GB/T 25385-2019Wind turbines—Operation and maintenance requirement (English PDF)

3.1 Operation

The production activity that is operated on the unit to ensure the safe and reliable operation of the unit, according to the grid conditions, dispatch requirements, weather conditions, power transformer substation and unit conditions.

3.2 Maintenance

The maintenance activity to ensure the normal operation of the unit according to the design requirements, unit conditions, data analysis results, including regular maintenance, condition-based maintenance, fault handling, flaw handling and so on.

3.3 First maintenance

The first regular maintenance after the unit is connected to the grid for the first time; the deployment time shall not exceed three months after the grid connection of the unit.

3.4 Semi-annual maintenance

The maintenance work of the unit that is carried out the first half a year after the first grid connection of the unit and every subsequent semi-annual period of an odd number of times.

3.5 Annual maintenance

The maintenance work of the unit that is carried out one year after the first grid connection of the unit and every subsequent year of integral multiples.

3.6 Work sheet

The record file that is used to record process information and work result data during unit operation and maintenance.

3.7 Flaw

Occurred anomalies and hidden dangers during the unit operation.

3.8 Consumables

Materials that are preventively replaced according to the design requirements of the unit and the statistical laws of equipment wear and aging.

3.9 Spare parts

Electrical and mechanical parts that are required for fault handling during operation and maintenance of the unit.

4.1 Personnel requirements

4.1.1 General requirements for personnel

All personnel involved in the unit work shall meet the following requirements:

a) In health; have physical examination from enterprise-accepted hospitals with physical examination qualifications according to relevant standards; do not have symptoms that hinder the operation and maintenance of the unit. Electrical workers and those who work high above the ground shall meet the requirements of Chapter 9 of GBZ 188-2014.

b) Have work license and certified qualification proof. For example, the worker who work high above the ground shall hold a high-altitude operation permit; the personnel engaged in electrical work shall hold an electric operation permit.

c) Master first-aid on electric shock sites and high-altitude rescue methods; master the use methods of safety tools/appliances and fire-fighting equipment, so as to cope with safety accidents during operation and maintenance.

d) Master the operating conditions and performance parameters of the wind farm equipment; master the working principle, basic structure and operation of the relevant units.

e) Master various of condition information, fault signals and fault types of the unit and emergency facilities; master the reasons and handling methods for general faults.

f) Master the work ticket system; master the requirements for filling and using work tickets.

4.1.2 Requirements for operating personnel

Operating personnel shall meet the following requirements:

a) Master the use of wind farm data collection and monitoring, weather forecasting, communication, scheduling and other systems;

b) Be able to strictly enforce the power grid and government-related department instructions;

c) Be able to complete the statistics and calculation of various operational indicators of the wind farm;

d) Have the ability of data analysis; be able to carry out operational data and indicator analysis work on a regular basis.

4.1.3 Requirements for maintenance personnel

Maintenance personnel shall meet the following requirements:

a) Master the unit maintenance work manual. Carry out any inspection and maintenance work within the planned time; strictly enforce the operation requirements in accordance with the manual.

b) Master the maintenance process, procedures, commissioning methods and quality standards of the unit.

c) For tools and instruments for maintenance use, train to master the use and maintenance methods of the equipment; master the judgment and treatment of general faults.

d) Master the filling specifications and requirements for the work sheet or other specific documents; fill and report them in time according to regulations.

4.2 Safety requirements

4.2.1 Before the work, perform the safety disclosure and record; formulate corresponding safety plans according to the operational risks.

4.2.2 Strictly follow the road traffic safety regulations of the wind farm; equip appropriate vehicles, to ensure the safety of the wind farm. Emergency supplies such as first-aid kits and emergency lights shall be equipped on the vehicles and regularly inspected, supplemented or replaced.

4.2.3 Equip wireless communication equipment and backup power supply; keep the contact between each operation point and the monitoring center at any time. Personnel shall not work alone in the unit.

4.2.4 Properly select and use personal protective equipment; perform detection on personal protective equipment regularly as required.

4.2.5 Before the maintenance work, know the weather. Do not maintain the unit during thunderstorms; do not approach the unit within 1 hour after the end of thunderstorm weather.

4.2.6 Before the maintenance work, stop the unit and set to "maintenance" status, and hang a warning sign; after the maintenance work is completed, adjust the unit to "running" status and remove the warning sign.

4.2.7 During the towering and operation, personnel shall ensure adequate lighting.

4.2.8 When ladders are used, personnel shall wear seat belt, protective shoes, non-slip gloves, and use anti-falling protective clothing.

4.2.9 When the engine room hoist is used, pay attention to the wind speed, wind direction and engine room direction. If necessary, use a wind rope or manual yaw to keep the chain away from the high-voltage lines and transformers. During the lifting, personnel on the bottom of the tower shall be away from the hanging objects. Prevent falling objects from causing personal injury. Ensure that the hanging objects are well tied, no obstacles or safety hazards on the hanging route. Take password-based operations.

4.2.10 When entering the hub or working on the impeller, reliably lock the impeller first. When the impeller is locked, the wind speed shall not be higher than the maximum allowable wind speed that is specified by the unit.

4.2.11 During operation and maintenance, tools and parts shall not be thrown in the air. Tools and parts shall be placed in an orderly manner. After the operation and maintenance work, tools and parts shall be inspected and shall not be left in the unit.

4.2.12 For electrical operation, implement the safety requirements of "power off, hang the tag and lock, power inspection, grounding, and isolation".

4.2.13 When personnel enter the confined space, take necessary measures to ensure that the location is well ventilated.

4.2.14 For work that requires fire, prepare all fire prevention measures in advance.

4.2.15 Regularly inspect fire-fighting equipment such as unit fire extinguishers.

4.2.16 For cleaning such as dust and toner, provide personal protective gear to prevent dust from inhaling.

4.2.17 When the converter is operated and maintained, cut off the power on the low-voltage side of the transformer on the grid side; perform the operation after the power is measured and confirmed to be cut off.

4.2.18 When the hydraulic system is maintained, relieve the pressure for the corresponding hydraulic circuit.

4.2.19 During the work outside the engine room, use seat belts; hang the double hooks on the safety anchor point; when railing on the top of the engine room is used as the hanging point, the hanging point shall meet the design requirements of the safety anchor point.

4.2.20 Before the high-speed shaft guard is removed, brake the high-speed shaft.

4.2.21 When approaching the rotating parts such as the high-speed shaft and the fluted disc, pay attention to safety and prevent pinching.

4.2.22 When cleaning the unit, the cleaning agent and absolute ethanol shall comply with relevant environmental protection requirements. Pay attention to fire prevention and ventilation during operation.

4.2.23 When the blade is frozen (the risk of falling ice outside the unit), keep away from the rotating surface of the impeller, and strictly forbid to stay in the dangerous area.

4.2.24 In case of thundering during operation, evacuate in time; when there is no time to evacuate, stand on the tower platform with both feet together and do not touch any metal objects.

4.2.25 In response to an emergency, the passages that rescuers may use shall be kept open.

4.2.26 In the emergency that directly threatens personal safety, the person in charge of the site has the right to stop the operation and organize the evacuation of the site.

4.2.27 For requirements which are not mentioned here, comply with DL/T 796.

4.3 Operation and maintenance file requirements

Operation and maintenance files shall contain the following contents:

a) equipment ledger;

b) equipment safety operation range and system description;

c) unit start and stop operation procedures;

d) unit subsystem and its operational description;

e) required conditions of the unit before maintenance work;

f) Define clear cycles, working methods, requirements, protective equipment, procedures and risks, according to the specific maintenance works (including lubrication and bolt inspection);

Note: Appendix A lists some of the lubrication items and cycles for reference.

g) recommended lists of consumables, spare parts, and tools;

h) maintenance work sheet (see Appendix B).

4.4 Environmental protection requirements

During the operation and maintenance of the unit, follow the relevant national environmental protection regulations; make garbage classification and treatment; protect the surrounding environment of the unit, including soil, water, forest land and grassland.

5.1 General requirements

5.1.1 The operation of the unit mainly includes:

a) monitoring and adjustment of the unit operation conditions;

b) unit operation data backup, statistics, analysis and reporting;

c) implementation and supervision of work tickets, operating tickets, etc.;

d) When flaws or faults are found during operation and maintenance of the unit, reasonably operate the unit's operation mode and organize the personnel to carry out corresponding work, so as to ensure the safe operation of the equipment. If it belongs to the power grid dispatching jurisdiction, the operating personnel shall immediately report the power grid dispatch;

e) supervision and inspection of the implementation of the unit maintenance standards;

f) Record the operating data of the unit, including fault record, flaw record, lost power, abandoned wind rate, etc.;

g) Perform unit file management, including hoisting records, commissioning records, maintenance records, consumables and spare parts records, drawings, etc.

5.1.2 Conditions that the unit shall have before it is put into operation:

a) For long-term power-off and out-of-operation and newly-introduced units, check various components and devices (power supply, control power supply, safety device, control device, remote communication device, high-voltage system, yaw system) of the unit according to the technical requirements of the unit before they are put into operation. If it is in a normal state, start after the generator stator and the rotor insulation are checked qualified;

b) Before the maintained unit is started, confirm that the safety measures during the operation have been canceled;

c) The external and internal environmental conditions are in accordance with the operating conditions of the unit; the temperature, humidity and wind speed are within the design parameters of the unit;

d) Before it is manually started, the surface of the impeller shall be free of ice;

e) The unit power supply and control power supply are in the on position; the power phase sequence is correct; the three-phase voltage is balanced; the frequency is normal; the unit control system self-test has no fault information;

f) All safety devices are in normal position; there is no fault, short circuit or withdrawal;

g) The oil temperature, oil pressure and oil level of each sub-system of the unit are normal; the energy storage device and brake device in the system work normally;

h) The remote communication device is in a normal state;

i) If it is unauthorized, do not modify the unit equipment parameters and protection settings; do not modify, short-circuit, shield or remove the control of the equipment or the measurement circuit wiring.

5.1.3 For the unit which has been powered-off and out-of-operation for more than three months, it should be maintained according to different lengths of time, including but not limited to the following maintenance items:

a) Check the shroud, engine room and other spaces for leakage of rain; ensure that there are no water erosion parts in the unit;

b) Check every bolted connection for abnormalities such as looseness and corrosion;

c) In areas of high humidity, for the electrical control cabinet of the unit which has been placed with simple dehumidification equipment or appliances, perform maintenance or replacement;

d) Check the corrosion of the electric control cabinet, gear box and yaw ring gear in the unit, and carry out maintenance on equipment that may have condensation and corrosion;

e) Regularly check the performance of the internal battery and supercapacitor of the unit. If it does not meet the requirements, record it, and process or replace it before the unit is restarted.

5.2 Data acquisition and monitoring system

5.2.1 The main contents of the general inspection of the monitoring system are:

-- Working condition of the primary server;

-- Working condition of each industrial computer;

-- Working condition of the core switch;

-- Working condition of the fiber switch;

-- Remaining space of the primary server disk.

5.2.2 The signals and data that are displayed by the system are normal; the storage and backup of the database are normal.

5.2.3 The auxiliary equipment such as printer and alarm sound work normally; test if necessary.

5.2.4 The condition monitoring system works normally.

5.2.5 If video surveillance is available, the video surveillance shall work normally.

5.2.6 Regularly acquire and back up the wind farm and monitoring system data; ensure the accuracy and completeness of the data.

5.2.7 Carry out hierarchical management on the wind farm data acquisition and the monitoring system software operation authority; do not cross the border to operate without authorization.

5.2.8 Monitoring system server, industrial computer, front desk workstation and other equipment shall be shut down and cleaned every year.

5.3 Unit abnormal operation and fault handling

5.3.1 When the unit has an abnormal alarm signal, the operating personnel shall analyze, judge or test the signal according to the operating procedures, and perform appropriate treatment according to the operating procedures.

5.3.2 When the unit is disconnected from the grid due to system factors such as grid frequency and voltage, implement in accordance with the requirements for wind power grid connection.

5.3.3 When conditions that may cause object falling from high altitudes, such as over-speed, blade damage, icing, occur during the operation of the unit, it shall not be operated locally. The operating personnel shall remotely stop it through the remote monitoring system and set up a safety protection zone to avoid people entering potentially-dangerous areas.

5.3.4 When the unit is on fire, stop immediately and disconnect the line circuit breaker that is connected to the unit and alarm at the same time.

5.3.5 When the unit brake system fails, deal according to the special treatment plan immediately.

5.3.6 The sequence of manual shutdown operations that are required by the unit due to other abnormal conditions:

a) normal shutdown;

b) When the normal shutdown fails, take remote or local emergency shutdown;

c) When the emergency shutdown fails, ensure personnel safety first.

5.3.7 The emergency response and emergency disposal during the operation of the unit shall comply with the provisions of Chapter 10 of GB/T 35204-2017.

5.4 Unit operation analysis

5.4.1 Unit operation analysis includes indicators such as availability, power curve, fault, and power consumption, which shall be analyzed monthly; an analysis report shall be formed.

5.4.2 For wind farms that are composed of several different types of units, the indicators shall be analyzed separately.

6.1 General requirements

6.1.1 Before the start of maintenance work, formulate the maintenance plan according to the actual operation of the unit; prepare the required materials and tools; meet the requirements for use.

6.1.2 When adding oil and grease to the unit, ensure that the oil is clean to avoid secondary pollution; the added oil shall be consistent with the original oil sample type and within the validity period. If the oil sample needs to be replaced, it shall meet the technical requirements and replacement process of the unit.

6.1.3 Other maintenance materials such as carbon brushes, filter elements, shall be identical with the original material type of the unit or confirmed to be replaceable, and shall meet the technical requirements of the unit and the replacement process requirements.

6.1.4 When using detergent to clean the unit, keep it well ventilated.

6.1.5 When replacing heavy spare parts, auxiliary lifting equipment inside the unit should be used.

6.1.6 After the maintenance work is completed, keep the working environment clean and unlock the unit.

6.1.7 After the wind farm is subjected to strong convective weather (thunderstorms, typhoons), inspect the tower, blades, pitch system and electronic control system of the unit.

6.1.8 The records of maintenance works shall be filled out in time according to the specifications to ensure that the recorded information is accurate and true; the record format is standardized for easy analysis.

6.2 Regular maintenance

6.2.1 The regular maintenance cycle shall be determined according to the design and operation requirements of the unit; it may include: first maintenance, semi-annual maintenance, and annual maintenance. See Appendix C for some of the contents and requirements for regular maintenance work.

6.2.2 The interval between semi-annual maintenance and annual maintenance of the unit shall be no more than 6 months.

6.2.3 For the regular maintenance, record the maintenance process, and form a maintenance summary or report. Archive the process record files; deal with problems that are found in the maintenance in a timely manner, and form the problem processing records and archive.

6.3 Consumables and spare parts

6.3.1 List spare parts and consumables that are commonly used by the unit; prepare adequate consumables and spare parts according to their performance and frequency of consumption; store in a suitable place. Chemical materials shall be stored separately according to the chemical storage regulations; the storage location and environment shall meet fire safety requirements.

6.3.2 The list of consumables and spare parts that is provided by the unit supplier shall include the following:

-- material installation location;

-- unit manufacturer's material number;

-- material name, brand;

-- specification model;

-- key characteristic indicators;

-- information such as recommended amount.

6.3.3 The spare parts of the unit that are repaired and replaced shall be managed separately by using labels that are not easily lost, and stored separately to avoid mixing. The label needs to record information such as the unit number, the operator, the fault status, the spare part fault point, and the replacement time.

6.4 Flaw handling

6.4.1 Divide flaws into three categories according to the possible power loss or the possible impact on production:

a) Type-I flaw: equipment or facilities directly has flaws that threaten the safety operation and need to be dealt with immediately, which may cause accidents such as equipment damage, personal injury or death, large-scale power outage, fire at any time, or have caused lower power generation that affects the external power supply;

b) Type-II flaw: flaws that seriously threaten people, power grids and equipment, which can still operate; they may cause accidents if not dealt with in time;

c) Type-III flaw: flaws that do not deteriorate into type-I or type-II flaws in a short period of time, but have an effect on the operation, while it can still operate.

6.4.2 During the maintenance process, record the discovered flaws to form a flaw item summary sheet.

6.4.3 Maintenance personnel shall follow up the technical plan and rectify the material progress in time, and complete the flaw rectification according to the rectification plan.

6.4.4 The process, content and data of the flaw handling shall be recorded. The contents of the record should include:

-- item name;

-- unit position number;

-- date;

-- name of the flaw;

-- solution;

-- flaw discovery method; […]