Quality Specification: Steelwork and Welding of Tower Sections and Embedments For Vestas Wind Turbines

Item-no.
990508 R6
2018-06-25
Quality Specification
Steelwork and welding of tower
sections and embedments
for Vestas wind turbines
Vestas Wind Systems A/S · Hedeager 42 · 8200 Aarhus · Denmark · www.vestas.com
VESTAS PROPRIETARY NOTICE: This document contains valuable confidential information of Vestas Wind Systems A/S. It is protected by copyright law as an unpublished work. Vestas reserves all patent, copyright, trade secret, and
other proprietary rights to it. The information in this document may not be used, reproduced, or disclosed except if and to the extent rights are expressly granted by Vestas in writing and subject to applicable conditions. Vestas
disclaims all warranties except as expressly granted by written agreement and is not responsible for unauthorized uses, for which it may pursue legal remedies against responsible parties.
Document no.: 990508 R6 Date: 2018-06-25
Steelwork and welding of tower sections and
Issued by: VWS embedments for Vestas wind turbines
Type: Quality Specification Page 1 of 26
1.0 Preface .......................................................................................................................................................... 2

1.1 Objective ............................................................................................................................................. 2
1.2 Definitions ............................................................................................................................................ 2
1.3 Use of Standards ................................................................................................................................ 4
1.4 Control of Deviations ........................................................................................................................... 4
1.5 Verification by VWS ........................................................................................................................... 5
1.6 CTQ ..................................................................................................................................................... 6
1.7 Request for Quality Specification changes ......................................................................................... 6
1.8 Implementation of Quality Specification .............................................................................................. 6
2.0 General Requirements to the Quality Management System ......................................................................... 6
2.1 General ................................................................................................................................................ 6
2.2 Personnel Qualifications ..................................................................................................................... 7
2.3 Equipment ........................................................................................................................................... 8
2.4 Handling of Non-Conformities. ............................................................................................................ 9
2.5 Additional Requirements to Sections for Italy ..................................................................................... 9
3.0 Production Preparation .................................................................................................................................. 9
3.1 Contract and Design Review............................................................................................................... 9
3.2 Process Flow and FMEA ..................................................................................................................... 9
3.3 Quality Activity Plan ............................................................................................................................ 9
3.4 Production Work Instruction (PWI) .................................................................................................... 10
3.5 Qualification of Welding Procedures ................................................................................................. 10
3.6 Welding Plan ..................................................................................................................................... 12
3.7 Welding Consumables ...................................................................................................................... 12
3.8 Storage of Primary Steel. .................................................................................................................. 13
3.9 ID-numbers for Sections ................................................................................................................... 13
3.10 Serial Numbers for Welded Items ..................................................................................................... 13
4.0 Quality Activities During Production ............................................................................................................ 13
4.1 Material Traceability .......................................................................................................................... 13
4.2 ID-numbers and Serial Numbers....................................................................................................... 14
4.3 Preparation of Weld Log ................................................................................................................... 14
4.4 Inspection and Testing Before and During Welding ......................................................................... 14
4.5 Non-Destructive Testing of Welds .................................................................................................... 15
4.6 Statistics of Weld Defects ................................................................................................................. 15
4.7 Leak Test on Sand Chamber ............................................................................................................ 16
4.8 Leak Test of Oil Bowl for Oscillation Damper ................................................................................... 16
4.9 Dimensional Inspection of Welded Doorframes and Segmented Flanges ....................................... 16
4.10 Dimensional Inspection of Sections .................................................................................................. 16
4.11 Surface Inspection ............................................................................................................................ 17
5.0 Release ....................................................................................................................................................... 17
5.1 General .............................................................................................................................................. 17
5.2 Records ............................................................................................................................................. 17
5.3 Release of Welded Doorframes and Segmented flanges ................................................................. 17
5.4 Release of Sections for Surface Treatment ...................................................................................... 17
5.5 Uploading via TowerDoc ................................................................................................................... 18
Statement of Quality .................................................................................................................................... 19
Material Traceability List .............................................................................................................................. 20
Weld Log ..................................................................................................................................................... 21
Report for Moving of Traceability Marking .................................................................................................. 22
Dimensional Inspection Report ................................................................................................................... 23
Leak Test Report ......................................................................................................................................... 24
Welded Doorframe Log ............................................................................................................................... 25
Segmented Flange Log ............................................................................................................................... 26

1.0 Preface
1.1 Objective
This Quality Specification (QS) has been prepared by Vestas Quality and describes the
requirements for quality assurance of steelwork and welding relating to the production of tower
sections, embedment and transition pieces for Vestas wind turbines. This QS also covers customer
supplied products. Lattice masts and offshore foundation are outside the scope of this specifica-
tion.
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 covered by
QS990518.
The specification describes minimum requirements. Quality assurance in accordance with this
specification does in no way release the welding workshop from the full responsibility for the sup-
plied product.
The target group for the specification is QA and QC personnel in the welding workshop, e.g. quality
manager, welding coordinator and NDT responsible.
NDT must be performed according to latest revision of QS 0004-6605.
1.2 Definitions
Attachment Welds (AW), means welds between primary steel and secondary steel
CEV (Carbon Equivalent) = C + Mn/6 + (Cr+Mo+V)/5 + (Ni+Cu)/15
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.
Contractually Affiliated, means a person who has a contract with the company covering a specific
amount of presence and defined responsibilities.
CTQ, means the Critical to Quality characteristics determined by Vestas Technology R&D and
Engineering.
Frame Welds (FW), means welds between shell plates and frames (doorframe, cable frame etc.).
HAZ, means Heat Affected Zone.
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.
Intermediate Flange, means middle flange in an embedment.
Longitudinal Welds (LW), means welds in shell plates, which is oriented in the longitudinal direction
of the section.
Lower Flange, means bolt flange at the bottom of a tower section and base flange at the bottom on
embedment.
MSA, means Measurement System Analysis.
MT, means Magnetic Testing.
NDT, means Non-Destructive Testing.
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.
P-FMEA, means Process Failure Mode and Effect Analysis
PPAP, means Production Part Approval Process.
Primary Steel, means bolt flanges, base and intermediate flanges in embedment, shell plates and
frames (doorframe, door segments, Cond. Air Segments, cable frames, vertical flanges etc.)
PSW, means Part Submission Warrant.

PWI, means Production Work Instruction.
QA, means Quality Assurance.
QC, means Quality Control.
QDA, means Quality Data Analysis.
Quality Manager, means the manager or head of quality department, appointed from the supplier.
Quality Responsible, means one who possesses quality responsibility for Vestas Wind Systems
A/S (VWS) products, appointed from the supplier.
R&R, means Repeatability and Reproducibility.
Responsible Manager, means the manager with responsibility for Vestas Wind Systems A/S
(VWS) products, appointed from the supplier.
RT, means Radiographic Testing.
Secondary Steel, means brackets, sand chamber flange etc.
Section, means tower section & embedment.
Segmented Flange, means a flange made from plate segments, which are welded together (not
bolt flanges).
Standard WPS, means a WPS not qualified by welding and testing a test specimen but qualified on
previous welding experience e.g. acc. to ISO 15611 or a prequalified WPS acc. to AWS D1.1sec. 3
SOQ, Statement of Quality
TowerDoc, means Vestas online documentation database used by the supplier to send as-built
documentation to Vestas via the Internet.
Upper Flange, means bolt flange at the top on tower section or embedment.
UT, means Ultrasonic Testing.
WPQR, means Welding Procedure Qualification Record.
WPS, means Welding Procedure Specification.
VT, means Visual Testing.
VUI, means Vestas Unique Identifier.
VWS, means Vestas Wind Systems A/S
Welding Coordinator, means one who coordinates and supplies the welding workshop with
necessary welding procedures and work instructions. The responsibilities for the welding
coordinator are specified in 4.4.
Welding Workshop, means a workshop with a specific address.

Identification of welds (per section), see Figure 1:

 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 the doorframe and shell plate is named FW1. The second frame is
named FW2.
 The welds between the shell plate and door segment /Cond. Air Segment (Segments in
general) is named as in example Figure 1.
 Weld repairs are named R1, R2 etc. in addition to the original identification, e.g. CW1R1. If
more repairs occur in the same weld, the repairs must be named R1-1, R1-2 etc
LW1 CW4
LW3 CW5
1 LW2
FW1 CW3
1
CW4 AW
CW3 CW2
1
CW2 LW4 LW1
CW1 LW2
CW1
1
LW3 CW3A
CW3
LW2A
LW2B
CW2
CW2A
LW1
CW1
Figure 1: Identification of welds in sections.
1.3 Use of Standards

The specifications refer to various International standards, a valid revision of the standards must
be used. Vestas may accept the use of standards other than EN Standards (AWS, etc.). But it is
the responsibility of the Supplier to demonstrate compliance between the (AWS, etc.) applied
standard and the EN standards.
In case of conflict between a standard and this specification, contact must be submitted to Vestas
for clarification agreement before start of production.
It is the responsibility of the supplier to be in possession of the relevant standards, and be familiar
with the content of the standards.
1.4 Control of Deviations

It is not allowed to deviate from Vestas drawings or specifications unless written and signed appro-
val by Vestas is granted and received prior to production start.
Deviation request with reference to specific items:
Vestas will determine if a signed deviation document is needed. Handling flow of deviations is tho-
roughly described in QS990530.
In general:
E-mail’s etc. is not considered as formal Vestas documentation, and as such cannot be used for
acceptance of deviation to any VWS Specifications.
1.5 Verification by VWS

VWS performs various kinds of verification of steelwork and welding, for example audit on the
welding workshops quality management system, PPAP, inspection during production, sample of
complete sections and review of documentation etc.
VWS will as part of supplier surveillance activities, perform NDT of approved sections at various
manufacturing stages.
The extent of the verification is decided by VWS based on experience and priority.
The following documents must be available for PPAP:

 PSW/SOQ
 Contract review record
 Process flow chart
 P-FMEA
 Measurement system capability studies
 Quality activity plan
 Dimensional plus further test reports
 Material Certificates
 Performance reports as per defined CTQ’s
 First article inspection report.
If a VWS supplier subcontracts any work such as cutting, bevelling, rolling, welding, NDT, surface
treatment, Vestas Wind Systems A/S (VWS) must approve the subcontractor.
Vestas Quality and Vestas Wind Systems A/S (VWS) customers must at all-time have access to
verifying the work at the premises of the welding workshop and subcontractors.
To secure that Vestas Quality can verify documents required by this specification, these must be
prepared in English.
No production must take place before relevant WPQR, WPS and other in this QS required
specification are forwarded to the allocated Vestas for review/verification by VWS.
Documentation list:
 Organisation chart.
 Equipment list.
 WPQR.
 WPS.
 Welder’s certificate.
 Calibration logs for welding equipment.
 Welding plan.
 Quality plan.
 TowerDoc documentation package.
 PWI for Flame Straightening.
 PWI for Welding Sequence for Flanges

- inclusive other mandatory documentation per this specification, must be kept by the welding
workshop for at least twenty (20) years, and during this period it may be requested by Vestas Wind
Systems A/S (VWS) without any cost.
1.6 CTQ
The term CTQ covers the definition of the key measurable characteristics of a product or process
whose performance standards or specification limits shall be met in order to satisfy the customer.
Having a high variation in these CTQs will significantly affect the fit, performance, or service life of
the final product. Hence CTQs must be registered and should always be subject to continuous
improvement.
Vestas has identified CTQs on various levels throughout the production processes and will reserve
the right to request that factories present the reporting of CTQ data leading to statistically analy-
sing them and trace performance development. Non-performance according to given targets re-
quires corrective actions to be performed.
1.7 Request for Quality Specification changes

Any remarks with regard to request for changes to the Quality Specifications must be made via the
request for changes input sheet. This document can be downloaded from TowerDoc. The change
request shall be sent to the Quality responsible for your factory and the appropriate Project
Manager. The supplier submitting this change request must also Cc. their appropriate contact
person / Project Manager. All remarks must be written in English.
A request for changes to the QS doesn’t relieve the supplier from following the QS.
1.8 Implementation of Quality Specification

After implementation of new QS or revised QS, an Implementation Letter must be filled out and
signed by the Supplier Responsible and Vestas Responsible. The Implementation Letter shall be
sent to the Quality responsible for your factory and the appropriate Project Manager. The
Implementation document can be found in the download area in TowerDoc.
2.0 General Requirements to the Quality Management System

2.1 General
The Welding Workshop must have an active and maintained quality management system including
NDT (if not outsourced), which secures that the requirements in this specification are fulfilled.
Quality system according to ISO 9001 or ISO 3834-2 fulfils these requirements.
The quality system must be reviewed and approved by Vestas prior to production start.
The organisation responsible for the performance of non-destructive testing (NDT) must have a
documented quality system for its operation.
An organisation chart, which as a minimum includes the names of:

 Responsible Manager
 Quality Responsible
 Welding Coordinator
 NDT Responsible
 NDT level III.
Requirements for use of external NDT companies:

An accreditation for inspection companies or a certification according to ISO 9001 meets this
requirement.
Equivalent standards can be used, if and only if, references to equivalent points in relevant EN
standards are clearly described, and these are reviewed and approved by Vestas.
2.2 Personnel Qualifications

The Welding Workshop must have sufficient resources of skilled personnel for the planning,
execution and monitoring the production in accordance with VWS requirements.
2.2.1 Quality Responsible

The Quality Responsible in the Welding Workshop must be trained in this specification and have
extensively knowledge about Vestas requirements. The Quality Responsible must have the autho-
rity to stop the work if necessary.
2.2.2 Welding Coordinator

At least one Welding Coordinator must be employed by or 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 must have sufficient authority to initiate the necessary action to ensure that welding is
performed in accordance with VWS requirements.
The Welding Coordinator must be able to demonstrate Comprehensive Technical Knowledge

according ISO 14731.
Changes of Welding Coordinator must be informed to contact person for Vestas immediately.
2.2.3 Welders
All welders and welding operators must be approved in accordance with the relevant section of
ISO 9606-1, ISO 14732, AWS D1.1 or an equivalent standard approved by VWS prior to commen-
cement of work.
Welders performing fillet welds must have a certificate in that specific welding area.
2.2.4 NDT Personnel

Personnel carrying out NDT (incl. VT) must be qualified according to QS 0004-6605.
2.2.5 Other Inspectors

Inspectors performing dimensional inspection, inspection of steel surface, leak testing of sand
damper and oil bowl must be educated for the purpose. They must have extensive knowledge with
regard to examination procedure, acceptance criteria and reporting.
Systemised training and education activities must reflect the process and be documented.

2.3 Equipment
2.3.1 Scope and Registration
All necessary and suitable equipment must be available for executing the work. The Welding
Workshop must maintain a list of the main items of equipment used for welding production. This list
must identify the individual items of larger equipment, which are important for assessing the
Welding Workshop’s capacity and capability, e.g.
 Capacity of largest cranes.
 Size of components the workshop can handle.
 Capability of mechanised or automated welding equipment.
 Capacity of turning rolls (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.
2.3.2 New Equipment

When installing new or newly restored equipment, relevant equipment tests must be carried out by
equipment supplier or internal by qualified personnel. The tests must confirm that the equipment
operates correctly. Tests must be carried out in accordance with relevant standards if such exist.
Records of such tests must be saved for future reference.
New welding equipment:

Test run and calibration process must be planned; documented and approved by appointed
responsible. Objects incorporated in test run and calibration must reflect welding positions and
circumstances similar to tower sections and embedment’s ordered by VWS.
2.3.3 Maintenance
The Welding Workshop must have documented plans for equipment maintenance. The plans must
ensure maintenance checks of parts of the equipment, which control the essential variables listed
in the relevant welding procedures, e.g. state of:
 Guides in equipment for thermal cutting in accordance with EN 1090-2.
 Mechanised tower welding fixtures.
 Amp meters, voltmeters, flow meters etc. used for the operation of the welding machines.
According to EN / ISO 15609-1.
 Cables, hoses, connections etc.
 Control system in mechanised and automated welding equipment.
 Instruments for temperature measurement.
 Wire feeders and conduits.
Defect equipment must not be used.
2.3.4 Welding Equipment

Welding equipment must, as a minimum, be calibrated/validated and documented every 12
months.
2.3.5 Measuring Equipment.

The measuring equipment used for controlling the quality characteristics, minimum for those
outlined in this QS and those identified in the Quality Activity Plan, must have undergone a MSA
study according to the Gage R&R principle to demonstrate their usability for its intended purpose in
the specific factory environment. Moreover, it must be demonstrated that gauges used to measure
these characteristics are calibrated. Records of the MSA and the regular calibration must be kept
and shown after request from Vestas.
2.4 Handling of Non-Conformities.

The organisation must have a fully implemented system for handling of non-conformities, 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.
2.5 Additional Requirements to Sections for Italy

Sections to be erected in Italy must be delivered according to the DM 14.01.08. The Welding
Workshop must according to Italian regulations declare the work activities to the Italian
Authorities1.
The welding workshop must have the certificate of “Centro di Trasformazione”.
(1. Servizio Tecnico Centrale del Consiglio superiore dei Lavori Pubblici)
3.0 Production Preparation

3.1 Contract and Design Review
The Welding Workshop’s Welding Coordinator and the other staff involved must review the
production basis handed over from VWS to ensure that all information necessary to carry out the
production is available and understood prior to commencement of the work.
The Welding Workshop must confirm its capability to meet Vestas Quality requirements and
ensure adequate planning of quality related activities, and before production start ensure that the
necessary personnel, equipment and required procedures are available.
Contract and design review documentation including the resulting activities must be kept and
shown on request.
3.2 Process Flow and FMEA

A process flow diagram for the specific Welding Workshop must be prepared, indicating all steps
and sequences in the manufacturing process, including incoming components. The process flow
diagram is input to the process risk analysis or P-FMEA.
The Welding Workshop must have prepared P-FMEA for the manufacturing process following the
process flow steps. A copy of the P-FMEA should be subject to Vestas review before start of
production. The P-FMEA must be updated when e.g., new products are introduced or change in
production processes. The P-FMEA should also be updated based on input from 8D reports.
3.3 Quality Activity Plan

The welding workshop must draw up a Quality Activity Plan, based on the findings of the P-FMEA,
listing the quality activities to be performed during production, including the collection of as-built
documentation and uploading to TowerDoc.
The reference documents and the responsible person must be listed for each of the activities.

3.4 Production Work Instruction (PWI)

Based on the P-FMEA the supplier must prepare a set of PWI’s, which must be included in the
Quality Activity Plan.
PWI’s must as minimum be made for the following processes.
3.4.1 Welding Sequence for Flanges

A PWI must be prepared describing welding sequence and other measures which must be taken,
in order to secure fulfilment of all flange dimensional requirements.
3.4.2 Heat Treatment of Weld

The welding workshop must prepare a PWI for post weld heat treatment in cases where this is
required.
3.4.3 Flame Straightening

If flame straightening is necessary, a PWI must be prepared in accordance with the requirements
in EN1090-2.
3.4.4 Use of temporary steel

Temporary steel is stiffeners, brackets used for fit-up, transport equipment, run off tabs etc.
When temporary steel is welded to the structure the following must be observed and incorporated
in relevant PWI.
 Welding of temporary steel must be performed according to relevant WPS in order not to
damage the base material.
 When removing temporary steel this must be performed by cutting and without damaging
the base material.
 It is not allowed to hammer / knock off temporary steel.
 Areas where temporary steel has been welded on must be checked with NDT according to
0004-6605.
3.5 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 can be covered by
standard WPS.
The welding procedure test must be made by each Welding Workshop (with specific address).
3.5.1 Welding Procedure Specifications

WPS must be prepared in accordance with ISO 15609-1, AWS D1.1 or an equivalent standard
approved by VWS prior to commencement of work.
WPS must be based on an approved welding procedure test and be signed by the Welding
Workshops Welding Coordinator. For manual welding the maximum qualified CEV must 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 must be performed
on a repair procedure test.

WPS can be used directly by the welder or the Welding Coordinator must alternatively prepare
specific PWI based on approved welding procedures.
3.5.2 Welding Procedure Tests

Welding procedures must be qualified by welding procedure tests which must fulfil the
requirements in TPS 900873 and be in accordance with ISO 15614-1, AWS D1.1 or an equivalent
standard approved by VWS.
Arc stud welding must be qualified according to ISO 14555 or AWS D1.1 or an equivalent standard
approved by Vestas Wind Systems A/S (VWS).
Fillet welds qualified by AWS D1.1 must be made in test plates equal to the maximum plate
thickness used in production.
A partly penetrated butt weld can be qualified by a WPQR for a partly penetrated welding
procedure test or a full penetrated butt weld.
A weld for repair of surface imperfection must be qualified separately, based on a test plate where
a small grove is ground and filled-up with one string. Minimum length of weld repair must be
specified and qualified to fulfil specified hardness requirement.
All tack welding must be carried out according to the qualified welding procedure for the joint or
qualified by a separate tack welding procedure test.
The material certificate of the steel used in the welding procedure test must be included in the
WPQR and the test plates must be marked (hard stamped) with charge and plate number.
The welded test piece must be marked (hard stamped) uniquely with an identification number.
All documentation including test report must refer to the identification number of the welded test
piece.
3.5.3 Additional Essential Variables

This section specifies additional essential variables to those of the chosen qualification standard
(e.g. AWS D1.1).
The following additional essential variables require a new welding procedure test:
 Welding in steel with higher specified yield strength compared with the steel used in the
welding procedure test.
 Change from butt weld to fillet weld or vice versa.
 Change from T-butt joint to fillet weld or vice versa.
 Change from butt weld to T-butt weld or vice versa
 One SAW run from both sides is to be considered as a singular run weld in accordance with
the reference standard.
 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.
 Weld repair more than two times.
 For manual welding (SMAW, FCAW and GMAW) a CEV of the steel in the production (ladle
analysis) that is more than 0.03% above the CEV of the steel used in the welding
procedure test See example.
Example of CEV 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 CEV equal to 0.37%. The welding procedure test
qualifies welding in steel with CEV of maximum 0.40% (0.37% + 0.03%), and the CEV of the doorframe and shell plate
must therefore not be more than 0.40%.
3.5.4 Examination and Testing

The extent of non-destructive and destructive testing of welding procedure must as a minimum be
as specified below.
The destructive testing must be done by a third-party laboratory with official accreditation.
Butt weld:
 VT, MT and UT or RT.
 2 transverse tensile tests (placement of fracture point must be stated).
 4 bend tests.
 Impact testing in weld metal and HAZ.
 1 macro specimen, inclusive picture.
 Hardness examination on the macro.
T-butt joint:
 VT, MT and UT or RT.
 2 transverse tensile tests (placement of fracture point must be stated).
 Impact testing in weld metal and HAZ
 2 macro specimens, inclusive picture.
 Hardness examination on one of the macros.
Note : 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, inclusive picture (only 1 for repair of surface imperfection) *).
 Hardness examination on one of the macros.
3.5.5 Hardness Testing

Hardness testing must be performed in accordance with ISO 9015-1
Butt welds: In accordance with figure 1, 3 and 7 in ISO 9015-1.
T-butt joint: In accordance with figure 1 and 5 in ISO 9015-1.
Fillet welds: In accordance with figure 1 and 4 in ISO 9015-1.
Partly penetrated butt welds: In accordance with figure 1, 3 and 7 in ISO 9015-1.
Repair of surface imperfections: In accordance with figure 1 and 3 in ISO 9015-1 *).
The hardness must not exceed 380 HV10 for single run welds, and 320 HV10 for multi-run welds.
*) The cut for macro specimen and for the hardness test must be made in the longitudinal direction of the test weld for
repair of surface imperfections.
3.6 Welding Plan

The Welding Coordinator must prepare an overview of the welding activities, by filling in a Welding
Plan for each section.
The Welding Plan must contain a sketch of the section with reference between each weld, the
used WPS and repair WPS.
3.7 Welding Consumables

The Welding Workshop must 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, damage etc. The procedures must be in accordance with the supplier’s
requirements and there must be a designated storage area for consumables.
3.8 Storage of Primary Steel.

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 of the Quality Management System.
3.8.1 Material certificates

The material certificates for the Primary Steel must be reviewed to ensure correct values (material
quality grade, thickness, tensile test, impact test, CEV, and if required Z-test, lamination test, and
brittle fracture test) and that the certificates are complete and identical with material on stock.
3.8.2 Inwards Inspection of Primary Steel

Before the primary steel is used for manufacturing, it must be verified that dimensions, surface
conditions etc. comply with specifications, and the primary steel must be checked for damages.
The process must be a part of the Quality Management System / Quality Activity Plan with speci-
fied extent; defined measurement points and mandatory documentation requirements.
3.9 ID-numbers for Sections

Vestas Wind Systems A/S (VWS) must give access to create the ID-number to the supplier before
production start.
3.10 Serial Numbers for Welded Items

The Welding Workshop must prior to production select a unique serial number for each welded
item. Unique serial number must be stamped into the individual part together with material
traceability number, to ensure traceability to material certificates and the NDT report.
4.0 Quality Activities During Production

4.1 Material Traceability
The material traceability number (charge, test etc.) must be visible on each primary steel part from
the inside of the final welded section, i.e. numbers must be transferred or moved where necessary.
For transferring the numbers, the supplier must have a written procedure and a soft stress stamp
with a letter height of 10mm must be used. The marking must be visible after surface treatment.
Movement of a traceability number must be documented in; Report for Moving of Traceability
Marking.
Material traceability for welded doorframes and segmented flange must be recorded on Welded
Doorframe Log and Segmented Flange Log.
If a welded doorframe or segmented flange is welded by the supplier who made the sections, the
traceability must be documented in Material Traceability List and Weld Log.
The traceability numbers must be recorded on Material Traceability List after the section is
completed.

4.2 ID-numbers and Serial Numbers

Section ID-numbers and unique serial numbers for welded items must be applied on the part as
early as possible in the process.
ID-numbers must be welded on secondary steel or stamped on to the section as specified on the
production drawings.
Unique serial numbers for welded doorframes and segmented flange must be applied as specified
on Welded Doorframe Log and Segmented Flange Log.
Numbers must be applied so that they are easy readable after surface treatment.
4.3 Preparation of Weld Log

Each weld in Primary Steel must be assigned a section unique identification in accordance with
Weld Log, Welded Doorframe Log and Segmented Flange Log to be used for reference between
weld and WPS and for reference on NDT reports.
The WPS used for each weld or any repair must be recorded on relevant document.
Traceability between weld, WPS and welder must always be available and documented in Weld
Log, Welded Doorframe Log or Segmented Flange Log.
4.4 Inspection and Testing Before and During Welding

The Welding Coordinator must ensure that the WPS are used correctly in the production.
Inspection and testing before and during welding must be performed at least every day where all
new welders (less than 2 weeks of operation) and WPS (used less than 4 weeks), are checked.
Other welders and WPS must be checked randomly, minimum every two (2) week, in order to
ensure requirement fulfilment.
The following must 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 must be checked during welding:

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

4.5 Non-Destructive Testing of Welds

4.5.1 Time of NDT Examination
The examinations must be carried out after completion of welding and any required heat treatment
incl. flame straightening.
Inspection time after welding:

In order to fulfil the TPS 900873 requirements regarding the time in between completion of welding
and executing final NDT (holding time), the following procedure must be followed:
 The thickest CW joint in a bottom section or embedment in production must be chosen.
 NDT (100% VT and UT) is carried out subsequently after cooling.
 NDT (100% VT, MT and UT) is carried out on the same butt weld after 16 hours t ≤ 40 mm
or 24 hours for t > 40 mm.
 This procedure must be carried out once for each calendar month.
 The results must be documented on internal documentation (template from QS 0004-6605)
and kept for at least twenty (20) years by the supplier.
The written procedure must be forwarded to VWS for review and be included in the Quality Activity
Plan.
4.5.2 Additional requirements in case of defects
Areas with weld defects must be repaired and re-examined with the inspection methods originally
specified.
Areas repaired with another process than submerged arc welding in butt welds must in addition be
examined by MT.
The welding workshop must seek the cause of defects and increase the extent of examination to
other batches in case of systematic errors. Necessary actions must be implemented to prevent that
defects occurs again, e.g. by optimising welding procedures or by training of personnel.
The same weld must not be repaired more than twice in the same place. More repairs must be
accepted by Vestas trough a non-conformity report.
4.6 Statistics of Weld Defects

The Welding Workshop must prepare statistics of weld defects and demonstrate it is used actively
to improve the welding process.

4.7 Leak Test on Sand Chamber

Sand chambers must be tested for leaks as described below:
 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 compressed air.
 Test the welds for leaks with soapy water and relieve the air 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 must be recorded on Leak Test Report.
4.8 Leak Test of Oil Bowl for Oscillation Damper

The oil bowl must be tested for leaks e.g. by applying fluorescent penetrant liquid on the outside
weld surface and detecting with UV-lighting inside the bowl (penetration time minimum 60 minutes
and the section must be turned frequently within the 60 minutes), vacuum test or air pressure test
(0,1 bar). MT is not acceptable as leak test. Leak test is not required if the oil bowl is welded with
fully penetrated welds.
Leak test of oil bowl must be recorded on Leak Test Report.
4.9 Dimensional Inspection of Welded Doorframes and Segmented Flanges

Dimensional inspection must be performed on welded doorframes and segmented flange. Results
must be recorded on Welded Doorframe Log and Segmented Flange Log.
4.10 Dimensional Inspection of Sections

All dimension specified on the production drawings must be checked.
Flange Calculator, referred to below, is Vestas Wind Systems A/S (VWS) developed software,
which must be used for calculation and documentation of flange dimensional requirements.
All Bolt Flanges (100%) must be measured with an Easy Laser or similar equipment accepted by
VWS and calculated with the use of Flange Calculator.
Grinding of the flange contact surface, for correction of flange flatness and tilt, is not permitted.
The final measurement must only be carried out at NDT approved sections.
If measured with other equipment than Easy Laser, the PWI 0008-6684 requirement must be
followed except points with direct reference to Easy Laser.
Printout from Flange Calculator must be used as Dimensional Inspection Report for upload to
TowerDoc.
First time production requires that the Welding Workshop performs a detailed documentation of all
dimensions.
It is always the responsibility of the Welding Workshop that dimensional requirements are in
accordance with Vestas Quality requirements.

4.11 Surface Inspection

Residuals from manufacturing (dust etc.) must be removed before surface inspection.
The surface must be inspected visually for dents, plate defects, chipping marks, scratches, sharp
edges and other imperfections before the section is released for surface treatment.
5.0 Release
5.1 General
Welded sections and welded doorframes must be completed and comply with Vestas
specifications before they are released for the next process.
All inspection and testing must have been performed with acceptable result.
5.2 Records
Records must be filled in by using a computer printed and signed. Signatures must be either hand
written or digital signatures.
The digital signatures must be delivered by a certified supplier of digital signatures which enables
the creation of compliant and legally enforceable electronic records. It is the responsibility of the
user of the digital signature to have a written procedure for the use of the digital signature and to
ensure that the digital signature is legally binding. The supplier of the digital signature must be
accepted by VWS and the written procedure must be forwarded to Vestas Wind Systems A/S
(VWS) for review.
Typed in signatures are not allowed.
Alternative Vestas QDA documents can be used.
Vestas NCR number relevant for the section must be registered in TowerDoc.
5.3 Release of Welded Doorframes and Segmented flanges

Welded doorframes and segmented flanges must be released by signature on Welded Doorframe
Log and Segmented Flange Log. Material certificates and NDT reports must be enclosed each
document, and the package must be considered as one material certificate for the relevant part.
The material certificate must 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 must sign the Statement of Quality to
document that the section is ready for surface treatment. Before signature it must be checked that
all required inspection is performed and reported, and that material traceability is correct.
Statement of Quality must be uploaded to TowerDoc for use in the subsequently processes.

5.5 Uploading via TowerDoc

The deliverance to Vestas Wind Systems A/S (VWS) as per relevant purchase order is the section
and the As-Built documentation. If any of the two is missing, the deliverance is incomplete, and
can, as such, not be accepted by VWS.
Vestas Quality has identified the following mandatory requirements in terms of ensuring the quality
in general for the documentation prior to uploading into “TowerDoc”.
Before uploading the documentation to TowerDoc the Welding Workshop ensure that the docu-
mentation is complete, correct filled-in, filled in by computer and correct signed.
Documentation must be transferred to PDF files before uploading to TowerDoc.

Documentation must be uploaded in TowerDoc no later than 5 working days after the section is
reported completed.
The following must be uploaded for each section:
 Material certificates for primary steel, one file for each material certificate (incl. documenta-
tion packages for welded doorframes 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 (if any) relevant NCR’s (if any).
 One file including Statement of Quality (partly filled in).
 Waivers as one file (if any).
Statement of Quality is to be considered as the original document which must follow the entire
manufacturing process documenting the product release after major production steps. This means
that after steelwork, surface treatment and mounting are complete the same document is signed.
The Statement of Quality must be uploaded to TowerDoc after each step.
VWS will provide TowerDoc (http://TowerDoc.vestas.com) user name and password and further
instruction in the system.

Statement of Quality
Bottom section Intermediate section Top section Embedment
Section ID no. (6 characters)
Section VUI no. (10 characters)
Release after Steelwork and welding:

Drawings / revision of drawings used for production (As-Built):
Welding drawing:
Flange drawing(s):
Shell plate drawing(s):
Segment drawing(s):
Deviations from Vestas requirements are approved on Waiver No.:

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 records for steelwork and welding have been reviewed and approved.
Date: Contractor:
Name: Signature:
Release after Surface Treatment:

Technical Purchase Specification / revision.:

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 records for surface treatment have been reviewed and approved.
Date: Contractor:
Name: Signature:
Release after Mounting of Internals:

Assembly Drawing / revision.:

This is to certify that mounting of internals has been performed in accordance with Vestas requirements. The complete section
has been inspected and is ready for storage and transportation. The final inspection report has been reviewed and approved.
Date: Contractor:
Name: Signature:

Material Traceability List
Description of Section:
Section ID No.: Welding Drawing No.: R.
Traceability list – flanges:

Drawing No. Traceability No. (Serial No., Charge/Heat, test.)
Traceability list – shell plates / flange segments:

Drawing No. & t [mm] Traceability No. (Serial No., Charge/Heat, test.)
Item No
Traceability list – Segments in general:

Drawing No. Traceability № (Serial No., Charge/Heat, Test.)
Contractor:
Date / Signature:

Weld Log
Description of Section:
Section ID No.: Welding Drawing No.: R.
CW Weld No. WPS No. Welder ID, date LW Weld No. WPS No. Welder ID, date
Fillet welds (AW): Repair of surface imperfections:

WPS No. Welder ID, date WPS No. Welder ID, date
Contractor:
Date / Signature:

Report for Moving of Traceability Marking

Plate information:
Plate dimensions – txwxl Original marking
____ Marking moved
____ Plate cut into components
Component information:
Item number Number of items New marking
Marking moved by:
Name: ________________________________________________________
Date/signature: ________________________________________________________
Marking approved by:
Name: _______________________________________________________
Date/signature: _______________________________________________________

Dimensional Inspection Report
EXAMPLE

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:

Welded Doorframe Log
Description of doorframe:
Doorframe serial number: Drawing number: .R
Note: The doorframe manufacturer must select a unique serial number for each doorframe. The number must be
stamped inside the doorframe, see sketch below.
Identification of welds:
Serial no.
 The weld below the serial number is named DW2
DW1, the second weld clockwise is named
Cut A-A
DW2, etc.
 Weld repairs are named R1, R2 etc. in Hinge
addition to the original identification, e.g. 1 HW1
A
DW1R1. Flat iron
XXXX Partly shown
Thermal cut frame, identification of welds: 2
HW3
A
 HW1 upper hinge, HW2 lower hinge, HW3
flat iron. Serial number Hinge
Identification of materials: HW2
 The doorframe part with the serial number is

named pos. 1, the second doorframe part
clockwise is named pos. 2, etc. DW1
Weld traceability Material traceability

Weld No. WPS No. Welder ID, date Pos No. Traceability number
Dimensions acceptable.
This is to certify that the doorframe has been manufactured in accordance with Vestas requirements. The complete
doorframe 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 must be enclosed
this log. The complete package must be considered as one material certificate for the welded doorframe.

Segmented Flange Log
Description of flange:
Flange serial number: Drawing number: .R
Note: The flange manufacturer must select a unique serial number for each flange. The number must be stamped in the
inside flange, see sketch below.
1
SW6 SW1
Identification of welds:
 The weld at clockwise compared with the 6 2
serial number is named SW1, the next SW2 Cut A-A
etc.
A
 Weld repairs are named R1, R2 etc. in
SW5 SW2 XXXX
addition to the original identification, e.g. X
SW1R1.
5
Material traceability: 3 SW1
 The flange segment with the serial number Serial
is named Pos. 1, the second flange segment number
SW4 SW3
clockwise is named Pos. 2, etc.
4
Weld traceability Material traceability

Weld No. WPS No. Welder ID, 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 must be enclosed this log.
The complete package must be considered as one material certificate for the welded flange.
The documentation package must be uploaded in TowerDoc as a flange.

Quality Specification: Steelwork and Welding of Tower Sections and Embedments For Vestas Wind Turbines

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Vestas Wind Systems A/S · Hedeager 42 · 8200 Aarhus · Denmark · www.vestas.com

1.0 Preface .......................................................................................................................................................... 2

Vestas Wind Systems A/S · Hedeager 42 · 8200 Aarhus · Denmark · www.vestas.com

NDT must be performed according to latest revision of QS 0004-6605.

PSW, means Part Submission Warrant.

Vestas Wind Systems A/S · Hedeager 42 · 8200 Aarhus · Denmark · www.vestas.com

Identification of welds (per section), see Figure 1:

Figure 1: Identification of welds in sections.

1.3 Use of Standards

1.4 Control of Deviations

1.5 Verification by VWS

The following documents must be available for PPAP:

Vestas Wind Systems A/S · Hedeager 42 · 8200 Aarhus · Denmark · www.vestas.com

1.7 Request for Quality Specification changes

1.8 Implementation of Quality Specification

2.0 General Requirements to the Quality Management System

An organisation chart, which as a minimum includes the names of:

Requirements for use of external NDT companies:

2.2 Personnel Qualifications

2.2.1 Quality Responsible

2.2.2 Welding Coordinator

The Welding Coordinator must be able to demonstrate Comprehensive Technical Knowledge

2.2.4 NDT Personnel

2.2.5 Other Inspectors

Vestas Wind Systems A/S · Hedeager 42 · 8200 Aarhus · Denmark · www.vestas.com

2.3.2 New Equipment

New welding equipment:

Defect equipment must not be used.

2.3.4 Welding Equipment

2.3.5 Measuring Equipment.

2.4 Handling of Non-Conformities.

2.5 Additional Requirements to Sections for Italy

3.0 Production Preparation

3.2 Process Flow and FMEA

3.3 Quality Activity Plan

Vestas Wind Systems A/S · Hedeager 42 · 8200 Aarhus · Denmark · www.vestas.com

3.4 Production Work Instruction (PWI)

PWI’s must as minimum be made for the following processes.

3.4.1 Welding Sequence for Flanges

3.4.2 Heat Treatment of Weld

3.4.3 Flame Straightening

3.4.4 Use of temporary steel

3.5 Qualification of Welding Procedures

3.5.1 Welding Procedure Specifications

Vestas Wind Systems A/S · Hedeager 42 · 8200 Aarhus · Denmark · www.vestas.com

3.5.2 Welding Procedure Tests

3.5.3 Additional Essential Variables

3.5.4 Examination and Testing

3.5.5 Hardness Testing

3.6 Welding Plan

3.7 Welding Consumables

3.8 Storage of Primary Steel.

3.8.1 Material certificates

3.8.2 Inwards Inspection of Primary Steel

3.9 ID-numbers for Sections

3.10 Serial Numbers for Welded Items

4.0 Quality Activities During Production

Vestas Wind Systems A/S · Hedeager 42 · 8200 Aarhus · Denmark · www.vestas.com

4.2 ID-numbers and Serial Numbers

4.3 Preparation of Weld Log

4.4 Inspection and Testing Before and During Welding

The following must be checked before welding: