- Original Document -

GE Renewable Energy

Technical Documentation
Wind Turbine Generator Systems
1&2 MW and 3 MW GE Onshore
Wind Turbine

Maintenance Manual
Introduction
General Information and Safety
1&2 MW: Single Main Bearing 1.5 MW to 2.9 MW
3 MW: Dual Main Bearing 2.3 MW to 4.2 MW

Rev. 09 - Doc-0072822 - EN 2020-07-07

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www.gerenewableenergy.com

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IMPORTANT

Read this manual carefully before use.

Keep the manual for future consultation.

All technical data is subject to change in line with ongoing technical development!

Copyright and patent rights

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be made available to third parties with the expressed written consent of General Electric Company.

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the documents, also in extracts, as well as the exploitation and communication of the contents are not allowed
without express written consent. Contraventions are liable to prosecution and compensation for damage. We
reserve all rights for the exercise of commercial patent rights.

 2020 General Electric Company. All rights reserved.

GE and the GE Monogram are trademarks and service marks of General Electric Company.

Other company or product names mentioned in this document may be trademarks or registered trademarks of
their respective companies.

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Table of Contents
1 Document Overview .................................................................................................................................................................................... 5
1.1 Task Frequency and Scope ............................................................................................................................................................. 5
1.2 Components of the GE 1&2 MW and 3 MW Platform Maintenance Manual ......................................................... 5
1.3 Related Reference Documents ..................................................................................................................................................... 5
2 Country / Regional Specific Requirements........................................................................................................................................ 6
3 Safety .................................................................................................................................................................................................................. 6
3.1 Critical Safety Note ............................................................................................................................................................................ 6
3.2 Industry Standard Safety Practices ............................................................................................................................................ 6
3.3 Basic Safety Information ................................................................................................................................................................. 7
3.4 Training and Safety Guidelines ..................................................................................................................................................... 8
3.5 Electric Power - Special Dangers ................................................................................................................................................. 8
3.6 Special Dangers – Hydraulic System.......................................................................................................................................... 8
3.7 Electromagnetic Fields (Pacemaker/Defibrillator Hazard) ............................................................................................. 8
3.8 Electric Shock/Electrocution/Arc Flash Hazards ................................................................................................................. 9
3.9 Special Dangers – Hub Access ...................................................................................................................................................... 9
3.10 Turbine Control and Monitoring Systems - Critical to Safety and Quality ............................................................ 10
3.11 Turbine Control System – Safety Chain................................................................................................................................. 10
3.12 Protective Systems for the WTGS............................................................................................................................................ 10
3.13 Turbine Electrical Protective Systems (Fuses, Circuit Breakers, ETC) .................................................................... 11
3.14 Wind Speed Limitations for Work............................................................................................................................................ 11
3.15 Alterations, Modifications, and Replacement Parts ........................................................................................................ 11
3.16 Markings and Signs Attached by GE Renewable Energy ............................................................................................... 12
4 Prerequisites to Performing Maintenance ..................................................................................................................................... 13
4.1 Maintenance Support .................................................................................................................................................................... 13
4.2 Maintenance Intervals ................................................................................................................................................................... 13
4.3 REPOWER Specific BIM Requirements .................................................................................................................................. 15
4.4 Abbreviations / Acronyms ........................................................................................................................................................... 15
4.5 Frequency Table Abbreviations / Acronyms ....................................................................................................................... 15
4.6 Definitions ........................................................................................................................................................................................... 16
4.7 Visual Inspections and System Checks shall consist of the following .................................................................... 16
4.8 Maintenance and Inspection Proof Requirements .......................................................................................................... 17
Appendix A: Maintenance and Inspection Proof.................................................................................................................................... 18
Appendix B: Damage Report - Rotor Blades ............................................................................................................................................ 20

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1 Document Overview
This manual covers the maintenance requirements for GE 1&2 MW and 3 MW onshore Wind Turbine
Generators. These requirements do not cover non-GE upgrades, some supplemental equipment available only
in certain markets (Sand Package upgrade), or additional recommended maintenance items based on specific
operating environment or conditions. Wind turbines operating in more extreme environments (sand, dust, cold,
heat, wind shear) may benefit from additional preventative maintenance.

1.1 Task Frequency and Scope

GE utilizes data analytics, where available, to determine the frequency and, in some cases, alternative scope of
work for tasks listed in the maintenance manual. This analysis allows GE to more efficiently target maintenance
based on operating conditions and turbine history to better protect the lifecycle of the turbine and minimize
disruptions to our customers’ operations. For units covered by a GE Managed Maintenance Program and
Odometer Based Maintenance (OBM), please look to your digital planning tool, such Digital Plan Of the Day
(DPOD) or equivalent, for your maintenance requirements on a unit by unit basis.

For units not covered by a GE Managed Maintenance Program with Odometer Based Maintenance, a default list
of task frequencies and recommended scope is provided in Section 7 – Frequency Tables. This will be
considered the minimum acceptable maintenance for units maintained by Customers or their 3 rd parties during
the warranty period to maintain warranty coverage.

1.2 Components of the GE 1&2 MW and 3 MW Platform Maintenance Manual

The following sections are necessary to cover the required maintenance of the GE WTG:

 Introduction – General Information and Safety

 Section 1&2 - Foundation and Tower
 Section 3 – Electrical System (3A: Non-ESS, 3B: ESS, 3C: PMG, 3D: DFIG)
(note: There are four sections, one for each electrical system. Use the applicable one for your
turbine)
 Section 4 – Nacelle/Machine Head
 Section 5 – Hub and Blades
 Section 6 – MVSG and Transformer (if applicable)
 Section 7 – Frequency Tables

1.3 Related Reference Documents

This manual is not a standalone document and must be utilized in conjunction with the appropriate Platform
Operating and Safety Manuals. It does not cover all the work or equipment usage details, possible variations in
components or contingencies which may be encountered. Users assume all responsibility for determining
applicability of these instructions and all liability associated with performing work or utilizing equipment. The
owner of the WTGS is responsible for ensuring all required maintenance is performed and properly
documented.

Additional guidelines and safety information is available in the reference documentation. Please refer to the
Operating, Maintenance and Safety documentation provided with your GE Wind Turbine Generator as well as
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checking for any applicable technical or safety communications from GE. Technical updates are generally
distributed as Technical Information Letters (TILs). These documents are available through the GE Customer
Technical Document portal or through your GE Service Representative.

Example of Reference Documentation

 GE WTG Safety Manual, GE WTG Operations Manual, etc.

 Assembly and Maintenance Wind Speed Limitations
 Bolt Torque Specification, Lubricant List
 Maintenance Manual Addendums: Sand Package (example)
 Technical Information Letter (TIL)
Prior to each maintenance cycle check for updates to these documents that may contain important changes
that will directly impact the operation and performance of the WTGS.

2 Country / Regional Specific Requirements

Due to the global nature of wind power and the various regulatory agencies worldwide it is impossible to
ensure compliance with the multitude of possible inspections required for various components within the
turbine. Site owners and operators are required to familiarize themselves with any additional inspection
requirements due to specific locations of their turbines. Examples include but are not limited to additional
inspections required for hoists, manlifts, etc. that may exist.

3 Safety
3.1 Critical Safety Note
Any operation of the turbine must be done with extreme care when technicians are in the turbine. Technicians
must be aware of the status of the turbine, environmental conditions and how this may affect their safety. Be
aware of possible consequences for issuing turbine commands or altering the state of the turbine. Examples
include but are not limited to manual control of turbine yaw or pitch systems or LOTO of the hydraulic system
for maintenance. Caution must be taken whenever commands are given to the turbine to ensure personnel
safety is not compromised.

When issuing pitch or “speed control” commands to the turbine care must be taken that rotor lock limits are
adhered to (specific limits exist for pitching all blades versus one). Speed control commands rely on generator
speed readings and should not be issued if any evidence of slippage exists along the drivetrain until this is
corrected.

3.2 Industry Standard Safety Practices

This manual and associated reference material is written with the expectation that standard industry safety
practices will be followed at all times. Basic industry work standards may not be specifically called out as the
customer is expected to understand and enforce these standards at their sites.

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3.3 Basic Safety Information

Individuals/companies performing this work are responsible for understanding the scope of work specified
within the Maintenance Manual and the associated activities necessary such as working at heights, WTGS
operation, etc. They are responsible for determining and enforcing the training and safety standards for
performing this work, complying with Local/National regulations, and the guidelines specified in the Operating
and Safety Manuals.

This document is meant to provide only a basic overview of maintenance related safety and operating
guidelines. The included safety warnings highlight only certain hazards and are not all inclusive. Variations in
equipment may pose additional hazards to those highlighted.

Critical operating and safety information is available in the GE 1&2MW or 3MW Platform Operating and Safety
Manuals. Follow the instructions included in these documents as well as all safety signs and marks within the
turbine. Adhere to all local and national safety requirements and standards.

Personnel should not be in the WTG with it in load operation or Manual Speed Mode. For personal to work
within the turbine, the turbine should be set to 'Repair' or 'Service' mode and in the 'Idle' or 'Stop' state. Never
enter, climb or perform work in the Wind Turbine Generator (WTG) without the appropriate Personal Protective
Equipment (PPE).

The turbine contains potential entrapment, pinch and crush hazards (drive train, yaw system, pitch, etc.).
Equipment guards must be in place unless specifically required for a particular maintenance activity such as
greasing or function checks. Associated equipment must be locked out whenever personnel are performing
maintenance, if guards are removed, or personnel will be exposed to these hazards.

When handling any chemical substance, you must observe all applicable regulations and the manufacturer’s
safety data sheets of these substances with regard to storage, handling, use and disposal! Ensure that all
consumables and materials (rags, cleaners, etc.) are disposed of in a safe and environmentally friendly manner.

DANGER
Critical to Safety!
“Are you planning to work on (or near) electrical equipment or cables, etc.?”
If you answered Yes!
Establish a Risk Assessment and train/issue/communicate the Site Specific LOTO
plan to all affected team members BEFORE executing ANY work.
Examples include but are not limited to:
 Maintenance of electrical generator, power cables, converter, sliprings, etc.
 Batteries (pitch or yaw backup system)
 Grid, temporary electrical connections to generators, etc.
Note: generators can induce voltage even if not energized through residual
magnetic fields (DFIG) or permanent magnets (PMG).

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3.4 Training and Safety Guidelines

The wind turbine is specialized equipment that requires equipment specific and other specialized training.
Working on/in a wind turbine has unique dangers and significantly reduces the ability of rescue personnel to
assist in emergencies. At a minimum, there should be two personnel at a time on a turbine trained in the
specific hazards and appropriate emergency procedures. This should include emergency isolation points for
electrical and hydraulic energy in addition to basic wind turbine controls and operations. Always refer to local
and national laws and regulations when determining safety, training, and staffing requirements.

3.5 Electric Power - Special Dangers

Working on/near electrical systems poses significant and unique dangers and all personnel must be properly
trained on these hazards. Follow all applicable LOTO rules and ensure that all power supplies (including
auxiliary) are disconnected, stored energy (capacitors, batteries, etc.) is discharged or isolated, and where
appropriate grounding or short-circuiting of the circuit is performed. Be aware that rotating machinery may
generate electrical energy even when offline and lock out where appropriate.

3.6 Special Dangers – Hydraulic System

For any work on/troubleshooting of the hydraulic system, personnel must understand the operation of the
hydraulic system, its function, how to properly isolate it for maintenance, and the possible consequences of
operator error. Prior to any work on the hydraulic accumulators, it must ensure that the hydraulic side of the
accumulator has been depressurized. The system must be de-energized and LOTO applied; disabling the
hydraulic system´s controls is not sufficient.

3.7 Electromagnetic Fields (Pacemaker/Defibrillator Hazard)

DANGER
Danger of electromagnetic field affecting cardiac pacemaker or
defibrillator!
 Before working in a WTG consult your doctor and/or device manufacturer to
determine whether or not you are at risk!
Non-observance of this warning notice will result in death or serious injury.

Electromagnetic fields (EMF) are present within the WTGS. EMFs have the potential to adversely affect the
operation of a cardiac pacemaker or defibrillator. If you have a cardiac pacemaker or defibrillator implanted
inside your body, consult your doctor and/or device manufacturer to determine whether or not you are at risk
around WTGS components. If EMF measurements are required, then please contact GE for assistance.

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3.8 Electric Shock/Electrocution/Arc Flash Hazards

DANGER
Danger of electric shock, electrocution and arc flashes!
 Take precautions to avoid (see below).
Non observance of this warning will result in death or serious injury.

Only use fuses with the prescribed amperage and time delays. Care must be taken that design features are not
modified such that safety is compromised (e.g. leakage distances and sparking distances in air/approach limits)
and that distances are not reduced by insulation materials.

The control system, monitoring, and protective functions (motor protection, speed monitoring, fault to ground,
etc.) may not be disabled – even for testing.

Cabinets must be properly secured and undamaged in order to contain/redirect any potential arc blast.

Cabinets must be inspected for any materials, tools, or conditions (loose wires) that may cause shorts prior to
energizing after work is completed.

3.9 Special Dangers – Hub Access

Life-threatening hazards (Fall from Heights, Crushing)

DANGER
Danger of falling from heights and crushing!
Never rely on the hydraulic brake solely for hub entry, a mechanical rotor lock
MUST be used to LOTO the hub whenever a technician will be on or work on the
hub.
On some models if the secondary brake Hydraulic Power Unit (HPU) loses power
the secondary brake will release unless a manual valve is closed. Non observance
of this warning may result in death or serious injury.

In order for any personnel to be tied off to, on top of, or inside the hub the following conditions must apply:

1. Wind speed limitations applicable for the WTG model and environmental conditions must be adhered to.
2. The drive train must be locked out (LOTO). Use of high speed rotor lock, if available, is required, if a high
speed rotor lock is not installed on the WTG then the low speed rotor lock shall be used instead.
3. Hydraulic secondary brake must be applied and in the normal operating range.
4. No one is allowed on or in the hub if hydraulic secondary brake pressure is below normal range

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5. Brake's Hydraulic Power System should be energized if possible whenever personnel are in the hub. If
manually applying the brake attention must be paid to ensure the system is maintaining pressure.
6. The safety rail, hub spinner (nosecone) and all associated hardware is a CRITICAL FALL PROTECTION
system. A thorough inspection must be performed prior to use.
7. Environmental/weather conditions must be taken into account including forecasted weather changes.
Examples include wind speeds, lightning, blade icing, etc.

Blade pitching limitations must be followed. Some WTG's rotor lock limits are calculated with only one blade
pitched.

Notes:

1. Each person working on/in the hub must LOTO the drive train.
2. Additional requirements and guidelines may exist in the Operations or Safety Manuals.
3. Unless the safety chain is activated, the hydraulic rotor brake will release if wind gusts ≥ 30 m/s.

3.10 Turbine Control and Monitoring Systems - Critical to Safety and Quality
The turbine relies on the control system to operate the turbine correctly and various other monitoring systems
to detect possible abnormal behavior or anomalies. Prior to beginning maintenance, technicians should review
these systems and review the status logs. Note any items which may require action and ensure these are
properly investigated. The two primary monitoring systems are the CMS and ALC. To take full advantage of the
Conditioned Based Maintenance programs the turbines should be kept up to date with the latest GE Digital
Systems and Analytics.

3.11 Turbine Control System – Safety Chain

The safety chain is designed to immediately bring the turbine offline by opening the grid circuit contactor,
pitching blades to the feathered position (around 90 degrees, depending on WTG configuration), and applying
the hydraulic brake to stop the rotor. The safety chain is designed as the last resort to protect the turbine from
entering an unsafe condition such as turbine over-speed. This system must be checked as part of the
maintenance procedure and any deficiencies corrected immediately. This includes the proper WTGS status
messages being displayed by the control system and prevention of the WTGS starting up.

If personnel are at risk, or for malfunctions of the energy supply of the Wind Turbine Generator System, actuate
the ‘Emergency Stop’ button immediately.

3.12 Protective Systems for the WTGS

The WTGS control system relies on the monitoring and protective functions (thermal motor protection, speed
monitoring, over current, fault to ground, etc.) in order to protect personnel and equipment. These systems may
not be masked or disabled and any deficiencies (malfunctioning components, incorrect settings, etc.) must be
corrected if found.

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3.13 Turbine Electrical Protective Systems (Fuses, Circuit Breakers, ETC)

The turbine electrical system is designed for the proper functioning of the protective devices installed. No
alterations without specific direction from GE engineering are allowed. Alterations include rewiring, changing
overload settings, and fuse amperage and time response ratings. These could affect the permissible approach
distance, leakage/spark distances, and arc flash potential and place personnel and equipment in danger.
Cabinets must be properly secured and all associated electrical protection devices functioning properly to
ensure they will contain/redirect any potential arc blast.

1&2MW WTG - Access under (and/or behind for non-ESS turbines) the DTA section is strictly prohibited unless
the grid voltage is completely isolated and grounded through an appropriate LOTO. The DTA is designed to
direct certain types of arc flash events under (and behind for non-ESS turbines) the DTA to protect personnel.

3MW WTG - Access behind any cabinet at the controller level or into the basement/transformer room is
prohibited while the MV transformer (aux XFMR for external MVSG units) is energized. Access is prohibited
behind the MVSG while grid cables are energized. Units with internal MVSG and XFMR may have the basement
accessed for visual inspection and if additional cable protection is installed for performing anchor/flange bolt
tensioning ONLY.

3.14 Wind Speed Limitations for Work

Reference the “Assembly and Maintenance Wind Speed Limitations” document for specific wind speed limits
for each platform. The maximum wind speed allowed for using the rotor lock at the high-speed shaft (HSS) or
low speed shaft (LSS) is temperature and in some cases altitude dependent. Use the outside nacelle
temperature reading to determine the appropriate limit. Rotor locks should not be used at temperatures below
-30°C (-22°F).

DANGER
Wind Speed Limitations for Work
Life-threatening danger from moving turbine parts!
Use HSS rotor lock during drive train maintenance work!
Unless safety chain is activated, the hydraulic rotor brake will release if wind
gusts ≥ 30 m/s.

3.15 Alterations, Modifications, and Replacement Parts

Alterations to the WTGS may adversely affect its operation and could potentially cause catastrophic failures
including life threatening situations. Only those alterations and modifications specifically authorized by General
Electric are permitted. Replacement and maintenance parts must meet all technical requirements specified by
GE Renewable Energy to ensure proper functioning of the WTGS and its protective systems. Ordering parts
through GE Renewable Energy will ensure these specifications are met.

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3.16 Markings and Signs Attached by GE Renewable Energy

Safety markings/instructions must be followed and may be texts, signs, signals, pictographs and colors. The
presence and legibility of safety signs must be checked as part of the regular maintenance. Immediately replace
missing or illegible safety signs. All signs should be in English and the respective national language.

Explanation of the Symbols

The basic information for the technical documentation for GE Renewables Energy Wind Turbine Generator
Systems is described in the Safety Manual. The following danger classifications and symbols are used in this
manual:

NOTICE
This word is used to address practices not related to physical injury.

CAUTION
This signal word is used to indicate a potentially hazardous situation which, if not
avoided, could result in minor or moderate injury.

WARNING
This signal word is used to indicate a potentially hazardous situation which, if not
avoided, could result in death or serious injury.

DANGER
This signal word is used to indicate an imminently hazardous situation which, if
not avoided, may result in death or serious injury.

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4 Prerequisites to Performing Maintenance

Never enter, climb or perform work in the WTGS without the appropriate Personal Protective Equipment (PPE).
Always adhere to all local and national safety requirements and standards.

Any unsafe conditions including abnormal turbine operation/response must be immediately addressed by
properly trained personnel.

During maintenances, the service switch on the control cabinet must be in the "Maintenance" position and
returned to the "Automatic" position after maintenance or repair work has been completed.

DANGER
Turbine Remote Start Possible
Life-threatening danger from moving turbine parts and electricity!
Precautions to prevent remote operation of the WTGs is recommended when
personnel are at the turbine, such as disconnecting it from the SCADA network.

Environmental limitations exist for certain activities on the WTGS. No work should occur with electrical storms
in the area or below the operating range for the WTGS, temperature, wind, etc.). Risks such as falls from the
nacelle or hub due to wind speeds, frostbite from wind chill, and other hazards should be considered.

The addition of Flexible Maintenance options to the Maintenance Manual requires maintenance personnel to
take additional measures to fully understand ALL applicable maintenance scopes BEFORE approaching a WTGS
to conduct maintenance. Personnel should check with the site's Lead Technician and/or Manager to
understand maintenance tasks in progress, not completed and/or overdue. Additional risk assessments may
need to be completed to account for partially completed maintenance tasks, work in progress and/or partially
completed maintenance sections. It may be necessary to complete Flexible Maintenance items prior to
commencing other work. See the Maintenance Intervals section for a further explanation of Flexible
Maintenance.

4.1 Maintenance Support

If there are any questions regarding the requirements of this manual, operation of the turbine, safety warnings,
or a specific condition of a WTGS please contact your GE Renewables representative.

4.2 Maintenance Intervals

GE utilizes data analytics, where available, to determine the frequency and, in some cases, alternative scope of
work for tasks listed in the maintenance manual. This analysis allows GE to more efficiently target maintenance
based on operating conditions and turbine history to better protect the lifecycle of the turbine and minimize
disruptions to our customers’ operations. For units covered by a GE Managed Maintenance Program and
Odometer Based Maintenance (OBM), please look to your digital planning tool, such Digital Plan Of the Day
(DPOD) or equivalent, for your maintenance requirements on a unit by unit basis.

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For units not covered by a GE Managed Maintenance Program with Odometer Based Maintenance, a default list
of task frequencies and recommended scope is provided in Section 7 – Frequency Tables. This will be
considered the minimum acceptable maintenance for units maintained by Customers or their 3 rd parties during
the warranty period to maintain warranty coverage.

Failure to maintain the equipment within the period specified may have an adverse effect on the performance
of the WTGS or its sub-components and could impact the warranty of certain components. The Optional 12-
month program is only available for WTGS with fully installed and operational auto-lubrication systems. These
are necessary for lubricating components to protect against wear and corrosion.

Maintenance tasks may be moved to occur at any maintenance cycle to accommodate site needs but must be
completed within the specified period. Example: the generator alignment can be performed during a low wind
period if the interval between generator alignments is within the allowed timeframe. An additional designation
of FLEX may apply to certain tasks, as described below, that offers greater flexibility for completion of these
tasks.
Notes:
1. Complete all tasks due based on their interval. Example: at 12 months all SA and A tasks should be
completed, at 24 months all SA, A and BA tasks should be completed.
2. All intervals less than 12 months have a one month grace period, intervals 12 months or longer
have a two month grace period. This is to account for weather and other unexpected delays and
should not be used for planning purposes.
3. The initial date on which intervals are based is the date of the turbine achieving 360 operating
hours. All subsequent intervals are based off the previous completion date for that task.

(BIM) Break in Maintenance Tasks – These tasks must occur no earlier than 360 operating hours and no later
than five months after it is achieved. These tasks are specific to the break - in of certain components on the
WTGS and are necessary only once in the lifetime of the system or if the component in question is replaced.

NOTICE
For all fasteners for any connection that becomes loose or replaced due to
maintenance, repair & component upgrade, one must follow all Break-In-
Maintenance requirements listed in the Bolt Torque Specifications. Any
connection effected by such work should begin a new set of BIM intervals and be
recorded In the WTG log.

(SA) Semi-Annual Maintenance – These tasks are to be completed within a six month interval.
(A) Annual Maintenance Tasks – These tasks are to be completed within a 12 month interval.
(BA) Bi-Annual Maintenance Tasks - These tasks are to be completed within a 24 months interval.

(BRM) Beyond Regular Maintenances – These tasks that occur at an extended or infrequent schedule
(Examples: oil changes, converter coolant exchange, and anchor bolt tensioning, etc.) These tasks should be
completed at the frequency specified within the pertinent maintenance manual section, as called for within the
vendor’s manual or as directed by GE engineering.

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(FLEX) Flexible Maintenance Tasks –These tasks have been identified as being more suitable for performance
during other tower visits to reduce the quantity of tasks during a typical maintenance visit. Annual tasks with
this designation have an 18 month window from the last time it was completed but should still be completed at
least once a year on average. BA tasks designated as such still have the same 24 month plus 2 month grace
period.

4.3 REPOWER Specific BIM Requirements

Units that have undergone REPOWER will require additional maintenance for specific components during the
break in period. The tasks that are required vary depending on the type of REPOWER upgrade that is performed
and can be identified using the “REPOWER Specific BIM Requirement Chart” included in Section 7: Frequency
Tables
The BIM must occur no earlier than 360 operating hours and no later than the five month anniversary of when
360 operating hours were achieved. These tasks are specific to the break in of certain components on the
WTGS and are necessary only once in the lifetime of the system.

4.4 Abbreviations / Acronyms

Abbreviation Definition

ALC Advanced Load Control

CWE Cold Weather Extreme
EHS Environment, Health & Safety
GE General Electric
GEI General Electric Instruction (Technical document that provides instruction on a specific piece of equipment)
GFCI Ground Fault Circuit Interrupter
LOTO Lock-Out Tag-Out
TIL Technical Information Letter
WTG Wind Turbine Generator

4.5 Frequency Table Abbreviations / Acronyms

Abbreviation Definition

BIM Break In Maintenance

SA Semi Annual Maintenance (every 6 months)
A Annual Maintenance (every 12 months)
BA Bi-Annual Maintenance (every 24 months)
BRM Beyond Regular Maintenance (interval defined in column of applicable tasks)
X Indicates the task, defined in the row, must be completed with the frequency defined in that column the X resides
% Values Indicates the percentage of fasteners that must be checked for the task in that row and joint in that section, as well
as the frequency defined in the column the % resides
1st Indicates that the task in that row must be performed at the first occurrence of the frequency defined in that column
the ‘1st’ resides
FLEX Indicates the task in that row may be included in the optional Flex Program.
See Note Notes highlighting specific details for the task in that row are located at the end of the Frequency table

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4.6 Definitions
Term Definition

Visual Inspection Inspection of the proper condition of installed equipment. This may require cleaning to allow proper inspection or
use of a tool such as a boroscope to inspect the internals of such components as the gearbox or shaft coupler.
Visual inspection of torque markings will fall under this section.
System Check An evaluation of a turbine component, system and/or solution to verify proper operation, identify additional
corrective actions or maintenance items. This may involve the use of test equipment such as meggers, calipers,
high potential testers, refractometers and other similar equipment. Maintenance activities such as generator
alignments and checking emergency lighting and battery backup systems will be included in this category.
Lubrication Task Testing, measuring, adding or exchanging oil, grease or coolant within WTG components. This is typically
associated with fluids that are maintained in bulk quantities. It does extend to the replacement of oil filters.
Fastener The 100% visual inspection of torque stripe markings on fasteners. Identification of movement resulting from
Inspection visual inspection will require a physical torque check of fasteners in accordance with the Bolt Torque Specification.
Torque The physical application of torque or tensioning of fasteners in accordance with the Bolt Torque Specifications.
Requirement Percentages listed in frequency table indicate the number of fasteners per connection, not the percentage of
connections (such as mounting brackets) that must be checked.
Replacement Items within the WTG that may be replaced as an expected wear item such as filters, grease cartridges and brake
Task pads. Any items found to have defects during inspection, but not specifically called out as a replacement task, are
considered to be corrective actions or repair of defects and not maintenance items.

4.7 Visual Inspections and System Checks shall consist of the following
Visual Inspections  General condition
Fasteners  Signs of stretching or shearing of bolt
 Torque marks (if applicable see below)
 Corrosion and corrosion protection coating condition
 Wear, fretting, polishing around fastener components and mating surfaces

Fastener Inspection Refer to the latest revision of the Bolt Torque Specification for additional visual
inspection requirements for fasteners with torque markings. Be aware that the
Fasteners with Torque Marks
standard visual inspections for fasteners also apply.

Visual Inspections  General condition (cleanliness, damage, wear, corrosion, paint damage)
Mechanical Systems and Cabinets  Signs of moisture, overheating, spark or arc marks
(including their electrical  Tight Connections
components) shall be visually  Mechanical: Components are properly seated and fastened, no vibration
inspected for the following: damage
 Electrical: grounding, wiring, connectors, cables, Lexan covers
 Coolant/hydraulic hoses: converter, gearbox, brake, yaw
 Seals, plugs/caps, valves, inspection ports are in good condition, properly
seated and not leaking
 Filters are clean and properly seated

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Visual Inspection  Insulation – signs of wear, cracking, heat damage, discoloration, distortion
Electrical Cables/Buss  Cable glands and inlets are installed
Bars/Connections  Lugs/Connectors
 Corrosion and dirt free
 Check torque marks
 No discoloration or signs of thermal/electrical damage
 Where applicable insulation shrinkage sleeves in place
 Properly routed, secured and any cable trays or protective devices (rubber
mats, buss bar cages, armor cast, cable bundle rings) are in place and in good
physical condition.
 Abnormal sounds/smells
 Signs of leakage (oil cooled transformers)

System Checks  Doors, hatches, covers, etc. properly open and close, are aligned and seat fully
when closed
 Fans/heaters/pumps/motors operate as designed without abnormal noise,
smell, or vibration. Verify as appropriate temperature settings, operating
pressures, etc.
 Controls/system operates as expected (example hydraulic pump kicks on to
maintain brake pressure in proper operating range)

NOTE
Refer to the Bolt Torque Specification document for detailed and component
specific instructions for inspecting fasteners as well as torque procedures and
values.

4.8 Maintenance and Inspection Proof Requirements

The Maintenance and Inspection Proof issued with the manual is a prerequisite for operation of the Wind
Turbine Generator System and may be requested as a prerequisite for warranty approval. The proof is included
and is the minimum required information to record proof of maintenance.

Conspicuous items or other items of concern must be recorded on the Maintenance and Inspection Proof. You
are also advised to contact your GE Renewables representative. Failure to do so in a timely fashion may impact
safety of personnel, turbine performance, component reliability and warranty claims.

Examples of conspicuous items include but are not limited to:

 WTGS is not functioning as stated within the Operating Manual and other applicable GE
Renewables Energy documentation or is operating differently than other turbines on the wind
farm.
 Items which raise a safety or component reliability concern (weld cracks, blade issues, tower dent,
excessive wear or corrosion)
 Electrical component arcing/heat damage, cable insulation cracking/excessive wear
 Abnormal condition of drive train components (coupling slippage, gearbox or generator defects)
 Visual inspections of bolted joints

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Appendix A: Maintenance and Inspection Proof

Site and WTG
Maintenance:
No.:

Date: Service Work Reference No.:

Foundation And Outer Area

All checks performed in accordance with WTG Manual? Completed No -
Any defects or incomplete maintenance items must be listed in the notes section. with no Include
defects details in
notes
Down Tower Assembly
All checks of the DTA were performed in accordance with WTG Manual? Completed No -
All torque checks must be performed in accordance with the Bolt Torque Spec. with no Include
Any defects or incomplete maintenance items must be listed in the notes section. defects details in
notes
Tower
All checks of the Tower Section were performed in accordance with WTG Manual? Completed No -
All torque checks must be performed in accordance with the Bolt Torque Spec. with no Include
Any defects or incomplete maintenance items must be listed in the notes section. defects details in
notes
Nacelle
All checks of the Nacelle Section were performed in accordance with WTG Manual? Completed No -
All torque checks must be performed in accordance with the Bolt Torque Spec. with no Include
Lubrication performed in accordance with Lubricant List. defects details in
Any defects or incomplete maintenance items must be listed in the notes section. notes

Yaw Friction Pads/Hydraulic Yaw Brake

Condition of either Yaw Friction Brake Pads or Hydraulic Brake Pads acceptable (Y/N)? Completed No -
Note: Refer to Machine Head Section for numbering. Entire yaw puck set must be changed if any with no Include
one pad is ≤1mm. defects details in
Wear pad thickness can be determined by: notes
1) Direct measurement 2) Feeler gauge 3) Depth gauge reading

1st Piston: 2nd Piston: 3rd Piston:

Drive train
All checks of the Drive Train Section were performed in accordance with WTG Manual? Completed No -
All torque checks must be performed in accordance with the Bolt Torque Spec. with no Include
Lubrication performed in accordance with Lubricant List. defects details in
Any defects or incomplete maintenance items must be listed in the notes section. notes

Hub and Rotor Blades

All checks of the Hub And Rotor Blades Section were performed in accordance with WTG Manual? Completed No -
All torque Checks must be performed in accordance with the Bolt Torque Spec. with no Include
Lubrication performed in accordance with Lubricant List. defects details in
Any defects or incomplete maintenance items must be listed in the notes section. notes

Pitch Motor Carbon Brushes Shortest measured value: Replaced (y/n):

Safety Equipment (if equipped)

All manufacture requirements and regulatory requirements have been completely, documented, Completed No -
and attached to this Maintenance Proof. with no Include
defects details in
notes

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Generator Slipring
All checks of the Generator Slipring Section were performed in accordance with WTG Manual. Completed No -
Any defects or incomplete maintenance items must be listed in the notes section. with no Include
defects details in
notes
Generator Power Brush Shortest measured value: Replaced (y/n):

Generator Ground Brush Shortest measured value: Replaced (y/n):

Note: Attach all note pages. Use “Damage Report – Rotor Blades” to record any blade defects or deviations
found.

WTG No.: Maintenance: Note page_________of___________

Section# Notes (List ANY and ALL deviations, incomplete tasks, or defects found)

Maintenance Personnel: I hereby confirm that the maintenance was performed in accordance with the manual
Name/Signature Date

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Appendix B: Damage Report - Rotor Blades

Details of rotor blade:

Manufacturer: Model / Length: Serial Number:

Site Name: Turbine Number: Commissioning Date:

Lightning receptor
Operating Hours: Production: (kWh)  (If performed)
line resistance:

Include type of observation, size, approximate

Mark diagram below with number Dist. to
Pos. Photo(s) orientation and other relevant information. Inspect
(1-15) indicating location of blade root
No. No. vortex generators (if installed) for proper
corresponding observation (approx.)
attachment.

10

11

12

13

14

15

Remarks:

Inspection Inspector’s
Date: Signature:
Note: Photos should include at least one close up (if possible), one overall blade and one blade width photo.
For tip damage please include additional photos of the leading and trailing edges.

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