ZPS 1040407-111600-Tubular Tower, EN1993, CE Marking-Product Specific Spec

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Object: Tubular towers, EN 1993, CE Marking, ZPS 1040407

Product specific specification
Turbine: ECN no: 111600
1. Product specific specification §1 – Scope of Work

1.1. General This document, in addition to the document ZPS 1008682, specifies the
technical requirements for fabrication of construction details used in the
tower sections and for fabrication of tower sections.
The design is based on EN 1993 with specific requirements to conformity

assessment of structural components according to EN 1090-1 (CE-
marking) and a coating system meeting the requirements given in the
purchase order.
2. Product specific specification §2 – Execution class and general requirements

2.1. Product specific specification §2a – Execution class
2.1.1. General The construction must be manufactured in accordance requirements
defined for execution class: EC3.
2.2. Product specific specification §2b – General quality assurance

2.2.1. General The manufacturer must ensure that:
NDT instructions for VT, MT, UT, and PT are prepared and
implemented in the production;
All required instructions are prepared in English and in a language
understood by the personnel.
The inspection plan from each individual production site(s) executing steel
work-, welding-, NDT-, and other test activities must by compiled and
contain information about:
Scope of work (with reference to the SWP documents which

provide the background for the instruction);
Reference to the welding plan to be used;
Overview of all inspections with reference to the appropriate work
instructions, roles and responsibilities used during the production
e.g.:
Incoming inspection;
Dimensional inspection during fabrication of individual
construction details;
Bevel preparation;
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© All Rights Reserved 2013 ZPS 1040407-111600.doc
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Inspection during execution of welding activities;

Inspection after execution of welding activities;
NDT of welds;
Final dimension inspection;
Review and release of as-built documentation.
2.3. Product specific specification §2c – Identification

2.3.1. Door frame – Before the execution of the cutting process of door frame segments (Pos.
Traceability 201 on the drawing), a traceability number must be stamped into each
number individual segment at the location specified for “Identification field 1-2”.
The number must ensure that there is full traceability between the
constituent product used for each part of a door frame and the constituent
product’s inspection document.
2.3.2. Tower section – The identification number must fulfill the requirements for process category
Traceability “Standard Ver. 3” given in Appendix D1.5 of ZPS 1009554.
number (Section
ID number) Welded identification number is prohibited.
3. Product specific specification §3 – Constituent products

3.1. Product specific specification §3a – Substitution of constituent products
3.1.1. Substitution of The constituent products defined on the drawings may be substituted as
constituent specified in Appendix C1.3 of ZPS1009554.
products
3.2. Product specific specification §3b – Supplementary requirements

3.2.1. General No supplementary requirements.

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4. Product specific specification §4 – Production requirements – Steelwork and welding

4.1. Product specific specification §4 – Production requirements
4.1.1. General The technical requirements given in Table 4-1 must be used as production
basis for the steelwork, fabrication and NDT of the construction.
Table 4-1 - Production requirements

Feature Requirement to be met for the feature in question is defined in
the document(s) or process category(s) listed hereafter
Quality system for welding work. The quality system must fulfill the requirements given for group 2 in
Product specific specification §4a ZPS 1009608.
In addition it is required that procedures are implemented in order to

ensure that contaminated welding flux is discarded.
Legislation The product must meet the requirements given in CPR 305/2011
Product specific specification §4b and meet the requirements given for group 21 in ZPS 1009608 for
the specified execution class.
In case of conflict between requirements in EN 1090-1/EN 1090-2

and the specification basis given in the PO, then the strictest
requirements must be prevail.
Welding plan Welding plan must fulfill the requirements for process category:
Product specific specification §4c ”High” given in Appendix C1 of ZPS 1009613.
Cutting process The cutting process must fulfill the requirements for process
Product specific specification §4d category: ”Standard cutting” given in Appendix D1.1 of ZPS
1009554.
Form, location tolerance and surface The form, location tolerance and surface quality of bevels, free edge
quality of the bevel, free edge and surfaces and holes must fulfill the requirements for process
hole category: ”Comprehensive – HV380 – ISO 9013:2002” given in
Product specific specification §4e Appendix D1.2 of ZPS 1009554.
WPS The WPS must fulfill the requirements given for group 1 in ZPS
Product specific specification §4f 1009613.

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Table 4-1 - Production requirements – Continued

Feature Requirement to be met for the feature in question is defined in
the document(s) or process category(s) listed hereafter
WPQR The WPQR must fulfill the requirements for one of the subgroups in
Product specific specification §4g ZPS 1009613 given for group 2.
The welding consumables used at the qualification of the WPQR

must:
conform to the requirements in EN 13479 and EN 1090-2;
be supplied with a declaration of conformity as specified in
EN 13479 (CE-marking);
for welding process 111 and 136 have a maximum content
of 5 ml. hydrogen per 100 gram weld metal;
have minimum impact properties of 47 J at -50° C;
be released by SWP prior to qualification of the WPQR.
Welding personnel The welder and welding operators must fulfill the requirements for
Product specific specification §4h one of the subgroups in ZPS 1009593 given for group 3.
Organization requirements The organization requirements must fulfill the requirements for
Product specific specification §4k process category: ”Comprehensive” given in Appendix D1.3. of ZPS
1009554.
Traceability – Manufacturing process The Traceability in the manufacturing process must fulfill the
Product specific specification §4m requirements for process category: ”High” given in appendix D1.4. of
ZPS 1009554.
NDT-personnel The NDT-personal must fulfill the requirements for one of the
Product specific specification §4n subgroups in ZPS 1009603 given group 2-1 or 2-8.
In addition to the requirements given in Clause A3-4.2 of ZPS

1009603 and A8-4.2 of ZPS 1009603 the level of education for the
NDT personnel has been restricted to Level 2 and Level 3. Level 1
personnel must not perform any kind of examination and recording.
Registration requirements Required DT, VT, MT, PT and UT must be documented by the use
Product specific specification §4q of templates given in ZPS 1007535.
The result of evaluation of the flange flatness and angular

displacement of flanges must be documented by the use of
templates given in ZPS1031936.

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Product specific specification §4o – Definition of lots
Lot Definition
Lot – no. 1 Each individual circumferential weld between shell pos. 1 and top-flange
on the top section, if indicated on the drawing as ground flush
Lot – no. 2 Each individual circumferential weld between shell and L-flanges, except
lot no. 1 if required as ground flush
Lot – no. 3 Each individual circumferential weld between two shells
Lot – no. 4 Each individual longitudinal welds
Lot – no. 5 Each individual weld between shell and door frame, Zone 1 (See drawing)
Lot – no. 6 All welds between shell and door frame, Zone 2 (See drawing) on each
construction
Lot – no. 7 Start/stop on each individual circumferential weld, including minimum 50
mm on each side of the start/stop
Lot – no. 8 Door frame weld, partial penetrated (weld between doorframe segments -
Item 201) at each construction, including 150 mm of the parent metal on
each side of the welds at each construction
Lot – no. 9 Door frame weld, fully penetrated (weld between doorframe segments -
Item 201) at each construction, including 150 mm of the parent metal on
each side of the welds at each construction
Lot – no. 10 Fillets welds between carbon/carbon steel at each construction
Lot – no. 11 Fillets welds between carbon/stainless steel at each construction
Lot – no. 12 Each individual zone, including a transition zone with a width of minimum
10 mm, if any, where temporary attachments have been welded on and
removed again, weld repair of surface defects has been performed, and
where stray arc has been removed by grinding.

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Product specific specification §4j – Weld quality level – NDT
Feature Acceptance level
Lot – Type 8 Prior to starting up the welding process the bevel geometry must comply
with the technical requirements and parameters given in the WPS.
Lot – Type 1 Level SWP-EC-3-Cat 112: ZPS 1030725
Lot – Type 2 to 4 Level SWP-EC-3-Cat 90: ZPS 1030725
Lot – Type 5 to 11 Level SWP-EC-3: ZPS 1030725
Lot – Type 12 Level SWP-EC-3: ZPS 1030725 specified for VT/MT/PT

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Table 4-1 – Production requirements - Continued

Product specific specification §4p – Extent of testing – NDT
Feature Examination Normal extent In case of non-fulfillment of
standard to of testing requirement, the extent of testing
be used must be extended to the next step:
Normal Inspection step
inspection (p%)
No. 1 No. 2 No. 3
1)
VT – Lot no. 8 ZPS 1030725 100%
VT – Lot no. 1-12 ZPS 1030725 100%
PT – Lot no. 11 ZPS 1030725 100%
MT – Lot no. 1-3 ZPS 1030725 20%2) 50% 100%
3)
MT – Lot no. 4 ZPS 1030725 5% 20% 50% 100%
MT – Lot no. 5 ZPS 1030725 100%
MT – Lot no. 6 ZPS 1030725 20% 50% 100%
MT – Lot no. 7 ZPS 1030725 100%
MT – Lot no. 8 ZPS 1030725 100%
MT – Lot no. 9 ZPS 1030725 100%
MT – Lot no. 10 ZPS 1030725 100%
MT – Lot no. 12 ZPS 1030725 100%
4)
UT – Lot no. 1-2 ZPS 1030725 100%
UT – Lot no. 3 ZPS 1030725 20%2) 50% 100%
3)
UT – Lot no. 4 ZPS 1030725 5% 20% 50% 100%
UT – Lot no. 5 ZPS 1030725 100%
UT – Lot no. 6 ZPS 1030725 20% 50% 100%
UT – Lot no. 9 ZPS 1030725 100%
Notes:
1)
The test must be performed prior to starting up the welding process.
2)
The examination must include:
a) Start and stop on both sides (inside and outside)
b) Intersection between the circumferential and the longitudinal weld seam
c) 1000 mm randomly taken of the whole circumference
d) Ground welds must be examined 100% (only valid for UT)
e) 250 mm adjacent to the door frame (only valid for UT)
3)
The examination must include both ends of the longitudinal weld seam.
4)
When performing the UT it is required that option “Scanning plans of UT” in Appendix A20.1 of ZPS
1030725 is used.

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4.2. Product specific specification §4r - Supplementary requirements

4.2.1. Dimensional The flatness and angular displacement of flanges must be measured as
inspection of specified in Appendix A1 of ZPS 1031936 when all the steel work, welding,
flange flatness and NDT on the tower section have been completed.
and angular
displacement It must be documented that no subsequent fabrication processes, handling,
and transportation will affect the flange flatness and the angular
displacement.
4.2.2. Dimensional Prior to coating the manufacturer must verify that the measurements D1,
inspection of the D2, D3, D4, D5, D6, D7, and D8 shown on the drawing in the region
bolt circle “Measurement of BCD” are meeting the specified acceptance level.
diameter
The measurements must be made by using a steel tape complying with the
requirements in Clause 15.23 of ISO 7976-1:1989.
The actual result must be documented.
4.2.3. Surface Any imperfection in the surface of the constituent products after steel work
imperfections and welding activities have been finalized must be examined.
It must be verified that:

no imperfections are exceeding the acceptance level given in
Table 4-2;
imperfections do not have any sharp edges and/or cracks.
Non-acceptable imperfections and required ground welds must be ground

flush by the use of a fiber disc or lamella disc with grade 80 or higher. The
transition zone between the ground area and the non-ground zones must
be smooth. The radius of the ground area must at least be “25 x depth of
imperfection” measured from the center of the imperfection.
When the depth of the imperfection and/or ground area exceeds the
acceptance level given in Table 4-2 it must be repaired by welding using a
qualified WPS as required in this specification.
Any repair weld must be ground flush with the base material using a fiber
disc or lamella disc with grade 80 or higher and subsequently tested with
MT (acceptance criteria in accordance with Table 4-1).
All main direction of the grinding trails must be located in the axial direction
of the tower section.

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Table 4-2 – Permitted depth of imperfections

Maximum permitted depth of
Nominal plate thickness [mm]
imperfection [mm]a)
8 t < 15 0,5
15 t < 25 0,7
25 t < 40 0,9
40 t < 60 1,1
60 t < 80 1,3
80 t < 150 1,6
a)
No depth must exceed 0,3 mm of the nominal thickness.
4.2.4. Grinding of door Grinding of the door frame (Zone 1) and brackets (if required) must be
frame and performed according to work instruction WI 575349.
brackets
5. Product specific specification §5 – Production requirements – Paint application system

5.1. Product specific specification §5 – General
5.1.1. General No general comments are defined.
5.2. Product specific specification §5a – Quality plan and quality documentation
5.2.1. General No supplementary requirements are defined.
5.3. Product specific specification §5b – Legislation

5.4. Product specific specification §5c – Identification

5.4.1. General The identification must fulfill the requirements for process category:
”Standard – Ver. 2” given in appendix D1.1. of ZPS 1009606.
The identification must be painted in black using a template and be

readable from a distance of 2 meters.
5.5. Product specific specification §5d – Technical requirement to coating system

5.5.1. General The requirements for the surface treatment will be stated in the purchase
order in the document “Addition to PO-text”.

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5.6. Product specific specification §5e – Appearance of the coating of last application
5.7. Product specific specification §5g – Records

5.8. Product specific specification §5h– Supplementary requirements

5.8.1. Protection of Before starting up of the surface corrosion process (blasting, metalizing,
bushings and and painting) the threads of all bushings must be protected with bolts as
flanges during illustrated in Figure 5-1 and flange thread holes must be protected with set
surface treatment screws (cf. EN ISO 4026) as illustrated in Figure 5-2:
Figure 5-1 – Protection of threads in bushings of thread using a bolt
Figure 5-2 – Protection of threads in flanges using a set screw
When using a set screw the top of the screw must be elevated 1-2 mm
above the flange surface.
Oil or any other lubrication is not allowed.
5.8.2. TSM Metalizing (TSM) and wet paint must be applied when the tower section is
rotating.

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5.8.3. Dimensional Prior to release for transportation the manufacturer must verify that the
inspection of the measurements D9, D10, D11, and D12 shown on the drawing in the region
flanges “Surface corrosion protection system” are meeting the specified
acceptance level.
The actual result must be documented.
5.8.4. Position of the The position of the tower section during assembly must be in accordance
tower section with “ASSEMBLY” as given on the drawing.
The position of the tower section during storage and transportation must be
in accordance with “TRANSPORT” as given on the drawing.
The table below describes modifications of this specification compared to the previous revision of the
specification.
Document Description of modifications
ZPS 1040407-111600 First revision of this document.


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Purchasing Specification

Object: Tubular towers, EN 1993, CE Marking, ZPS 1040407

Turbine: ECN no: 111600

1. Product specific specification §1 – Scope of Work

The design is based on EN 1993 with specific requirements to conformity

2. Product specific specification §2 – Execution class and general requirements

2.2. Product specific specification §2b – General quality assurance

Scope of work (with reference to the SWP documents which

Siemens Wind Power A/S 1/11

Inspection during execution of welding activities;

2.3. Product specific specification §2c – Identification

3. Product specific specification §3 – Constituent products

3.2. Product specific specification §3b – Supplementary requirements

Siemens Wind Power A/S 2/11

4. Product specific specification §4 – Production requirements – Steelwork and welding

Table 4-1 - Production requirements

In addition it is required that procedures are implemented in order to

In case of conflict between requirements in EN 1090-1/EN 1090-2

Siemens Wind Power A/S 3/11

Table 4-1 - Production requirements – Continued

The welding consumables used at the qualification of the WPQR

In addition to the requirements given in Clause A3-4.2 of ZPS

The result of evaluation of the flange flatness and angular

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Table 4-1 - Production requirements – Continued

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Table 4-1 - Production requirements – Continued

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Table 4-1 – Production requirements - Continued

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4.2. Product specific specification §4r - Supplementary requirements

The actual result must be documented.

It must be verified that:

Non-acceptable imperfections and required ground welds must be ground

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Table 4-2 – Permitted depth of imperfections

5. Product specific specification §5 – Production requirements – Paint application system

5.3. Product specific specification §5b – Legislation

5.4. Product specific specification §5c – Identification

The identification must be painted in black using a template and be

5.5. Product specific specification §5d – Technical requirement to coating system

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5.7. Product specific specification §5g – Records

5.8. Product specific specification §5h– Supplementary requirements

Figure 5-1 – Protection of threads in bushings of thread using a bolt

Figure 5-2 – Protection of threads in flanges using a set screw

Oil or any other lubrication is not allowed.

Siemens Wind Power A/S 10/11

The actual result must be documented.

Document Description of modifications

ZPS 1040407-111600 First revision of this document.

Siemens Wind Power A/S 11/11

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