Professional Documents
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Item-no. 990508 R7
2020-10-26
Quality Specification
Steelwork and welding of tower
sections and embedments
for Vestas wind turbines
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document contains valuable confidential information of Vestas Wind Systems A/S. It is protected by copyright law as an unpublished work.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 R7 Date: 2020-10-19
Steelwork and welding of tower sections and
Issued by: VWS embedments for Vestas wind turbines
Type: Quality Specification Page 2 of 29
Contents
1.0 Preface .................................................................................................................................. 4
1.1 Objective....................................................................................................................... 4
1.2 Definitions ..................................................................................................................... 4
1.3 Use of Standards .......................................................................................................... 6
1.4 Control of Deviations .................................................................................................... 6
1.5 Verification by VWS ...................................................................................................... 7
1.6 CTQ .............................................................................................................................. 8
1.7 Request for Quality Specification changes .................................................................... 8
1.8 Implementation of Quality Specification ........................................................................ 8
2.0 General Requirements to the Quality Management System ................................................... 8
2.1 General......................................................................................................................... 8
2.2 Personnel Qualifications ............................................................................................... 9
2.2.1 Quality Responsible .......................................................................................... 9
2.2.2 Welding Coordinator .......................................................................................... 9
2.2.3 Welders ............................................................................................................. 9
2.2.4 NDT Personnel .................................................................................................. 9
2.2.5 Other Inspectors ................................................................................................ 9
2.3 Equipment .................................................................................................................. 10
2.3.1 Scope and Registration ................................................................................... 10
2.3.2 New Equipment ............................................................................................... 10
2.3.3 Maintenance .................................................................................................... 10
2.3.4 Welding Equipment ......................................................................................... 10
2.3.5 Measuring Equipment...................................................................................... 10
2.4 Handling of Non-Conformities ..................................................................................... 11
2.5 Additional Requirements to Sections for Italy .............................................................. 11
2.6 Additional Requirements to Sections for Japan ........................................................... 11
3.0 Production Preparation ........................................................................................................ 11
3.1 Contract and Design Review....................................................................................... 11
3.2 Process Flow and FMEA ............................................................................................ 11
3.3 Quality Activity Plan .................................................................................................... 12
3.4 Production Work Instruction (PWI) .............................................................................. 12
3.4.1 Welding Sequence for Flanges........................................................................ 12
3.4.2 Heat Treatment of Weld .................................................................................. 12
3.4.3 Flame Straightening ........................................................................................ 12
3.5 Qualification of Welding Procedures ........................................................................... 12
3.5.1 Welding Procedure Specifications ................................................................... 13
3.5.2 Welding Procedure Tests ................................................................................ 13
3.5.3 Additional Essential Variables ......................................................................... 13
3.5.4 Examination and Testing ................................................................................. 14
3.5.5 Hardness Testing ............................................................................................ 14
3.6 Welding Plan .............................................................................................................. 15
3.7 Welding Consumables ................................................................................................ 15
3.8 Storage of Primary Steel. ............................................................................................ 15
3.8.1 Material certificates ......................................................................................... 15
3.8.2 Inwards Inspection of Primary Steel ................................................................ 15
3.9 ID-numbers for Sections ............................................................................................. 15
3.10 Serial Numbers for Welded Items ............................................................................... 15
4.0 Quality Activities During Production ..................................................................................... 16
4.1 Material Traceability .................................................................................................... 16
4.2 ID-numbers and Serial Numbers ................................................................................. 16
4.3 Preparation of Weld Log ............................................................................................. 16
4.4 Inspection and Testing Before and During Welding .................................................... 16
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 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 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.
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 (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 (door segments, Cond. Air Segments, cable frames, vertical flanges etc.)
PSW, means Part Submission Warrant.
PWI, means Production Work Instruction.
Vestas Wind Systems A/S · Hedeager 42 · 8200 Aarhus · Denmark · www.vestas.com
Document no.: 990508 R7 Date: 2020-10-19
Steelwork and welding of tower sections and
Issued by: VWS embedments for Vestas wind turbines
Type: Quality Specification Page 5 of 29
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
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.
In general:
Vestas Wind Systems A/S · Hedeager 42 · 8200 Aarhus · Denmark · www.vestas.com
Document no.: 990508 R7 Date: 2020-10-19
Steelwork and welding of tower sections and
Issued by: VWS embedments for Vestas wind turbines
Type: Quality Specification Page 7 of 29
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.
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.
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 analysing
them and trace performance development. Non-performance according to given targets re-quires
corrective actions to be performed.
A request for changes to the QS doesn’t relieve the supplier from following the QS.
Quality system shall meet the requirements of ISO9001, and ISO3834-2 and shall be certified
accordingly. Uncertified systems shall be approved by Vestas.
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.
Equivalent standards can be used, if and only if, references to equivalent points in relevant EN or
EN/ISO standards are clearly described, and these are reviewed and approved by Vestas.
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 start of work.
Welders performing fillet welds must have a certificate in that specific welding area.
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.
2.3.3 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.
(1. Servizio Tecnico Centrale del Consiglio superiore dei Lavori Pubblici)
Under specific buyer’s approval, the tower may be fabricated at a non-certified (JIS) factory
providing the manufacturer presents documentation demonstrating that the factory is equivalent to
JIS grade H or higher, and in this case, testing shall be performed with reference to JIS, and
welding wire and flux shall be JIS grade H certified.
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.
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.
The reference documents and the responsible person must be listed for each of the activities.
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.
The welding procedure test must be made by each Welding Workshop (with specific address). When
suppliers want to use Global WPQR (same WPQR in different plants belonging under the same
corporation) the following additional requirements must be fulfilled:
1. The corporation must appoint / nominate a person who retains complete responsibility for
all welding activities in workshops or sites.
2. ISO 3834-2 must be in place in each plant / site, where the supplier intends to use Global
WPQR.
Vestas Wind Systems A/S · Hedeager 42 · 8200 Aarhus · Denmark · www.vestas.com
Document no.: 990508 R7 Date: 2020-10-19
Steelwork and welding of tower sections and
Issued by: VWS embedments for Vestas wind turbines
Type: Quality Specification Page 13 of 29
3. WPQR must be witnessed, inspected / tested and approved by a third party accepted by
Vestas. Laboratory which performs test must be accredited according ISO / IEC 17025.
4. All qualifications will take place in one plant.
5. Supplier must share in a monthly base the “UT defect rate".
6. Supplier will share the “Welding Audits Reports", done by corporate in each plant.
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.
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.
The following additional essential variables require a new welding procedure test:
Vestas Wind Systems A/S · Hedeager 42 · 8200 Aarhus · Denmark · www.vestas.com
Document no.: 990508 R7 Date: 2020-10-19
Steelwork and welding of tower sections and
Issued by: VWS embedments for Vestas wind turbines
Type: Quality Specification Page 14 of 29
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.
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 non-heat-treated welds and 320 HV10 for heat-treated
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.
The Welding Plan must contain a sketch of the section with reference between each weld, the used
WPS and repair WPS.
A storage management plan must be elaborated and be a part of the Quality Management System.
The process must be a part of the Quality Management System / Quality Activity Plan with specified
extent; defined measurement points and mandatory documentation requirements.
Movement of a traceability number must be documented in; Report for Moving of Traceability
Marking.
Material traceability for segmented flange must be recorded on Segmented Flange Log.
Traceability of door segments and segmented flange must be documented in Material Traceability
list after section is completed. In addition, if segmented flanges are welded by Tower Manufacturer
traceability need to be documented in Welding Log. The traceability numbers must be recorded on
Material Traceability List after the section is completed.
ID-numbers must be welded on secondary steel or stamped on to the section as specified on the
production drawings.
Unique serial numbers for segmented flange must be applied as specified on Segmented Flange
Log.
Numbers must be applied so that they are easily readable after surface treatment.
Traceability between weld, WPS and welder must always be available and documented in Weld Log,
or Segmented Flange Log.
Bevel preparation.
Positioning, fixing and tack-welding.
Environmental conditions.
The inspection and testing must be documented by reference to the welder and WPS no.
The written procedure must be forwarded to VWS for review and be included in the Quality Activity
Plan.
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.
EasyLink software will 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 EasyLink software.
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.
Dimensional Inspection Report for upload to TowerDoc, must be made using Template A011-6542,
instructions on reporting data from easylink can be found in PWI 0008-6684.
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.
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 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
handwritten 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.
Vestas NCR number relevant for the section must be registered in TowerDoc.
The material certificate must be sent together with the part, if the part is used by another Welding
Workshop.
Statement of Quality must be uploaded to TowerDoc for use in the subsequently processes.
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
documentation is complete, correct filled-in, filled in by computer and correct signed.
Material certificates for primary steel, one file for each material certificate (incl. documentation
packages for 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 at final 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)
Welding drawing:
Flange drawing(s):
Shell plate drawing(s):
Segment drawing(s):
Date: Contractor:
Name: Signature:
Date: Contractor:
Name: Signature:
Date: Contractor:
Name: Signature:
Description of Section:
Drawing No. & t [mm] Traceability No. (Serial No., Charge/Heat, test.)
Item No
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
Contractor:
Date / Signature:
Component information:
Name: ________________________________________________________
Date/signature: ________________________________________________________
Name: _______________________________________________________
Date/signature: _______________________________________________________
Description of flange:
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 serial 6 2
number is named SW1, the next SW2 etc. Cut A-A
A
to the original identification, e.g. SW1R1.
SW5 SW2 XXXX
X
Material traceability:
The flange segment with the serial number is 5
3 SW1
named Pos. 1, the second flange segment
clockwise is named Pos. 2, etc. Serial
number
SW4 SW3
4
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.