email from Bob Anders regarding Vestas Letter submitted by Liz Argo
Contents
1. Lock screws Lock screws for for sideways longitudinally directions direction p O xm Pee i t tz d or REED Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item no 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 29 of 32 e Lifting transformer Max work load is 12000 kg This operation is only to be done by authorized personnel Transformer lowering position Transformer lifting position e Lifting generator Max Work load is 12000 kg This operation is only to be done by authorized personnel p O xm Pee i t tz d or REED Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item no 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 30 of 32 Generator lowering2. fa 69 Internal crane for lifting components in the hub This operation is only to be done by authorized personnel rss 2 cr 227 Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item no 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 31 of 32 Hub components position mn m Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 32 of 32 Internal crane for lifting gear stages Max work load is 12000 kg This operation is only to be done by authorized personnel Tower centerline Gear stages Service lifting position QO QO MO n
3. 21 19 Operating the Internal Crane 25 n mat A 27 27 RR Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item no 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 3 of 32 1 Introduction A turbine connected to the grid implies certain elements of danger if it is handled without exercising proper caution For safety reasons at least two persons have to be present during a work procedure The work must be properly carried out in accordance with this manual and other related manuals This implies among other things that personnel must be instructed in and familiar with relevant parts of this manual Furthermore personnel must be familiar with the contents of the Substances and Materials regulations Caution must especially be exerted in situations where measurement and work is done in junction boxes that can be connected to power Consequently the following safety regulations must be observed 2 Stay and Traffic by the Turbine Do not stay within a radius of 400m 1300ft from the turbine unless it is necessary If you have to inspect an operating turbine from the ground do not stay under the rotor plane but observe the rotor from the front Make sure that children do
4. mat A 27 27 RR Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Vestas November 15 2010 RE Vestas Safety Manual Correction and Clarification of Language Certain older versions of the General Precautions chapter of Vestas Safety Regulations manuals including the manual entitled Safety Regulations for Operators and Technicians V90 3 0 MW V100 2 75 MW warn turbine operators and technicians to stay outside certain radius from a wind turbine unless necessary This language however was meant to apply only in case of abnormal operation such as fire The warning was never intended to apply to turbines operating normally Accordingly the specific warning was misplaced in the manual s General Precautions chapter Vestas has no documentation studies or analysis proscribing a specified safety zone around its wind turbines in normal operation As a result Vestas has recently undertaken efforts to remove the warning from the General Precautions chapter in all of its manuals However Vestas does continue to specify a radius that should be evacuated in case of abnormal operating conditions such as fire Vestas Safety Regulations manuals should not be cited as Support for any specific safety zone or setback for wind turbines in normal operation Wind turbines are sophisticated pieces of equipment and Vestas takes great care to ensure the safety of its equipment
5. Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Class Approved T09 964106 Ver 00 Item 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 1 of 32 Safety Regulations for Operators and Technicians V90 3MW V 100 2 75MW History of this Document Rev no Date Description of change 0 2005 06 23 First edition 1 2005 09 19 947554 replaced by 959055 Chap 9 However the capacitors in the converter and AGO2 section might be energized inserted Chapter 10 Converter and AGO2 Sections Figure numbers updated 2 2006 01 17 Reference to 947554 added again page 12 3 2006 03 03 Chapter 18 1 1 New wind speed limit 23m s 4 2006 05 08 Language revision Inserted section 14 2 Access to roof text and picture 5 2006 09 11 Reference to V100 added Section 19 updated with new pictures and new text rss 2 cr 227 Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item no 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 2 of 32 15 3 2 wctayadnd Trafic DY Ne 2 pE 3 Addres
6. its employees and their communities As with any sophisticated electric generation equipment abnormal operating conditions can occur Nevertheless Vestas wind turbines in normal operation are safe Vestas employs thousands of service and maintenance technicians who work safely within close proximity to wind turbines every day Vestas Americas 1881 SW Naito Parkway Portland OR 97201 USA Tel 1 503 327 2000 Fax 1 503 327 2001 vestas americas vestas com www vestas com Company Reg Name Vestas American Wind Technology Inc
7. F60 in the nacelle When working on the electrical part of the controller the controller must be disconnected by the circuit breaker marked Q7 Q26 and Q27 in the board arrangement and locked by means of a padlock Only authorised personnel must have access to the key keys When working on the terminal of the generator inspecting the generator cables or the controlling as such the generator must be disconnected by the circuit breaker Q8 and Q23 in the board arrangement and locked by means of a padlock Only authorised personnel must have access to the key keys When working on the yaw system the yaw motors must be disconnected in the control panel at the contactors F35 1 and F35 2 Always make sure that there is nobody below the turbine while you are working in the nacelle Even a small screw is highly dangerous when falling from a height of 60m or more Unauthorised persons must under no circumstances move the covering plates which cover rotating or electrical parts especially the high voltage installation Be cautious that safety straps are not caught on any rotating shafts during stay in the nacelle while the turbine is in operation n mat A 27 27 RR Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 11
8. When disconnected only the control system in the turbine is supplied from the UPS for approx 6 hours Usually the local power station must take part when the turbine is connected to the grid 5 2 Lift Optional If a lift is installed it has several emergency stop buttons Note These buttons only stop the lift emergency stop buttons for turbine do not apply to the lift 5 3 Internal Crane The crane is equipped with an emergency stop button This only applies to the crane and otherwise the emergency stop buttons in the turbine do not apply to the crane 6 Practical Advice at Inspection When inspecting the machinery always look very closely for oil spills and loose bolts Dirt must be wiped off otherwise it can be difficult to determine whether there is a significant leak Loose bolts in the structure mean danger They must be tightened immediately If it is a matter of several bolts or repetitions please contact Vestas Wind Systems A S service department f Influence by Lubricants The lubricants used in the turbine can be aggressive Lubricants must not get in contact with skin or clothes At inspection of a gearbox if removing a cap while the oil is still hot be careful not to breathe in the hot oil vapours 8 High Voltage Installations As a basic rule it is not allowed to dismount cover or open locked doors to the high voltage installations An operator service technician is only allowed to move around behind th
9. important to know where it came from and that it carries the same legal authority as the owners safety manual What 1s the Proper Perimeter Under Normal Circumstances to Ensure Safety Against Abnormal Operation We also firmly believe that even in the event that this correction proves to be authentic that the Commission should consider carefully the extent to which it 1s willing tol sanction the exposure of property buildings businesses employees residents roads recreational users and other people and structures to risk from abnormal operation of a wind turbine whose individual blades weigh more than 14 000 Ibs If the Joint Committee and the Commission do decide to allow industrial wind turbines to be constructed in such a manner that buildings residents innocent bystanders and motorists may all be subjected to this kind of risk within the stay clear area even under abnormal operation we believe that they should give some serious thought to whether an operator would realistically be capable of sounding the alarm and evacuating a vast area a circular area with a diameter of approximately half a mile on short notice It goes without saying that lightning strikes fires mechanical malfunctions blade throw and the like are not scheduled events Furthermore it is worth noting that the wind turbines are usually remotely managed by technicians off site to a large degree What sort of procedures should a wind turbine
10. when climbing lattice towers when it is wet or icy Moreover special cautions must be taken when climbing on the outside of the lattice tower since the back of the blade is close to the lattice tower when the blade is turning around its longitudinal axis This happens if anyone pushes PAUSE or EMERGENCY STOP and also at an unintended EMERGENCY STOP n mat A 27 27 RR Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 12 of 32 14 Safety Equipment See Figure 2 Safety Equipment 1 Safety helmet 2 H belt delivered by Vestas 3 Lanyards one line with a fall damper device one line with a shortening device delivered by Vestas 4 Fall protection device delivered by Vestas J Rubber soled footwear properly tightened Figure 2 Safety Equipment When climbing the tower fasten the fall protection device directly to the H belt s D ring Only one person is allowed on each ladder section at a time If a service lift is installed in the turbine bring along the safety equipment in it rss ren Me S loris Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and T
11. www vestas com Item no 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 21 of 32 Hotor lock system After use reset handle in lock position lock M d Figure 4 Handle positions 18 2 Operating the Manual Rotor Locking System with Bolts The manual rotor locking system is used in case of servicing e Gearbox repairs e Gearbox replacements e Transport of nacelle e Turbine standstill for long period of time gt 48 hours The manual rotor lock must be used as an alternative to the hydraulic rotor lock The following components must be used when operating the manual rotor lock Item number Description Quantity 950461 Centering mandrels 3 782137 M42 special nut 16 782138 Washer 16 782139 M42 special bolt 16 782142 Shim for rotor lock 16 782141 Hex soc h scr M16x60 yellow 16x8 128 Prior to mounting the manual rotor lock e Set the turbine in PAUSE mode and activate the emergency stop button to activate the disc brake rss 2 cr 227 Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item no 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 22 of 32 18 2 1 Mounting the manual rotor lock 1 Turn the hub until the highest poin
12. 00 2 75MW Page 10 of 32 12 Overspeed Guard If the turbine rotation exceeds its limit the overspeed guard VOG is activated and the turbine will go into EMERGENCY STOP mode The state of failure cannot be reset until the VOG has been de energized 13 Inspection of the Turbine At inspection of the turbine the following procedure must be followed When inspecting the turbine there must always be at least two persons present Full feathering of the blades is done by pressing lt PAUSE gt When the rotor comes to a standstill or rotates slowly activate the lt Emergency stop button gt to stop the turbine It is now possible to climb the turbine but remember as a minimum to wear e Safety footwear suitable for climbing towers e H belt with fall protection device fastened directly to the H belts D ring on your chest e Safety helmet Always make sure that there is nobody above you in the turbine when you start the ascent If you bring tools lubricants etc with you keep these in a rucksack or a bag which is attached to the safety belt During the ascent the fall protection and the supporting strap MUST be mounted Do not mount the fall protection hook on the aluminium ladder rungs or on the fittings for the ladder as they might brake in case of falling Instead the swivel eye plate yellow must be used Close the trap doors of the landings when passing them Please notice the location of the emergency stop buttons and Trip
13. William Cundiff From Robert Anders lhanders3 aol com Sent Wednesday January 26 2011 5 31 AM To wCundiff DouglasMa org Subject Fwd Unsigned Letter on Vestas Letterhead Submitted by Ms Argo and Mr Jane Attachments Vestas Letter submitted by Liz Argo pdf AT TO00007 htm vestasv90 100_safetymanual pdf ATT00010 htm Begin forwarded message From Eric Bibler lt ebibler gmail com gt Date January 26 2011 12 16 06 AM EST To Kristy Senatori lt ksenatori capecodcommission org gt Martha Hevenor lt mhevenor capecodcommission org gt Page Czepiga lt pczepiga capecodcommission org gt Paul Niedzwiecki lt pniedzwiecki capecodcommission org gt Ryan Christenberry lt rchristenberry capecodcommission org gt Sarah Korjeff lt skorjeff capecodcommission org gt Sharon Rooney lt srooney capecodcommission org gt Subject Unsigned Letter on Vestas Letterhead Submitted by Ms Argo Return Path lt randers caf_ lhanders3 aol com blueberryhillassociation com gt Received from mtain dk07 r1000 mx aol com mtain dk07 r1000 mx aol com 172 29 180 11 by air ma08 mail aol com v129 4 with ESMTP id MAILINMA084 b5334d3fae543e4 Wed 26 Jan 2011 00 17 08 0500 Received from mail vw0 f51 google com mail vw0 f51 google com 209 85 212 51 by mtain dk07 r1000 mx aol com Internet Inbound with ESMTP id 66367380000FF for lt lhanders3 aol com gt Wed 26 Jan 2011 00 16 59 0500 EST Received by vws20 with SMTP id 20s0264696vws 38
14. ar Ms Christenberry Thank you for providing me with a copy of the letter that was submitted by Ms Liz Argo a paid spokesperson for the Cape and Vineyard Electric Cooperative CVEC during the meeting of the Cape Cod Commission on January 20th 2011 I ve attached a copy of the letter here for reference According to Ms Argo this is a letter from Vestas which corrects and clarifies certain errors in the Vestas Safety manual for the Vestas Model V90 Wind Turbine which CVEC The letter is dated November 15 2010 and it bears the heading RE Vestas Safety Manual Correction and Clarification of Language To be frank we are concerned about the authenticity and the significance of this letter for reasons that are enumerated below 1 To the best of my recollection Ms Argo said in her remarks that she would be submitting a letter from Vestas stating that the Safety Manual for the Vestas V90 contained an error but she did not say how this letter came into her possession Where did it come from and how did Ms Argo obtain it 2 The letter is not addressed to anyone 3 The letter 1s not signed by anyone at Vestas nor is there any indication what authority if any that it carries 4 The letter states that in certain older versions of the Vestas V90 manual the specific precaution that workers stay outside a specific radius was misplaced in the General Precautions section and was meant to apply only in case of abnormal operat
15. e covering when the high voltage is disconnected locked and visibly earthed The work must be carried out and approved by authorised personnel only power station or selected coupling leader One of these persons must give permission to access the HV installation Work done on high voltage installations must be carried out in accordance with national regulations and related Vestas Wind Systems A S manuals rss 2 cr 227 Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 9 of 32 9 Drop Out A grid drop out causes an EMERGENCY STOP The blades pitch out of the wind full feathering the yaw system the hydraulic pump and the nacelle ventilator stop Consequently all moving parts will be brought to a standstill except for emergency lubrication system for the gearbox The power supply for the light and the nacelle hub and ground controllers is partly off However the capacitors in the converter and AGO2 section might be energized 10 Converter and AGO2 Sections WARNING If working on the converter section or AGO2 section note that the capacitors inside can be charged to 800 V and those in the filters can be charged to 690 V The capacitors are discharged to below 50 V in 5 minutes after disconnection from the grid S
16. echnicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 13 of 32 14 1 ResQ Emergency Rescue Equipment In case the escape route via the tower should be cut off by fire or other unforeseen events a rescue and descent device is located in the nacelle behind the main controller section in an aluminium box Please see user manual for rescue equipment item number 959055 VCS 50 Hz turbines or 947554 VCRS 60 Hz turbines Picture 7 Fixing Point for ResQ descent device Fixing point for ResQ descent device Open the left service hatch Lift the arm above the opening Fasten the ResQ descent device to the arm Ready for lowering SWL 2000kg Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 14 of 32 14 2 Access to Roof Place the ladder on machine foundation at the rear of the nacelle to gain access to nacelle roof as shown in the picture below Picture 8 Ladder to roof p O xm Pee i t tz d or REED Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 15 of 32 15 Hoo
17. esaseeeesaseseeeasess 4 Please see Mechanical Drawings amp Parts List Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com 9 964106 Ver 00 Approved Class II Exported from DMS 28 06 2007 by JANOM Item no 964106 R00 Date 2007 06 29 Issued by Technology Mechanical Operating and Maintenance Manual Class 1 Type MAN Preface Page 3 of 4 1 Preface This manual applies to the wind turbine V90 3 0MW VCRS 60 Hz Mk 7 It is the turbine owner s responsibility that only qualified persons operate the turbine Do not operate the turbine before as a minimum having studied the following carefully v 960314 Safety Regulations for Operators and Technicians 950173 User Guide Do not hesitate to contact your plant manager or Vestas Service Department if you need more detailed explanations Vestas Wind Systems A S Alsvej 21 DK 8900 Randers Telephone 45 9730 0000 2 Updating of the Manual The manual will continuously be brought up to date Corrections to each specific chapter are listed for the past year under the heading of History of this Document 3 The Header The latest revision date of a specific chapter is stated in the header of the chapter Class ll indicates that the document is only handed out according to agreement with Vestas Technology Department Each specific chapter has its own item number followed by a revision number Rx First editions have revision numbe
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19. ion such as fire and was not meant to apply to normal operations The manual also states in the preamble however in a Section entitled Updating of the Manual that The manual will continuously be brought up to date Corrections to each specific chapter are listed for the past year under the heading of History of this Document 2 Why not simply produce an updated version of the safety manual Or at minimum the relevant pages Why does the letter not say that the manual has been corrected and the new language reads as follows 5 The letter asserts that the wind turbines are safe under normal operation but affirms that the prescribed safety perimeter applicable to the particular model still obtains in case of abnormal operation such as fire What does it mean from a legal standpoint for a manufacturer to say that no safety perimeter is required if the machine functions normally but that the prescribed perimeter should be enforced if the machine malfunctions or catches fire Can abnormal operations be predicted Isn t that like saying that one needn t wear a seat belt in a car as long as one doesn t have an accident and hit anything Under the circumstances we would respectfully ask the Joint Planning Committee and the Commission not to accept this letter at face value until it s authenticity can be verified by the Vestas legal department or until a revised version of the Safety Manual can be obtained We believe that it 15
20. k www vestas com Item 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 27 of 32 M Figure 10 The Crane Winch placed on foundation Figure 11 The crane in parked position General crane functions The internal nacelle overhead traverse trolley support 4 lifting functions each with specific manual e Normal service operation Max Work load is 800 kg Prior to lowering the trolley must be locked in sideways direction by tightening lock screws extra turn after contact and in longitudinally direction locked by keeping the steel wire tensioned and tightening lock screw for longitudinally direction by tightening lock screws extra turn after contact Warning Visual inspect p O xm Pee i t tz d or REED Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 28 of 32 e he bridge and trolley for corrosion wear defect bolts and connections before using the crane e Winch for oil grease leaks and corrosion The crane must not be used before defects are repaired Service crane work range Restricted area Crane movements
21. king Points and Safety Chains A number of hooking points is installed at different locations in the nacelle A hooking point is shown in Picture 9 Hooking point Figure 3 Hooking points in the nacelle and position of safety chains zs DDR Ue To SA 90 ey YP AA i TT Fu x de P Picture 9 Hooking point rss 2 cr 227 Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 16 of 32 Picture 10 Safety chains must be mounted when the bottom hatch is open Figure 3 Picture 11 Hooking points on the roof ren nme Mee ars gee Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item no 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 17 of 32 16 Precautions in Case of Fire At any type of fire in or near a turbine the power to the turbine must always be disconnected at the main high voltage circuit breaker To disconnect supply switch off by pushing the red button marked TRIP F60 on the nacelle controller in the nacelle In the tower bottom the power supply is switched off by pushing the red button situated on the breaker i
22. laxed d gmail com s gamma h domainkey signature mime version date message id subject from to content type bh nVT9 z5rHH9utLaySwOqlEPOSWwNZ4dQUqlYAGV4Kuo b E8nXT oryxczGwOCTRqdXOFPOXyOIDpjrFBMxwtMEPpJwsjVzdcrwplwAtl9ds7cBD DHlpcRFOdoQlBuHh55ljG YeGx nnkqGKliaXehdeterFCj4KB ml1mHhOuS3iPyhq3rX 87D5CYh5LOdHptH1k2vp vC NsLai 1uS39law Domainkey Signature a rsa sha1 c nofws d gmail com s gamma h mime version date message id subject from to content type b soRygp8SUHRBTLJyGoPDNmFDseOwNHbtxuYT69FxIZK8S3nSd7KxmqNJrgETnQzOnn XfqzWvLulAx47Hp6OsO8KWNrmzk z5xO2P8bEA Ealte qaFKVHZ1F 4OxzOLpTp4IB7 oj7DmwpbNibdD xWazb5YMGijvscge9h805XQE Mime Version 1 0 Message Id AANLkTim8H6 tnGnGH2sjmtR7azuYfi3rGrBuOYx4uLM1 mail gmail com gt Content Type multipart mixed boundary 002354435d18c7d05e049ab8ee05 X Aol Global Disposition G X Aol Vss Info 5400 1158 67703 X Aol Vss Code clean X Aol Scoll Authentication mail antispam dkim d006 2 domain gmail com fail X Aol Sid 3039ac1db40b4d3fae4b5190 X Aol Ip 209 85 212 51 X Mailer Unknown No Version For Distribution to CCC planners members of the Joint Planning and Regulatory Committee Members of the Cape Cod Commission and New Generation Wind Bourne DRI Subcommittee Ms Ryan Christenberry Energy Planner Cape Cod Commission Ms Page Czepiga Regulatory Officer Cape Cod Commission Re Letter Submitted by Ms Argo Regarding Vestas Safety Manual January 25 2011 De
23. mbly and adjustment of mechanical parts b tensioning c activation of shrink disc d internal inspection unless it is a visual inspection 3 Work on coupling and braking system if this involves a disassembly and adjustment of mechanical parts n mat A 27 27 RR Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 18 of 32 b tensioning inspection of coupling d lubrication 4 Work on generator if this involves a disassembly and adjustment of mechanical parts b tensioning c work on slip ring systems units 5 Work on yaw system In addition to rotor locking the turbine must be secured against unintentional yawing if this involves a disassembly of mechanical parts b yaw brakes cannot be activated 6 Work on electricity in the nacelle if this involves a that the turbine controller is switched off and work at rotating parts of the drive train has to be carried out Work on hydraulics for pitch as well as brake system if this involves a disassembly of mechanical parts b that the pumps are out of operation 8 Work on the turbine s exterior In addition to rotor locking the turbine must be secured against yawing if this involves a use of crane b use of front lift c use
24. n the high voltage section If it is impossible to get to the main circuit breaker contact the power station for a disconnection of the grid In case of a fire during an uncontrolled operation do under no circumstances approach the turbine Evacuate and rope off the turbine in a radius of minimum 400m 1300ft In case of a fire in a non operating turbine the fire can be put out by means of a powder extinguisher ALCAUTION Use of a CO2 extinguisher in a closed room can result in lack of oxygen 17 Directions for Use of Rotor Lock To avoid accidents and near accidents which can be prevented via mechanical locking of the rotor the following guidelines must be followed IN GENERAL Besides following the requirements listed in this document it is important also to use ones common sense and assess the specific situations When the wind speed exceeds the values of the mechanical design of the locking system it is not allowed to work in a turbine as listed below A technical solution must be prepared before starting work on a turbine that cannot be locked mechanically The work listed below must not be carried out before the turbine has been mechanically locked Mechanical rotor locking must be used in connection with jn Hub and blades a stay in hub and nose cone b stay on near the blade is not allowed unless both the rotor and the blade has been locked 2 Work on gearbox and gear oil system if this involves a disasse
25. not stay by or play nearby the turbine If necessary fence the foundation The access door to the turbine must be locked in order to prevent unauthorised persons from stopping or damaging the turbine due to mal operation of the controller 3 Address and Phone Number of the Turbine Note the address and the access road of the turbine in case an emergency situation should arise The address of the turbine can often be found in the service reports in the ring binders next to the ground controller Find the phone number of the local life saving service rss 2 cr 227 Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 4 of 32 4 Controller and Operating Panel Only authorised or instructed persons are allowed to open the doors of the controller cabinet l E f LJ f X i mmi T Sel E Picture 1 Before inspecting or working on the turbine the remote control MUST be deactivated Use the breaker key and set it in position local Remember to activate the remote control when the inspection or the work has been completed 9 Emergency Stop Buttons For safety reasons please note the location of the 4 emergency stop buttons The buttons are located Figure 1 Locatio
26. ns of emergency stop buttons and trip F60 in nacelle at Ground controller at the bottom of the turbine Gearbox pos 1 Yaw ring pos 2 Nose cone pos 3 only local stopping function Nacelle controller pos 4 Trip F60 pos 5 The emergency stop buttons are red with a yellow background An emergency stop is activated by pressing one of the red buttons When an emergency stop is activated the controller switches to EMERGENCY STOP mode meaning that no power will be supplied to the contactor solenoids the blades will pitch full feathering the brake will be applied and the turbine will stop The yaw system the hydraulic pump the gear oil pump and the nacelle ventilator will also stop Consequently all moving parts will be brought to a standstill However the power supply to the light the nacelle the hub and the ground controllers will still be on The stop button in pos 3 is not an emergency stop button but a local stopping function p oex rex lf es loris ee Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 5 of 32 Remember The hydraulic system is still under pressure Due to the accumulators up to 6 litres of hot oil will pour out if the hydraulic system is intervened Please n
27. of 32 Before entering the hub or working on rotating parts in the nacelle make sure that the rotor is locked and that the blades are fully feathered See section Operating the Rotor Locking System on how to activate the rotor locking system Before descent close the nacelle skylights and the service hatch Make sure that you have gathered all tools and remember that the red emergency stop buttons must be off If the blades are iced up it is highly dangerous to stay below or close to the rotor If the turbine is to be restarted with iced up blades the operator must be very careful and make sure that no persons are nearby because of the risk of falling pieces of ice Do not stay in the nacelle while the turbine is in operation unless if checking for gear and generator noise Any oil or grease spills must be cleaned up because of the risk of slipping Make sure that the covering and the locking of the high voltage installations are undamaged Make sure that the high voltage cable between the high voltage installations in the nacelle and the bottom are undamaged and do not have any visible mechanical damages such as having been squeezed cut by cable binders mechanical parts etc When working in the nacelle spinner or roof please pay attention to safety hooking points See figure 3 When working on the roof of the nacelle secure a safety line on the roof rail See Picture 11 Hooking points on the roof opecial caution must be taken
28. of other lifts or scaffold systems 9 Replacement of components if this involves a replacement of components sensors etc close to unshielded rotating parts of the drive train n mat A 27 27 RR Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 19 of 32 18 Operating the Rotor Locking System The rotor must not be locked unless it is necessary however always when servicing the hub and it must be unlocked as soon as possible after the service operation which caused the locking If the rotor has to be locked for more than 48 hours it must be bolted to the main foundation following the procedure description in section 18 2 18 1 1 Operating the hydraulic rotor locking system for normal service The rotor locking system must not be set or used at wind speeds exceeding 23 m s The rotor locking system must not be used while the rotor is rotating Pitching of blades is not allowed while the rotor is locked except at wind speeds below 15 m s In this case only one blade may be pitched at a time The rotor locking system is located at the upper right hand side of the main gear see Picture 12 Rotor locking system 1 Set the turbine to PAUSE mode and select test picture 11 7 Manual Pitch and Brake
29. operator have in place And how much margin for error should be tolerated in terms of the clear area These are all relevant questions in addition to the question of what the most recent Vestas Safety Manual actually says I would appreciate it if you would provide me with any additional information that you receive which serves to authenticate the source and its authority Sincerely Eric Bibler President Cc Bourne Planning Board Cc Brewster Planning Board Cc Assembly of Delegates APPENDIX OPERATION AND MAINTENANCE PLAN 630464 5 Class Il Item no 964106 R00 2007 06 29 Mechanical Operating and Maintenance Manual V90 3 0 MW VCRS 60 Hz Onshore Offshore Mk 7 LG EL Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com 9 964106 Ver 00 Approved Class Exported from DMS 28 06 2007 by JANOM Item no 964106 R00 Date 2007 06 29 Issued by Technology Mechanical Operating and Maintenance Manual Class 1 Type MAN History of this Document Page 2 of 4 History of this Document Rev no Date Description of changes oo X 2007 06 29 First edition Table of Contents 1 21 2 9 2 3 2 Updating of th MAING Al etn SX0 SX 3 3 3 4 lt ceeeececeenececeeneeeseeeeeesaeeeeesasaseeeesasaeeesaseeeesacaseeeesaseeeeseseeees
30. ote When the emergency stop buttons are activated the brake is activated Figure 1 Locations of emergency stop buttons and trip F60 in nacelle Picture 2 Yaw ring emergency stop button pos 2 Figure 1 ren nme Mee ars gee Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 6 of 32 Picture 3 Gearbox emergency stop button pos 1 Figure 1 f Picture Emergency stop button at nacelle controller pos 4 Figure 1 ren REED Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 7 of 32 Picture 5 Emergency stop button in hub pos 3 Figure 1 Picture 6 The trip F60 button pos 5 Figure 1 ren nme Mee ars gee Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item no 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 8 of 32 5 1 F60 F60 is situated on the nacelle controller pos 4 F60 disconnects the high voltage supply for the turbine
31. r RO Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com 9 964106 Ver 00 Approved Class Exported from DMS 28 06 2007 by JANOM Item no 964106 R00 Date 2007 06 29 Issued by Technology Mechanical Operating and Maintenance Manual Class 1 Type MAN Contents Page 4 of 4 4 Contents Title Safety Regulations for Operators and Technicians Chapter Manual Rotor Lock Rescue Equipment RED Pro Conversion Tables Blades Blade Bearing Pitch System Gearbox Brake System Composite Coupling Gear Oil Lubrication System Generator and Transformer Yaw Gear Yaw Bearing System Hydraulic System Wind Sensor and Anemometer Air Conditioning System 950263 958637 958639 962638 962649 960301 958658 963560 Tubular Tower l lt O Exported from DMS 28 06 2007 by Surface Treatment Lightning Current Transfer Unit 20 Rotating Contact ND end Generator Rotating Contact in D end Cooling System Rotating Transfer O71 O1 O1 O1 O1 O11 CE CO or NM Mechanical Drawings amp Parts List Supplier Drawings 20 21 22 23 24 25 Wemm Cher
32. s and Phone Number of the Turbine cccccccccccceccceeceseeeceeeeeeeeseeeeseeeseeseseeseeesseeesaees 3 4 Controller and Operating 4 5 Emergency DUMOMG TE 4 5 1 E RU 8 5 2 COON A m 8 5 3 Internal 8 6 Practical Advice pier gm 8 Influence by nns anser rna nns 8 8 High Voltage Installations E omm 8 Sra DOr OUT ats 9 10 Converterand 602 SECHONS tex UON oo 9 11 Turbine 9 12 Guard eerie E E eE E EEEE EOE EEr ra Er nnns 10 to TUDI MTM 10 l cem 12 14 1 ResQ Emergency Rescue 13 14 2 ACCESS TO ROOI RUD NIU 14 15 Hooking Points and Safety Chains 15 16 Precautions in Case Of Fire 17 17 Direcions TOF USE OF TSOLOF CROCO SUE bad 17 18 Operating the Rotor Locking 19 18 2 Operating the Manual Rotor Locking System with Bolts
33. so w Figure 5 rss mat A 27 cr 227 Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item no 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 24 of 32 18 2 2 Dismantling the manual rotor lock after service work Loosen all the M16 special bolts Loosen and remove all M42 special nuts Remove all the M42 special pin bolts Remove the centering mandrels or pull back the hydraulic rotor lock PU IS Centering mandrel 950461 a i 1 L sJ e t tee vo Figure 6 950084 R1 Bolt M42x200 782139 Shim 782142 Washer 782138 M 42 nut 782137 Spec bolt M16 782141 rss nm A 2 RR Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 25 of 32 All these components are shown in an additional document 958627 19 Operating the Internal Crane Limitations on use e Lift or landing to floating vessels is not permitted for any crane constellation e Lift or lowering of personnel is not permitted for any crane constellation e Do not use any of the crane constellations for external operation above wind
34. speed 15 m sec 10 min e Do not operate the crane without correct authorization After 50 lifts with 12000 kg load the crane must be recertified e Inspect all welding on both trolleys for cracks Repair or replace damaged items e Inspect all welding on lattice construction for cracks In case of cracks Vestas Technology must be contacted e Replace all bolts nuts and washers on bridge and trolley e Check rollers for free rotation replace if malfunction e Perform overload test Attach chain to prevent accidental access to hazardous area Open the service hatch and secure it to transformer partition wall Keep the service hatch closed after hoisting operation is completed The internal crane and the traverse must be fastened in parked position when turbine in operation E HER 3 9 Figure 7 Attach chain Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 26 of 32 Figure 8 Service Hatch Release the chain from the chain box Figure 9 The chain box The crane can be moved longitudinally by a winch mounted on the machine foundation p O xm Pee i t tz d or REED Vestas Wind Systems A S Alsvej 21 8900 Randers Denmar
35. t points up and one of the blade bearings points downwards Lock the rotor with the hydraulic rotor lock or mount the three centering mandrels using 3 x 2 M20x40 from in front of the hub flange and into the locking holes of the main foundation 3 Place 16 x M42 bolts 782139 5 on each side and 6 in the top 4 Insert 16 shims 782142 so the bolt is placed in the slot and the shims Use a small hammer for mounting to ensure there is no space between the shim and the hub main foundation 5 Screw on the special nut with washer underneath so it hits the hub flange 6 Tighten the yellow M16 special bolts 782141 following this procedure Tighten the 8 M16 bolts to 7ONm Then tighten the 8 M16 bolts to 140Nm in a circular way and proceed with this operation with the first 3 bolts again so you at the end have tightened 11 bolts to 140Nm see figure on the following page n mat A 27 27 RR Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item no 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 23 of 32 NOTE Do not at any time remove the centering mandrels when the M 16 bolts are not tightened Tightening force sequence the full sequence has to be used Bolt nr Torque Nm NEN 5 m 2 Me 43 w M 6 tw _ 7 tw
36. where the brake can be activated 2 Align the locking system position holes in the hub with the locking system mandrels by manoeuvring the brake press until the V notch marking pos 1 on the hub is aligned with pointer on machine foundation see pos 2 See Picture 13 3 At the correct position set the handle in position and pump the locking system mandrels out Observe at the right side during the pumping See Figure 4 4 The locking takes place with the hydraulic hand pump located above the main gear on right hand side The locked position of the handle 1 45 When locking set the handle in position the handle perpendicular to the gearbox centre shaft When unlocking set the handle in position and pump in the locking system mandrels When the mandrels are fully out or set the handle in lock position see Figure 4 Verify the fully in or out position by looking at picture 11 7 B at the operator panel rss 2 cr 227 Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V100 2 75MW Page 20 of 32 Hydraulic hand pump Upper locking mandrel Picture 13 Alignment markings seen from machine foundation side ren nme Mee ars gee Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark
37. witch Q7 and Q8 must be turned off Before opening the cabinet check the DC link voltage in picture 17 Before working on the converter AGO2 check the DC link voltage with a Fluke multimeter 11 Turbine Standstill After a period of maximum 14 days without grid connection necessary equipment for humidity and temperature control must be installed in the turbine in order to fulfil the following requirements For 90 9o of the shutdown period the relative humidity RH must not exceed 45 96 The RH must be between 45 and 6096 for max 1096 of the shutdown period only Within a period of 12 hours the temperature in the turbine must not drop more than 10 C The temperature and humidity must be logged During a period without grid connection the following inspections must be carried out on a monthly basis e Check the functionality of the equipment as regards humidity and temperature Check the RH and temperature logging in accordance with the requirements mentioned above Check the emergency lubrication Recharge emergency lubrication batteries only every 3 months Check the blade locking system Check that the brake is released and without pressure n mat A 27 27 RR Vestas Wind Systems A S Alsvej 21 8900 Randers Denmark www vestas com Item no 960314 R5 Date 2006 09 11 Issued by Technology Safety Regulations for Operators and Technicians Class 11 Type MAN V90 3 0MW V1
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