The invention relates generally to wind turbines and more specifically to an apparatus and method for lowering and raising a single wind turbine rotor blade from the six-o'clock position.
Rotor blades are attached to a rotor hub of a wind turbine at a rotor hub flange. Installation of the rotor blades to the rotor hub flange may be in the initial installation of the wind turbine. Removal and replacement of rotor blades may be required over the operational life of the wind turbine. Rotor blades may require replacement due to damage caused by environmental sources such as lightning strikes, corrosion and hail or from physical stresses or defects within a blade.
With environmental demands for clean, non-carbon dioxide generating energy sources, wind energy is becoming an increasingly larger source of electric power domestically and internationally. Taller wind towers with larger and heavier rotor blades are being produced to more effectively capture the wind and its power-generating capacity. Wind turbine towers may be 100 meters tall and individual wind turbine rotor blades may extend 50 meters. Rotor blade removal and replacement operations therefore take place at great heights.
The replacement of a rotor blade may often be accomplished with a large crane. Such a large crane must have load capacity for the full blade and be able to lift the full blade to the height of the rotor hub. The rotor blade may be positioned hanging vertically with respect to the ground or horizontally facing to one side of the wind turbine. Significant expense is incurred in renting, procuring, operating and removing the large crane. Further, when a blade is removed/replaced in the horizontal position, the remaining 2 blades are in the 11 o'clock and 7 o'clock positions, creating a large moment on the hub. This naturally unstable position relies on the integrity of the brake to ensure no incidents associated with inadvertent rotation occur. The instability issues associated with the horizontal lift of a wind turbine rotor blade may be avoided by positioning the rotor hub for which the blade is to be removed or replaced in a six-o'clock position.
Accordingly, it is desirable to provide a simple, safe and cost-effective means for mounting single rotor blades of wind turbines without the need for the large cranes used in prior art for lifting of rotor blades.
The present invention relates to a lifting arrangement and method for lifting and lowering a single rotor blade from a six-o'clock position without a need for a crane large enough and with sufficient load capacity to raise the rotor blade to the height of the rotor hub mounting location.
Briefly in accordance with one aspect of the present invention, a method is provided for removing a rotor blade from a rotor of a wind turbine installed atop a wind turbine tower. The method includes attaching a first pulley to a first attachment point at a first adjacent rotor blade to a rotor blade being removed and attaching a second pulley to a second attachment point at a second adjacent rotor blade to the rotor blade being removed. The method further includes positioning the rotor blade being removed in a six-o'clock position. A blade harness is attached over a substantial length of the blade being removed. A first lifting line from a first ground winch over the first pulley is attached to a first side of the blade harness. A second lifting line from a second ground winch is attached over the second pulley to a second side of the blade harness. The method further includes lowering the blade being removed by coordinated winch operation. A tail end support line is further attached between the blade harness and a tail pick crane. The rotor blade being removed is rotated to a horizontal resting position by coordinated winch operation and tail pick crane operation.
In accordance with a second aspect of the present invention, a method is provided for installing a rotor blade onto a rotor of a wind turbine installed atop a wind turbine tower. The method includes positioning a mounting flange of a hub for a rotor blade being installed in a six-o'clock position and locating the rotor blade being installed underneath the hub of the rotor. The method further includes attaching a blade harness over a substantial length of the rotor blade being installed. A lifting line from a first ground winch over a first pulley at the hub is attached to a first side of the blade harness and a lifting line from a second ground winch over a second pulley at the hub is attached to a second side of the blade harness. The method also includes attaching a tail end support line between the blade harness and a tail pick crane and rotating the rotor blade being installed from a horizontal position to a vertical position by coordinated winch operation and tail pick crane operation. When in a vertical position, the rotor blade is raised by coordinated ground winch operation
According to another aspect of the present invention, an arrangement for lifting and removal is provided for a single wind turbine blade from a six-o'clock position on a wind turbine tower. The lifting arrangement includes a rotor hub wherein a mounting for the rotor blade is parked at a six-o'clock position. A first pulley and a second pulley are mounted symmetrically on the rotor hub about the mounting for the rotor blade. A blade harness is disposed over a substantial length of the rotor blade. A first ground winch and a second ground winch are disposed around the base of the wind turbine tower. A lifting line from the first ground winch over a first pulley on the hub attached to a first side of the blade harness is provided along with a lifting line from a second ground winch over a second pulley on the hub attached to a second side of the blade harness. A tail pick crane is provided, supporting a tail end support line between the blade harness and the tail pick crane.
These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
The following embodiments of the present invention have many advantages, including allowing replacement of a wind turbine rotor blade without the need for a large expensive heavy-duty crane. The method further allows removal and replacement of the rotor blade with simple equipment in a manner that protects the blade from damage. A blade harness is provided that distributes the weight during the lift over a substantial length of the rotor blade and provides protection for the trailing edge against damage during the lift.
The bolts 150 holding outer flange 140 may also serve for attaching mounting 160 in place on the rotor hub 135. As attached, the mounting 160 may project generally radially from the hub 135, and circumferentially with respect to the outer flange 140 of the rotor blade bearing, such that mountings on adjacent rotor blade bearing outer flanges 140 line up symmetrically with respect to the rotor blade being replaced. At least one hole 165 may be provided in the mounting 160 for lifting slings 170 (
More particularly, the first pulley 240 may be supported by a first mounting block 280 attached to a first attachment point 250 on the hub 235 to a first side of the rotor blade 305. A second mounting block 285 for the second pulley 245 may be attached to a second attachment point 255 on the hub 235 to a second side of the rotor blade 305. The first mounting block 280 may be attached at the pitch blade bearing flange 250 on first adjacent rotor blade 225. A second mounting block 285 may be attached at the pitch blade bearing flange 255 at a second adjacent rotor blade 230.
Herein the mounting of the first mounting block 280 and the second mounting block 285 on the hub 235 are generally symmetrical with respect to the rotor blade 305 to facilitate lifting and lowering of the rotor blade. Preferred attachment points for the first mounting block 280 second mounting block 285 may be to studs associated with the pitch bearing flanges 250, 255 for the respective first adjacent blade 225 and second adjacent blade 230. However, other attachment points may be provided on the hub 235. A plurality of nuts 253, 254 preferentially about five nuts may be removed from the respective pitch bearing flange studs 251, 252 to make the studs available for attachment for each of the mounting blocks. The nuts removed 253, 254 may centered forward-to-aft along the hub so as to line up with the mounting blocks 280, 285 generally centered forward-to-aft on the rotor blade surface 226, 231 (See 150
The blade harness 300 also includes a plurality of transverse straps 340 adapted for deployment around the rotor blade at various longitudinal positions. Such deployment may provide for distribution of the weight of the rotor blade 305 along a substantial length of the rotor blade, avoiding concentration of weight in a specific area such as the neck or root end 306. The transverse straps 340 include tightening means to form a snug fit around the rotor blade 305 at the various longitudinal positions. Such tightening means may include, but not be limited to, turnbuckles 343, as illustrated in
One or more transverse straps 340 may be joined with the main longitudinal straps 310 at a lifting plate 350. At least one lifting plate 350 is provided on the pressure side 315 of the rotor blade 305 and at least one lifting plate is provided on a suction side 325 of the rotor blade 305. Preferentially, the transverse strap 345 closest to the root end 306 of the rotor blade 305 includes the lifting plates 350 providing for attachment to lifting lines (270, 275
The lifting arrangement according to
Referring again to
One aspect of the present invention provides a method for lowering and raising a single wind turbine rotor blade from the six-o'clock position. In preparation for lifting, the area under the tower should be cleared of unnecessary personnel and equipment. Ground winches are positioned in an area that will allow for the best position to run the lifting line over the pulleys and to the rotor blade. Usually a position about 50 meters behind or in front of the tower is a good position, however, alternative placement may be required due to geographical constraints,
The rotor may be rotated so blades are rabbit-eared with the replaceable rotor blade in the 3 o'clock position and the left side of a first adjacent blade is in the top position of the hub as viewed from the nacelle. A rotor lock is applied to prevent blade rotation. A mounting block with an attachment eye for a first pulley is attached to the blade mounting hub for the first adjacent blade. To accomplish a preferred mounting, a plurality, normally five, of pitch bearing bolts are removed from the pitch bolt studs of the first adjacent blade. The mounting block may be bolted to the five pitch bolt studs. The pulley block may then be attached to the mounting block attachment eye. However, other mounting locations may be provided on the hub.
The rotor lock is released and the rotor rotated so the blades are rabbit-eared, with the replaceable blade in the 9 o'clock position and the right side of the second adjacent blade is in the top position of the hub as viewed from the nacelle. The high speed rotor lock is applied. A plurality of nuts may be removed from the pitch bearing bolts for the blade adjacent to the replaceable blade
A mounting block with an attachment eye for a second pulley is attached to the blade mounting hub for the second adjacent blade. To accomplish a preferred mounting, a plurality, normally five, of pitch bearing bolts are removed from the pitch bolt studs of the second adjacent blade. The mounting block may be bolted to the live pitch bolt studs. The pulley block may then be attached to the mounting block attachment eye. However, other mounting locations may be provided on the hub.
The rotor lock is released and the rotor rotated so the blades are rabbit-eared, with the replaceable blade in the 9 o'clock position, and the right side of the adjacent blade is in the top position of the hub as viewed from the nacelle. The blade harness is wrapped around the blade tip, ensuring the adjustable turnbuckles are loosened to its maximum looseness, allowing the blade harness to slip over the blade as it is raised. The blade harness may be attached the blade harness to man basket for lifting. The man basket and blade harness are raised, keeping the harness around the blade to the point on the blade where the blade harness will rest. The blade harness is tightened until snug to the blade. A plurality of tag lines may be attached to the rotor blade for lateral support during lifting and lowering.
A first lifting line from a first ground winch may be raised and threaded through the first pulley block. The first lifting line is lowered and attached to a lifting plate on a first side of the blade harness. A second lifting from a second ground winch may be raised and threaded through the second pulley block. The second lifting line is lowered and attached to a lifting plate on a second side of the blade harness.
Operation is coordinated between operators of the ground winches to take up slack evenly between winches so wire ropes are taught. Blade nuts for rotor blade being removed are carefully removed, maintaining the level control over the blade, while taking up slack with coordinated action of the first ground winch and the second ground winch and the tag lines.
The rotor blade is lowered by coordinated operation of the two ground winches simultaneously.
When the rotor blade is at a point where the tail pick crane can be attached, winch operation is stopped and the blade tip is attached to the tail pick crane. The rotor blade is further lowered to a horizontal position on the ground or on a mounting truck using the tail pick crane and tag lines as guides. Lateral movement of the blade is controlled with the tag lines. The tail pick crane controls all other directional movement of the blade, as the coordinated ground winches complete lowering.
In preparation for restoration of the rotor, a replacement rotor blade is positioned on the ground directly underneath hub. The blade harness is attached to the replacement rotor blade. The blade harness is tightened to fit snugly on new blade such that no slippage will occur when blade is raised. Lift lines and tag lines are attached to the blade harness.
Normally, for such a replacement, it would be anticipated that the pulley blocks would have been mounted on the hub and the lifting lines run over the pulley blocks. Otherwise this equipment would be installed as previously described. The replacement rotor blade is raised using coordinated operation of the ground winches and tail pick crane. Lateral movement of the blade is controlled with the tag lines. When blade is at a point where the tail pick crane can be removed, winch operation is stopped and the attachment to the rotor blade tip from the tail pick crane is removed. Lifting with coordinated winch operation continues until the rotor blade gets close enough to the hub to zero the blade with the mount, aligning the rotor blade bolts with the correct holes to zero the blade. Once the rotor blade bolts in the correct position, winch operators will slowly move the blade bolts into the bolt holes. A tightening sequence is performed for the nuts on bolts.
When the rotor blade is secured to the hub, lifting lines are slacked. A man-basket may be positioned to support the blade harness. The blade harness is untightened from the rotor blade and the connections with the lifting lines are detached. The blade harness is lowered to the ground. The ground winches raise the lifting lines to the pulley blocks. The lifting lines are then lowered to the ground.
The rotor locks are released and the rotor is positioned for removal of the first pulley block and the first mounting block on the hub. The rotor is then positioned for removal of the second pulley block and the second mounting block on the hub. When the equipment has been removed from the hub and lowered to the ground, the installation may be operationally checked.
While various embodiments are described herein, it will be appreciated from the specification that various combinations of elements, variations or improvements therein may be made, and are within the scope of the invention.