990508[1]rev.3

Vestas towers Engdraget 20

6800 Varde Denmark

Class II

Item-no. 990508.R3

29 Nov 2007

Quality SpecificationSteelwork and welding of

towers and foundation sections for Vestas wind turbines

Item-no..: 990508.R3 Date: 29 Nov 2007 Class: II

Issued by: PE

QUALITY SPECIFICATION (QS) Steelwork and welding of towers and

foundation sections for Vestas wind turbines

Type: QS

Page 1 of 34

Table of contents Table of contents ................................................................................................................................... 1 1.0 Preface ......................................................................................................................................... 2

1.1 Objective ............................................................................................................................. 2 1.2 Definitions............................................................................................................................ 2 1.3 Use of standards ................................................................................................................. 3 1.4 Control of deviations............................................................................................................ 3 1.5 Verification by Vestas.......................................................................................................... 4

2.0 General requirements to the quality system ................................................................................. 4 2.1 General................................................................................................................................ 4 2.2 Personnel qualifications ...................................................................................................... 4 2.3 Welding consumables ......................................................................................................... 5 2.4 Equipment ........................................................................................................................... 6 2.5 Handling of deviations. ........................................................................................................ 6 2.6 Additional requirements to towers for Germany .................................................................. 6

3.0 Production preparation ................................................................................................................. 7 3.1 Contract and design review................................................................................................. 7 3.2 Quality plan ......................................................................................................................... 7 3.3 Qualification of welding procedures..................................................................................... 7 3.4 Welding plan........................................................................................................................ 9 3.5 Welding sequence at flanges .............................................................................................. 9 3.6 Heat treatment of welds ...................................................................................................... 9 3.7 Flame straightening............................................................................................................. 9 3.8 Preparation of procedures for non-destructive testing....................................................... 10 3.9 Verification of steel ............................................................................................................ 10

4.0 Quality activities during production ............................................................................................. 11 4.5 Non-destructive testing of welds ....................................................................................... 12 4.6 Statistics of weld defects ................................................................................................... 18 4.7 Leak test on sand chamber ............................................................................................... 18 4.8 Leak test of oil bowl for oscillation damper........................................................................ 18 4.9 Dimensional inspection of welded doorframes, top skirts and segmented flange ............. 19 4.10 Dimensional inspection of sections ................................................................................... 19 4.11 Surface inspection............................................................................................................. 20 4.12 General inspection ............................................................................................................ 20

5.0 Release....................................................................................................................................... 20 5.1 General.............................................................................................................................. 20 5.2 Review of records (as-built)............................................................................................... 20 5.3 Release of welded doorframes, top skirts and segmented flange..................................... 20 5.4 Release of sections for surface treatment ......................................................................... 20 5.5 Uploading via Towerdoc.................................................................................................... 20 Attachment 1, - Example of quality plan. .................................................................................... 21 Attachment 2, - Statement of Quality.......................................................................................... 22 Attachment 3, - Material traceability list ...................................................................................... 23 Attachment 4, - Weld log ............................................................................................................ 24 Attachment 5, - VT / MT report ................................................................................................... 25 Attachment 6, - UT report ........................................................................................................... 26 Attachment 7, - UT repair report ................................................................................................. 27 Attachment 8, - Dimensional inspection report ........................................................................... 28 Attachment 9, - Leak test report ................................................................................................. 29 Attachment 10, - Welded doorframe log ..................................................................................... 30 Attachment 11, - Top skirt log (page 1 of 2) ............................................................................... 31 Attachment 11, - Top skirt log (page 2 of 2) ............................................................................... 32 Attachment 12, - Welding plan for Vestas towers and foundation sections................................ 33 Attachment 13, - Segmented flange log. .................................................................................... 34


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1.0 Preface

1.1 Objective This Quality Specification (QS) has been prepared by Vestas and describes the requirements for quality as-surance of steelwork and welding in connection with the production of towers and foundation sections for Vestas wind turbines. This QS also covers customer supplied goods. Lattice masts and offshore foundations are outside the scope of this specification.

The specification is valid for the primary steel and secondary steel, which is welded together with the primary steel. Welded internals that are bolted to the section, incl. the door, are not included in this QS.

The specification describes minimum requirements, and quality assurance in accordance with this specifica-tion does in no way release the welding workshop from the full responsibility for the supplied product.

The target group for the specification is QA and QC personnel in the welding workshop, e.g. quality man-ager, welding coordinator and NDT responsible.

1.2 Definitions Quality manager, means the manager or head of quality department, appointed from the supplier.

Responsible manager, means the manager with responsibility for Vestas products, appointed from the sup-plier.

Quality responsible, means one who possesses quality responsibility for Vestas products, appointed from the supplier.

Welding coordinator, means one who coordinates and supplies the welding workshop with necessary proce-dures and work instructions,

NDT level III, means internal level III or external level III contractually affiliated to the NDT department.

NDT responsible, means one who has the overall responsibility for performing NDT in a correct way

Contractually affiliated, means one who has contract with the company covering a specific amount of pres-ence and defined responsibilities.

Section, means tower section and foundation section.

Segmented flange, means a flange made from plate segments, which are welded together (not bolt flanges).

Upper flange, means bolt flange at the top on tower section or foundation section.

Intermediate flange, means middle flange in a foundation section.

Lower flange, means bolt flange at the bottom of a tower section and base flange at the bottom on a founda-tion section.

Welded doorframe, means a doorframe rolled from plate and welded.

Top skirt, means a top flange with brake disk welded together with a shell plate.

Primary steel, means bolt flanges, base and intermediate flanges in foundation section, shell plates and frames (doorframe, cable frames etc.).

Secondary steel, means brackets, sand chamber flange etc.

CEQ (Carbon Equivalent) = C + Mn/6 + (Cr+Mo+V)/5 + (Ni+Cu)/15

ID-number, means a unique number for each section. The number, which is supplied by Vestas, is the key to traceability in the welding workshop and afterwards when the section is included in a complete Vestas wind turbine.

Towerdoc, means Vestas on-Line documentation database used by the welding workshop to send as-built documentation to Vestas via the Internet.


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Longitudinal welds (LW), means welds in shell plates, which is oriented in the longitudinal direction of the section.

Circumferential welds (CW), means welds between shell plates and welds between flanges and shell plates, which are oriented perpendicular to the longitudinal direction of the section.

Frame welds (FW), means welds between shell plates and frames (doorframe, cable frame etc.).

Attachment welds (AW), means welds between primary steel and secondary steel

Identification of welds (per section):

• The lowest circumferential weld is named CW1, the second lowest CW2 etc. • The lowest longitudinal weld is named LW1, the second lowest LW2 etc • The weld between doorframe and shell plate is named FW1. Second frame is named FW2. • The weld between plate doorframe and shell is named LW2A and LW2B looking at the tower from the

outside as shown in the above diagram. • Weld repairs are named R1, R2 etc. in addition to the original identification, e.g. CW1R1.

1.3 Use of standards This specification refers to various International, European, American and Australian standards. The specific standards which apply are specified on Vestas production drawings.

For a given standard the latest edition shall always be followed.

In case of conflict between a standard and this specification, the most stringent shall apply.

1.4 Control of deviations It is not allowed to deviate from Vestas drawings or specifications unless a beforehand approval has been issued by Vestas in writing.

Any written approval shall be part of the as-built documentation package for the relevant section.

LW1

CW1

FW1 AW

CW1

LW1

LW2

CW3

LW2A LW2B

CW1

LW1

CW2

CW3

CW3

CW2

CW4

CW4

CW5

CW2 LW2

LW4

LW3

LW3


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1.5 Verification by Vestas Vestas performs various kinds of verification of steelwork and welding, for example audit on the welding workshops quality management system, inspection during production, sample of complete sections and re-view of documentation etc. The extent of the verification is decided by Vestas based on experience and pri-ority.

Vestas must approve subcontractors when cutting, bevelling, rolling, welding, NDT, surface treatment are subcontracted and Vestas and Vestas customers shall at all times have access to verifying the work at the premises of the welding workshop or subcontractor.

To secure that Vestas is able to verify documents required by this specification, these shall be prepared in English. PQR/WPAR, WPS and NDT procedures required in QS must be forwarded to allocated Vestas Pro-ject Manager for review before production is started. As-built documentation shall be prepared in English only. Documents required by this specification shall be kept by the welding workshop for at least ten years, and during this period it may be requested by Vestas without costs.

2.0 General requirements to the quality system

2.1 General The welding workshop shall have an active and maintained quality management system, which secures that the requirements in this specification are fulfilled. ISO 9001, ISO 3834-2 fulfils these requirements.. Equiva-lent standards must be accepted by Vestas Towers,

The organisation responsible for the performance of non-destructive testing (NDT) shall have a documented quality system for its operation.

For external NDT companies: an accreditation for inspection companies or a certification according to ISO 9001 meets this requirement.

For internal NDT: a certification according to ISO 9001 for NDT-organisations within manufacturing compa-nies meets this requirement. Equivalent standards must be accepted by Vestas Towers,

An organisation chart, which as a minimum includes the names of Responsible Manager, Quality Responsi-ble, Welding Coordinator, NDT Responsible and NDT level III shall be available.

2.2 Personnel qualifications The welding workshop shall have sufficient resources of skilled personnel for the planning, execution and monitoring the production in accordance with Vestas requirements.

2.2.1 Quality responsible The quality responsible in the welding workshop shall be trained in this specification and be familiar with Ves-tas requirements. The quality responsible shall have the authority to stop the work if necessary.

2.2.2 Welding coordinator At least one welding coordinator shall be contractually affiliated to the welding workshop whereby welding personnel can be supplied with the necessary procedure specifications and work instructions to ensure that the work is correctly executed and managed. The welding coordinator shall have sufficient authority to initiate the necessary action to ensure that welding is performed in accordance with Vestas requirements.

The welding coordinator shall be able to demonstrate technical knowledge according ISO 14731 Personnel having one of the following qualification examples will be accepted:

• European Welding Engineer (EWE) • Welding supervisor in accordance with AS/NZS 1554.5

2.2.3 Welders All welders and welding operatives shall be approved in accordance with the relevant section of EN 287-1, EN 1418, ISO 9606-1, ISO 14732, AWS D1.1, ASME IX, AS/NZS1554.5 or an equivalent standard approved by Vestas.


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2.2.4 NDT personnel Personnel carrying out NDT (incl.VT) shall be qualified according to one of the following certification sys-tems:

• Nordtest GEN 010 • EN 473 • ISO 9712 • SNT-TC-1A • AS – 3998 • CSWIP (visual only) Other equivalent certification schemes shall be subject to approval by Vestas.

Personnel shall, as a minimum, be certified as level II in the relevant method, or be level I and work under direct supervision of a certified level II person (direct supervision is one level I to be attached to one level II). The above mentioned certifications shall be in an industrial sector which includes welds.

All welding workshops shall appoint a NDT responsible person within their own organisation. This person shall be responsible for the NDT activity and act as contact person to Vestas with regards to NDT.

A level III certified individual in VT, MT and UT shall in addition be contractually affiliated to the welding work-shop. The level III and the NDT responsible should be the same person if the level III is a part of the welding workshop staff. The level III person shall:

• Prepare the required NDT procedures in accordance with Vestas requirements or verify already existing procedures, which are adopted (the level III shall sign the NDT procedures as documentation for this ac-tivity

• Provide technical directions and knowledge in NDT-methods to NDT-personnel and other relevant per-sons in departments within the organisation.

• Perform training, examination and certification of level I and II NDT-personnel. • Verify calibration of equipment e.g. by preparation of calibration instructions or review of documentation

for external calibration. • By documented audits verify that NDT in the workshop is performed in accordance with Vestas require-

ments. The performance of each NDT operator shall be verified continuously, however documented with intervals not exceeding 6 months.

2.2.5 Other inspectors Inspectors performing dimensional inspection, inspection of steel surface, leak testing of sand damper and oil bowl shall be trained for the purpose. They shall have sufficient knowledge with regard to examination procedure, acceptance criteria and reporting.

2.3 Welding consumables The welding workshop shall describe and implement procedures for the storage, handling and use of welding consumables, which will prevent moisture pick-up, reduce risk for hydrogen induced cracks, oxidation, dam-age etc. The procedures shall be in accordance with the supplier’s recommendations and there must be an assigned storage area for consumables.


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2.4 Equipment

2.4.1 Scope and registration All necessary and suitable equipment shall be available for executing the work. The welding workshop shall maintain a list of the main items of equipment used for welding production. This list shall identify the individ-ual items of larger equipment, which are important for assessing the welding workshop’s capacity and capa-bility, e.g.

• Capacity of largest cranes. • Size of components the workshop is able to handle. • Capability of mechanised or automated welding equipment. • Capacity of roller beds, rolling and cutting equipment. • Other equipment is to be specified by the approximate number of each type, e.g. the total number of

power sources per welding method. • A risk assessment for breakdown of critical equipment must be made. Maintenance plan and spares in

stock must reflect result of risk assessment.

2.4.2 New equipment When installing new or newly restored equipment, relevant equipment tests shall be carried out by equip-ment supplier or internal by qualified personnel. The tests shall confirm that the equipment functions cor-rectly. Tests shall be carried out in accordance with relevant standards if such exist. Records of such tests shall be saved for future reference.

New welding equipment:

The extent of NDT inspection shall be 100% of minimum the first 5 circumferential joints, or 10m longitudinal joint and documented in a separate report stored together with documentation for the welding equipment.

2.4.3 Maintenance The welding workshop shall have documented plans for equipment maintenance. The plans shall ensure maintenance checks of items of the equipment, which control the essential variables listed in the relevant welding procedures, e.g. state of:

• Guides in equipment for thermal cutting and mechanised welding fixtures. • Ammeters, voltmeters, flow meters etc. used for the operation of the welding machines. • Cables, hoses, connections etc. • Control system in mechanised and automated welding equipment. • Instruments for temperature measurement. • Wire feeders and conduits. Defective equipment shall not be used.

2.4.4 NDT equipment NDT-equipment shall be subject to a documented system for calibration and verification in accordance with the relevant European, American or Australian/New Zealand standard.

2.5 Handling of deviations. The organisation must have a fully implemented system for handling of deviations, and ensure that products that do not conform to the requirements are identified and controlled, in order to prevent its unintended use or delivery.

Results of corrective and preventive actions must be monitored and documented.

2.6 Additional requirements to towers for Germany Welding workshops producing towers or foundation sections for erection in Germany shall have a valid

Herstellerqualifikation Klasse E in accordance with DIN 18800, Teil 7, issued by the German authorities.


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3.0 Production preparation

3.1 Contract and design review The workshop’s welding coordinator and the other staff involved shall review the production basis handed over from Vestas to ensure that all information necessary to carry out the production is available and under-stood prior to commencement of the work.

The welding workshop shall affirm its capability to meet Vestas requirements and ensure adequate planning of quality related activities, and before production start ensure that the necessary personnel, equipment and procedures are available.

3.2 Quality plan The welding workshop shall draw up a quality plan listing the quality activities to be performed during produc-tion. The reference documents and the responsible person shall be listed for each of the activities.

A quality plan must be prepared for each project

Example of quality plan can be seen in Attachment 1

3.3 Qualification of welding procedures This section describes requirements to welding procedures for welds in primary steel and welds between primary and secondary steel. Welds between two secondary steels must be covered by standard WPS.

3.3.1 Welding procedure specifications (WPS) WPS shall be prepared in accordance with ISO 15609-1, AWS D1.1, AS/NZS 1554.5 or an equivalent stan-dard approved by Vestas. WPS shall be based on an approved welding procedure test and be signed by the workshops welding coordinator. For manual welding the maximum qualified CEQ shall be stated on the WPS.

Repair of weld defects may be carried out under the original WPS or under a different WPS approved for the original welded joint. Alternatively, a specific WPS for repairs may be prepared, based on a repair procedure test. Full non-destructive and destructive testing shall be performed on a repair procedure test.

WPS for repair of surface imperfections (torn surface, chipping marks, scratches etc.) shall be qualified by fillet weld procedure tests, or alternatively a test plate where a small grove is grinded and filled-up with one string. Minimum length of weld repair must be specified and qualified to avoid to high hardness.

WPS may be used directly by the welder or the welding coordinator may alternatively prepare specific work instructions on the basis of approved welding procedures.

3.3.2 Welding procedure tests Welding procedures shall be qualified by welding procedure tests in accordance with ISO 15614-1, AWS D1.1, AS/NZS 1554.5 or a similar standard approved by Vestas and TPS 900873. Arc stud welding shall be qualified according to ISO 14555 or AWS D1.1 or a similar standard approved by Vestas.

A partly penetrated butt weld shall be qualified by:

• A butt weld PQR, • A PQR for a partly penetrated welding procedure test with the same bevel as used in the production, • or a PQR for fillet welds. The material certificate of the steel used in the welding procedure test shall be included in the procedure qualification record (PQR / WPAR).


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3.3.3 Additional essential variables This section specifies additional essential variables to those of the chosen qualification standard (e.g. AWS D1.1).

The following requires a new welding procedure test: • Welding in steel with higher specified yield strength compared with the steel used in the welding proce-

dure test. • Change from butt weld or T-butt joint to fillet weld or visa versa. • Welding on shop primer if the welding procedure test is performed without shop primer, or if the thickness

of the shop primer is higher in the production compared with the welding procedure test. • For manual welding (SMAW, FCAW and GMAW) a CEQ of the steel in the production (ladle analysis) that

is more than 0.03% above the CEQ of the steel used in the welding procedure test See example. Example of CEQ qualified: Flux cored arc welding is used for the weld between doorframe and shell plate. The weld is qualified by a welding procedure test performed in a plate with a CEQ equal to 0.37%. The welding procedure test quali-fies welding in steel with CEQ of maximum 0.40% (0.37% + 0.03%), and the CEQ of the doorframe and shell plate shall therefore not be more than 0.40%.

3.3.4 Examination and testing Extent of non-destructive and destructive testing of welding procedure tests shall as a minimum be as speci-fied below.

Butt weld:

• VT, MT and UT or RT. • 2 transverse tensile tests. • 4 bend tests. • Impact testing in weld metal and HAZ. • 1 macro specimen. • Hardness examination on the macro.

T-butt joint:

• VT, MT and UT or RT. • 2 transverse tensile tests 1. • Impact testing in weld metal and HAZ 1. • 2 macro specimen. • Hardness examination on the macro. Note 1: Tensile and impact testing may be performed on a butt weld that is welded with the same welding parameters.

Fillet weld, partly penetrated butt weld and repair of surface imperfection

• VT and MT. • 2 macro specimens. • Hardness examination on one of the macros.


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3.3.5 Hardness testing 1 row of indentations shall be carried out maximum 2 mm below each surface. Additionally 1 row of indenta-tions shall be carried out in the root area of double-sided welds, T-butt welds and fillet welds.

For each row of indentations there shall be a minimum of 3 individual indentations in each part of the weld, the HAZ (both sides) and the parent metal (both sides). See typical example below.

For the HAZ the first indentation shall be placed as close to the fusion line as possible.

The hardness shall not exceed 380 HV10 for single run welds, and 350 HV10 for multi-run welds.

3.4 Welding plan The welding coordinator shall prepare an overview of the welding activities, by filling in the welding plan At-tachment 12

3.4.1 Additional requirements to towers for Germany The welding plan shall be accepted by the German authorities - Note before welding of towers or foundation sections for erection in Germany is commenced.

Note: E.g. SLV Hannover.

3.5 Welding sequence at flanges A work instruction must be prepared describing welding sequence and other measures which shall be taken, in order to secure fulfilment of all flange dimensional requirements.

3.6 Heat treatment of welds The welding workshop shall prepare a procedure for post weld heat treatment in cases where this is re-quired.

3.7 Flame straightening If flame straightening is necessary, a specific instruction shall be prepared.

Vestas requires that satisfactory performance of flame straightening is a proven ability.

Weld Parent material

2mm

m

ax.

HAZ wide HAZ narrow

Parent material


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3.8 Preparation of procedures for non-destructive testing Vestas specific VT, MT and UT procedures/instructions shall be prepared based on this specification and TPS 900873. The procedures/instructions shall be written to a certified level II or level I operator under direct supervision of a certified level II, with the following points as a minimum:

• Scope • References • Qualification of personnel • Extent of the examination • Equipment • Examination technique • Evaluation of indications • Acceptance level • Reporting

3.9 Verification of steel The welding workshop shall secure that the necessary steel is available.

Storage of materials must be managed under conditions which does not in any way degrade the quality of the materials.

A storage management plan must be elaborated, and be a part the quality management system.

3.9.1 Material certificates Material certificates for the primary steel must be reviewed before production start, to secure that all certifi-cates are available, complete and identical with material on stock.

3.9.2 Bolt flanges Inwards inspection shall be performed on at least every fifth flange, where the flange dimensions are in-spected, and compliance between the material certificate and the information stamped in the flange is veri-fied.

3.10 ID-numbers for sections Vestas must give the ID-number to the supplier before production start.

3.11 Serial numbers for welded doorframes, top skirts and segmented flange The welding workshop shall prior to production select a unique serial number for each welded doorframe, parts for segmented flanges, top skirt and stamp this number into the individual part together with ID and heat number, to ensure traceability.


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4.0 Quality activities during production

4.1 Control of steel Before the steel is used it shall be verified that grades, dimensions, surface conditions etc. comply with the specified and the steel shall be checked for damages.

4.1.1 Material traceability The material traceability number (charge, test etc.) shall be visible on each primary steel part from the inside of the final welded section, i.e. numbers shall be transferred or moved where necessary. For transferring the numbers the supplier must have a written procedure and the stamp must be soft nose and the height must be 10 mm.

Material traceability for welded doorframes, top skirts and segmented flange shall be recorded on Attach-ment 10, Attachment 11 and Attachment 13

The traceability numbers shall be recorded on Attachment 3 after assembly of the complete section.

4.2 ID-numbers and serial numbers Section ID-numbers and serial numbers for welded doorframes, top skirts and segmented flange shall be applied on the part as early as possible in the process.

ID-numbers shall be welded on secondary steel or stamped on to the section as specified on the production drawings.

In cases where the location of the ID-number is not specified on the drawing, the ID-number shall be stamped inside in the lowest bolt flange in the section, in line with the ladder. In bottom sections without a lower bolt flange (to be welded on site), the number shall be stamped inside in the bottom of the doorframe. In foundation sections without bolt flange, the number shall be stamped inside in the shell plate 100mm be-low the bevel for site weld. The stamp must be soft nose and the height must be 10 mm.

Serial numbers for welded doorframes, top skirts and segmented flange shall be applied as specified on At-tachment 10, Attachment 11 and Attachment 13

Numbers shall be applied in such a way they are easy readable after surface treatment.

4.3 Preparation of weld log Each weld in primary steel shall be assigned a section unique identification in accordance with Attachment 4, Attachment 10, Attachment 11 and Attachment 13 to be used for reference between weld and WPS and for reference on NDT reports.

The WPS used for each weld and also for any repair shall be recorded on relevant document.

Traceability between weld and welder shall be available until NDT has been performed. This can be obtained by applying the welder’s name or number by paint stick or “soft nose” stamping on the side of the weld. Al-ternatively a record with reference between weld and welder may be prepared.


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4.4 Inspection and testing before and during welding The welding workshop shall ensure that the welding procedures are used correctly in the production.

Inspection and testing before and during welding shall be performed at least every week where all new welders (less than 2 weeks of operation) and welding procedures (used less than 4 weeks), are checked.

Other welders and welding procedures are checked regularly and adequately, in order to ensure requirement fulfilment.

The following shall be checked before welding:

• The welder’s certificate. • Use of the correct WPS. • Identity of parent material. • Identity of filler material. • Bevel preparation. • Positioning, fixing and tack-welding • Environmental conditions. The following shall be checked during welding:

• Important welding parameters such as welding current, arc voltage and welding speed. • Preheating and interpass temperature. • Cleaning between runs. • Grooving out root run (if applicable). • Welding sequence. • Correct use and handling of filler metal. The inspection and testing shall be documented by reference to the welder and WPS no.

4.5 Non-destructive testing of welds

4.5.1 Time of Examination The examinations shall be carried out after completion of welding and any required heat treatment incl. flame straightening.

4.5.2 Sequence of examination methods Where more than one examination method shall be applied on a component, VT shall be performed and ap-proved first followed by MT prior to UT

4.5.3 Surface conditions The surface to be examined shall be clean, free from oil, grease, sand, scale or any other condition, which could interfere with the examination or the interpretation.

The surface conditions shall meet the requirements of the standard for the actual examination method.

4.5.4 Marking of defects All defects shall be marked on the item. Marks shall be visible until the defects have been repaired and tested.

4.5.5 Random testing In case of random testing, the welds shall be divided into batches as follow:

• Each longitudinal weld shall be considered as one batch. • Each circular weld shall be considered as one batch. • Each frame welds shall be considered as one batch. • All attachment welds shall be considered as one batch. The specified extent of examination shall be performed on each batch. Intersections between longitudinal and circular welds shall be included in the examination area.


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4.5.6 Visual examination (VT) EN 970, AWS D1.1 or AS/NZS 1554.5 shall be used as examination technique for visually examination of finished welds.

The extent shall be as specified on the production drawing or specification. ISO 5817 level B apply as accep-tance level.

VT shall be recorded on Attachment 5 only acceptable welds require recording.

4.5.7 Magnetic particle examination (MT) MT shall be performed on fillet welds between the primary and secondary steel. The extent shall be as speci-fied on the production drawing or specification.

In addition 100% MT shall be performed;

• on welds at safety brackets. • on welds at suspension bracket for service platform (top section). • in areas where non-specified welding have been applied on to the primary steel, e.g. where temporary

welded attachments, torn surfaces, stray flashes or arc strikes have been removed. • after weld repairs in the repaired areas of primary steel welds. Examination technique shall be in accordance with EN 1290, ASTM E 709 or AS 1171. Examination shall be performed for indications in any directions. Alternating-current electromagnetic yoke shall be used.

Detection media shall be of liquid form, fluorescent or black. Background shall be painted white when black detection media is used.

Acceptance criteria is no linear or non-linear indication.

MT shall be recorded on Attachment 5 only acceptable welds require recording.

4.5.8 Ultrasonic examination (UT) UT shall be performed on full penetration butt welds in primary steel. The extent shall be as specified on the production drawing or specification.

4.5.8.1 Performance of examination The examination shall be performed and evaluated as follows.

Examination level / Acceptance level EN 1714 level B / EN 1712 level 2

Or

AWS D1.1 / AWS D1.1 table 6.3

Or

AS 2207 / AS/NZS 1554.5 table 6.1.1.

The parent metal shall be examined for lamination and other imperfections, which can influence the exami-nation of the welds.

Only examination for longitudinal defects is required unless suspicion of transverse defects occurs.

The examination shall be performed with an overlap of minimum 10% of the crystal diameter and manual-scanning speed shall not exceed 150mm/sec.

Cracks and lack of fusion are not allowed.

Beforehand acceptance by Vestas shall be obtained if mechanized or automatic examination is used (e.g. P-scan or Phased-array etc.). System approval by Vestas must be based suppliers ability regarding system use and documentation for fulfilling relevant standards.


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4.5.8.2 Full penetration Butt joints For butt joints, the below listed probes (or equivalent) shall as minimum be used.

Thickness Probe Positions

Probes Crystal Dimensions

Scanning zone width

Number of scans

8 ≤ t < 15 mm A or B 70° angle beam 2 - 4 MHz 8 x 9 mm 1,25p+WHAZ 2

15 ≤ t < 25 mm A or B 70° angle beam 2 MHz 14 x 14 mm 1,25p+WHAZ 2

25 ≤ t < 40 mm A or B

A or B

70° angle beam 2 MHz

Angle beam 2 MHz Note 1

14 x 14 mm

14 x 14 mm

1,25p+WHAZ

1,25p+WHAZ

2

2

t ≥ 40 mm A & B

A or B

70° angle beam 2 MHz


14 x 14 mm

14 x 14 mm

0,75p+WHAZ

1,25p+WHAZ

4

2

Note 1: The probe angle shall be selected so the weld bevel areas are examined with a sound beam, which is perpendicular to the original bevel ± 8 degrees.

With two different plate thicknesses the requirements from thickest plate apply.

Skip (p) = 2 x t x tan α

WHAZ = width of the Heat Affected Zone

Note: WHAZ shall be set to minimum 10mm.

B

A A

B

0,75 (p) 1,25 (p)

α

skip (p)

t

WHAZ


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Page 15 of 34

4.5.8.3 Full penetration T-Butt joints For T-joints, the below listed probes (or equivalent) shall as minimum be used.

Thickness (t1) Probes positions

Probes Crystal di-mension

Scanning zone width

Number of scans

8 ≤ t < 15 mm

A or B

A or B

D

70° angle beam, 2 - 4 MHz


Straight beam 2 - 4 MHz with focus in the weld area. Note 2

8x9mm

8x9mm

1,25p+WHAZ1,25p+WHAZ

1

1

1

15 ≤ t < 40 mm A

B

D

70° angle beam, 2 MHz



14x14mm

14x14mm

1,25p+WHAZ

1,25p+WHAZ

1

1

1

t ≥ 40 mm A & B

A & B

D




14x14mm

14x14mm

0,75p+WHAZ

0,75p+WHAZ

2

2

1


Note 2: To be substituted by examination with 80° angle beam 14x14mm 2 MHz from A or B, if D is not possi-ble, or if t2 > 2 x t1.

A B

D

t1

t2


Issued by: PE



Type: QS

Page 16 of 34

4.5.8.4 Bolt flanges (normal) For Flange-Butt joints, the below listed probes (or equivalent) shall as minimum be used.

Thickness (t) Probes positions

Probes Crystal dimension

Scanning zone width

Number of scans

8 ≤ t < 15 mm

A & C

A & B

D


Angle beam 2 - 4 MHz Note 1

Straight beam 2 - 4 MHz with focus in the flange welds area. Note 2

8 x9mm

8 x9mm


2

2

1

15 ≤ t < 40 mm A & C

A & B

D




14 x14mm

14 x14mm

1,25p+WHAZ

1,25p+WHAZ

2

2

1

t ≥ 40 mm A, B & C

A & B

D




14x14mm

14x14mm

0,75p+WHAZ

1,25p+WHAZ

3

2

1


Note 2: To be substituted by examination with 80° angle beam 14x14mm 2 MHz from B or C, if D is not possi-ble and flange neck is to short for 1,25p+WHAZ.

A B

C D

t


Issued by: PE



Type: QS

Page 17 of 34

4.5.8.5 Bolt flanges (special USA bottom flange) The below listed probes (or equivalent) shall as minimum be used.

Thickness (t) Probes positions

Probes Crystal dimension

Scanning zone width

Number of scans

8 ≤ t < 15 mm

A or B

A or B

D


Angle beam 2 - 4 MHz Note 1

Straight beam 2 - 4 MHz with focus in the flange welds area.

8 x9mm

8 x9mm


1

1

1

15 ≤ t < 40 mm A

B

D




14 x14mm

14 x14mm

1,25p+WHAZ

1,25p+WHAZ

1

1

1

t ≥ 40 mm A & B

A & B

D




14x14mm

14x14mm

0,75p+WHAZ

0,75p+WHAZ

2

2

1


B A

D

t


Issued by: PE



Type: QS

Page 18 of 34

4.5.8.6 Recording The following procedure must be followed for UT examination:

Sections without defects:

UT results must be recorded on Attachment 6.

Sections with defects:

UT results must be recorded on Attachment 6. Welds with defects must be noted under remarks “welds with defects”, and the remaining welds without defects must be noted under “Accepted welds”. The weld defects must be recorded on Attachment 7. For acceptance of weld defects, a new Attachment 6 must be filled out, however only with examination and acceptance of repair.

4.5.9 Additional requirements in case of defects Areas with weld defects shall be repaired and re-examined with the inspection methods originally specified, and repaired areas in butt welds shall in addition be examined by MT.

The welding workshop shall seek the cause of defects and increase the extent of examination to other batches in case of systematic errors. Necessary actions shall be implemented to prevent that defects occurs again, e.g. by optimising welding procedures or by training of personnel.

The same weld shall not be repaired more than twice in the same place, unless the mechanical properties of the repair weld have been demonstrated by means of a welding procedure test.

4.6 Statistics of weld defects The welding workshop shall prepare statistics of weld defects.

Each month, the following information shall be available.

• Total welded length, [mm]. • Total length examined with the NDT methods UT, [mm]. • Total length of weld defects found with UT, [mm]. • Repair rate, [%]. Repair rate = Defect length x 100% / welded length.

Repair rates above 2% require corrective action to be performed.

4.7 Leak test on sand chamber Sand chambers shall be tested for leaks under the following procedure:

• Mount an inlet for a compressed air fitting on one of the flanges. • Fill the chamber with sand and weld shut the sand filling hole. • Raise the pressure in the chamber approx. 0.1 bar with air. • Test the welds for leaks with soapy water and release the pressure. • Weld any continuous pores and repeat the leak test. • Weld shut the compressed air inlet and leave airtight. Test with VT/MT. Leak test of sand chamber shall be recorded on Attachment 9

4.8 Leak test of oil bowl for oscillation damper The oil bowl shall be tested for leaks e.g. by applying fluorescent penetrant liquid on the outside weld surface and detecting with UV-lighting inside the bowl, vacuum test or air pressure test. (MT is not acceptable as leak test)

Leak test of oil bowl shall be recorded on Attachment 9


Issued by: PE



Type: QS

Page 19 of 34

4.9 Dimensional inspection of welded doorframes, top skirts and segmented flange Dimensional inspection shall be performed on welded doorframes, top skirts and segmented flange. Results shall be recorded on Attachment 10, Attachment 11 and Attachment 13

4.10 Dimensional inspection of sections Flange Calculator referred to below, is a Vestas developed software, which must be used for

calculating and documenting of flange dimensional requirements.

V82 top flange requirements:

All flanges (100%) must be measured with Easy Laser, and calculated with the use of Flange

Calculator.

All other flanges:

The supplier must ensure and document a stable manufacturing process, by measuring all (100%) flanges until the defined processes and measures acc. to 3.5 are providing fulfilment of all dimensional requirements.

As a part of the measurement monitoring process, all major factors to the end result must be identified (e.g. new equipment; personnel; processes etc) and any occurrences of these, all (100%) flanges must be meas-ured and documented until, - and in order to provide evidence of a stable process.

In order to monitor and document the process results, every 5th flange must be measured with the use of Easy Laser, and calculated via Flange Calculator.

If any repairs have been performed on the flange circumferential weld, the flange must be measured with use of Easy Laser, and calculated in Flange Calculator.

All (100%) flanges must be measured in terms of angle displacement and ovality, and subsequently the re-sult must be typed in Flange Calculator.

The following dimensions shall be measured on the NDT approved sections and documented via Flange Calculator.

• Ovality of bolt flanges (when measuring ovality the item weight / gravity influence must be considered and the measures shall therefore be performed as shown in Flange Calculator).

• Distance between inner flange and circular welds at bolt flanges.

The following dimensions shall be measured on the NDT approved sections and calculated for pass or fail using Flange Calculator.

• Angle displacement of bolt flanges. • Flatness of flanges shall be measured. Flange flatness will be documented by a “best fit” calculation based on measurements of points on the out-side diameter distributed with a distance calculated by Flange Calculator. These measurements are made in a similar way on the inside diameter of the flange.

Printout from Flange Calculator must be used as Attachment 8 for upload to Towerdoc.

Other dimensions than mentioned above must be checked on a random basis, except from first time produc-tion where the welding workshop shall perform a detailed dimensional inspection and documentation of all dimensions.

Easy Laser measuring equipment must be used for all specified measurements involving Flange Calculator.

It is always the responsibility of the tower supplier that all flange dimensional requirements are in accordance with Vestas requirements.


Issued by: PE



Type: QS

Page 20 of 34

4.11 Surface inspection The surface shall be inspected visually for dents, plate defects, chipping marks, scratches, sharp edges and other imperfections before the section is released for surface treatment.

4.12 General inspection For all types of inspection the following applies:

In case of change of processes, personnel or equipment or other situations having impact on the result of the manufactured items, the extent must be increased to 100% in a period until a stable production outcome is maintained.

5.0 Release

5.1 General Welded sections, welded doorframes and top skirts shall be completed and comply with Vestas specifica-tions before they are released for the next process.

All inspection and testing shall have been performed with acceptable result.

5.2 Review of records (as-built) Records may be printed from computer or made on typewriter.

A review shall be performed to secure that the necessary records are available and completed in accordance with the requirements of this specification.

It shall be checked that the traceability numbers recorded on the material traceability list matches the mate-rial certificates, and that the item numbers and grades listed on the material certificates complies with the numbers and grades specified on the drawings.

5.3 Release of welded doorframes, top skirts and segmented flange Welded doorframes, top skirts and segmented flange shall be released by signature on Attachment 10, At-tachment 11 and Attachment 13 Material certificates and NDT reports shall be enclosed each document, and the package shall be considered as one material certificate for the relevant part.

The material certificate shall be sent together with the part, if the part is used by another welding workshop.

5.4 Release of sections for surface treatment The quality responsible or his appointed representative shall sign the Statement of Quality Attachment 2 to document that the section is ready for surface treatment. Before signature it shall be checked that material traceability is correct. Statement of Quality Attachment 2 must be uploaded to Towerdoc for use in the subsequently processes.

5.5 Uploading via Towerdoc As-built documentation shall be transferred to PDF files and uploaded via Towerdoc (http://towerdoc.vestas.com), maximum 5 working days after release of the welded section.

The following shall be uploaded for each section:

• Material certificates for primary steel, one file for each material certificate (incl. documentation packages for welded doorframes, top skirts and segmented flange, where applicable).

• One file including material traceability list for primary steel, weld log, NDT reports, report for dimensional inspection, leak test report (in any).

• and one file including Attachment 2 Statement of Quality (partly filled in), • Waivers as one file (if any). Material certificate packages for welded doorframes and top skirts shall be uploaded separately if the part is used by another welding workshop.

Vestas will provide Towerdoc user name and password and further instruction in the system.


Issued by: PE



Type: QS

Page 21 of 34

Attachment 1, - Example of quality plan.

Acc

epte

d

Rec

ord

WP

S +

WP

S p

lan

ND

T pr

oced

ures

Insp

ectio

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Mat

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ceab

ility

list

Wel

d lo

g

Insp

ectio

n sh

eet

VT

/ MT

repo

rt

VT

/ MT

repo

rt

UT

repo

rt

Leak

test

repo

rt

Dim

ensi

onal

i. re

port

Sta

tem

ent o

f Qua

lity

Spec

ifica

tion

QS

9905

08, 3

.1

QS

9905

08, 3

.3

QS

9905

08, 3

.8

QS

9905

08, 3

.9.

QS

9905

08, 4

.2

QS

9905

08, 4

.1

QS

9905

08, 4

.3

QS

9905

08, 4

.4 –

WP

S

ND

T pr

oced

ure

ND

T pr

oced

ure

ND

T pr

oced

ure

QS

9905

08, 4

.7

QS

9905

08, 4

.10

QS

9905

08, 4

.11

QS

9905

08, 5

.0

Res

pons

ible

Pro

ject

man

ager

Wel

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eng

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II

Qua

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man

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Wel

ding

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Qua

lity

man

ager

Wel

ding

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Wel

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eng

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VT

leve

l II

MT

leve

l II

UT

leve

l II

Wel

ding

fore

man

Qua

lity

man

ager

Qua

lity

man

ager

Qua

lity

man

ger

Qua

lity

Plan

– S

teel

wor

k an

d w

eldi

ng

Pro

ject

: 45

off

V80

78m

tow

ers

W

orks

hop:

Tow

er s

uppl

ier

Pre

pare

d by

: Qua

lity

resp

onsi

ble

Act

ivity

- Con

tract

and

des

ign

revi

ew

- Qua

lific

atio

n of

wel

ding

pro

cedu

res

- Pre

para

tion

of N

DT

proc

edur

es

- Ins

pect

ion

of s

teel

and

cer

tific

ates

- Mar

king

of I

D-n

umbe

r on

sect

ion

- Mat

eria

l tra

ceab

ility

- Pre

para

tion

of w

eld

log

- Ins

pect

ion

befo

re a

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g w

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ng

- Vis

ual e

xam

inat

ion

of w

elds

- Mag

netic

par

ticle

exa

min

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n of

wel

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- Ultr

ason

ic e

xam

inat

ion

of w

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- Lea

k te

st o

f san

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ensi

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insp

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insp

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ctio

n


Issued by: PE



Type: QS

Page 22 of 34

Attachment 2, - Statement of Quality EN 10204 - 3.1B Description of sec-

tion:

Section ID-number: Sales item number: Foundation section Intermediate section I Intermediate section III Bottom section Intermediate section II Top section Description in text: Release after steelwork and welding: Drawings / revisions of drawings used for production (as-built): Welding drawing: Flange drawings: Shell plate drawing(s): Frame drawing(s)

Deviations from Vestas requirements are approved on waiver №: This is to certify that steelwork and welding has been performed in accordance with Vestas requirements. The complete

welded section has been inspected and accepted and the records for steelwork and welding have been reviewed and ap-proved.

Date: Contractor: Name: Signature: Release after surface treatment: Technical Purchase Specification / revision: Deviations from Vestas requirements are approved on waiver №: This is to certify that surface treatment has been performed in accordance with Vestas requirements. The complete surface

treated section has been inspected and accepted and the surface treatment records have been reviewed and approved.

Date: Contractor: Name: Signature: Release after mounting of internals: Assembly drawing / revision: Deviations from Vestas requirements are approved on waiver №: This is to certify that mounting of internals has been performed in accordance with Vestas requirements. The complete sec-

tion has been inspected and accepted and is ready for storage and transportation. The final inspection report has been re-viewed and approved.

Date: Contractor: Name: Signature:


Issued by: PE



Type: QS

Page 23 of 34

Attachment 3, - Material traceability list

Description of section:

Section ID-number: Welding drawing number: .R

Foundation section Intermediate section Bottom section Top section

Traceability list – flanges:

Drawing № Traceability № (Serial No., Vendor, Charge, test.)

Traceability list – shell plates / flange segments:

Drawing № t [mm] Traceability № (Serial No., Vendor, Charge, test.)

Traceability list – door frame/cable frame:

Drawing № Traceability № (Serial No., Vendor, Charge, test.)

Contractor:

Date/ Signature:


Issued by: PE



Type: QS

Page 24 of 34

Attachment 4, - Weld log

Description of section:

Section ID-number: Welding drawing number: .R

Foundation section Intermediate section Bottom section Top section

Weld No. WPS No. Welder ID, date and

sign Weld No. WPS No. Welder ID, date and

sign

Fillet welds:

WPS No. Welder ID, date and sign Location of weld Repair of surface imperfections: WPS No. Welder ID, date and sign

Contractor: Date/Signature


Issued by: PE



Type: QS

Page 25 of 34

Attachment 5, - VT / MT report VT examination date Technician (Init.) Certificate No. Examination organization / Inspection authority MT examination date Technician (Init.) Certificate No. Client

Contractor Location

Description in text Section ID. No. Drawing No. / Rev. No.

Visual examination

Examination procedure Acceptance criteria

Aids

Ruler Tape measure Calliper gauge Feeler gauge Weld gauge Contour gaugeTime of examination

After welding RepairsExtent of examination Surface condition

100 % Ground Smooth Coarse Primer CoatedRemarks

VT acceptable Enclosures Technician (Date/Signature)

VT not acceptable Sheet(s)

Magnetic particle examination Examination procedure Acceptance criteria

Surface condition Reinforcement

Ground Smooth General Primer As welded Ground AC Yoke

S

Type S max.= mm

Reg. No.

Water/black Kerosine/black Background

Water/fluocent Kerosine//fluocent White Ground Non-treated Field strength kA/m Other Lighting

Oerstedm. Value Oe White UV-lamp No. Magnetized for

Indications in any direction Extent of examination % Remarks

MT acceptable Page Technician (Date/Signature)

MT not acceptable of


Issued by: PE



Type: QS

Page 26 of 34

Attachment 6, - UT report

Period of examination / Date Technician (Init.) Certificate No. Examination organization / Inspection authority

Assistant (Signature) Certificate No. Client

Contractor Location

Description in text Section ID. No. Drawing No./Rev. No.

Examination procedure Acceptance criteria Equipment type / Reg. No.

/ Compression probes Angle probes Probe type A: B: C: D: E: F: Reg. No. / True angle / MHz / MHz / ° / ° / ° / °Sensitivity setting Basic sett.~ref.curve dB dB dB dB dB dBTransfer Correction dB dB dB dB dB dBExtra when scanning dB dB dB dB dB dBTotal dB dB dB dB dB dB

Sensitivity: Diam.= mm, range = mm DGS (AVG): Disc diam. = mm, range = mm

V1 No. V2. No. TIF-block No. Other

Probe check Parent metal Couplant

Operator check of ultrasonic probes carried out Scanning area tested for lamination Scanning position for longitudinal defects

Weld No. / Thickness / Probe type / Probe position / Inspection area in % Weld No. / Thickness / Probe type / Probe position / Inspection area in %

/ mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % / mm / - - - - / - - - / % Remarks Welds with defects:

Accepted welds: Acceptable Page Technician (Date/Signature)

Not acceptable (reported on Attachment 7) of

1

4

2

3

8

5 6

7

10 9

11


Issued by: PE



Type: QS

Page 27 of 34

Attachment 7, - UT repair report Period of examination / Date

Technician (init.) Certificate No. Examination organization / Inspection authority

Assistant (Signature) Certificate No. Client

Contractor Location

Description in text Section ID No. Drawing No. / Rev. No.

/

Scanning deatils Location of indication Type of indication

Result Remarks

Depth from

Pla

te th

ickn

ess

Coo

rdin

ates

Def

ect L

engt

h

Ext

erna

l sid

e

Inte

rnal

sid

e

Weld No. In

dica

tion

No.

Sca

nnin

g P

ositi

on

Bea

m a

ngle

(tru

e)*

Acc

epta

nce

leve

l (d

b/di

sk d

ia.)

[mm] [mm] [mm] [mm] [mm] Long

itudi

nal

Tran

sver

se

Exc

eeds

acc

epta

nce

Leve

l with

: db/

disk

dia

.

Acc

epta

ble

Not

acc

epta

ble

Repairs marked Page Technician (Date/Signature) On object of

A general description of the coordinate sys-tem to be used when defects are reported.

The 0 point for all lon-gitudinal welds is lo-cated at the circular weld below.

The 0 point for all circular welds (except from the one at the top) is located at the longitudinal weld abo-ve.

X

X

X

X X

X


Issued by: PE



Type: QS

Page 28 of 34

Attachment 8, - Dimensional inspection report

EXAMPLE


Issued by: PE



Type: QS

Page 29 of 34

Attachment 9, - Leak test report

Description of top section:

Section ID-number: Welding drawing number: .R Contractor:

The sand damper has been filled with air until 0.1 Bar pressure above the atmosphere. All welds have been tested for leaks with soapy water. Any leak has been repaired and tested again. The sand damper is airtight! Date/Signature:

The oil bowl for the oscillation damper is leak tested and found acceptable. Date/Signature:


Issued by: PE



Type: QS

Page 30 of 34

Attachment 10, - Welded doorframe log

Description of doorframe:

Doorframe serial number: Drawing number: .R Note: The doorframe manufacturer shall select a unique serial number for each doorframe. The number shall be stamped inside the doorframe, see sketch below. Identification of welds: • The weld below the serial number is named

DW1, the second weld clockwise is named DW2, etc.

• Weld repairs are named R1, R2 etc. in addi-tion to the original identification, e.g. DW1R1.

Thermal cut frame, identification of welds: • FW1 upper hinge, FW2 lower hinge, FW3

flat iron. Identification of materials: • The doorframe part with the serial number is

named pos. 1, the second doorframe part clockwise is named pos. 2, etc.

Weld traceability Material traceability

Weld No. WPS No. Welder ID No. and date

Pos No. Traceability number

Dimensions acceptable. This is to certify that the doorframe has been manufactured in accordance with Vestas requirements. The complete door-frame has been inspected and accepted and material certificates and NDT reports have been reviewed and approved.

Date/Contractor: Date/Signature:

Note: Material certificates for the doorframe parts and reports for Non-Destructive Testing of the welds shall be enclosed this log. The complete package shall be considered as one material certificate for the welded doorframe.

Cut A-A

XXXX

Serial number

DW1

DW2

A

A

1

2

Hinge

Flat iron Partly shown

FW1

FW2 Hinge

FW3

Serial no.


Issued by: PE



Type: QS

Page 31 of 34

Attachment 11, - Top skirt log (page 1 of 2)

Description of top skirt:

Top skirt serial number: Drawing number: .R Note: The top skirt manufacturer shall select a unique serial number for each top skirt. The serial number shall be stamped outside on the flange at the longitudinal weld. After machining shall the serial number be stamped inside on the flange at the longitudinal weld. Weld and material traceability: Identification of welds: • The longitudinal weld is named TW1. • The weld between shell and flange is

named TW2. • Weld repairs are named R1, R2 etc. in ad-

dition to the original identification, e.g. TW1R1.

Weld traceability Material traceability

Weld No. WPS No. Welder ID No. and date

Material Traceability number

TW1 Shell plate TW2 Flange

The signature below confirms that the top skirt has been manufactured in accordance with Vestas requirements by use of the correct materials. Welds have been inspected and the top skirt is ready for machining.

Date/Contractor: Date/Signaure:

XXXXXX

Shell plate TW1

Flange

TW2

Serial number


Issued by: PE



Type: QS

Page 32 of 34

Attachment 11, - Top skirt log (page 2 of 2)

Top skirt serial number: Drawing number: .R Measurement results:

BCD Dy di Ø n t1 t2 t3 da db X** 1 2 3

** Correct placements of bolt holes must be indicated with a cross. Maximum tolerance for placement of the holes = ± 1.0 mm (accumulate defect is not allowed).

Dimensions acceptable. Contractor: Date/Signature:

Release of top skirt:

This is to certify that the top skirt has been manufactured in accordance with Vestas requirements. The complete top skirt has been inspected and accepted and material certificates and NDT reports have been reviewed and approved.

Date/Contractor: Date/Signature:

Note: Material certificates for the shell plate and flange and reports for Non-Destructive Testing of the welds shall be

enclosed this log. The complete package shall be considered as one material certificate for the top skirt.

1. Measurement

2. Measurement

3. Measurement

t1

Dy Ø di

t2

db

da

BCD, n (number of holes)

t3

Serial number after machining


Issued by: PE



Type: QS

Page 33 of 34

Attachment 12, - Welding plan for Vestas towers and foundation sections. Contractor:

Welding procedures for longitudinal welds: WPS No. Thickness range [mm] WPAR / PQR No. Remarks

Welding procedures for circular welds between shell plates: WPS No. Thickness range [mm] WPAR / PQR No. Remarks

Welding procedures for circular welds between shell plates and flanges: WPS No. Thickness range [mm] WPAR / PQR No. Remarks

Welding procedures for repair of shell surfaces (manual process): WPS No. Thickness range [mm] WPAR / PQR No. Remarks

Welding procedures for smaller repairs in longitudinal or circular welds (manual process): WPS No. Thickness range [mm] WPAR / PQR No. Remarks

Welding procedures for frame welds: WPS No. Thickness range [mm] WPAR / PQR No. Remarks

Welding procedures for attachment welds: WPS No. Thickness range [mm] WPAR / PQR No. Remarks

Welders qualified in accordance with: Date: Weld. coordinator sign: Date: German authority sign:


Issued by: PE



Type: QS

Page 34 of 34

Attachment 13, - Segmented flange log.

Description of flange:

Flange serial number: Drawing number: .R Note: The flange manufacturer shall select a unique serial number for each flange. The number shall be stamped in the inside flange, see sketch below. Identification of welds: • The weld at clockwise compared with the

serial number is named SW1, the next SW2 etc.

• Weld repairs are named R1, R2 etc. in ad-dition to the original identification, e.g. SW1R1.

Material traceability: • The flange segment with the serial number

is named Pos. 1, the second flange segment clockwise is named Pos. 2, etc.

Weld traceability Material traceability Weld No. WPS No. Welder ID No. and

date Pos. No. Traceability number

This is to certify that the flange has been manufactured in accordance with Vestas requirements. The complete flange has been inspected and accepted and material certificate(s) and NDT report(s) have been reviewed and approved.

Contractor: Date/Signature: Note: Material certificate(s) for the flange segments and report(s) for Non-Destructive Testing shall be enclosed this log. The complete package shall be considered as one material certificate for the welded flange.

Cut A-A

XXXXX

Serial number SW2

SW1 SW4

SW3

SW1

A

3

1

2

A

4

5

6

990508[1]rev.3

Documents

Transcript of 990508[1]rev.3