitch flange face of hub.

Note: decide which blade should be connect to the hub based on site

condition,keep the blade same direction with the wind,prevent the blade

from the more stress.

2) 00

40 41

Make the 0 calibration tail at the top of blade align at 0 calibration tail of pitch

bearing by adjusting the rotation of pitch bearing manually. Adjust the crane and

control the direction of blade at the same time to make connecting bolt of blade

pass through flange hole of pitch bearing, thus realizing butt joint. Distinguish

direction when installing spacer and nut, with the flat side facing pitch

bearing.(refer to Pic40,41)

40 41

Pic40 blade fitting up Pic41 align mark

5130mm,

-90 6544mm

Note: Before the pitch operation, the factory hub with a configuration such as a short

tooth belt (tooth belt with a length of only 5130mm, It can not make the blade pitch

to -90 position) you need to replace the tooth belt (tooth belt length about 6544mm).

Long tooth belt replacement when the short tooth belt removed, the tooth belt

tensioners mounted on the long trip on the pitch plate position. Install long tooth belt

and tensioners refer to 8.3.2. Restore the factory configuration toothed belt after the

blade fitting up operations is completed.

3) -90

Remove the blade lock block,pitch to -90position.

4)

50%75%100%

Use hydraulic wrench (lengthened sleeve) to adjust the torque of hydraulic wrench

and fasten flange bolt at the diagonal. Hit the bolt torque by three times with the value

being 50%, 75% and 100% of the required torque value respectively.

-90 11

0

Attention: when torque the bolts near the -90, there are about 11 bolts near the

pitch motor bracket we cant put the spanner on these bolts. We can

pre-tighten them by open spanner,then torque the bolts by pitch the blade

to 0 degree later.

5)

42 2t

Use sleeper to support the fitted-up blade, using soft materials between blade

and vertical bracing to protect the blade.Or use a crane to lift the blade,maintain

2T.refer to Pic42.

6)

Follow the above steps to fit up the second and third blades.

7)

, 43

If the rotor is not hoisted right after being fit up and needs to be put on site,

reliable support must be provided for blade to ensure that the rotor will not be

damaged during placement.(refer to Pic43)

42 43

Pic42 blade support Pic43 the rotor position

8) 90 44 45

Before lifting, change the 2#,3# blades to the position of 90. Lock the locking device

of blade and perform 90 hoisting.refer to Pic44,45.

44 -90 45 90

Pic44 blade -90fitting up Pic45 rotor 90 lock state

Considerations:

Clear up the blade flange and pitch bearing flange and keep the hub inside clean

when operating in it; protect anticorrosive coating with leather or rubber to avoid

damage when hitting moment.

8.3 Assembly installation of blade collar

8.3.1 preparation work

21 22

Table 21

Table21 assembly components and parts

No.

name

specification

quantity

remark

1

blade collar

assembly

3 set

2

Core rivet 18pcs

22

No.

name

specification

quantity

remark

1 lashing belt TMLS058m 3set

2 glue gun

structural adhesive 1pcs

3 hand riveter 1pcs

4 sealant gun

sealant 1pcs

5 angle grinder 1pcs

6 drill M5 1pcs

7 mark pen 1pcs

8 structural

adhesive Plexus MA310 4group

9 sealant SM7108 or MS939 3bottle

10 cutting disk 2disk

8.3.2 Steps forinstallation

1)

Cut open the blade collar, and chamfer and polish the edges with polishing

machine to prevent abrading sling when hoisting.

2

46

Marking-off: clean blade root and bonding face of blade sealing assembly, keep

the bonding face clean and install blade sealing assembly at the blade root,

move blade sealing assembly to make it be close to hairbrush, and then mark on

the blade along the outer edge of blade sealing assembly with marking

pen.(refer to Pic46)

3) Plexus MA310

Install Plexus structural adhesive MA310 into glue gun and install mixing nozzle

according to instructions. The glue solution outgoing first cannot be used; glue

on blade formally till the color of outgoing glue is uniform.

4) 25mm

8mm10mm 47

Gluing: at the position 25mm away from the marking line on blade (middle

position of bonding width), glue continuously to form a closed ring, with the

diameter of adhesive tape being around 8mm~10mm.refer to Pic47.

46 47

Pic46 marking-off Pic47 gluing

1) ()

48 49

1

Pull open blade collar assembly and move it to installation position (above

gluing), cling to hairbrush and press it down tightly; fix and clamp blade collar

assembly with tightener to solidify the glue.Fill any gaps with structural

adhesive.remove the lashing belt after completing the collar installation.

Note:the lashing belt cant be removed in less than 1 hour.

48 49

Pic48 fix the collar with lashing belt Pic49 gluing

6)

50 51

Paint sealant between blade collar assembly and blade (marking-off part); use

fingers stained with cleanser essence water to sleek and press tightly the

sealant.(refer to Pic50 51)

50 51

Pic50 paint sealant Pic51 press tightly the sealant

7 6(525)

52

Connect junction plate at the opening of blade collar assembly with six rebites (525),

with the edges and rivets painted with sealant.refer to Pic52.

52

Pic52 Installing Junction Plate at the Opening of Rain Blocking Rain

8.3.3 technical requirements

a)

The gaps between the collar and the blade should be full of blue.

b) ,

This product belongs to flammable items, please keep it away from flame and spark.

a

Do not tread the sealing assembly of blade collar when painting sealant,

to prevent misplacement and moving of blade collar when bonding glue is not

solidified.

b

When using the drill and angle grinder,avoiding damage the surfae of the

blade or the hub.

c 1518min

The installation should be completed in 15-18min after gluing.

8.4 spinner cap installation

8.4.1 Preparation

23

Table23 installation components and parts

No.

name

specification

quantity

remark

1

Spinner cap 1pcs

2

bolt M10100GB/T 5783-2000 A4-70 15pcs

3

washer 10GB/T 96-2002 A140 30pcs

4

Self-lock

nut

M10 15pcs

24

Table24 installation tools list

No.

Name

specification

quantity

remark

1

sealant gun for sealant 1pcs

2

Open spanner 17mm 2pcs

3

Adjustable

spanner

20024mm 2ps

4 U

U type shacle 1t 2ps

5

Sling belt 1t-3m 1pcs

6

ladder 4m 1pcs

7

sealant SM7108 or MS939 2bottle

8.4.2

1 1t-3m

15 M10

100 40N.m SM7108

MS939 53

Hoist spinner cap with a 1t-3m sling and install it onto the dome; connect nose

cone and the dome with fifteen bolts M10100 with the fastening torque value of

40N.m, then paint the circumference and bolt head with SM7108 or Loctite MS939

sealant.

53

Pic install the spinner cap

a)

b)

Considerations:

a) Do not tread the sealing assembly of blade collar when painting sealant, to prevent

misplacement and moving of blade collar when bonding glue is not solidified. Pay

attention to personal safety as well.

b) Use properly in accordance with the instructions on bottle of locking glue, do not

waste.

8.5 Rotor lifting

8.5.1 Preparation

25

Table25 Standard Parts for Rotor Installation

No. Name Specification Quantity Remark

1 Bolt M36240-10.9 (GB/T 5782-2000) 54

2 Washer 36-300HV (GB/T 1230-2006) 54

26

Table26 Spreader for Rotor Installation



1

Protective

belt 1 for rip of

blade

JF2500.85.027 1

2

Protective

belt 2 for rip of

blade

JF2500.85.026 2

3 Hawser cable 20300m 3

4 round sling 8t-10m 1

5

Protective

clothing at tailing

edge of blade

JF2500.85.020 1

6 Flat sling W04-30t20m (width: 250mm) 2

27

Table27 install tools list


1

Chain block 5t*3m 2pcs

2

Hairbrush 2pcs

3

Electric wrench 800N.m 1set

4

Hydraulic wrench

4514N.m

1set

5 55mm 1pcs

socket

6

Solid lubrication

grease

MOLYKOTE G-Rapid Plus p.s.

8.5.2 Steps for- 90 hoisting of rotor

-90()

Method One: - 90 hoisting of rotor(recommend)

1 23

-90290

According to the location selected two blades installed crane main spreader.

According to the location selected two blades installed crane main spreader, The

blade which Install auxiliary spreader to maintain -90 pitch position, The other

two blades pitch to 90 pitch position, with the pitch locking pin lock.

2 21

20300m54

Install a short protective belt on the rip of blade of the two blades respectively and

fix two guiding ropes of 20 and 300m by protective belt of rip of blade

respectively.refer to Pic54

54

Pic54 Install the protective belt

55 -90

Pic55 auxiliary spreader installation

3 318t*10m

50

55

Install the protective clothing at tailing edge of blade on the third blade and one

sling of 18t-10m on the third blade. Play buckle at end of the sling which in the top

of the protective clothing at tailing edge of blade, the other end hanging on the

crane's hook. Tie a 50m rope at the part of sling buckle.refer to Pic55

4 2W04-3030t-20m)250mm

,500mm

56

Install flat sling W04-30 (30t*20m) at the root of the two blades with the width of

250mm. Notice that the sling should bear at least a space of 500mm from blade

collar for fear of abrading the sling when hoisting. The sling should keep dry in

winter.refer to Pic56.

56

Pic56 install the flat sling

5

80

5758

Cranes are hoisted simultaneously; the main crane goes up slowly while auxiliary

crane cooperates to lean the rotor from level slowly and ensure that the rip of

blade do not contact the ground. After the vertically downward rip of blade is off

ground completely and when the vertically downward blade forms an angle of

about 80, tension the guiding rope of vertically downward blade manually, then

loose the sling of auxiliary crane and unhook the auxiliary crane; hoist the rotor to

the height of hub by main crane.

57 58

Pic57 turn over of the rotor Pic58 rotor fitting up

6

(MOLYKOTE G-Rapid Plus

Make the rotor approach generator slowly, and pull haulage rope to cooperate

with the crane to make flange face of pitch system of hub parallel to cooperating

flange face of generator; paint the bolt with solid lubricating grease (MOLYKOTE

G-Rapid Plus) and screw it in.After finishing the butt joint of rotor, fix the

connecting bolt used in installation pedestal of gap bridge onto flange face of

generator rotor which is just against 1# pitch cabinet when installing connecting

bolt, with the elbow pointing at generator.

7

50%75%100%B1

Screw all bolts into bolt holes with open spanner firstly and then fasten the

moment with hydraulic torque wrench by three times with the value of 50%, 75%,

100% of the required torque value respectively.

Table for Tighten Force of Bolt

No. Location

Quantit

y(inspected

number)

Type and strength grade

of bolt

Wre

nch

(m

m)

Torq

ue value

(N.m

)

Rotor

1 Hub-rotation shaft 54 (6) GB/T 5782-2000

M36240-10.9 55

240

0*

8

After the bolt moment is fastened according to requirements, the crane can be

unhooked and spreaders can be disassembled.

9

Q/JF 2FW2500.4-20102.5MW

When disassembling protective belt for rip of blade, unlock the locking device of

generator rotor firstly and then rotate the blade manually. Refer to document Q/JF

2FW2500.4-2010 Work Standards for Rotor Locking of Goldwind 2.5MW Series

Wind Turbine Generator System for specific steps of unlocking locking device of

generator rotor.

1

2

3

4

5

6

Considerations:

1) The surface of sling should be kept clean and tidy to prevent damage to blade

surface caused by particles on sling surface; strictly forbid twining, folding,

twisting and knotting wide sling. In winter, wide sling should be kept dry to prevent

freezing and slipping; paint with rosin to increase friction if it is slippy.

2) When installing rotor, guiding bar can be chosen to install as required;

the process of hoisting rotor should maintain the hoisting speed of crane constant

and slow, preventing rotor rocking.

3) The bolt can be threaded in manually only after hub flange and rotor flange

are fit tightly and bolt holes are aligned as well. Besides, the thread part of bolt

is required to be painted with solid lubricating grease which is also used between

bolt root and spacer.

4) Operators must wear full body safety clothing and safety rope, safety rope

and reliable fixed.

5) Remove auxiliary spreader, note the speed and demolition demolition, so as

not to damage the leaves.

6) Parts in contact with the spreader of blades to make full protection to

avoid damage to blades in the lifting process.

Operational requirement: during rotor installation, body-safety-belt must be

worn while the safety rope should be fixed at reliable position of nacelle.

Documents

Rotor Assembly and Lift