0036-0228_v00 - using t.yoke for blade installation_ v112

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Document no.: 0036-0228 V00

Using T.Yoke for Blade Installation

Date: 2012-12-21

Issued by: Turbines R&D Restricted

Type: T09 - Manual of 13

Vestas Wind Systems A/S · Hedeager 44 · 8200 Aarhus N · Denmark · www.vestas.com

QMS00085V01


Anyone using this document must read this document in its entirety before performingany work.

Any questions or concerns regarding any of the instructions contained in thisdocument must be referred to Vestas.

Turbine type Mk version

V112-3.0 All

History of this document

Version

no

Date Description of changes Technical

approver

0 2012-12-21 First edition KEHVI

Table of contents

1 Safety .................................................................................................................................... 2

2 Educational Requirements of Service Technician ............................................................. 2

3

Abbreviations and Technical Terms ................................................................................... 2

4 Reference Documentation ................................................................................................... 3

4.1 General Documents ............................................................................................................... 3

5 Purpose ................................................................................................................................ 3

6 Risk Assessment ................................................................................................................. 3

7 Tools ..................................................................................................................................... 4

8 Weights ................................................................................................................................. 5

9

Estimated Time Use ............................................................................................................. 5

10 Procedure ............................................................................................................................. 5

10.1

Prepare Lifting Yoke .............................................................................................................. 5

10.1.1 Assembly of Lifting Yoke Sections ......................................................................................... 5

10.1.2 Mounting the Chain Set ......................................................................................................... 6

10.1.3

Applying Weight Plates .......................................................................................................... 8

10.2 Preparing Lifting of Blade ....................................................................................................... 9

11

Removal of T-Lifting Yoke ................................................................................................. 12

: s ocument conta ns vaua e con ent a n ormat on o estas n ystems / . t s protecte y copyr g t aw as an unpu s e wor . estas reserves a patent, copyr g t ,trade secret, and other proprietary rights to it. The information in this document may not be used, reproduced, or disclosed except if and to the extent rights are expressly granted by Vestas in writing and subject to applicableconditions. Vestas disclaims all warranties except as expressly granted by written agreement and is not responsible for unauthorized uses, for which it may pursue legal remedies against responsible parties.





Safety

Date: 2012-12-21




1 Safety

All work involved in the handling, transportation, storage, construction, operation

and maintenance of a Vestas turbine, including work methods and practices,employee training and protective measures, and use of tools and equipment,

shall be in accordance with the requirements of the applicable governmental and

private occupational safety and health codes and standards. Employers engaged

in such work are also required to be familiar with and comply with ‘Vestas

Corporate OH&S Manual’. Vestas shall not be responsible for any liabilities

arising from failure to comply with such requirements. Vestas reserves the right to

inspect such work to ascertain such compliance.

Personal Protective Equipment

Item no. Quantity Description

Standard personal protective equipment (PPE).

Table 1-1: Required PPE.

2 Educational Requirements of Service Technician

At least two of the service technicians working in a wind turbine are required to

possess valid course certificates for the ‘Vestas Basic Safety Training for Service

Technicians’, including basic safety theory, first aid, fire prevention and fire

fighting, emergency descent and any additional safety courses owing to local

requirements.

At least one service technician must possess the wind turbine specific course

certificate for the turbine in question.

Some tasks require one or more advanced training modules or job specific

training as described in the Vestas ‘Technical Training Programme’. The person

planning a specific task must ensure that the service technicians involved

possess the proper know-how for completion of that task.

3 Abbreviations and Technical Terms

Abbreviation Spelled-out form / explanation

OH&S Occupational health & safety.

PPE Personal protective equipment.

SWI Service work instruction.

V-AME Vestas Americas.

WCT Wood carbon technology.

WLL/SWL Working load limit/safe working load.

Table 3-1: Abbreviations.





Reference Documentation

Date: 2012-12-21




Term Explanation

Table 3-2: Explanation of terms.

4 Reference Documentation

4.1 General Documents

Document no. Title

0000-0496 Vestas Corporate OH&S Manual

Safety Regulations for Operators and Technicians’ for therelevant turbine type. ‘(Not V-AME).

‘Warnings and Safety’ (V-AME).

920098 Torque Wrench Settings.

960501 Bolt Connections

V112 Blade installation and Decommissioning chapter for

relevant Mk version.

Table 4-1: Required documentation.

5 Purpose

The purpose of this instruction is to describe how to assemble and use lifting

yoke for V112 blades (55 m blade)

6 Risk Assessment

0000-2743 RA for Lifting Equipment for MW Blades.





Tools

Date: 2012-12-21




7 Tools

.

Item no Quantity Text

227720 2 Ring fixed spanner 30 mm ACESA

VT20001377 1 Chain set, three legged for V112 blade

VT20001470 1 Chain shorter, WLL 6,7 T

VT20001374 1 Lifting yoke for 55 M Blade

20001375 1 Tube weld assy for T. lifting yoke

VT201292 2 Weight unit

VT20001450 1 Lift shell

1 Webbing sling for root end 90 x 21000 mm WLL 3000

kgVT200776 1 Webbing sling for lift shell 600 x 8000 mm WLL 5700

kg

2 Round sling 4000/8000 mm WLL 3000 kg for extending

VT200776

VT730071 3 Shackle 6500 kg.

152188 16 Bolt M20x70 8 .8U TZN

157066 16 Hex HD. Nut M20 8 TZN

157020 32 Washer-21-HV300-TZN-IK900194

Table 7-1: Tools for handling blades for V112

Chain set VT20001377 must be up shorted with 2000 mm in the chain attached

between lifting yoke and blade tip by use of VT20001470 (from 17004 mm to

approx. 15000 mm)

Webbing sling shorter than 21000 mm can be used as attach sling in the root, if

the attaching sling is extended to 21000 mm by use of webbing/round sling with

appropriate WLL.

One webbing sling VT730583 can replace both 4000/8000 mm round sling as

extender in lifting shell, by extending VT200776 in one side only.

NOTE





Weights

Date: 2012-12-21




8 Weights

Heavy equipment!

Serious injury may result from lifting heavy equipment by hand.

Do not lift heavy equipment by hand.

Always use crane or similar lifting equipment.

Item No Description Weight

VT203540 Compl. rear section (lifting yoke) 235 kg

VT203541 Compl. middle sections (lifting yoke) 210 kg

VT203542 Compl. front section (T-section lifting yoke) 323 kg

10103518 Compl. extension section for V100 (49 and 55 m blade) 91.2 kg

20001375 Compl. extension section for V112 (55 m blade) 157 kg

VT730877 Chain set 154.8 kg

VT201299 Weight plate 22.6 kg

Table 8-1: Weight overview.

9 Estimated Time Use

It takes approximately two hours to assemble the lifting yoke.

10 Procedure

10.1 Prepare Lifting Yoke

10.1.1 Assembly of Lifting Yoke Sections

Manual handling!

Injury may result from handling the sections if instructions are not followed.

Do not lift the sections by hand.

Always use crane or forklift when handling the sections.

The lifting yoke consists of 6 sections; one for the root, one T-section, two middle

sections (VT739022) and the extension sections for 55 m blades (10103518 and

20001375).

1. Assemble the sections: use M20x70 bolts with nuts and washers.

NOTE





Procedure

Date: 2012-12-21




Tighten the bolts according to SWI 920098 ‘Torque Wrench Settings’ or 960501

‘Bolt Connections’.

Figure 10-1: Sections and anchor points. Figure 10-2: Assembling T-section.

1 10103518 1

2 Anchor point for lifting blades V112 blade 2

3 Anchor point for lifting blades V100 blade 3

10.1.2 Mounting the Chain Set

Risk of personal injury!

Personal injury may occur if chain set is mounted incorrectly and blade is

dropped from height.

Always mount the chain set according to the instructions specified in this

document.

Always use the tools specified in this document.

Risk of damage to components and tools!

Damage to components and tools may occur if chain set is mounted incorrectly.

Always use shackles designed for the task.

Always tighten the shackles as specified.

Always mount the chain set in the correct anchor point. See Figure 10-5, p. 7

and Figure 10-6, p. 8

NOTE





Procedure

Date: 2012-12-21




1. Mount the two shortest chains on the T-section. See Figure 10-5, p. 7

2. Mount the last one in the outermost bracket on the root section. Figure 10-6,

p. 8

The root end of the lifting yoke has two anchor points, one for lifting blades forV66-V90 and V112 turbines and one for lifting blades for V100 turbines.

The three ends of the chain set are assembled with a shackle, SWL 6.5 metric

tonnes in each end.

Figure 10-3: Bracket not for attaching chain set

for a V112 blade

Figure 10-4: Bracket for attaching chain set for a

V112 blade

Figure 10-5: Chain set mounted in one of the sides of the T-section.

NOTE





Procedure

Date: 2012-12-21




Figure 10-6: Chain set mounted in the anchor point on the root section usedwhen lifting V112 blades.

10.1.3 Applying Weight Plates

Risk of personal injury!

Injury may result from lifting a weight plate.

Do not lift a weight plate by yourself.

Always have two persons handle a weight plate.

Place the weight plates one opposite the other as illustrated in Figure 10-8,

p. 8.

1. Place 16 weight plates in the weight plate frame placed in the T end of the T

yoke. See Figure 10-9, p. 9

Figure 10-7: One weight plate. Figure 10-8: Stacked weight plates inthe frame.





Procedure

Date: 2012-12-21




Figure 10-9: Placed and stacked weight plates in the T end of the T.yoke.

10.2 Preparing Lifting of Blade

Crushing by falling loads!

Risk of crushing by falling load if lifting equipment fails during lifting.

Never stand under a suspended load.

Never expose lifting equipment to loads exceeding the specified safe working

load/working load limit (SWL/WLL) value. Only use lifting equipment designed for the task.

Check lifting equipment visually for damage prior to use.

If replacing parts, only use original parts authorized by Vestas.

Ensure that all cables, chains, slings or other moorings are properly attached

to the load prior to lifting.

Use guiding ropes when situations are endangered by the rotation or

uncontrolled motion of a load.

Always make a test lift before installation/dismantling of blade.

Manual handling!

Injury may result from handling the lift saddle if instructions are not followed.

Do not lift the lift saddle by hand.

Always use forklift when handling the sections.

1. Mount root sling in pos. 1. See Figure 10-11, p. 10





Procedure

Date: 2012-12-21




2. Turn the sling all the way around the root and place it as illustrated in Figure

10-10, p. 10

3. Mount the other end of the sling in pos. 2. Figure 10-11, p. 10

Figure 10-10: Attaching the root end with

use of 90 mm webbing

sling on a V112

Figure 10-11: Sling mounted on the root.

4. Place the lifting shell in the same radius as the T-section. See Figure 10-12,

p. 11

5. Hook the sling onto the T-section in both sides. Figure 10-15, p. 11

6. Place the attaching saddle on the lifting tool under blade right below the spar.

See Figure 10-13, p. 11

Place an extra piece of friction rubber on the middle of the saddle,

(500x1000x20mm)NOTE





Procedure

Date: 2012-12-21




7.Figure 10-12: Lifting plate Figure 10-13: Lifting shell (V112) attached under

the blade

Figure 10-14: Slings hooked onto the T-section. Figure 10-15: Illustration of attached slings to the T

end of the T. yoke

For attach the webbing sling to the T yoke in the tip end, the webbing slingVT200776 must be extended in each side with 2000 mm round sling with

appropriate WLL if a 21000 mm webbing sling is used in the root.

8. Align the T.yoke for lifting by place the root end of the T.yoke offset to the left

of centreline of the blade root. See Figure 10-16, p. 12

NOTE





Removal of T-Lifting Yoke

Date: 2012-12-21




Figure 10-16: T yoke offset against trailing edge in

the root.

Figure 10-17: Example of lifting configuration (Fig

shows a V82 blade

The distance from crane hook to anchor point is approximately 10000 mm.

Lift the blade carefully

Check visually that the root and tip is lifted from the support at the same time.

Check the angel in the root (optimal angel is between 87 and 89 degree.

Install the blade in according to the relevant installation manual

11 Removal of T-Lifting Yoke

Work at height!

When staying or working on the roof or nose cone shell, always use personal

fall arrest equipment (approved full-body harness, lanyard with energyabsorber, positioning rope and fall arrester for wire or rail) and be fastened to

approved (yellow) anchor points on both sides of the nacelle.

When approximately 40 evenly distributed bolts have been tightened, the

lifting yoke can be removed.

Remove the T yoke from blade by detach the sling attach to the hook in the

root end. Pos 2 in Figure 10-11, p. 10

Remove the T yoke with the lift shell carefully out over the tip end and lower

the T-Yoke carefully down.

NOTE





Removal of T-Lifting Yoke

Date: 2012-12-21




Figure 11-1: Removing sling at root end. Figure 11-2: Sling secures in the hook

1. Guide the crane operator when removing the lift shell and, at the same time,

guide the ground personnel controlling the guiding ropes.

Sometimes it is required to yaw the nacelle in small amounts to yaw away from

the crane boom when removing the blade bar from the blade.

Figure 11-3: Removing T-yoke with lift shell.

NOTE