Uptower wind turbine component replacement

Patent metadata

Field	Value
Publication number	US-2023213022-A1
Application number	US-202318182769-A
Country	US
Kind code	A1
Filing date	Mar 13, 2023
Priority date	Oct 4, 2013
Publication date	Jul 6, 2023
Grant date	—

Abstract

A method for performing uptower maintenance of a wind turbine in order to replace the main bearing on the turbine shaft is disclosed. Embodiments of this method to perform maintenance may include installing a rotor lock to resist rotation of the main shaft during maintenance, providing a lifting device in order to elevate the main shaft, removing the main bearing from its main bearing housing, and installing a replacement split main bearing. A crane may also be installed uptower to assist in the maintenance.

First claim

What is claimed:

1 . A method for performing maintenance of a wind turbine, the wind turbine comprising one or more turbine blades connected to a main shaft and a nacelle housing for enclosing components of the wind turbine including at least a portion of the main shaft and a main bearing, the main bearing fixable to a stationary position with respect to the main shaft by a main bearing housing, the method comprising the steps of:
installing a rotor lock in order to resist rotation of the main shaft during maintenance of the wind turbine; providing a lifting device in order to elevate the main shaft to a clearance height; removing the main bearing from the main shaft; and installing a split main bearing to the main shaft.

2 . The method of claim 1 further comprising affixing a crane on or proximate to a portion of the nacelle housing, the crane operable to maneuver and lift components of the wind turbine.

3 . The method of claim 2 , wherein the crane is sectionable into components and, wherein the step of affixing a crane further comprises assembling the components of the crane uptower.

4 . The method of claim 1 , wherein the rotor lock circumscribes at least a portion of the main shaft when installed.

5 . The method of claim 4 , wherein the rotor lock is installed between the turbine blades and the main bearing housing.

6 . The method of claim 1 , wherein the clearance height is approximately one inch.

7 . The method of claim 1 further comprising removing the main bearing housing, prior to removing the main bearing, and providing a replacement main bearing housing for the holding the installed split main bearing.

8 . The method of claim 7 , further comprising repairing the main shaft after the main bearing and main bearing housing are removed, and before the replacement bearing housing and the split main bearing are installed.

9 . The method of claim 8 , wherein repairing the main shaft includes removing damage to the main shaft at or near the surface of the main shaft and adding material to the main shaft in order to reestablish an operating outer diameter of the main shaft.

10 . The method of claim 1 , wherein the split main bearing comprises a plurality of semi-circular components.

11 . The method of claim 10 , wherein the plurality of semi-circular components includes a first inner race, at least one set of rollers, and an outer race.

12 . The method of claim 11 , wherein the first inner race, the at least one set of rollers, and the outer race are each provided as pairs of substantially semi-circular components.

13 . The method of claim 12 , wherein the step of installing the split main bearing comprises installing the bottom half of the housing, securing the pair of first inner race components about the main shaft, positioning the pair of at least one set of rollers about the first inner race, and securing the pair of outer race components about the at least one set of rollers thereby securing the first race, the at least one set of rollers, and the outer race together about the main shaft, lowering the main shaft, installing the top half of the housing.

14 . The method of claim 1 , further comprising affixing a first crane and at least one additional crane on or proximate to a portion of the nacelle housing, the first crane and at least one additional crane operable to maneuver and lift components of the wind turbine.

15 . The method of claim 14 , wherein the first crane is affixed on or proximate to a portion of the nacelle housing and is utilized for lifting and positioning the at least one additional crane in order to affix the at least one additional crane on or proximate to a separate portion of the nacelle housing.

16 . The method of claim 15 , wherein the at least one additional crane is divisible into components, the first crane operable to lift and position the components in order to assemble the additional crane.

17 . The method of claim 16 , wherein the components of the at least one additional crane individually weigh 50 lbs or less.

18 . A method for performing maintenance of a wind turbine, the wind turbine comprising one or more turbine blades connected to a main shaft and a nacelle housing for enclosing components of the wind turbine including at least a portion of the main shaft and a main bearing, the main bearing fixable to a stationary position with respect to the main shaft by a main bearing housing, the method comprising the steps of:
affixing a first crane on or proximate to a portion of the nacelle housing, the first crane sectionable into components; affixing a second crane on or proximate to a separate portion of the nacelle housing, portions of the second crane lifted into place using the affixed first crane, the second crane operable to maneuver and lift components of the wind turbine; installing a rotor lock between the turbine blades and the main bearing housing in order to resist rotation of the main shaft, the installed rotor lock circumscribing at least a portion of the main shaft; providing a lifting device in order to elevate the main shaft to a clearance height; removing the main bearing housing; removing the main bearing from the main shaft; installing a split main bearing to the main shaft, the split main bearing composed of a plurality of semi-circular components; and providing a replacement main bearing housing for holding the installed split main bearing,
wherein the steps of installing a rotor lock through providing a replacement main bearing housing occur uptower on the wind turbine.

19 . The method of claim 18 , wherein the components of the first crane each weigh about 50 lbs or less.

20 . The method of claim 18 , further comprising repairing the main shaft after removing the main bearing, and before installing a split main bearing.

Assignees

• Inventus Holdings Llc

Inventors

• Lohan Martin E
• Fenger Per Eske
• Asheim Charles
• Gonzalez Miguel A
• Brake Daniel M

Classifications

• F03D80/70

  Bearing or lubricating arrangements · CPC title

• F05B2230/80

  Repairing, retrofitting or upgrading methods · CPC title

• F05B2260/31

  Locking rotor in position · CPC title

• F03D80/50 Primary

  Maintenance or repair · CPC title

• F05B2240/50

  Bearings · CPC title