Project Quality History Card - Mechanical: S E L, P, I

Project Quality History Card – Mechanical ISO 9001-2008;
ISO 14001-2004;
For 2.1MW STV , S111 Tubular Tower WTG –90m HH OHSAS 18001-2007
(Applicable for India Installation)
Technology BOP- PE
PM.2100G.75.01.01.QC.117/ Rev 03/22.07.2015 F
Project Quality History card - Mechanical

For 2.1MW STV ,S111 Tubular Tower WTG – 90m HH
SUZLON ENERGY LIMITED, PUNE, INDIA
Document Class:3
Reviewed By Approved By
Rev. No. 03 Page 1 of 15
S.K.Patil Jitendra R. Deshpande
AIG\D\Project Engg.\QMS Documents \Project Quality
Technology BOP- PE, SEL, Pune History card _2. 1MW_S111_90M.HH.doc
ISO 14001-2004;
Technology BOP- PE
PM.2100G.75.01.01.QC.117/ Rev 03/22.07.2015 F
DISCLAIMER:
All the Information provided in this document is based on the approved designs, engineering standards, technical publications,
rules of regulatory authorities and data gathered from practical experience of project execution. While Technology BOP- PE
makes every effort to provide accurate, current, clear and complete information in this document, it cannot be guaranteed that
the information furnished in this document by itself is complete in all respects to carry out the work intended or ordered.
This document is applicable for Suzlon’s India projects only and not for use outside India. It contains information that is
confidential and protected from disclosure and copying in full or part. Any circulation, dissemination or review of this document
or its contents by any unauthorized person is strictly prohibited. It may be downloaded from Suzlon’s Intranet portals ‐
Technology Portal/ KM Portal/ Ewims. The document is for own use by Suzlon group employees or their authorized
representatives including Sub‐Contractors and its Customers.
Our liability with the document is limited to the extent of the information provided in it and any liability arising out of any
misunderstanding, misuse, partial misuse or other such consequence of incomplete using of information on the part of users is
disclaimed.
The document or its content is subject to revision without notice to accommodate the latest designs and best practices
developed based on the most current project experiences and continuous innovation.
ISO 14001-2004;
Technology BOP- PE
PM.2100G.75.01.01.QC.117/ Rev 03/22.07.2015 F
ISO 14001-2004;
Technology BOP- PE
PM.2100G.75.01.01.QC.117/ Rev 03/22.07.2015 F
Project details:-
Project
(mW Size x
customer order
Ref.)
Customer Name
Site/State/ Country
Location no.
Tower Type STEEL TUBULAR STRUCTURE WTG Assembly No.

Blade, Wind Class & Blade
Temperature Wind
Temperature Type & SB 54 STV IIIa
Version Class
Version Version
WTG type Rotor ø 111 m Hub height 90 Meter
WTG Foundation Erection Electrical Yard
Dates of Works Start Finish Start Finish Start Finish
Suzlon *Customer Sub Contractor
Name
Project In-charge Sign
Date
(* Customer signature is optional and as per applicable contractual conditions)
ISO 14001-2004;
Technology BOP- PE
PM.2100G.75.01.01.QC.117/ Rev 03/22.07.2015 F
WTG Components Traceability Details:-
Manufacturer Additional detail
Components Make / Plant / Serial No. as applicable
Supplied by
WTG Nacelle
Gear Box
Generator
Bottom Power Panel
DFIG Panel
Lift
Cooler System
Nacelle Control Panel
Yaw drive 1
Yaw drive 2
Yaw drive 3
Yaw
drive
Yaw drive 4
Yaw drive 5
Yaw drive 6
Casting
Hub
Control Panel
Pitch Drive 1
Pitch
Pitch Drive 2
Drive
Pitch Drive 3
Nose Cone
Blade No. 1
Blades Blade No. 2
Blade No. 3
ISO 14001-2004;
Technology BOP- PE
PM.2100G.75.01.01.QC.117/ Rev 03/22.07.2015 F
Shell No. T1
ECIII Shell No. T2
Tower Shell No. T3
Shell No. T4
ISO 14001-2004;
Technology BOP- PE
PM.2100G.75.01.01.QC.117/ Rev 03/22.07.2015 F
Check points before start of the process:
Sr. Details of check point Required value / Observed Status Actual Remark
No. status OK Not OK
1 Compressive strength of the M37-28 Mpa
foundation cubes on the day
of installation.
2 PCD of inside bolt circle 4075 +/- 1mm
diameter
3 PCD of outside bolt circle 4425 +/- 1 mm
diameter
4 Condition of foundation Rust free and no
studs. damage to threads.
5 Anchor Stud length
Minimum: 265mm
projection above concrete
Maximum: 295mm
top of pedestal
6 Level of Shim Plate 0 mm +/- 2 mm
7 Receipt inspection clearance Availability of receipt
for WTG components from inspection report
customer and from site
stores-
1. Nacelle,
2. Hub,
3. Blade,
4. Nose cone,
5. Panels,
6. Tower
7. Lift
8. Cables clamps &
support system
(*Customer signature is optional and as per applicable contractual conditions)
Suzlon Representative
*Customer
Contractor
Representative
Project Engineer Quality Engineer Engineer
Name
Sign
Date
ISO 14001-2004;
Technology BOP- PE
PM.2100G.75.01.01.QC.117/ Rev 03/22.07.2015 F
Mile stone No. 1: Tower erection: (ECIII Tower)
Sr. Details of check point Required value / Observed Status Actual Remark
No. status OK Not OK
1 Placement of LSP on the Easy Fitment
shim plate
2 Power , DFIG panel fitted to Tight Fitment
bottom platform
Check tower painting from Without damage
3
inside and outside
Check tower for cleanliness Inside and outside
4
clean and dust free.
5 T1 door direction Door centre line
matching with north
point
6 Torquing / Pretension of Torque 1250Nm /
foundation bolts to T1 shell Pretension 150KN
7 Safety chart and fire Available & within the
extinguisher date of expiry.
8 Fixing of cooling systems Tight fitting
9 Lift installation in T1 shell Tight fitting
10 Torquing of T1 and T2 flange 1000Nm
joint
11 Tower sections matching of Arrow mark –Matching
T1 and T2 Ladder joint- Matching
12 Torquing of T2 and T3 shell 1000Nm
14 Torquing of T3 and T4 flange 1000Nm
joint
16 T4 Tower shell water level:
Position Allowable deviation Deviation in mm
0º Ref. ladder position 0
45º ± 2 mm
90º ± 2 mm
135º ± 2 mm
180º ± 2 mm
225º ± 2 mm
270º ± 2 mm
315º ± 2 mm
ISO 14001-2004;
Technology BOP- PE
PM.2100G.75.01.01.QC.117/ Rev 03/22.07.2015 F
*Customer
Contractor
Representative
Name
Sign
Date
(* Customer signature is optional and as per applicable contractual conditions)
ISO 14001-2004;
Technology BOP- PE
PM.2100G.75.01.01.QC.117/ Rev 03/22.07.2015 F
Mile Stone No. 2- Nacelle Erection:
Sr. Details of check point Required value / Observed status Actual Correction
No. status ok Not ok record
1 Torquing of gear rim to T4 1500Nm ,3000Nm
shell joints
2 Projection of nacelle stud Projection :-
below top flange of T4 65mm (+/-2mm)
(Stud size M39 x 370mm)
3 Grease collection tray under
gear rim Fitted
4 Check Pipe line connections No leakage
of gear box.
5 Check drain plug of gear box. No tampering
6 Check man hole door of gear No damage
box.
7 Oil level in gear box. Between minimum & Parallax
maximum mark error to be
avoided.
8 Oil level in yaw drive Oil level should be in Parallax
the middle of the error to be
indicator avoided.
9 Check fitment of nacelle Tight fitment
Generator Rear Exhaust Duct
10 Check fitment of nacelle Tight fitment
Exhaust inner top duct
11 Fire extinguisher & first aid Available and within
kit the date of expiry.
12 Paint on anchorage points All the anchorage
points are painted with
yellow colour
13 Ensure fitment of platform Tight Fitment
above the front side lifting
point inside the Nacelle
14 Ensure fitment of L.A. rods Tight Fitment
on the Nacelle top
15 All lifting jig windows/
access windows of nacelle Closed
cover
16 Fitment of 8 mm safety wire Fitted and tight-Within
rope in tower . the limiting marks
ISO 14001-2004;
Technology BOP- PE
PM.2100G.75.01.01.QC.117/ Rev 03/22.07.2015 F
No. status record
ok Not ok
17 Torquing of T4 to T3 shell
1000Nm
joint
18 Torquing of T3 to T2 flange
1000Nm
joint
19 Torquing of T2 to T1 flange
2000 Nm
joint
20 Torquing /Pretension of Torque 1250Nm /
foundation bolts to T1 shell Pretension 150KN
* Customer
Contractor
Representative
Name
Sign
Date
ISO 14001-2004;
Technology BOP- PE
PM.2100G.75.01.01.QC.117/ Rev 03/22.07.2015 F
Mile Stone no.3- Rotor Erection:
No. status ok Not record
ok
1 Alignment of rotor to nacelle Matching
orientation mark
2 Hub door handle & lock Tight & fixed
3 Hub 3 way entry ladder fixing Fixed & torque mark
nuts torque them to 65Nm present.
for M12 and 155Nm for M16
Nose cone holders brackets nuts torquing for SBT
4
Nose Cone
a Tight all hex bolted
225Nm & torque
connection of M16 between
mark present.
nose cone bracket to Hub
b Tight all hex bolted
connection of M16 between 100Nm & torque
nose cone bracket to Nose mark present.
Cone
c Handrails to nose cone parts- 100Nm & torque
M16 Bolts mark present.
d Nose cone parts to nose cone 55Nm & torque mark
parts-M10 Bolts present.
5 Mounting of switch wing on Available
reinforcement plate
6a Alignment of blades with 3rd hole counter
slew ring clockwise between S
mark and zero
marking blade
calibration plate.
b Matching of blade stud with ( Viewing towards
the slewring’s 3rd stud hole blade tip )
For SB 54 Blade Count 2nd Blade stud
clockwise from blade
seam
7. a Torquing of blade studs for 300Nm, 500 Nm and No
three blades 120 degree rotation looseness &
of nut damage in
Rota bolts
ISO 14001-2004;
Technology BOP- PE
PM.2100G.75.01.01.QC.117/ Rev 03/22.07.2015 F
Details of check point Required value / Observed status Actual Remarks
Sr. status
OK NOT Ok
No.
b Torquing marks on blades 100% and for all
studs blade studs
8 Check the fixing of the
platform plate to the
65Nm
reinforcement plate on all the
three sides of hub
9 a Torquing of Rotor to nacelle
1000Nm,
bolt
1000Nm,1650Nm
(Bolt Size:-M30X245 )
b Torquing marks on rotor to
100% and for all
nacelle.
bolts
10 a Torquing of Nacelle to T4
tower studs 3850Nm
(Stud Size:-M39X370)
Torquing marks on nacelle to 100% and for All
b tower flange studs
Check the flange gap. 0.1mm gap, max. for
20mm depth from the
c
inside of the flange is
acceptable
11 a Torquing of Tower section T4
to T3 (Bolt Size:-M30X165 ) 1810 Nm
Torquing marks on T4 to T3
b All Bolts
flange joint
Check the flange gap. 0.1mm gap, max. for
c 20mm depth from the
acceptable
12 a Torquing of T3 and T2 flange
joint (Bolt Size:-M30X175 ) 1810Nm.
b
Torquing marks on T3 to T2
All Bolts
flange joint
c Check the flange gap. 0.1mm gap, max. for
20mm depth from the
acceptable
ISO 14001-2004;
Technology BOP- PE
PM.2100G.75.01.01.QC.117/ Rev 03/22.07.2015 F
Sr. Details of check point Required value / Observed status Actual Remark
No. status
OK NOT Ok
13 a Torquing of T2 to T1 flange 3080Nm.
joint (Bolt Size:-M36X225)
b Torquing marks on T2 to T1 All bolts.

flange joint
c Check the flange gap. 0.1mm gap, max. for
20mm depth from the
acceptable
14 a Only sample
Tensioning of T1 to Pretension–310KN check for 2%
foundation studs. Elongation–4.6mm anchor bolts
for elongation
b Tensioning marks on All studs
Foundation studs
c Application of Molub alloy 160No of anchor
777-2 / Mobilarma 798 studs. ( Inside &
grease on anchor studs Outside)
d Fitment of bolt head caps on Outside 80 numbers
the outer side of anchor of anchor studs.
studs.
15 Tower entry stair case fitting Fitted
16 Ensure Cable box fitment to Fitted
the bottom tower shell
Note: In case of torque value check, 10% of the bolts shall be checked. Failure of even one
needs 100% re-torquing.
* Customer
Contractor
Representative
Name
Sign
Date
(* Customer signature is optional and as per applicable contractual conditions.)
ISO 14001-2004;
Technology BOP- PE
PM.2100G.75.01.01.QC.117/ Rev 03/22.07.2015 F
Milestone 4 – Handing over to commissioning team:
Sr. Details of check point Required value / status Observed status Actual Correction
No. Ok Not Ok record
1 Handing over to Completion of all the
commissioning team above three milestones.
*Customer
Commissioning
Representative
Name
Sign
Date
HISTORY OF MODIFICATION:-
Sr. No. Rev No. Date Details of revision Symbol Remarks

1 00 30.08.2014 New document
2 01 11.10.2014 Overall Review

Project Quality History Card - Mechanical: S E L, P, I

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Project Quality History Card – Mechanical ISO 9001-2008;

Project Quality History card - Mechanical

SUZLON ENERGY LIMITED, PUNE, INDIA

Tower Type STEEL TUBULAR STRUCTURE WTG Assembly No.

WTG Foundation Erection Electrical Yard

Dates of Works Start Finish Start Finish Start Finish

Suzlon *Customer Sub Contractor

Project In-charge Sign

(* Customer signature is optional and as per applicable contractual conditions)

Bottom Power Panel

Nacelle Control Panel

Blades Blade No. 2

ECIII Shell No. T2

Tower Shell No. T3

(* Customer signature is optional and as per applicable contractual conditions)

(*Customer signature is optional and as per applicable contractual conditions)

b Torquing marks on T2 to T1 All bolts.

(* Customer signature is optional and as per applicable contractual conditions.)

(*Customer signature is optional and as per applicable contractual conditions)

Sr. No. Rev No. Date Details of revision Symbol Remarks

2 01 11.10.2014 Overall Review

3 02 27.04.2015 Overall Review

4 03 22.07.2015 Overall Review

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