BOLTED JOINT ASSEMBLY COMMON WIND TURBINE BOLTING APPLICATIONS 1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly BOLTED JOINT ASSEMBLY COMMON WIND TURBINE BOLTING APPLICATIONS This course is focused on the practical principles of assembly, not the design of bolted joints. It is targeted to field service technicians, supervisors, engineers and others who are responsible for quality in bolting and who need to acquire or refresh their knowledge of best practices so that they can better assess performance and achieve the results they seek. A one-day course for mechanics is also available.

1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly The following material is intended to make you aware of the commonly accepted and recognized principles and methods used in assembling bolted joints. However, every possible application of these methods cannot be foreseen and these general guidelines do not supersede any other applicable rules or regulations. ALWAYS FOLLOW CURRENT COMPANY AND LOCAL SAFETY RULES AND PROCEDURES WHEN PERFORMING ANY OF THE WORK DESCRIBED IN THIS PRESENTATION. Hytorc has no control over, and assumes no responsibility for any damage, injury or work interruptions due to any person’s use of, or reliance upon these generally accepted methods and principles. > No course can cover all possibilities and address all problems. The key is to know what to look for, and where to go to get the answers. Hopefully that is what you will take away from this course.

PRODUCTION APPLICATIONS 1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly PRODUCTION APPLICATIONS GEARBOX BEARINGS GENERATOR COUPLING MAIN BEARINGS BLADE BEARINGS BEDPLATE BOLTS YAW BEARING

INSTALLATION APPLICATIONS 1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly INSTALLATION APPLICATIONS ROTOR TO MAIN SHAFT BLADES TO HUB TOWER TO NACELLLE TOWER BOLTS

MAINTENANCE APPLICATIONS 1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly MAINTENANCE APPLICATIONS BEDPLATE BOLTS GENERATOR COUPLING GEARBOX BEARINGS MAIN BEARINGS YAW BEARING BLADE BEARINGS ROTOR TO MAIN SHAFT TOWER TO NACELLLE TOWER BOLTS BLADES TO HUB

BRAKE CALIPER BOLTS STEALTH-2 MAKE UP TORQUE 530 FT.LBS. 1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly BRAKE CALIPER BOLTS 36MM BOLT HEADS STEALTH-2 MAKE UP TORQUE 530 FT.LBS. GE-WIND PRODUCTION TEHACHAPI, CALIFORNIA

YAW MOTOR ASSEMBLY HY-.7MXT 17MM ALLEN BOLTS 17MM DIRECT HEX DRIVE 1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly YAW MOTOR ASSEMBLY 17MM ALLEN BOLTS HY-.7MXT 17MM DIRECT HEX DRIVE MAKE UP TORQUE 510 FT. LBS.

HUB BOLTS PUCK COVERS HY-3SA 50MM NUTS 60MM BOLT HEADS MAKE UP TORQUE 1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly HUB BOLTS HY-3SA 50MM NUTS MAKE UP TORQUE 1400 FT. LBS. PUCK COVERS 60MM BOLT HEADS MAKE UP TORQUE 1550 FT. LBS.

BED PLATE BOLTS LOW CLEAR. 60MM LINK 60MM NUTS MAKE UP SPEC. 1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly BED PLATE BOLTS 60MM NUTS LOW CLEAR. 60MM LINK MAKE UP SPEC. 270 DEGREE NUT TURN

MODEL 5 PEDESTAL BLOCK BOLTS 60MM BOLT HEADS MAKE UP TORQUE 1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly 60MM BOLT HEADS MODEL 5 MAKE UP TORQUE 2080 FT. LBS.

Let’s Try A Few Questions To Ensure 1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly Let’s Try A Few Questions To Ensure We Understand About Wind Applications And Loosening Read the slide) Please take a few minutes to complete exercise 1 and discuss it. > (Quiz #2)

1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly QUIZ 1. Proper bolting techniques are important during which phases of wind turbine work? A. Production B. Installation C. Maintenance D. All of these 2. Elastic interaction refers to the loosening of one bolt when others around it are tightened. How should this problem be addressed? ________________________________________ 3. T / F There is no need to worry about tightening bolts in gradually increasing steps in wind turbines because what I do to one bolt has very little effect on the others?

1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly QUIZ 4. T / F Shear loads try to move the two sides of a joint past one another, while axial loads try to separate or compress the joint? 5. It is rapidly vibrating shear loads that are most responsible for bolts coming loose. Wind turbines have many joints that are susceptible to this kind of vibration. The best thing I can do to avoid bolts coming loose is: A. Use loc-tite B. Tighten properly in the first place C. Use lock washers D. Avoid lubrication 6. T / F Each manufacturer has a specification document that tells me the appropriate torque values and bolting procedures for each critical joint in the tower and turbine?

Quiz answers: D. All of these Gradual incremental tightening and a check pass on all bolts False. Most of the bolts are close enough to one another to have great effect on each other. True B. Tighten the bolts properly in the first place True. Each manufacturer will have specific Bolt Torque Specifications and Work Instructions which must be followed)