TÜV NORD Standard. for. Certification of Wind Turbines

Transcription

1 Body for Wind Turbines TÜV NORD Standard for of Wind Turbines Reference No P20-001, Rev. 0 March 2009 Headquarters TÜV NORD CERT GmbH Langemarckstraße Essen Phone: Fax: windenergy@tuev-nord.de Director Dipl.-Volksw. Ulf Theike Deputy director Dipl.-Ing. Wolfgang Wielpütz Registration Office Amtsgericht Essen HRB 9976 VAT No.: DE Tax No.: 111/5706/2193 Deutsche Bank AG, Essen Bank Code: Account No.: BIC (SWIFT-Code): DEUTDEDE IBAN-Code: DE

2 Body for Wind Turbines Content: 1. Background 2. Scope of 2.1 Design evaluation 2.2 Type testing evaluation 2.3 Manufacturing evaluation 2.4 Foundation design evaluation (optional module) 2.5 Type characteristic measurements (optional module) 3. Type Certificate P doc Seite 2 von 8

3 Body for Wind Turbines 1. Background Due to the demand of the Wind Turbine Market TÜV NORD offers a special certification program for type certification of wind turbines. This certification scheme is based on the internationally well accepted IEC guidelines, especially the IEC WT01 (2001). The IEC WT01 scheme is modified with respect to the design evaluation conformity statement (also known as design assessment, class A ) with intermediate steps class C and B the full-scale dynamic rotor blade test which becomes an optional test for the module type testing. During the last years the discussions among the international rotor blade experts about the relevance of such a test for the rotor blade design remains controversial. For many experts as well as for TÜV NORD there are many problems and open points such as: The loading in a test rag and in real operation is significant different. Normally the test load is optimised to fit the design load only at areas of interest (normally the high stressed areas). Special problems can arise from the areas of load application. The requirements for a practical test duration and the additional safety factors lead to test loads which can be in the range of the extreme loads. From this again failure modes can be induced which are untypical for fatigue and therefore unrealistic. Normally the test blade is a prototype or one of the first blades from the pilot production. The behaviour of the serial blade can be different. Therefore on TÜV NORD opinion the test primarily can be an option for design optimization under the responsibility of the manufacture whereas the safety relevance is not really verified. The assure the blade safety special attention has to be taken to realistic load assumptions for extreme and fatigue loads considering also the influence of mean values adequate calculation methods and verified material data static blade test to verify the overall stability due to extreme loads as well as the calculation models and procedures quality assured production process. P doc Seite 3 von 8

4 Body for Wind Turbines Because the last point has a very big influence on the overall quality of the blade the manufacturing inspection of the rotor blade shop for the blade under certification is mandatory. 2. Scope of As above mentioned this certification scheme is based on the IEC WT01 scheme and comprises of the following modules: 2.1 Design assessment The following elements are evaluated: load assumptions control and protection system electrical components rotor blades machinery components nacelle, spinner tower foundation (optional) personal safety manuals (manufacturing, commissioning / maintenance Plan) The satisfactory evaluation is confirmed by the statement of compliance for the design assessment (class A). In order to account for the different stages in the development of a wind turbine TÜV Nord may in addition to the modified design evaluation to IEC WT 01 type certification scheme issue the following design assessment classes: TÜV NORD prototype design assessment, class C This design assessment is issued to enable testing of prototypes and is based on the following scope of approval: Plausibility check of the control system. Load calculations for the design driving load cases (extreme and fatigue loads). P doc Seite 4 von 8

5 Body for Wind Turbines Plausibility check of the design of the rotor blades based on the relevant drawings and the design calculations. The static rotor blade test is mandatory before operating the prototype. Plausibility check of the design of the machinery components based on the main drawings and a plausibility verification, e.g. comparison with the design of a wind turbine of similar size. Plausibility check of the electrical installation based on a general description. Design approval of the tower and foundation (optional) based on preliminary design calculations and drawings. The location of the turbine is stated on the design assessment, Class C. The period of validity is limited to 2 years. TÜV NORD design assessment, class B The design assessment class B is issued if all items for the design evaluation have been finished with the exception that not safety related items are outstanding. The period of validity for the TÜV NORD design assessment, class B is limited to 1 year and has to be replaced by a TÜV NORD design evaluation, class A within this period. 2.2 Type testing evaluation The following elements are evaluated: commissioning / safety and function test static rotor blade test (full scale) dynamic rotor blade test (full scale) optional load measurements power performance measurements other tests (e.g. gearbox prototype test) The tests are preferably performed by accredited test institutes (DIN ISO 17025). The load measurements have to be compared with the design load calculations. For verification of the simulation models it can be necessary to perform special load calculations which have to be performed with the site specific wind conditions of the test location. P doc Seite 5 von 8

6 Body for Wind Turbines The satisfactory evaluation is confirmed by the type test conformity statement. 2.3 Manufacturing evaluation The requirement for the evaluation of the quality system is satisfied if the manufacturer operates a certified quality system according to ISO Otherwise the certification body has to perform this evaluation taking into account the following aspects: responsibilities control of documents sub-contracting purchasing process control inspection and testing corrective measures quality recordings training product identification and traceability. The Body shall verify by inspection that at least one specimen is manufactured according to the design under certification. The inspection shall comprise: verification that design specifications are properly implemented in workshop drawings, workshop instructions, purchase specifications and installation instructions; evaluation of manufacturer s workshop, if relevant; verification of fabrication methods, procedures and qualifications of personnel; review of material certificates; random checks on effectiveness of procedures for acceptance of purchased components and Inspection of critical components shall take place at the wind turbine manufacturer unless the manufacturer s incoming goods inspection is insufficient to ensure that the requirements identified during the design evaluation are met. In general, the following components shall be considered for inspection: P doc Seite 6 von 8

7 Body for Wind Turbines rotor blades (shop inspection is mandatory for the blade under certification) rotor hub rotor shaft main, pitch and yaw bearings (pitch and yaw drives) main bearing housings gear box locking devices and mechanical brake generator, transformer main frame, generator frame tower sub-structure (optional) foundation (optional) bolted connections hub and nacelle assembly (in workshop). A satisfactory manufacturing conformity evaluation is concluded with a Manufacturing Conformity Statement. 2.4 Foundation design evaluation (optional module) Based on the relevant design drawings, design calculations and soil parameters the foundation design has to be evaluated with reference to a specific tower for the wind turbine under certification. The satisfactory evaluation is confirmed by the certification report for the foundation (conformity statement for foundation design evaluation). 2.5 Type characteristic measurements (optional module) These optional performance related tests can be selected by the applicant and are one or more of the following measurements: Acoustic noise measurements Power performance tests The measurements have to be performed by accredited test laboratories or the certification body shall verify that the party conducting the testing complies with at least the criteria of ISO/IEC or ISO/IEC 17020, as applicable. P doc Seite 7 von 8

8 Body for Wind Turbines The satisfactory evaluation is confirmed by the type characteristics measurements conformity statement. 3. Type Certificate The type certificate is issued if the mandatory and / or optional modules are confirmed by the applicable conformity statements without outstandings. Furthermore the design basis is described in the final evaluation report with special attention to the scope of this TÜV NORD Standard. The validity of the certificate is normally 5 years. P doc Seite 8 von 8