Warwick Wind Turbine Build Report.pdf - Engineers Without Borders ...

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Appendix M Maintenance PackWind Turbine Maintenance Pack1 BackgroundIn October 2010 Engineers Without Borders, a Students Union society, installed andconnected to the University grid a 1.1kW wind turbine built by the students on a courseled by DIY wind turbine specialists V3 Power. The wind turbine is located over byCryfield Maintenance Depot [1].The aim of this document is to provide all the information necessary to maintain thewind turbine into the future.2 Maintenance ProgrammeThe aim of the maintenance programme is: for EWB to carry out regular maintenance checks according to the MaintenanceSchedule record any maintenance completed and the energy production in theMaintenance Log present the Maintenance Log to Nick Hillard of Estates Office on a monthly basisto ensure payment for energy production which funds future maintenance of thewind turbine.3 Useful Documents1. Engineers Without Borders Warwick Wind Turbine Report – contains allinformation on EWB Warwick Wind Turbine including financing, planningpermission, installation, risk assessments, safety testing [2].2. Maintenance Schedule – timeline of checks to be carried out by EWB [3].3. Maintenance Log – document recording maintenance and energy production ofwind turbine [4].4 Useful ContactsNick Hillard, Environment Manager, University of Warwick Estates Office,nick.hillard@warwick.ac.ukAndy Leeson, Engineer, University of Warwick Estates Office,a.d.leeson@warwick.ac.ukAdam Perrin, Engineering Student who organised course, 07884353290,adamgperrin@msn.com1
Tom Dixon, V3 Power, 07553250605, info@v3power.co.ukAran Eales, V3 Power, 07985727925Tom Hooley, V3 Power, 077688247685 Component TroubleshootingBlades – The blades need repainting every year in order to remain waterproof. Leadingedge blade erosion can occur due to particles in the air colliding with the blade. This willreduce the efficiency of the turbine as the aerofoil will be altered and a rougher surfacecreated. Filling in groves with wood filler and sanding can help this problem. If theblades are damaged beyond repair they will need to be re carved. In windy locations ithas been found that blades need re carving after around 10 years.Stator and rotor – The air gap between the rotors is designed to be as small as possiblein order to maximise power output. This means that any position alteration of the statorcould cause the rotor and stator to rub, causing wear. Rubbing can be checked by avisual inspection of the erected turbine using binoculars and by listening for unexpectedsounds. If a misalignment is detected take down the turbine on a calm day and checkthe positions. The rotors should be about 1mm away from the stator and parallel to it.Nuts and blots can be tightened which should reposition the components. If rubbing hasoccurred resin may need to be reapplied. No magnets or coils should be exposed. If awire of a coil has been worn through it may need re soldering, or the stator replacing.Any work involving removal of rotor discs should make use of jacking rods to avoid therotor discs colliding due to the strong magnetic forces.Bearing – The bearing used is designed for a trailer wheel, so is expected to last 10year. It takes around 1,000 revolutions for the bearing to wear in, in which time thegrease warms up and becomes less stiff. If the bearing is making a grinding sound orfeels jolty it may need to be re greased or the tapered roller bearings realigned. It canbe taken apart and cleaned with petrol before re greasing. The tightness of the bearingmay need to be adjusted if it feels too stiff or too loose.Mounting – This is made of metal that will need re painting every year. In particular thewelds need checking for signs of failure or rust.Tail – Check welds. Plyboard degrades rapidly, in particular in hot climates. Apply extracoats of paint as necessary.Yaw and tail bearing – These are both simply greased pipes slotted together, that willneed additional greasing annually. The metal on these pivots can wear away andshould be checked.Tower – Turnbuckles and shackles are tied up with winding wire which can becomeloose or rust, these should be checked every month. The shackles will need grease orVaseline in order to prevent rust. Turnbuckles can work loose and should be tightened.The tension of the guy ropes needs to be maintained. Anchors should not incurproblems, but their position can be checked. In the annual take down the welds shouldbe inspected.2
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Engineers Without Borders Warwick W
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Table of Contents1 Introduction ...
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The application forms for the bursa
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the turbine yaws into the direction
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Appendix A Funding Application Form
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If your application is on behalf of
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e.g. Warwick SportSource Amount £
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NPowerDear Louis,I am writing in re
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Appendix B Workshop Risk Assessment
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General Risk Assessment for AreaEng
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Control Measures:• Suitable tools
Page 26 and 27: Containment: The use of these subst
Page 28: Appendix D Planning Application25
Page 40 and 41: Adam Perrin07884353290Adam.Perrin@w
Page 42 and 43: Figure 2 View from Wind Turbine loc
Page 44 and 45: Figure 4 View from Wind Turbine loo
Page 46 and 47: Figure 6 View of Turbine from East4
Page 48 and 49: Figure 8 View of Turbine from West4
Page 50 and 51: Figure 10 Example Wind TurbineSourc
Page 53 and 54: Appendix F CFD SimulationIn respons
Page 55 and 56: Appendix G Archaeological Groundwor
Page 57 and 58: The photo below shows the maintenan
Page 59: Appendix I High Speed Testing Repor
Page 72 and 73: 5. The complete rotor can now be li
Page 74 and 75: Assessment of overall risk ratingPo
Page 78 and 79: Cable - If the turbine yaws consist
Page 83: 7 Load Diversion Regulator Manual8
Page 98 and 99: References1. Wind turbine location,
Page 100 and 101: Xmas4Xmas3Xmas2Xmas1Wk10Wk9Wk8Wk7Wk
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