David A. Rivkin, PhD

Laurel Silk, MEdr BA

JONES & BARTLETT

LEARNING

Contents

Preface X|

About the Authors xiii

^^^^^fl Determining Wind Turbine Value 1

Maintenance, Repair, and Cost Overview 2

General Operating and Maintenance Cost Overview 2

Fixed and Variable Costs 3

Safety Cost Considerations 4

Wind Energy Value Considerations 6

Fuel Savings 7

Capacity Value 8

Environmental Value 9

^^^^^9 Conversions 19

Units of Measure 20

Meter 20

Kilogram 20

Second 20

Joule 21

Watt 21

Coulomb 21

Volt 21

Ampere 21

Ohm 21

Hertz 21

Contents v

Calculations 22

Addition 22

Subtraction 22

Multiplication 22

Division 23

Conversion of Units 24

Converting Dimensions and Units 24

Functions and Equations 24

^^^^^9 Safety on the Job 35

What Is OSHA? 36

1910 Regulations 37

Sample Training Course Syllabi 39

Job Risk 41

Proper Safety Techniques: PPE and the Two-Person Rule 43

Proper Safety Techniques: Grounding and the

Three-Stage Safety Model 46

Proper Safety Techniques: Tower-Climbing Safety 49

OSHA Regulationsfor Special Industries 50

Other Common Technician Safety Concerns 54

!! Electrical and Mechanical AspectsliliUIJifcB of Wind Turbines 63

Wind Turbine Electrical Devices 64

Electrical Devices 65

Power Cables 70

Contactors, Circuit Breakers, and Fuses 72

Wind Turbine Mechanical Devices 73

Rotor 73

Main Shaft 76

Couplings 76

Disk and Clutch Brakes 76

Gearbox 78

Other Mechanical Devices 80

vi Contents

General Mechanical Principles 80

Inertia Forces 80

Cantilevered Beam Bending 80

Rigid Body Planar Rotation 81

Gears and Ratios 81

Gyroscopic Motion 81

Vibration 82

^^^^^fl Wind Turbine Manufacturing and Materials 89

Wind Turbine Materials Overview 90

Steel 90

Composites 90

Copper 92

Concrete 92

Machine Components 93

Industry Standards 93

Shafts 94

Couplings 94

Bearings 94

Gears 95

Dampers 95

Fasteners 96

Principal Rotor Components 98

Industry Standardsfor Rotors 98

Rotor 98

Blades 98

Drive Train 102

Industry Standardsfor Drive Trains , 102

Main Shaft 102

Couplings 102

Gearbox 102

Generator 103

Brakes 103

Contents vii

Yaw System, Main Frame, and Nacelle Housing 104

Industry Standardsfor Yaw Systems 105

Main Frame 105

Nacelle Housing 105

^^^^^9 Gear Failure and Preventive Maintenance 111

Gear Terminology Defined 112

Pitch Circle 112

Tooth Face 112

Face Width 113

Circular Pitch 113

Backlash 113

Gear Types 114

Spur Gear 114

Rack and Pinion 114

Internal Ring Gear 115

Helical Gear 115

Helical Rack 115

Double Helical 115

Face Gear 117

Worm Gear 117

Straight Bevel 117

Spiral Bevel 118

HypoidGear 119

Screw Gear 120

Components of Planetary Gearboxes 120

Planet Carrier 120

Planet Gear 121

Ring Gear 121

Sun Gear 122

Gear Functions 122

Rotation Speed 122

Gear Ratios 123

Relationships Between Torque, RPM, and Power 125

x Contents

Documentation Procedures 174

Accurate Measurements 174

System Control and Data Acquisition (SCADA) Systems 174

Historical Data and Event Logging 175

^^^^^M Wind Turbine Operating Costs 179

Onshore Operating and Maintenance Costs 180

Operating Costs 180

Maintenance Costs 180

Other Costs 181

Offshore Operating Costs 181

Grid Connection Costs 182

Tower and Support Structure Costs 182

Offshore Turbine Operations and Maintenance 183

Answer key 189

Glossary 191

References 200

Index 203