GB2569949A

GB2569949A - Method of handling a wind turbine component and crane for same

Info

Publication number: GB2569949A
Application number: GB1722289.4A
Authority: GB
Inventors: HØy Lars; Sanderhoff Johansen Rasmus
Original assignee: Vestas Wind Systems AS
Current assignee: Vestas Wind Systems AS
Priority date: 2017-12-29
Filing date: 2017-12-29
Publication date: 2019-07-10
Also published as: GB201722289D0

Abstract

A method of handling a wind turbine component 18, 26, 28, 30, 32 in a nacelle 14 of a wind turbine 10, the nacelle 14 having structural gallery beams 84, includes installing a temporary, high load capacity crane 40 in the nacelle 14 and using the crane 40 to move the wind turbine component 18, 26, 28, 30, 32. Installing the crane 40 in the nacelle 14 includes providing the crane 40 as a plurality of separate crane components 42, 44, 46, 48, 50, transporting the crane components to the nacelle 14, and assembling the crane components in the nacelle 14 to form the high load capacity crane 40. The crane may be assembled manually and in a tool-less manner. The crane may comprise a structural frame 46 coupled to girder supports 42, 44, a trolley 48 coupled to the structural frame 46 and a high load capacity hoist 50 coupled to the trolley 48. The structural frame 46 may be formed from girder segments 122, 124 and cross support frames 114. The high load capacity hoist 50 may be raised to the trolley 48 using a lift frame 196, low load capacity hoist (218 fig. 10C) and lock plate (172 fig 10C) and then secured to the trolley using the lock plate (172 fig. 10C) and a locking device 168 including a lock bar (170 fig. 10C).

Description

METHOD OF HANDLING A WIND TURBINE COMPONENT AND CRANE FOR SAME

Technical Field [0001] The present invention generally relates to wind turbines, and more particularly to a method of installing a temporary, high capacity crane in the nacelle of a wind turbine for handling a high load wind turbine component.

More particularly, the invention relates to a modular crane which can be installed by just a few service technicians in a substantially manual and toolless manner.

Background [0002] A typical horizontal axis wind turbine includes a wind turbine tower on which a wind turbine nacelle is mounted, and a wind turbine rotor having a central rotor hub and at least one wind turbine blade mounted thereon. The rotor hub is connected to the nacelle through a shaft (not shown) extending from the nacelle front which is operatively coupled to a generator positioned in the nacelle. The nacelle can be turned, using a yaw drive positioned at the top of the tower, to change the direction in which the rotor hub and blades are facing. The blades are aerodynamically profiled so that they experience a 'lift' or pressure from the wind as the wind flows past the surface of the blades. The angle or pitch at which the leading surface of the blade aerodynamic profile meets the incident wind can be altered using a pitch drive, which turns the blades with respect to the hub.

[0003] The nacelle includes a number of components that provide for the operation of the wind turbine. For example, the nacelle may include a main bearing, a primary drive shaft, a gear box, a secondary drive shaft, and the generator. The nacelle may also include various electrical components for supplying electrical energy to the electrical grid. This may include, for example, various inverters, converters and transformers. Some of the various components in the nacelle are very heavy, some weighing on the order of several tonnes. Accordingly, locating these heavy components in the nacelle, which may be a hundred or more meters in the air, becomes a challenge. In this regard, large scale cranes are typically used to assemble the wind turbine during initial installation and these large scale cranes can be used to locate heavy components in the nacelle in the first instance.

[0004] The operating life of a wind turbine is about twenty years. During this time, it may be necessary to replace one or more of the heavy components located within the nacelle of the wind turbine. Of course to achieve such a replacement, the damaged component must be removed from the nacelle, and a new or refurbished component must be reinserted back into the nacelle. One approach to lift these heavy components during a replacement operation is to transport a large, heavy-duty crane, similar to those used during initial assembly, back to the wind turbine installation site to perform the necessary lifts for removing and installing the various large components necessary for the repair. As one might imagine, transporting such a large scale crane back to the installation site becomes cost prohibitive and labor intensive. This is especially true when the wind turbine is located in a remote location or at sea, which is the case in many instances.

[0005] Accordingly, wind turbine manufacturers have sought improved solutions for removing and installing heaving components from the nacelle of the wind turbine in a replacement operation. One alternate approach is to incorporate a large, heavy-duty crane within the nacelle itself such that the heavy-duty crane is a permanent part of the wind turbine installation. While this avoids transporting large scale cranes back and forth to wind turbine installation sites, heavy-duty nacelle cranes are also very expensive and has to be incorporated into each and every wind turbine that is commissioned. Thus, while providing certain conveniences during the replacement of a heavy nacelle component, in that the heavy-duty crane is already located at the wind turbine site, such a solution is also cost prohibitive and ads significant weight to the wind turbine.

[0006] Another solution that has been proposed is to provide a crawler tower crane to the wind turbine site that is capable of lifting the heavy loads required for component replacement. Tower cranes are typically smaller than the large scale installation cranes and are transportable to a wind turbine site on a truck, such as a tractor trailer or the like, or a small seafaring vessel. The tower cranes are typically attached to the tower at the base of the tower and then move upwardly along the tower in order to position the crane for operation in removing and installing the heavy components. While crawler tower cranes are generally successful for their intended purpose, such cranes are typically heavy and complicated devices. In this regard, the tower cranes generally include expensive and complicated grippers and traction devices that allow the crane to stick to the tower and provide movement along the tower. Additionally, using the tower to support the crane results in high loads and stresses being applied to the tower. This, in turn, increases the chances of damaging the tower during the replacement operation, which becomes increasingly more expensive to repair.

[0007] Accordingly, there is a need in the wind turbine industry for a method of providing a heavy-duty crane to a wind turbine so as to achieve the replacement of a heavy component in the nacelle in a more efficient, cost-effective manner.

Summary [0008] To address these and other shortcomings, an improved method of handling a wind turbine component in a nacelle of a wind turbine is disclosed. The method includes installing a temporary, high load capacity crane in the nacelle capable of lifting a high load wind turbine component, and using the crane to move the high load wind turbine component. Installing the crane in the nacelle includes providing the crane as a plurality of separate crane components, transporting the plurality of crane components to the nacelle, and assembling the crane components in the nacelle to form the high load capacity crane. In one aspect of the invention, substantially all of the crane components are within the load capacity of two or fewer service technicians. In this way, nearly the entire high load capacity crane may be assembled in the nacelle manually. Additionally, and in another aspect of the invention, nearly the entire high load capacity crane may be assembled in a tool-less manner. These aspects provide significant benefits to maintenance operations in which high load wind turbine components, such as a generator, gearbox, etc., are replaced.

[0009] The high load capacity crane may include several components. Accordingly, in one embodiment, providing these crane components may include providing a plurality of girder supports configured to be secured to the gallery beams of the nacelle; providing a structural frame configured to be coupled to the gallery beams of the nacelle; providing a trolley configured to be coupled to the structural frame; and providing a high capacity hoist configured to be coupled to the trolley. Accordingly, assembling the crane components may further include positioning the plurality of girder supports on a respective gallery beam and coupling the plurality of girder supports to the respective gallery beam. In this regard, a plurality of locking devices may be provided, wherein the method further includes coupling the plurality of locking devices to the plurality of girder supports, and coupling the plurality of locking devices to the gallery beams. The steps of positioning the plurality of girder supports on a respective gallery beam and coupling the plurality of girder supports to the respective gallery beams may be done manually and in a tool-less manner. [0010] In one embodiment, providing the structural frame further includes providing a plurality of girder segments and providing a plurality of cross support frames. Accordingly, assembling the crane components further includes coupling a plurality of girder segments to form a first girder; coupling a plurality of girder segments together to form a second girder; coupling the first and second girders to respective girder supports; and coupling each of the cross support frames to each of the first and second girders. Even more specifically, in one embodiment the method is implemented by coupling a first end of the first girder segment to a girder support; coupling a first end of the second girder segment to a girder support, wherein the first and second girder segments are self-supported by their respective girder supports; and coupling a second end of the first girder segment to a second end of the second girder segment to form a girder. The steps of coupling the plurality of girder segments together; coupling the girders to the girder supports; and coupling the cross support frames to the girders may be done manually and in a tool-less manner.

[0011] In one embodiment, the structural frame includes a pair of generally parallel beams that form a track, and the assembly of the crane components further includes coupling the trolley to the track. In an exemplary embodiment, this step may be performed manually and in a tool-less manner.

[0012] In a further aspect, assembling the crane components also includes coupling the high capacity hoist to the trolley. To this end, the method may further include providing a lift assembly having a lift frame and a low load capacity hoist; coupling the lift frame to the trolley; coupling the low load capacity hoist to the lift frame; coupling a lock plate to the high load capacity hoist; coupling a lift cable from the low load capacity hoist to the lock plate; lifting the high load capacity hoist using the low load capacity hoist; engaging a lock bar with the lock plate, and coupling the lock bar to the trolley to secure the high load capacity hoist to the trolley. The steps of coupling the lift frame on the trolley; coupling the low capacity hoist to the lift frame; engaging the lock bar with the lock plate; and coupling the lock bar to the trolley may be performed manually and in a tool-less manner.

[0013] In one embodiment, transporting the crane component further comprises using a low load capacity nacelle crane to transport the plurality of crane components to the nacelle, such as from the ground, platform, or deck of a vessel, wherein the load capacity of the nacelle crane is less than the load presented by the high load wind turbine component, but greater than the load presented by each of the separate crane components. Thus the nacelle crane may be lighter in weight and more cost effective.

[0014] The temporary crane as described herein may be used to remove a high load wind turbine component from the nacelle and to position another high load wind turbine component back in the nacelle. After using the crane, the method may further include disassembling the crane, and removing the crane components from the nacelle. Thus, each wind turbine does not need its own dedicated heavy-duty crane.

[0015] In another aspect, a crane kit for assembling a temporary, high load capacity crane in a nacelle of a wind turbine, the nacelle having a plurality of structural gallery beams for supporting the crane, is disclosed. In an exemplary embodiment, the crane kit includes a plurality of girder supports, each girder support configured to be coupled to a gallery beam of the nacelle; a structural frame, the structural frame including a plurality of girder segments and a plurality of cross support frames, the structural frame configured to be coupled to the plurality of girder supports; a trolley configured to be coupled to the structural frame; and a high load capacity hoist configured to be coupled to the trolley. Of course, the components are initially in a disassembled state.

[0016] In an exemplary embodiment, each of the plurality of girder supports are within the load capacity of two or fewer service technicians such that the plurality of girder supports may be coupled to the gallery beams manually. Additionally, the plurality of girder supports is configured to be coupled to the gallery beams of the nacelle in a tool-less manner. Moreover, in an exemplary embodiment each of the plurality of girder segments and each of the cross support frames are within the load capacity of two or fewer service technicians such that the structural frame may be manually assembled. Additionally, the structural frame is configured to be coupled together and coupled to the girder supports in a tool-less manner. Furthermore, the trolley is within the load capacity of two or fewer service technicians such that the trolley may be manually coupled to the structural frame. This may also be done in a tool-less manner.

[0017] The crane kit may include additional components for facilitating the coupling of the high load capacity hoist, which may be beyond the load capacity of two or fewer service technicians, to the trolley. In this regard, the crane kit may further include a lift assembly having a lift frame and a low load capacity hoist. The lift frame and the low load capacity hoist are each within the load capacity of two or fewer service technicians such that coupling the lift frame to the trolley and coupling the low load capacity hoist to the trolley may be done manually and in a tool-less manner.

[0018] In an exemplary embodiment the assembled crane is a gantry crane and is able to be moved relative to the gallery beams of the nacelle.

Additionally, the trolley may also be movable relative to the structural frame to which it is coupled. In this regard, the plurality of girder supports and/or the trolley may include one or more motion bearings, such as wheels, casters, bearing transfer units, etc. that facilitate relative motion. These motion bearings may be selectively lockable once the crane is positioned in a desired location relative to the nacelle and/or the trolley is in a desired location along the structural frame. In one embodiment, the trolley and/or crane may be moved manually, such as by two or few service technicians.

Brief Description of the Drawings [0019] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the invention and, together with the general description given above and the detailed description given below, serve to explain the one or more embodiments of the invention.

[0020] Fig. 1 is a perspective view of a wind turbine in which embodiments of the invention may be used; [0021] Fig. 2 is a perspective view of an upper portion of the wind turbine of Fig. 1; [0022] Fig. 3 is an assembled perspective view of a high load capacity crane in accordance with an embodiment of the invention; [0023] Fig. 4 is a perspective view illustrating the attachment of the girder supports to the gallery beams of the nacelle; [0024] Fig. 4A is a disassembled perspective view of a girder support and locking device in accordance with an embodiment of the invention; [0025] Fig. 4B is an assembled perspective view of a girder support and locking device; [0026] Fig. 5 illustrates the girder supports coupled to the gallery beams; [0027] Fig. 5A is a cross-sectional view of a girder support and locking device shown in Fig. 4B; [0028] Fig. 6 is a disassembled perspective view of a girder in accordance with an embodiment of the invention; [0029] Figs. 6A and 6B illustrate girder segments in accordance with an embodiment of the invention; [0030] Fig. 7 is a perspective view of one girder coupled to the girder supports on the gallery beams of the nacelle; [0031] Fig. 8 is a disassembled perspective view of the structural frame of the crane; [0032] Fig. 9 is an assembled perspective view of the structural frame shown in Fig. 8; [0033] Fig. 10 is a perspective view illustrating the coupling of the trolley to the crane; [0034] Fig. 10A is a disassembled perspective view of a trolley, locking device, and lifting assembly in accordance with an embodiment of the invention; [0035] Fig. 10B is an assembled perspective view of a trolley and lifting assembly in accordance with an embodiment of the invention; [0036] Fig.lOC is an assembled perspective view of a trolley, locking device, and lifting assembly in accordance with an embodiment of the invention; [0037] Fig. 11 is a perspective view of the high load capacity hoist being coupled to the crane; [0038] Fig. 12 is a perspective view of the high load capacity hoist being coupled to the trolley; [0039] Fig. 13 is a perspective view of the crane with the high load capacity hoist being coupled to the structural frame; and [0040] Fig. 14 is a perspective diagrammatic view of a crane kit in accordance with an embodiment of the invention.

Detailed Description [0041] With reference to Figs. 1 and 2, a wind turbine 10 includes a tower 12, a nacelle 14 disposed at the apex of the tower 12, and a rotor 16 operatively coupled to a generator 18 housed inside the nacelle 14. In addition to the generator 18, the nacelle 14 houses miscellaneous components required for converting wind energy into electrical energy and various components needed to operate, control, and optimize the performance of the wind turbine 10. The tower 12 supports the load presented by the nacelle 14, the rotor 16, and other components of the wind turbine 10 that are housed inside the nacelle 14, and also operates to elevate the nacelle 14 and rotor 16 to a height above ground level or sea level, as may be the case, at which faster moving air currents of lower turbulence are typically found.

[0042] The rotor 16 of the wind turbine 10, which is represented as a horizontal-axis wind turbine, serves as the prime mover for the electromechanical system. Wind exceeding a minimum level will activate the rotor 16 and cause rotation in a direction substantially perpendicular to the wind direction. The rotor 16 of the wind turbine 10 includes a hub 20 and at least one rotor blade 22 that projects outwardly from the hub 20. In the representative embodiment, the rotor 16 includes three rotor blades 22 at locations circumferentially distributed thereabout, but the number may vary.

The rotor blades 22 are configured to interact with the passing air flow to produce lift that causes the hub 20 to spin about a longitudinal axis 24. The design and construction of the rotor blades 22 are familiar to a person having ordinary skill in the art and will not be further described.

[0043] The rotor 16 is mounted on an end of a main rotary shaft 26 that extends into the nacelle 14 and is rotatably supported therein by a main bearing assembly 28 coupled to the framework of the nacelle 14. The main rotary shaft 26 is coupled to a gearbox 30 having as an input the main rotary shaft 26 and output a secondary rotary shaft 32. The main rotary shaft 26 has a relatively low angular velocity, while the secondary rotary shaft 32 has a higher angular velocity and is operatively coupled to the generator 18.

[0044] The wind turbine 10 may be included among a collection of similar wind turbines belonging to a wind farm or wind park that serves as a power generating plant connected by transmission lines with a power grid, such as a three-phase alternating current (AC) power grid. The power grid generally consists of a network of power stations, transmission circuits, and substations coupled by a network of transmission lines that transmit the power to loads in the form of end users and other customers of electrical utilities. Under normal circumstances, the electrical power is supplied from the generator 18 to the power grid as known to a person having ordinary skill in the art.

[0045] As discussed above, aspects of the present invention are directed to an improved approach for providing a high load capacity crane to a wind turbine. In this approach, a high load capacity crane is assembled together in the nacelle from a plurality of separate crane components or elements. Nearly every component in the crane is configured to be manipulated by three or fewer, and preferably two or fewer, service technicians in the nacelle and assembled in a tool-less manner. In this regard and as explained in more detail below, the high load capacity crane may have a modular design wherein most of the components of the crane may be lifted by just a few service technicians and assembled together within the nacelle in a substantially manual and toolless manner. The various modules of the crane may be transported to a wind turbine site on a small truck or small seafaring vessel. Accordingly, the high transportation costs associated with other high load capacity cranes may be avoided. Additionally, the assembly of the crane and replacement of a heavy wind turbine component may be effectuated by just a few people, which reduces labor costs. Furthermore, the high load capacity crane of the invention is intended to be a temporary structure of the nacelle, which may be assembled/disassembled many times so that the same temporary, modular and high load capacity crane may be repeatedly used on different wind turbines in need of replacement of one of the heavy components in the nacelle. These benefits and advantages of the present invention will become clearer based on the description provided below.

[0046] Fig. 3 illustrates the temporary, modular high load capacity crane 40 in accordance with an exemplary embodiment of the invention in an assembled state. The crane 40 may be configured as a gantry style crane capable of lifting heavy loads presented by one or more components within the nacelle 14. By way of example, the high load capacity crane 40 may be configured to lift loads greater than about 1 tonne, and preferably on the order of several tonnes, such as between about 2 tonnes and about 5 tonnes. In one embodiment, the crane 40 may be configured have a capacity of about 2.5 tonnes. The crane 40 includes a pair of girder supports 42, 44 for coupling the crane 40 to the structural frame of the nacelle 14, a latticed structural frame 46, a trolley 48, and a high load capacity hoist 50 having a load capacity as described above. Each of these components will now be described in further detail.

[0047] Each of the girder supports 42, 44 are similar in construction and function, thus only one of the girder supports will be described in detail. As illustrated in Figs. 4-4B, the girder support 42 includes a generally rectangular base plate 52 having a first end 54 formed by a first base portion 56 and a second end 58 formed by a second base portion 60. The first and second base portions 56, 60 may be coupled by a pair of struts 61 extending therebetween. Each base portion 56, 60 includes a first pair of spaced-apart lugs 62 having aligned apertures 64 and a second pair of spaced-apart lugs 66 also having aligned apertures 68. The lugs 62, 66 on each base portion 56, 60 are aligned to define a receiving channel 70. Each of the base portions 56, 60 further include a bearing plate 72 extending away from an inner longitudinal edge 74 of the base plate 52 adjacent the lugs 66. Adjacent the end of the bearing plate 72 is a bearing unit 78, which may be selectively loosened/tightened via a nut and bolt fastener 80.

[0048] The girder supports 42, 44 may further include one or more locking devices 82 configured to secure the girder supports 42, 44 to the structural frame of the nacelle 14. For example, the structural frame of the nacelle 14 may include one or more gallery beams 84 (e.g., configured as one or more I-beams) at the sides of the nacelle 14 to which the girder supports 42, 44 may be coupled. The girder supports 42, 44 may be configured to be coupled to the gallery beams 84 and secured thereto with locking devices 82. In one embodiment, the locking devices 82 may include a first elongate leg 86 having a first end 88 and a second end 90, and a J-shaped retention clip 92 coupled to the second end 90 of the leg 86, such as with a suitable fastener. The first leg 86 may include a first bore 94 adjacent the first end 88 and a second bore 96 spaced from the first bore 94 toward the second end 90.

[0049] In use, the locking device 82 is intended to slide or clip over the upper flange of the gallery beam 84. In this regard, the first end 88 of the leg 82 is configured to be inserted into the receiving channel 70 defined by the lugs 62, 66 such that the first bore 94 is general aligned with the apertures 68 in the lugs 66. Fasteners 98 may then be inserted through the apertures 68 and bore 94 to secure the locking device 82 to the base plate 52. By way of example, the fasteners 98 may include a primary pin and cotter pin, lynch pin, or other lock pin secured through the end of the primary pin. In one aspect of the invention, the fasteners may be manually applied to the crane 40 without the use of tools (i.e., tool-less fasteners). When so fastened, the end of the retention clip 92 extends beneath the upper flange of the gallery beam 84 to help retain the girder supports 42, 44 to the gallery beams 84. The bearing units 78, which may be slidably retained in slots 100 in the bearing plates 72, may be pushed inwardly and tightened to essentially clamp the girder supports 42, 44 on to the upper flange of the gallery beams 84. This is illustrated in Figs. 5 and 5A.

[0050] As illustrated in Figs. 3 and 6-9, the structural frame 46 includes a pair of spaced apart, generally parallel latticed girders 110, 112, and cross support frames 114 extending between the girders 110, 112. Each of the girders 110, 112 includes an upper beam 116 and a lower beam 118 interconnected by a plurality of angles braces 120 arranged, for example, in a zig-zag pattern along the length of the beams 116, 118. To provide modularity and allow the various crane components to be manipulated by a few service technicians (such as two or fewer service technicians), the girders 110, 112 may be divided into two or more girder segments which are coupled in an end-to-end fashion to produce the full girder. In an exemplary embodiment, each of the girders 110, 112 may be divided into a first girder half 122 and a second girder half 124. The first and second girder halves 122, 124 are not limited to being half the length of the full girder 110, 112, but connotes that the girders may be formed by connecting two girder segments. As noted above, there may be more than two girder segments in alternative embodiments and the invention is not limited to only two segments.

[0051] Each girder half 122, 124 includes an attachment interface 126 at a first end 128 for connecting the girder half 122, 124 to a respective girder support 42, 44. In this regard, the attachment interface 126 may include one or more apertures through the lower beam 118 adjacent an end thereof. Each girder half 122, 124 may further include one or more attachment interfaces at a second end 130 thereof for connecting to the second end 130 of the other girder half. In an exemplary embodiment, the upper beam 116 includes an attachment interface 132 at its second end 130 and the lower beam 118 includes an attachment interface 134 at its second end 130. In an exemplary embodiment, the attachment interfaces 132, 134 may include one or more apertures through their respective beams at an end thereof. The apertures at the second end 130 of the girder halves 122, 124 may be aligned and fasteners 98 may then be inserted through the apertures to couple the two girder halves 122, 124 together. By way of example, the fasteners 98 may include a primary pin and cotter pin, lynch pin, or other lock pin secured through the end of the primary pin. The fasteners may be tool-less fasteners which may be manually applied to the girder halves 122, 124.

[0052] In an exemplary embodiment, the cross support frames 114 extend between the first and second girders 110, 112 adjacent opposed ends thereof.

In this regard, each of the first and second girder halves 122, 124 include an end angled brace 136 adjacent their first ends 128 (i.e., the end that is coupled to the gallery beams 84 of the nacelle 14). Each of the end angled braces 136 include two or more posts 138 configured to receive a portion of a cross support frame 114 thereover. As illustrated in Fig. 8, each cross support frame 114 includes two generally parallel struts 140 and a plurality of cross struts 142.

The parallel struts 140 are generally arranged to overlie the end angled braces 136 of the girder halves 122, 124 and include two or more apertures 144 configured to receive the posts 138 therein. For example, the apertures 144 may be disposed adjacent the ends of the parallel struts 140. In an exemplary embodiment, a cross strut 142 extends between the two parallel struts 140 at one end thereof (e.g., an upper end), and two cross struts 142 extend between the two parallel struts 140 in a crossed or X fashion. The cross support frames 114 are sized and configured to be handled by just a few service technicians (e.g., three or fewer, and preferably two or fewer) and may be positioned on the girders 110, 112 without the use of tools. In this regard, once the cross support frames 114 are placed over the posts 138, a cotter pin, lynch pin, or other lock pin may be secured through the end of the posts 138 to secure the cross support frames 114 to the girders 110, 112 such lock pins may be omitted. [0053] As illustrated in Figs. 10-10C, the upper beams 116 of the girders 110, 112 provide generally parallel rails of a track 150 which supports a selectively movable trolley 48 thereon. The trolley 48 includes a pair of track supports 152, 154 configured to engage with the upper beams 116 of the track 150, and two or more cross supports 156, 158 extending between the two track supports 152, 154. Each track support 152, 154 has an inverted U-shaped configured with a top wall and two depending sidewalls that generally define a channel 160 for receiving a beam 116 therein. The cross supports 156, 158 extend between the two track supports 152, 154 along a central region thereof in a spaced-apart relation and are generally parallel to each other. Each of the cross supports 156, 158 may be generally L-shaped having a top wall and one side wall (e.g., along an inner edge of the top wall), and the top wall of the cross supports 156, 158 may be generally flush with the top wall of the track supports 152, 154. Each of the track supports 152, 154 further includes and a pair of spaced-apart lugs 162 having aligned apertures 164. The lugs 162 on each track support 152, 154 are aligned to define a receiving channel 166. The receiving channel 166 is generally parallel to the cross supports 156, 158 and generally disposed therebetween.

[0054] The trolley 48 further includes a locking device 168 for selectively securing the high capacity hoist 50 to the trolley 48. In an exemplary embodiment, the locking device 168 includes a lock bar 170 and a lock plate 172. The lock bar 170 may be configured as an elongate, generally rectangular bar which may be solid or having a hollow construction. The lock bar 170 has a length that spans the distance between the two track supports 152, 154. As illustrated in the figures, the lock bar 170 is configured to be received in the receiving channel 166 defined by the lugs 162 on the track supports 152, 154 and secured thereto. In this regard, the lock bar 170 includes apertures 174, which when the lock bar 170 is properly positioned relative to the lugs 162, align with the apertures 164 in the lugs 162. Fasteners 98 may then be inserted through the apertures 164, 174 to secure the locking bar 170 to the trolley 48.

Similar to the above, the fasteners 98 may include a primary pin and cotter pin, lynch pin, or other lock pin secured through the end of the primary pin and are configured to be tool-less fasteners which may be manually applied.

[0055] The lock plate 172 is a plate-like member that, in an exemplary embodiment, is generally elliptical in shape having a first generally arcuate upper end 176, and a second generally arcuate lower end 178. The lock plate 172 includes a plurality of passages extending through the plate. More particularly, the lock plate 172 includes an upper opening or bore 180 adjacent the upper end 176 of the lock plate 172, and a lower opening or bore 182 adjacent the lower end 178 of the lock plate 172. The lower bore 182 is configured to receive a hook, eyelet or other connector from the high capacity hoist 50. As explained in more detail below, the upper bore 180 may utilized during assembly of the crane 40. The lock plate 172 further includes a central opening or bore 184 disposed between the upper and lower bores 180, 182 and configured to receive the lock bar 170 therethrough. In this regard, the central bore 184 includes a shape that generally corresponds to the shape of the lock bar 170. Thus, in one embodiment, the central bore 184 may have a generally rectangular shape to receive the generally rectangular lock bar 170 therethrough. The non-circular profile prevents the lock plate 172 from rotating relative to the lock bar 170. Moreover, the lock plate 172 may be configured to be positioned in a generally central region of the lock bar 170 (e.g., in the mid region between the two track supports 152, 154). The lock bar 170 and lock plate 172 are sized and configured such that just a few service technicians may manipulate these components during assembly of the crane 40. Additionally, and as noted above, the lock bar 170 is configured to be coupled to the brackets 162 in a tool-less manner.

[0056] Finally, the high load capacity hoist 50 is coupled to the lock plate 172 of the locking device 168. For example, the high load capacity hoist 50 may include a hook, eyelet or other connector that is coupled to the lower bore 182 of the lock plate 172 (Fig. 11). The trolley 48 supports the load presented by the hoist 50 (and the load being carried thereby) via the lock bar 170. Of course, this load is then transferred from the trolley 48, to the structural frame 46, and ultimately to the gallery beams 84 that form part of the nacelle 14. In an exemplary embodiment, the high load capacity hoist 50 may weigh anywhere from around 100 kg to 200 kg and have a load capacity of greater than one tonne, and preferably greater than about two tonnes. For example, the hoist 50 may have a load capacity of about 2.5 tonnes. It is believed that the crane 40 as described above is able to accommodate a high capacity hoist having a load capacity of around 5 tonnes. Such large capacity hoists are generally known in the art and will not be further described herein. It should be noted that if the hoist 50 is at the lower end of the range described above, it may be feasible for the coupling of the hoist 50 to the lock plate 172 to be achieved manually, such as by a few service technicians. More likely, however, the coupling of the high load capacity hoist 50 to the crane 40, and to the trolley 48 in particular, may be achieved by using a low load capacity hoist. This will be described in more detail below. In any event, the coupling of the high load capacity hoist 50 to the crane 40 may be the only step of the crane assembly that is not performed manually, such as by two or fewer service technicians. [0057] The assembly and use of the crane 40 will now be described in detail. Once a decision has been made to conduct a replacement operation on one or more of the heavy components (e.g., generator 18, gearbox 30, etc.) located in the nacelle 14 of a wind turbine 10, a disassembled, modular crane kit 190 may be dispatched to the identified wind turbine along with a few service technicians. For example, it is contemplated that three, and preferably two, service technicians may be all that is necessary to assemble the crane 40 and operate the crane 40 to remove a heavy component from the nacelle 14, and replace the heavy component with another component. As illustrated in Fig. 14, the crane kit 190 includes, for example, the girder supports 42, 44; locking devices 82, half girders 122, 124 for forming girders 110, 112; cross support frames 114; trolley 48; lock bar 170 and lock plate 172; high capacity hoist 50; and a plurality of fasteners 98 (including lock pins). As explained in more detail below, the crane kit 190 may include additional elements that facilitate the assembly of the crane 40, but do not form part of the final assembly. In any event, the crane kit 190 and possibly the service technicians may be transported to the wind turbine site in a relatively small truck or small seafaring vessel. Because the crane 40 has a modular design and is in a disassembled state, the crane kit may be generally compact. Accordingly, the vehicle used to transport the crane kit 190 to the wind turbine site may be generally small. [0058] Once the crane kit 190 is at the wind turbine site, one service technician may be positioned in the nacelle 14 while the other service technician may be positioned on the ground, platform, or deck of the seafaring vessel. It should be recognized that many wind turbines generally include a low load capacity nacelle crane. For example, the low load capacity nacelle crane may have a load capacity of less than one tonne, and perhaps more likely less than half of a tonne. Thus, while the low load capacity nacelle crane is capable of lifting relatively light loads (e.g., less than 500 kg to and from the nacelle 14 (such as from ground, platform, or deck of a seafaring vessel), the nacelle crane does not generally have the load capacity to lift one of the heavy components in the nacelle to effectuate a replacement procedure. With that said, however, the nacelle crane does generally have the load capacity to lift the disassembled components of the crane kit 190 from the ground, platform, deck, etc. to the interior of the nacelle 14. This includes the high load capacity hoist 50, which as noted above may weigh between about 100 kg to about 200 kg, which is well within the limits of the nacelle crane.

[0059] With several or all of the components of the crane kit in the nacelle, the service technician that was on the ground, platform, deck etc. may move to the nacelle 14 to join the first service technician. Once in the nacelle 14, the service technicians may position the first and second girder supports 42, 44 on respective gallery beams 84 on opposed sides of the nacelle 14. In this regard, the fasteners 80 of the bearing units 78 may be loosened such that the girder supports 42, 44 may be positioned loosely on the top flange of the gallery beams 84. This may be achieved manually by one or both of the service technicians. In other words, the weight of the girder supports 42, 44 is generally within the lifting capacity of one or both of the technicians such that the nacelle crane is not necessary to place the girder supports. Once positioned on the gallery beams 84 in the desired positions, the locking devices 82 may be positioned about the gallery beams 84 and secured to the girder supports 42, 44. Similarly, the locking devices 82 are generally within the lifting capacity of one or both of the technicians such that the coupling of the locking devices 82 with the girder supports 42, 44 may be achieved manually and without the nacelle crane. With the retention clips 92 of the locking devices 82 disposed underneath the upper flange of the gallery beams 84 and the apertures 68 in the lugs 66 are generally aligned with the bores 94 in the locking devices 82, the service technicians may insert fasteners 98 therethrough. The service technicians may then tighten the fasteners 80 associated with the bearing units 78 to firmly secure the girder supports 42, 44 to the gallery beams 84. This is generally illustrated in Figs. 4-5A.

[0060] With the girder supports 42, 44 in place, the service technicians may now turn to assembling the structural frame 46, such as assembling girder 110. To this end, the service technicians may position the girder half 122. The weight of the girder half 122 is within the lifting capacity of one or both of the service technicians such that the nacelle crane is not necessary to place the girder half. In this regard, the service technicians may position the girder half 122 such that the attachment interface 126 (e.g., apertures in lower beam 118) is generally aligned with the apertures 64 in a respective lugs 62 of the girder support 42. One of the service technicians may then insert a fastener 98 therethrough to secure one end of the girder half 122 to the girder support 42.

In one aspect of the invention, once the girder half 122 has been secured to its respective girder support 42, the service technicians may release their hold on the girder half 122. The girder half 122 is self-supported and will remain in a stable cantilevered position within the nacelle 14, thereby allowing the service technicians to continue with the assembly without someone continuing to hold or support the girder half. This provides an advantage to the manual assembly aspect of the present invention.

[0061] With the girder half 122 stable in its cantilevered position in the nacelle 14, the service technicians may then position the second girder half 124. Again, in an exemplary the weight of the girder half 124 is within the lifting capacity of one or both of the service technicians such that the nacelle crane is not necessary to place the girder half 124. In this regard, the service technicians may position the girder half 124 such that the attachment interface 126 (e.g., apertures in lower beam 118) is generally aligned with the apertures 68 in a respective bracket 66 of the girder support 44. One of the service technicians may then insert a fastener 98 therethrough to secure one end of the girder half 124 to the girder support 44. Similar to the above, once the girder half 124 has been secured to its respective girder support 44, the service technicians may release their hold on the girder half 124. The girder half 124 is self-supported and will remain in a stable cantilevered position within the nacelle 14 and allow the service technicians to continue with the assembly. At this point, the second ends 130 of the girder halves 122, 124 are adjacent each other and the service technicians may couple the girder halves 122, 124 together at their respective attachment interfaces 132, 134. More particularly, the attachment interfaces 132, 134 may include apertures through the upper and lower beams 116, 118 (e.g., such as through extension fingers or tongues) and the service technicians may align the apertures and insert fasteners 98 to couple the girder halves 122, 124 together and thereby form the girder 110.

This connection may be achieved manually and in a tool-less manner. This is generally illustrated in Figs. 5-7.

[0062] The process described above for assembling girder 110 may be repeated for forming girder 112. As the steps are similar, the description for forming girder 112 will be omitted. In any event, with the girders 110 and 112 assembled and coupled to the girder supports 42, 44, the cross support frames 114 may be coupled to the girders 110, 112. The weight of a cross support frame 114 is within the lifting capacity of one or both of the service technicians such that the nacelle crane is not necessary to place the cross support frame.

In this regard, one or both of the service technicians may position the cross support frame 114 over the end angled braces 136 such that the apertures 144 in the struts 140 of the cross support frame 114 generally align with the posts 138 extending from the end angled braces 136 at one end of the structural frame 46. The cross support frame 114 may then be lowered so that the posts 138 extend through the apertures 144. One or more lock pins may then be inserted through the ends of the posts 138 to secure the cross support frame 114 to the girders 110, 112. Of course, the same process may be repeated to secure the second cross support frame 114 to the other end of the structural frame 46. The positioning and securing of the cross support frames to the girders 110, 112 may be achieved manually and in a tool-less manner. This is generally illustrated in Figs. 8 and 9.

[0063] With the structural frame 46 assembled and attached to the girder supports 42, 44, the trolley 48 may be coupled to the crane 40. In this regard, the weight of a trolley 48 (e.g., minus the lock bar 170 and lock plate 172) is generally within the lifting capacity of one or both of the service technicians. In this regard, the service technicians may elevate the trolley 48 above the structural frame 46 and orient the track supports 152, 154 so as to generally align with the track 150 formed by the upper beams 116 of the girders 110, 112. The service technicians may then lower the trolley 48 so that the beams 116 are received in the channel 166 of the track supports 152, 154.

[0064] Lastly, the high load capacity hoist 50 may be attached to the trolley 48. As noted above, the nacelle crane has a load capacity sufficient to lift the high load capacity hoist 50 to the nacelle 14. However, due to logistics within the nacelle 14, the nacelle crane is typically unable to couple the high load capacity hoist 50 directly to the trolley 48 of the crane 40. Instead, the nacelle crane is configured to position the high load capacity hoist 50 at a first location within the nacelle 14, such as at a location on the floor of the nacelle 14 beneath or substantially beneath the structural frame 46 of the crane 40. Then, a temporary, low load capacity lift assembly 194 may be assembled and used to couple the high load capacity hoist 50 to the trolley 48. In this regard and as illustrated in Figs. 10-13, a lift frame 196 may be positioned on the trolley 48.

As illustrated in these figures, the lift frame 196 includes a pair of spaced apart lift supports 198, 200 configured to engage with the cross supports 156, 158 of the trolley 48, a pair of elongate upright beams 202, 204 coupled to and extending away from the lift supports 198, 200, and a cross support 206 extending between the two upright beams 202, 204.

[0065] Each lift support 198, 200 has an inverted U-shaped configuration with a top wall and sidewalls extending downwardly therefrom at respective edges of the top wall to define a receiving channel 201. The width of the lift supports 198, 200 is sufficient to just fit over the cross supports 156, 158 of the trolley 48. Each elongate beam 202, 204 includes a first end 208 coupled to the top wall of the respective lift support 198, 200 and a second end 210 opposite thereto. The elongate beams 202, 204 may be generally rectangular in cross-section and may have a solid or hollow configuration. The first end 208 of the beams 202, 204 may, for example, be welded or bonded to the lift supports 198, 200. A plurality of gussets 212 may further facilitate the coupling of the elongate beams 202, 204 to their respective lift support 198, 200. These may likewise be attached by welding or bonding. The cross support 206 may be coupled to the second ends 210 of the beams 202, 204. By way of example, the second ends 210 of the elongate beams 202, 204 may include notches in which the cross support 206 may be received and secured such as by welding, bonding or the like. The cross support 206 may have an arched configuration in the direction from one beam 202 to the other beam 204. Additionally, the upper edge 214 of the cross support 206 may further include a generally arcuate indentation 216, for purposes described below.

[0066] As noted above, the lift frame 196 may be coupled to the trolley 48.

In this regard, the weight of a lift frame 196 is generally within the lifting capacity of one or both of the service technicians such that a lift device is not necessary to place the lift frame 196 on the trolley 48. In this regard, the service technicians may elevate the lift frame 196 above the cross supports 156, 158 of the trolley 48 and orient the lift supports 198, 200 so as to generally align with the cross supports 156, 158 of the trolley 48. The service technicians may then lower the lift frame 196 so that the cross supports 156, 158 are received in the channel 201 of the lift supports 198, 200.

[0067] In an exemplary embodiment, the lift assembly 194 further includes a low load capacity hoist 218. The low capacity hoist 218 may be configured to lift relatively small loads, such as loads less than about 200 kg, more specifically less than about 150 kg, and even more specifically loads of around 100 kg. Essentially, the load capacity of the hoist 218 is such as to lift the high load capacity hoist 50. The weight of the hoist 218 is generally within the lifting capacity of one or both of the service technicians such that a lift device is not necessary to place the hoist 218 on the lift frame 196. In this regard, the low load capacity hoist 218 may include an upper connector 220, such as a hook or the like, which may be coupled to the lift frame 196. More particularly, the upper connector 220 may be configured to be coupled to the upper cross support 206 at the indentation 216 formed therein such that the hoist 218 hangs therefrom.

[0068] The free end of the hoisting cable 222 may include a connector 224, such as a hook or the like, which may be coupled to the lock plate 172, and more specifically the upper bore 180 of the lock plate 172. The hoist 218 may be configured to pay out the cable 222 so that the connector 224 and lock plate 172 are adjacent the high capacity hoist 50 that resides in the nacelle 14. A connector 226, such as a hook or the like, associated with the high capacity hoist 48 is coupled to the lower bore 182 of the locking plate 172 (Fig. 11). The low load capacity hoist 218 is then activated to lift the high load capacity hoist 50 upwardly toward the trolley 48 and between the girders 110, 112 (Fig. 12).

As the high load capacity hoist 50 and coupled lock plate 172 are lifted, the central bore 174 in the lock plate 172 becomes positioned between the two cross supports 156, 158 of the trolley 48 and just above the top wall of the track supports 152, 154.

[0069] At this point, an end of the lock bar 170 may be positioned between the brackets 162 on one of the track supports 156 and slidably moved toward the other track support 158 so as to enter and extend through the central bore 174 in the lock plate 172. The weight of the lock bar 170 is generally within the lifting capacity of one or both of the service technicians such that the positioning of the lock bar 170 relative to the trolley 48 and lock plate 170 may be done manually. With the lock bar 170 so positioned, the service technicians may use fasteners 98 to couple the lock bar 170 to the trolley 48. This may be done in a tool-less manner. Of course, the lock plate 172 is then fixed to the lock bar 170 and the high load capacity hoist 50 is coupled to the lock plate 172. This is illustrated in Fig. 13. With the high load capacity hoist 50 coupled to the trolley 48, the lift assembly 194 may be disassembled. In this regard, the hoist 218 may be removed from the lift frame 196 and then the lift frame 196 may be removed from the trolley 48. The removal of the lift assembly 194 may be achieved manually and without the use of tools.

[0070] From here, the crane 40 is assembled and may be used in a replacement procedure for high load components in the nacelle 14. In this regard, a connector of the high load capacity hoist 50 may be coupled to a high load component in the nacelle 14 and lowered to the ground, platform, deck of a seafaring vessel, etc. The crane 40 with its high load capacity hoist 50 is capable of handling the loads presented by these high load components. In a similar manner, the connector of the high load capacity crane 50 may be coupled to another high load component (a new or refurbished component) on the ground, platform, deck of a seafaring vessel, etc. and lifted up to the nacelle 14 using the crane 40.

[0071] During the replacement process, it may be desirable to move the trolley 48 and/or structural frame 46 within the nacelle 14. In this regard, the trolley 48 may be movable on the track 150 defined by the upper beams 116 of the girders 110, 112. To this end, the trolley 48 may include a plurality of motion bearings 230 that facilitate movement of the trolley 48 along the track 150. The motion bearings 230 may include wheels, rollers, casters, low friction pads, ball transfer units or other elements that promote movement along the track 150. In one embodiment, the trolley 48 may include drive units (not shown), such as electric motors, hydraulic motors, or other drive devices, for driving the movement of the trolley 48. In an alternative embodiment, the trolley 48 may be manually movable along the track 150. By way of example, the manual movement of the trolley 48 may be achieved by one or two service technicians when the trolley us in an unloaded state. Additionally or alternatively, the girder supports 42, 44 may include motion bearings 230 that facilitate movement of the girder supports 42, 44 along the gallery beams 84, such as along the upper flange thereof. In a similar manner, the girder supports may include drive units (not shown) for driving the movement of the girder supports 42, 44 along the gallery beams 84. Alternatively, the girder supports 42, 44 may be manually moved, such as moved together once the crane 40 is assembled, along the gallery beams 84. By way of example, the manual movement of the girder supports 42, 44 may be achieved by one or two service technicians when the crane 40 is in an unloaded state.

[0072] Aspects of the present invention provide a number of advantages over the current methods of providing a high load capacity crane to a wind turbine site for a replacement operation of a high load component in the nacelle. In this regard, the crane of the present invention is a temporary crane having a modular design. Thus, in a disassembled state the crane may be transported to the wind turbine site in a compact configuration which may fit on a relatively small truck or a small seafaring vessel. Accordingly, the transportation costs associated with the crane may be significantly reduced relative to current methods. Second, a high load capacity crane is not required to be a permanent part of the nacelle of the wind turbine. Instead, a low load capacity nacelle crane may be provided in the nacelle, which significantly reduces costs. The low capacity crane has a load capacity such that the low capacity crane can lift the various (disassembled) components of the high load capacity crane from ground, platform or deck to the nacelle.

[0073] Once all or certain components of the high load capacity crane have been delivered to the nacelle, the crane may be assembled in a manner that uses few workers. In this regard, many of the components of the crane (e.g., substantially all of the components but for the high capacity hoist) have a weight such that a few service technicians (e.g., such as two technicians) may position the crane components and assemble the components together manually. In other words, but for the high capacity hoist, the nacelle crane does not have to be used to assemble the high capacity crane. Thus, substantially all of the crane 40 may be assembled manually. In this regard, over 50%, preferably 70%, and even more preferably over 90% of the assembly of the crane may be done manually. In other words, nearly all of the assembly of the crane may be done manually. Moreover, the connection of the various components of the crane are configured to be tool-less. Substantially all of the crane 40 may be assembled in a tool-less manner. In this regard, over 50%, preferably 70%, and even more preferably over 90% of the assembly of the crane may be done in a tool-less manner. Similarly, nearly all of the assembly of the crane may be done in a tool-less manner. This greatly simplifies the assembly process and allows the assembly process to occur more quickly. Once the high capacity crane is done being used in the replacement process, the crane may be disassembled, lowered back down to the ground, platform or deck, and transported to another wind turbine in need of a replacement process or to storage. Thus, the crane may be used many times and on many wind turbines. This avoids a dedicated high load capacity crane for each wind turbine. In embodiments, the crane may be utilized for hoisting a length of power cable from ground level, up through the tower and into the nacelle. The power cable may be dimensioned to serve to connect the nacelle power generation and power conversion elements to a grid connection.

[0074] While the invention has been illustrated by a description of various embodiments, and while these embodiments have been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the general inventive concept.

Claims

1. A method of handling a wind turbine component in a nacelle of a wind turbine, the nacelle having a plurality of structural gallery beams, the method comprising: installing a temporary, high load capacity crane in the nacelle capable of lifting a high load wind turbine component, comprising: providing the crane as a plurality of separate crane components; transporting the crane components to the nacelle; and assembling the crane components in the nacelle to form the high load capacity crane; and using the crane to move the high load wind turbine component.

2. The method according to claim 1, wherein assembly of the crane components is substantially done manually.

3. The method according to claim 1 or 2, wherein substantially all of the separate crane components are within the load capacity of two or fewer service technicians.

4. The method according to any of claims 1 -3, wherein assembly of the crane components is substantially done in a tool-less manner.

5. The method according to any of claims 1-4, wherein providing the crane as a plurality of separate crane components further comprises: providing a plurality of girder supports configured to be coupled to the gallery beams of the nacelle; providing a structural frame configured to be coupled to and supported by the plurality of girder supports; providing a trolley configured to be coupled to the structural frame; and providing a high load capacity hoist configured to be coupled to the trolley.

6. The method according to claim 5, wherein assembling the crane components further comprises: positioning the plurality of girder supports on a respective gallery beam of the nacelle; and coupling the plurality of girder supports to the respective gallery beam.

7. The method according to claim 6, further comprising: providing a plurality of locking devices; coupling the plurality of locking devices to the plurality of girder supports; and coupling the plurality of locking devices to a respective gallery beam.

8. The method according to claim 6 or 7, wherein the steps of positioning the plurality of girder supports on a gallery beam and coupling the plurality of girder supports to a respective gallery beam are performed manually.

9. The method according to any of claims 6-8, wherein coupling the plurality of girder supports to a respective gallery beam is done in a tool-less manner.

10. The method according to any of claims 5-9, wherein providing the structural frame further comprises: providing a plurality of girder segments; and providing a plurality of cross support frames.

11. The method according to claim 10, wherein assembling the crane components further comprises: coupling a plurality of girder segments together to form a first girder; coupling a plurality of girder segments together to form a second girder; coupling the first and second girders to respective girder supports; and coupling each of the cross support frames to each of the first and second girders.

12. The method of claim 11, wherein each of the first and second girders is formed by a first and second girder segment, the method further comprising: coupling a first end of the first girder segment to a girder support; coupling a first end of the second girder segment to a girder support, wherein the first and second girder segments are self-supported by their respective girder supports; and coupling a second end of the first girder segment to a second end of the second girder segment to form a girder.

13. The method according to claim 11 or 12, wherein the steps of coupling the plurality of girder segments together, coupling the girders to the girder supports, and coupling the cross support frames to the girder are performed manually.

14. The method according to any of claims 11-13, wherein the steps of coupling the plurality of girder segments together, coupling the girders to the girder supports, and coupling the cross support frames to the girders are done in a tool-less manner.

15. The method according to any of claims 5-14, wherein the structural frame includes a pair of generally parallel beams that define a track, and wherein assembling the crane components further comprises coupling the trolley to the track.

16. The method according to claim 15, wherein the step of coupling the trolley to the track is performed manually.

17. The method according to 15 or 16, wherein the step of coupling the trolley to the track is done in a tool-less manner.

18. The method according to any of claims 5-17, wherein assembling the crane components further comprises coupling the high load capacity hoist to the trolley.

19. The method according to claim 18, further comprising: providing a lift assembly including a lift frame and a low load capacity hoist; coupling the lift frame on the trolley; coupling the low load capacity hoist to the lift frame; coupling a lock plate to the high load capacity hoist; coupling a lift cable of the low load capacity hoist to the lock plate; lifting the high load capacity hoist using the low load capacity hoist; engaging a lock bar with the lock plate; and coupling the lock bar to the trolley to secure the high load capacity hoist to the trolley.

20. The method according to claim 19, wherein the steps of coupling the lift frame on the trolley, coupling the low capacity hoist to the lift frame, engaging the lock bar with the lock plate, and coupling the lock bar to the trolley are performed manually.

21. The method according to claim 19 or 20, wherein the steps of positioning the lift frame on the trolley, coupling the low load capacity hoist to the lift frame, coupling the lock plate to the high load capacity hoist, coupling the lift cable to the low load capacity hoist to the lock plate, engaging the lock bar with the lock plate, and coupling the lock bar to the trolley are done in a tool-less manner.

22. The method according to any of the preceding claims, wherein transporting the crane components further comprises using a low load capacity nacelle crane to transport the plurality of crane components to the nacelle, wherein the load capacity of the nacelle crane is less than the load presented by the high load wind turbine component, but greater than the load presented by each of the separate crane components.

23. The method according to any of the preceding claims, wherein using the crane to move the high load wind turbine component further comprises: using the crane to remove a high load wind turbine component from the nacelle; and using the crane to position another high load wind turbine component in the nacelle.

24. The method according to any of the preceding claims, further comprising: disassembling the crane; and removing the crane components from the nacelle.

25. A crane kit used for assembling a temporary, high load capacity crane in a nacelle of a wind turbine, the nacelle having a plurality of structural gallery beams for supporting the crane, the crane kit comprising: a plurality of girder supports, each girder support configured to be coupled to a gallery beam of the nacelle; a structural frame, the structural frame including a plurality of girder segments and a plurality of cross support frames, the structural frame configured to be coupled to the plurality of girder supports; a trolley configured to be coupled to the structural frame; and a high load capacity hoist configured to be coupled to the trolley.

26. The crane kit according to claim 25, wherein each of the plurality of girder supports are within the load capacity of two or fewer service technicians such that the plurality of girder supports may be coupled to the gallery beams manually.

27. The crane kit according to claim 25 or 26, wherein each of the plurality of girder supports is configured to be coupled to the gallery beams of the nacelle in a tool-less manner.

28. The crane kit according to any of claims 25-27, wherein each of the plurality of girder segments and each of the cross support frames are within the load capacity of two or fewer service technicians such that the structural frame may be manually assembled.

29. The crane kit according to any of claims 25-28, wherein the structural frame is configured to be coupled together and coupled to the girder supports in a tool-less manner.

30. The crane kit according to any of claims 25-29, wherein the trolley is within the load capacity of two or fewer service technicians such that the trolley may be manually coupled to the structural frame.

31. The crane kit according to any of the preceding claims, further comprising a lift assembly including a lift frame and a low load capacity hoist, the lift assembly configured to couple the high load capacity hoist to the trolley.

32. The crane kit according to claim 31, wherein the lift frame and the low load capacity hoist are each within the load capacity of two or fewer service technicians such that coupling the lift frame to the trolley is done manually and coupling the low load capacity hoist to the lift frame is done manually.

33. The crane kit according to any of the preceding claims, wherein the plurality of girder supports and/or the trolley includes one or more motion bearings that allow the structural frame to move relative to the gallery beams of the nacelle and/or allow the trolley to move relative to the structural frame.