Wind Turbine Generator (WTG) Audit Checklist by Gensol - 16.06.18

WTG has many components & the audit checklist helps to maintain the WTG. Checklist covers the following options -
a) Transformer
b) Isolator
c) VCB Panel & Switch Yard
d) Power Panel
e) Capacitor Panel
f) DFIG Panel
g) Control Panel
h) Junction Box
i) Tubular Tower Shell
j) Climb Arrestor
k) Cables
l) Yaw System
m) Main Bearing
n) Gear Box
o) Generator
p) Rotor Brake
q) Hydraulic Unit
r) Hub Lock
s) Nacelle Control Panel
t) Anemometer & Wind Pane
u) Rotor Blade
v) Battery Bank
w) Nose Cone

1. WTG Audit Checklist V1.2 Revision 1 Edition 2018 Gensol Engineering Private Limited (Wind Division) Page 1 of 37


Wind Turbine Generator (WTG) Check List
WTG- Location Number

OEM Name

Model/ Hub Height

State Name

Site Name

WTG- Location SAP Number

Customer Name

Control Reading

Name Of Auditor

Date Of Inspection

WTG- Location Number

WTG Stop Time

WTG Start Time



Auditor Signature Site In-Charge Signature
Date: Date:

2. WTG Audit Checklist V1.2 Revision 1 Edition 2018 Gensol Engineering Private Limited (Wind Division) Page 2 of 37


Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

A WTG TRANSFORMER
1 Check Transformer oil leakages from radiator Fins, HV
Bushings,

Tank, Conservator & Valve,

Transformer Parts Corrosion,
Oil Level,

Bushing Connections ,



1.1 Check WTI & OTI are working,

OTI/WTI Protection with Metal mesh Cover,

WTI & OTI Cables condition,

WTI & OTI Pointer Okay & Mirror Condition,

1.2 Corrosion on transformer parts,

Radiator, Tank, Conservator & Hardware’s



1.3 Transformer junction Box Cable routing through Metal/PVC
Pipes ( Duct),

Alignment of Metal/PVC Pipes with Transformer Junction
Box,

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Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

Cables are rubbing to Metal pipes/PVC Pipes,
1.4 Check Condition Of Breather ( Silica gel, oil Cup),

Position of Arching Horns ,

Transformer plinth condition & Transformer Mounting,

1.5 Check Transformer Earthling I.e. Neutral Earthling, Body
Earthling & Junction Box Earthling,

1.6 Visual Check of CT/PT ( Any Bulging, Oil level & Connections),

CT & PT Earthling

CT & PT Junction Box

CT & PT Mounting

1.7 OTI & WTI Temp.

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Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

B Isolator Condition
2 Check for smooth operation,

Ensure that all the phases open and close fully and
simultaneously,

Ensure Proper Spring pressure at female contacts so
that good ,

2.1 Drop out (DO) fuse Availability
2.2 Isolator Operating pipe Condition/Handle condition
2.3 Isolator Earthling
2.4 LOTO Provision

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Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

C VCB Panel & Switch Yard Condition
3 VCB Tripping with activation of protection relay &
manual,
Tripping,
Trip circuit,
Power pack & all Protection Fuses,
Protection Relays,
Panel meters & Switches,
Panel door,


3.1 Switch yard all Earthlings,
Vegetation,
Gravel spreading (stone pitching),
Switch yard stay wires condition,

3.2 Check air circuit breaker and vacuum circuit breaker for
correct operation, indicators ON/OFF condition, springs
charged/discharged condition.

3.3 Lighting Arrester (LA) availability

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Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

D WTG Outside
4 Check availability of all Earth pits,
Check for corrosions & Rust on Earth pit’s connection,
Earth Flats connection,
Earth Flat connection to Earth Electrode (Pipe),

4.1 Foundation Cracks
4.2 Tower door Ladder
4.3 Tower door Ladder Locking
4.4 Tower door rubber bidding
4.5 Check the Radiator is Cleaned or Not
4.6 Check radiator fan smooth operation
4.7 Check the SCADA link properly installed

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Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

E Power Panel
5 Power Panel door condition,
Condition panel door & Hinges,

5.1 Panel Cooling, availability of fans,
Filter mat availability,

5.2 Condition of Sealing for cable Entry,
Fire retardant paint application on cables (1 Meter),

5.3 Bus Bar condition ( for Pitting & Overheating)
5.4 Humming/chattering Noise while operation
5.5 Arcing at bus bar connection
5.6 Decolouring at bus bar
5.7 Arcing/ Decolouring cable terminations
5.8 Cable termination / loose lug – Crimping quality
5.9 Contactor condition / decolouring
5.10 Water leakage in the panel (find leakages point)
5.11 Cable insulation/Sheath damage from bottom panel air
circuit breaker of Transformer connectors

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5.12 UPS availability,
UPS Tripping PCB Mounting,
UPS Mounting,

5.13 Power cable lug condition,
(air circuit breaker –I/p & o/p connections)

5.14 Soft starter & Snubber tightness check,
Soft starter mounting,

5.15 Air Circuit breaker (ACB) operation (manual Check)
5.16 ACB Settings :-

Nominal Current (In)
Rated Current (Ir)
Short Circuit current (Isd)
Short circuit time (Tsd)
Ground fault current ( Ig-B)
Ground fault time (Tg)

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Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

F Capacitor Panels
6 Capacitor discharge resistor
6.1 Condition of capacitor (Bulged/punctured), capacitor
contactors & fuse units, pre charging coils

6.2 Check of connection tightness and born marks, fuse
base condition

6.3 Capacitor panel door condition,
Condition panel door & Hinges

6.4 Check all capacitor should be in good condition and
voltage must be approx 400-417 VDC

6.5 Panel cooling, availability of fans,
Filter mat availability

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Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

G DFIG Panel
7 Capacitor discharge resistor
7.1 Power, Earthling and control cable connection in DFIG
panel torque marks check at DC and AC power
terminals

7.2 Condition of DFIG panel cooling duct and tightness at
termination,
Coolant pressure should be 2.2 bar,
Leakage of coolant,

7.3 Check condition of DC limiter resistor,
Check condition of DC capacitors,

7.4 All acrylic sheets/ insulation cover used on live
terminals/Bus bars

7.5 Bus lines should be earth by clips at the shield ,
Condensation in DFIG Panel,

7.6 Heating and cooling System
7.7 DFIG Panel door lock,
DFIG panel Hinges,
Cooling Fans,

7.8 Arcing at bus bar connection
7.9 Decolouring at bus bar

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7.10 Arcing/Decolouring cable terminations
7.11 Contactor condition / Decolouring
7.12 Fuse condition / tightness
7.13 DFIG panel cable coming should be routed with rubber
gland to avoid any damages with sharp edge of panel

7.14 Power cables & control cables routing inside DFIG panel
7.15 Cooling System :-

Motor condition
Pump condition
Connection Pipes condition
Structure mounting
Cooling Liquid availability
Protection System

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Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

H Control Panel
8 Component- Mounting in Panels,
Cables routing,
Loose connection and tightness checks for 25% of
connection,

8.1 Bottom Earthling PAS Bus Bar earthling connections
8.2 Emergency Switch operation
8.3 SAFETY Chain Circuit operation
8.4 Panel cooling, availability of fans ,
Filter mat availability,

8.5 Check functionality of RCCBs
8.6 Surge arrestors, setting of power supply 24V

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Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

I Junction Box
9 All connection tightness,
Sparking / Burnt marks at connections,
Bus Bar condition,
Bus Bar Mounting,
Insulator condition,

9.1 Connection Lugging,
Cable Glands,

9.2 Junction box mounting,
Junction box cover,

9.3 Junction Box connections

14. WTG Audit Checklist V1.2 Revision 1 Edition 2018 Gensol Engineering Private Limited (Wind Division) Page 14 of 37


Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

J Tubular Tower Shell : T1 + T2 + T3 + T4 (as
Possible no of sections)

10 Platform chequer plate status & hardware’s condition
10.1 Tubular Tower bottom earthlings
10.2 Ladder condition in Tower Shell
10.3 Gap between tower to tower shell joints (use filler
gauge),
Sun light is coming inside tower from flanges (check
360 degree),

10.4 Any linear indication (crack) on welds joints/near
surface

10.5 Corrosion on welds joints/near surface
10.6 Any types of linear indication(Crack) on tower shell
plates

10.7 Flange bolts (Looseness/condition),
Flange bolts corrosion,

10.8 Flange Bolts Make
10.9 Tower shell to shell earthling
10.10 Condition of safety rope

15. WTG Audit Checklist V1.2 Revision 1 Edition 2018 Gensol Engineering Private Limited (Wind Division) Page 15 of 37

10.11 Safety rope clamps condition
10.12 Safety rope routing
10.13 Check the discharge flume for blockage
10.14 Check the bolted tower connection between each
section

10.15 Check the bolted tower connection between tower
section 1 and tower section 2.

10.16 Measurement of tower inclination max. 8mm/m tower
height (Misalignment & settlement).

10.17 Grease /Oil spillages on Platforms

Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

K Climb Assistor(Wherever applicable)
11 Operation is proper

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Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

L Cable Inspection
12

Fire retardant paint at bottom cabinet
12.1 Cable uniformly distributed on cable tray
12.2 Cable rubbing/Insulation damage/crack
12.3 Cable decoloration
12.4 Cable loop holder Orange color PVC sleeve
Welding contact to tower,corrosion at welding portion

12.5 Cable routing through cable guide/Cable holder
12.6 Cable guide ring Holding
12.7 End Cap on the cable clamp stud below cable drum
12.8 Cable twisting
12.9 Cable Hitting with ladder and tower
12.10 At Tower top plateform cut-out,cable damage/rubbing

17. WTG Audit Checklist V1.2 Revision 1 Edition 2018 Gensol Engineering Private Limited (Wind Division) Page 17 of 37

12.11 Cable Hanging Cable Socks mounting
Cable socks Corrosion
Cable Socks Holding

12.12 Cable Socks D-shackle bolt orientation/piercing in cable
12.13 Cable Laying from tower to nacelle(below Gear box) for
cutting rubbing at sharp edges/support channel/cable
tray clamps

12.14 Cable loop length and loop to cable drum routing
12.15 Cable drum Cables routing
12.16 Cable drum Cables Holding
12.17 Tightness of Cables in cable joint
12.18 No of Cable joints in tower Power Cables
12.19 Check the available joint in power Cables crimping
12.20 Control Cable joints
12.21 Power Cables Clamping
12.22 Fire retardant paint at junction box
12.23 Crimping as per specification.
12.24 Lugs used are standards and as mention in specs

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12.25 No pinching condition seen


12.26 Check all the cables clips(Clip and Plastic lining)
12.27 Check the cables at the grips and their fastening bolts.
12.28 Cable edge protection at sharp edges,cable drum

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Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

M Nacelle
13 Nacelle to tower Cables routing
13.1 Operation of winch
Condition of chain

13.2 Nacelle Libero window
Winch bottom window road

13.3 Nacelle bottom FRP Door
13.4 Nacelle GRP Cracks
Nacelle joints & Nacelle cover Shifting

13.5 Cables Laying inside the Nacelle
13.6 Water leakages from Nacelle joints
Water leakages from Nacelle Hoods


13.7 Vibration Sensor condition
PCH Box mounting
PCH Box Connections

13.8 All Nacelle earthings ( Panels + platform + Generator +
Gear Box + Brake Unit + Main Bearing + Slew ring)

13.9 All Nacelle Spark Gaps
13.10 Nacelle PAS Earthing Bus bar Condition
Nacelle PAS to WTG Bottom PAS Earthing Connection

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13.11 Nacelle Metal Platforms availability
Cable Twist Limit Switch Assembly
North position Sensor availability
Yaw Sensor availability

13.12 Check the bolted Connection of generator cantilever for
attaching the conical mounts (elastomeric bearings) of
the generator.

13.13 Check the elastomer of the generator conical mounts
the regarding cracks or damages.

13.14 Check the conical mounts for cracks or other
damages.(Connection between casing suspension and
GRP)

13.15 Nacelle Cooling Fans availability

Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

N YAW System
14 Rim Teeth Greasing
14.1 Backslash between Rim & Pinion Teeth
Grease Lubber Condition
Grease lubber connections

14.2 Yaw drive
14.3 Yaw drive mounting bolt tightness
Yaw motors availability

21. WTG Audit Checklist V1.2 Revision 1 Edition 2018 Gensol Engineering Private Limited (Wind Division) Page 21 of 37

14.4 Leakage from the Yaw Drives
14.5 Abnormal Noise during Yawing
14.6 Yaw Brake availability & setting
14.7 Distance between sensor and metal of Yaw angle
sensor

14.8 Distance between sensor and metal of north position
sensor

14.9 Yaw brake air gap
14.10 Measure the distance between Yaw rim bottom surface
and lateral suspender

14.11 Measure the distance between Yaw rim top surface and
main frame

14.12 Check the disk spring preload in the lateral suspenders.
14.13 Measure the distance between Yaw rim lateral surface
and lateral suspender

22. WTG Audit Checklist V1.2 Revision 1 Edition 2018 Gensol Engineering Private Limited (Wind Division) Page 22 of 37


Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

O Main Bearing
15 Lubrication pump Operation
Grease lubber condition
Main bearing operation
Grease lubber electrical connections

15.1 Lab Type
15.2 Grease leakages
15.3 Labyrinth ring Rubbing
15.4 Gap at lock nut
15.5 Noise and temperature/shifting
15.6 Main Bearing fasteners condition

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Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

P Gear Box
16 Alignment & Mounting
16.1 Tightness of gearbox connections
16.2 Gearbox mounting to mainframe
16.3 Brake calliper air gap
16.4 Bearing temperature DE & NDE
16.5 Oil Level
16.6 Oil pressure Switch settings
16.7 Silica gel breather availability & color
16.8 Shifting of gear box
Gear box noise

16.9 Gear box leakage (slip ring area, LSS, HSS, & radiator)
16.10 Condition of hosepipes
Cable routing below gear box

16.11 Radiator – mountings

24. WTG Audit Checklist V1.2 Revision 1 Edition 2018 Gensol Engineering Private Limited (Wind Division) Page 24 of 37

16.12 Leakages from radiators
16.13 Radiators fins condition
16.14 Bellow cover condition
16.15 Oil pump motor condition
16.16 Check the elastomer of contamination by oil or grease
16.17 Check the rubber elements of the noise decoding
elements for cracks

16.18 Check the circuit for blocking by touching the
lubrication pipes shortly after turbine

16.19 Check the gear box oil cooling fan 1 and 2 circuitry
16.20 Check working of the mechanical driven pump
16.21 Gap between main frame and gear rim at locations

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Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

Q Generator
17 Bearing lubrication (DE & NDE)
17.1 Grease Collector
Check greasing extension pipe at DE side

17.2 Cover mounting
Power cable connections
Availability of cable glands
Fire retardant paint (FRP) application on cables
CU Bus condition

17.3 Check the axial, radial, and angular alignment of the
generator drive shaft to the gear box output shaft

17.4 Check all O-ring seals regarding leakage and damage
(cracks)

17.5 Generator mount bolt tightness & generator alignment
bolt tightness

17.6 Check the function of the slip ring space heater
17.7 Check the function from the internal cooling circuit fan
1 and fan 2

17.8 Check the Earth terminals and located on each NDE
foot and Earthing cable is attached to it

17.9 Check the connector and coupling on incremental
rotary transducer

26. WTG Audit Checklist V1.2 Revision 1 Edition 2018 Gensol Engineering Private Limited (Wind Division) Page 26 of 37

17.10 Check the gas – recharge pressure in expansion vessel
17.11 Check the system pressure for the cooling circuit on the
gauge (2.6 to 3.0)

17.12 Generator earthling and its terminal
17.13 Check the function from the internal cooling circuit fan
1 and fan 2

17.14 Bellow cover condition
17.15 Check control slip ring mounting bolt with GB
Torque arm support

17.16 Check Control slip ring holder mounting tightness
Check control slip ring cover

17.17 Control slip ring brushes
Contact ring condition
Separators insulation rings condition
Brush connections
Brush holders conditions

17.18 Power slip ring Brushes
Contact ring condition
Separators insulation rings condition
Brush connections
Brush holders conditions
Limit switches condition
Bellow

17.19 Additional Earthing brush provision (Grounding
Insulators) :-
Contact ring condition
Separators insulation ring condition

27. WTG Audit Checklist V1.2 Revision 1 Edition 2018 Gensol Engineering Private Limited (Wind Division) Page 27 of 37

Brush connections
Brush holders conditions
17.20 Power Cable connections in stator terminal box

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Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

R Rotor Brake
18 Disc Brake Pads wears / break sensor
18.1 Brake Gap
18.2 Rotor Brake structure mounting
18.3 Rotor Brake sensor condition
18.4 Check hydraulic brake system for oil leaks

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Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

S Hydraulic Unit
19 Electrical operation of hub lock
19.1 Brake operating electrical box
19.2 Check the brake hydraulic line for any damage and
leakage and check the expiration date of the flexible
tubes

19.3 Check the gas pressure in the rotor brake /pressure
supply line accumulator

19.4 Check the rotor lock hydraulic line for any damage and
leakage and check the expiration date of the flexible
tubes

19.5 Check the hydraulic unit for leakages

30. WTG Audit Checklist V1.2 Revision 1 Edition 2018 Gensol Engineering Private Limited (Wind Division) Page 30 of 37


Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

T Hub Lock
20 Functionality

Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

U Nacelle Control Panel
21 Panel Mounting
Nacelle Fan

21.1 Check Panel door lock
Condition of hinges

21.2 Modules (MPCB, MCB, Contactors, Surge Arresters,
Battery Charger Module) Mountings

21.3 EMERGENCY Switch Operation
21.4 SAFETY Chain Circuit operation
21.5 MPCB Settings

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Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

V Anemometer & Wind Vane
22 Anemometer condition & mounting lock nut
22.1 Anemometer & Wind Vane availability
22.3 Anemometer stand lighting arrester availability
22.4 Lighting arrester cable joint to WTG bottom CU PAS Bus
bar/ Separate earth pit connection

22.5 Anemometer & Wind Vane Setting

32. WTG Audit Checklist V1.2 Revision 1 Edition 2018 Gensol Engineering Private Limited (Wind Division) Page 32 of 37


Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

W Rotor Blade
23 Blade mounting bolts
23.1 Blade rota cap condition
23.2 Check 0 Degree setting in all blades both physically and
at controller

23.3 Lightning Protection Strips availability
Flash Finger
Blade platform condition

23.4 Blade surface cracks
Blade tip availability
Vortex generator (VA) availability

23.5 Check the spar connection
23.6 Check that the drain hole in the area of the blade tip is
not clogged

23.7 Check the connections and contact points of the
lightening cables of the rotor blades and the brushes

23.8 Check the trailing edge bonding
23.9 Angle encoder Condition

33. WTG Audit Checklist V1.2 Revision 1 Edition 2018 Gensol Engineering Private Limited (Wind Division) Page 33 of 37

Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

X HUB Inside
24 HUB Entry doors condition
24.1 Panel mounting channels & bolts with hub body
24.2 Slip ring cable adapter support at panel side
24.3 Hub cable dressing and damages due to sharp edges
24.4 Hub cooling fans availability & mounting condition
24.5 Hub all cables connections routings
HUB cable cutting at glands

24.6 Grease collecting bottle fixing/leak/damage
24.7 Electrical connections
Cables laying & availability of all panels cable glands

24.8 Decolourisation of connector at power supply
24.9 Flash point, burning marks, MPCB & contactor in panels
24.10 Emergency-stop functioning
24.11 Panel door & Channel mounting
24.12 DC-DC supply connector tightness and burnt mark

34. WTG Audit Checklist V1.2 Revision 1 Edition 2018 Gensol Engineering Private Limited (Wind Division) Page 34 of 37

24.13 Safety Speed check ( Pitch batteries healthiness check)
PITCH Battery voltage are Ok

24.14 Pitch motor cover condition
24.15 Resolver Mounting condition
24.16 Frequency Drive condition
24.17 Leakage from the PITCH drive
Pitch drive mounting

24.18 Rim teeth – Lubrication
Grease Lubber condition

24.19 Rim teeth thickness of worn out teeth
24.20 EMERGENCY Switch operation
24.21 Hub all Earthings
24.22 Blade and hub Spark gap
24.23 Hub metal Structure
24.24 Hub Platforms
Grease Leakages

24.25 Tightness of bolt connection
Battery box to frame
Frame to Hub

24.26 Check the setting of feathering position proximity
sensor and its operation for all three blades

35. WTG Audit Checklist V1.2 Revision 1 Edition 2018 Gensol Engineering Private Limited (Wind Division) Page 35 of 37

24.27 Check the position and tightness of -5 degree limit
switch sensor in all three blades

24.28 Setting of thermostats (Heating)

Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

Y Battery Banks
25 Mounting Channels condition
All mounting channels condition with all hardware’s

25.1 Battery Box mounting channel tightness/ bush
condition V2 hub

25.2 Battery Voltages
25.3 Battery operational life

36. WTG Audit Checklist V1.2 Revision 1 Edition 2018 Gensol Engineering Private Limited (Wind Division) Page 36 of 37


Sl. No. Inspection Points Limits
Remarks/Comments
(if any)
Photograph

Z Nose Cone
26 Nose cone mounting bracket tightness
Nose cone mounting bracket hardware’s & Rubber
bush condition

26.1 Nose cone holding railings
26.2 Crack in Nose cone mounting
26.3 Spark gap (finger) gap setting
26.4 Nose cone lightening arrestor connection with the
platform
Nose cone LA Copper flat available

37. WTG Audit Checklist V1.2 Revision 1 Edition 2018 Gensol Engineering Private Limited (Wind Division) Page 37 of 37


*
Annexure Verification & Availability
1 List Software Version
2 List of Latest PLCs version
3 List of Latest applicable motor protection switches settings
4 List of Latest fuses applicable in different part of turbines
5 List of Latest applicable hygrostat settings
6 Standard Earthing value defined in specs.
7 Latest Parameter setting, which needs manual entry in
turbine for its validations

8 Applicable offsets of turbine (i.e. blade angle, yawing, north
direction setting etc.)

9 List of Latest applicable modification/TCIs for its Validation
10 The applicable setting for at different junctions in complete
path of lightening protection system ( Blade tip-root-hub-
nacelle-tower-earth)

11 Audit Check list
12 Health Card Of WTG



Auditor Signature Site In-Charge Signature