Thursday, July 7, 2016

Generator repair continues

After removing the blades and adding a second set of wheels to the gen stand/log mover I was able to wheel it into the shop.

With the nacelle removed I used the engine hoist to lift and separate the parts for inspection and repair of the unit.

The surprises just keep coming. Upon removal of a junction box cover this looks bad.

Looks like the wire nut did not do the job in  this case and over time the connection got hot. Could have been a disaster for sure. The repair for this will be a split nut connector to give the connection a more solid connection.

Removed the base mount from the unit. This is where the mounting plate was cracked. I broke it off the rest of the way so I could grind a nice vee into the plates and increase the weld penetration. The small angle brace welds were a poor factory job with very little penetration and will be replaced with 1/4 inch thick material. A second 3/8 inch thick is being drilled and will be edge welded to the bottom of this plate for the repair.  Same thing will have to be done for the blade mounting plate as the three holes where it attached to the generator hub are also showing some cracking.

Then it will be on to refinishing of the blades. Stay tuned.

Sunday, June 26, 2016

Wind generator repair

The crane is back. My grandson, Gus would love it! It has been 11 years since I put the Enertech 1800 up. Thanks Mick Sigrillo. Now because of a crack in the mounting plate I brought it down.

Working on the top of a 50 foot tower is... lets say exciting. When you have to let go and use both hands on something putting all your trust in a thin strap of nylon and a couple of clips!

The the wind was low (about 5 mph) and since there is no good way to lock the yaw of the head I was at the mercy of the wind to hook the crane to the generator lifting eye screw. Finally I made the hook and removed the nuts so the head could be lifted. Unfortunately as luck would have it the balance was off and the mounting plate jammed on the bolt threads. With nothing to lever with or against I decided to screw the nuts below the mounting plate up and raise the head to the top of the three bolts. Problem solved.

For years I have had a family of birds nesting in the nacel. Each year I would evict them and each year they would come back. Looks like this year they really did a number on some of the wiring. One of my repairs will be to bird proof the unit!

OK. Now now a new project. Let the learning begin.