Purchasing Specification

General technical requirements for aluminium constructionsPS1005341-30201.doc

Conveyed confidentially as trade secret

Object: General technical requirements for aluminium PS 1005341

constructions.
Designer: CMO
Date: 19.01.2009
Turbine: ECN no.: 30201
Doc. ref.: ECN date: 19.01.2009

1. SCOPE
1.1. General This specification specifies the requirements and general technical
delivery conditions for aluminium constructions designed for static loaded
conditions.
1.2. Cross-references For cross-references:
• To tables or clauses in this specification no reference will be
given to the document number of this specification.

• To tables or clauses in other than the above mentioned

documents, a subsequent reference will be given to the number
relevant for the document in question e.g. “table 1 of EN 10308”.
1.3. Revision The revision of all drawings, technical and quality document from SWP is
numbering of given by the ECN-number.
documents The supplier shall ensure the all received documents are in accordance
with the PO and ECN send to the supplier as updates to the PO.
The supplier shall inform SWP, about the construction number or date
from where the ECN update is implemented in the production.

1.4. Units All required registrations must be documented in SI-units.

1.5. Modifications Clause 6 describes new modifications of this document.

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General technical requirements for aluminium constructionsPS1005341-30201.doc
Conveyed confidentially as trade secret

2. NORMATIVE REFERENCES
2.1. General These normative references are cited at the appropriate places in the text
and the publications are listed hereafter. For dated reference, subsequent
amendments to, or revisions of any for these publications apply to this
specification only when incorporated by amendment or revision.

For undated references the latest edition of the publication, which is

referred to, applies.

• DS/EN 473, Non-destructive testing - Qualification and

certification of NDT personnel - General principles.
• DS/EN 485-1, Aluminium and aluminium alloys – Part 1:
Technical conditions for inspection and delivery
• DS/EN 485-2, Aluminium and aluminium alloys – Part 2:
Mechanical properties
• DS/EN 485-3, Aluminium & alum alloys– Part 3: Tolerances on
dimensions and form for hot-rolled products
• DS/EN 485-4, Aluminium & alum alloys– Part 4: Tolerances on
shape & dimensions for cold-rolled products
• DS/EN 571-1, Non-destructive testing – Penetrant testing – Part
1: General Principles.
• DS/EN 1011-4, Welding – Recommendations for welding of
metallic materials – Part 4 – Welding of aluminium and
aluminium alloys.
• DS/EN 10204, Metallic products – Types of inspections
documents.
• DS/EN 12062 + DS/EN 12062/A1, Non-destructive examination
of weld- General rules for metallic materials.
• DS/EN ISO 3834-3, Quality requirements for fusion welding of
metallic materials – Part 3: Standard quality requirements.
• DS/EN ISO 4063, Welding and Allied processes – Nomenclature
for processes and reference numbers.
• DS/EN ISO 9001. Quality management systems – Requirements.
• DS/EN ISO 9606-2, Qualification test of welders – Fusion
welding – Part 2: Aluminium and aluminium alloys
• DS/EN ISO 10042, Welding – Arc-welded joints in aluminium
and its alloys – Quality levels for imperfections
• DS/EN ISO 14001. Environmental management systems.
• DS/EN ISO 14731, Welding coordinator – Tasks and
responsibilities.
• DS/EN ISO 15609-1, Specification and qualification of welding
procedures for metallic materials - Welding procedure
specification - Part 1: Arc welding.
• DS/EN ISO 15614-2, Specification and qualification of welding
procedures for metallic materials - Welding procedure test - Part
2: Arc and gas welding of aluminium and its alloys.

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3. DEFINITIONS
SWP The term “SWP” means Siemens Wind Power A/S.
IWE / EWE The term “IWE / EWE” means International Welding Engineer / European
Welding Engineer.
IWT / EWT The term “IWT / EWT” means International Welding Technologist /
European Welding Technologist.
Construction The term “construction” means all welded constructions for SWP, except
towers.
PO The term “PO” means Purchasing Order.
WPS The term “WPS” means Welding Procedure Specification.
WPQR The term “WPQR” means Welding Procedure Qualification Record.
NDT The term “NDT” means Non- destructive testing.
VT The term “VT” means Visual testing.
PT The term “PT” means Penetrant testing.
CI The term “CI” means Control Instruction.
ECN The term “ECN” means Engineering change note.
FCS The term “FCS” means Factory control system

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4. Quality Assurance System

4.1. Factory control The supplier shall have a factory control system in compliance with ISO
system – General 3834-3 and with the additional requirements given in 4.1.1
4.1.1. Additional The manufacturer must have at his disposal an appropriated welding
requirement to coordination personnel who:
ISO 3834-3 • The welding coordinator must be qualified, in accordance with
DS/EN ISO 14731 given for IWE/EWE or IWT/EWT personnel.
• The welding coordinator personnel must be affiliated to the
production during the entire production period.
• The welding coordinator personnel must have positions in the
organization that enables the persons to act, independent of the
production.
• The tasks and responsibilities of the coordination must be clearly
defined.
4.2. NDT-Personnel Personnel performing VT and PT shall be qualified in accordance with EN
473 or with similar qualifications, with the additions listed hereafter:
• An individual certified to level 1 is required to carry out NDT under
direct supervision of level-2 or level-3 personnel.
• The NDT-operator must be certified by an accredited body.
• NDT according to level WQ-D can be done by internal QA-
personnel or by the welder, if the supplier has no QA-department.
5. Technical requirements
5.1. General The product shall meet the technical requirements specified in section 5
including all sub-clauses, of this specification.
5.2. Base Material
5.2.1. General The bill of material will specify the materials required. All material shall be
delivered with a 3.1 inspection document according to EN ISO 10204

The material shall be Inspected and delivered in accordance with the

standards

Mechanical properties shall meet the requirements of the given standards

Tolerances on dimensions and shapes shall meet the requirements given

in the standards

The base material shall have the heat/charge number stamped with soft
nose, or painted onto each plate or profile, to ensure traceability.
5.2.2. Use of The use of alternative material must be in accordance with the Appendix
alternative grade 3
and quality
5.3. Manufacturing process
5.3.1. Cutting If plasma or water-jet cutting is used, the edges shall be ground clean to
remove any traces of impurities. The area shall be ground flush to match
the required geometry.
5.3.2. Grinding. All grinding discs shall be those designed specifically for aluminium and

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shall not be used on other materials previously.

5.3.3. Temporary It is not acceptable to weld on temporary attachments to the construction.
attachments
5.3.4. Cut outs in base It not acceptable to make repair of the base materiel by use of welding
material.
5.3.5. Misalignment If not specified by the drawing, the misalignment of a joint must comply
with the requirements given in ISO 10042.
5.3.6. Welding Welding shall be performed by qualified welders and by use of qualified
WPS’s.
5.3.7. Finish of welded Before the construction leaves the production for surface treatment, it must
constructions be ensured that:
• The surface must be free of all welding spatter and slag.
• All edged must be ground with fiber disc or lamella disc grit 80 to
one of following criteria:

o de-burr to radius 2 mm

o chamfer to 2x1,5x22,5°

5.4. Qualification of Specification and qualification of welding procedure specifications shall be

welding performed according to the requirements stated in Appendix 1 and
processes Appendix 2 of this purchasing specification.
5.5. Qualification of Welders and tack welders shall be qualified in accordance with DS/EN ISO
welders 9606-2 or standards with similar level of qualifications.
5.6. Weld quality
5.6.1. Quality level for The quality requirements for welds are specified in tabel 1, The specific
welds quality level for each welding is given by the drawings of the specific
construction.

Table 1, Quality level of welds

Level Requirement to be met.
WQ-B Level B: EN ISO 10042
WQ-C Level C: EN ISO 10042
WQ-D Level D: EN ISO 10042

5.6.1.1. Sequence for The sequence for performing NDT shall be:
performance of • Visual Testing (VT)
NDT. • Penetrate Testing (PT)
•
5.6.1.2. Requirement to EN 12062 must be used for determination of examination techniques and
examination their acceptance levels for VT and PT.
techniques

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5.6.1.3. Extent and Test VT PT

acceptance
criteria for NDT WQ-B 100% according to: 100% according to: EN 571-1 and
EN ISO10042 Acceptance level: EN 1289
WQ-C 100% according to: 20 % according to: EN 571-1 and
EN ISO10042 Acceptance level: EN 1289
WQ-D 100% according to: 0%
EN ISO10042
5.7. Traceability and documentation
5.7.1. Traceability If any test documentation is made for a given construction, this must be
traceable to the construction.
5.7.2. Traceability A traceability number must be stamped in to the construction with a “soft
number nose stamp”. The traceability number must consist of the supplier no., the
item no. and a consecutive no. (XXXX-XXXX-XXXX)

NOTE: Do not use welding

5.7.3. Documentation The documentation shall be made as one package for each construction.
package This shall consist of:
• VT-report
• PT-report
• Control sheets from SWP
5.7.4. Documentation It shall be ensured that:
send to SWP • As-built documentation is forwarded to the E-mail address:
qc.pg@siemens.com.

The syntax in the E-mail’ subject shall be:

“[SSSS]- [XXXX], [YYYY]”
where
[SSSS] Name of main drawing
[XXXX] As-built doc
[YYYY] Is the vendor name
The syntax of the pdf-file shall be
“[VEN]_[DWG]_[PO]_ [ID]”
where
[VEN]: is the vendor number.
[DWG]: is the drawing number.
[PO]: Purchase order number
[ID]: Identifications number of the construction
5.7.5. Receiving of If any documentation is made, this documentation shall be send to SWP
documentation as soon as possible, but no later than 1 week after shipping the
construction to SWP.

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6. Modifications
6.1.1. PS 1005341- First issue.
30201

Appendix 1 - Qualification of welding procedure

1.1.1. Qualification of The qualification of WPQR’s shall in accordance with DS/EN ISO 15614-2
welding and with the following additional requirements given in 1.1.1.1 to 1.1.1.9
procedure
(WPQR)
1.1.1.1. Grouping of base Aluminium alloys shall be grouped as given in section 3 of DS/EN ISO/TR
material. 15608
1.1.1.2. Acceptable The following welding processes according to DS/EN ISO 4063 are
welding acceptable:
processes • 131 - Metal inert gas (MIG), or gas metal arc welding
(GMAW)
• 141 - Tungsten inert gas (TIG), or gas tungsten arc welding
(GTAW)
• 15 - Plasma arc welding (PAW)
1.1.1.3. Welding For any combination of the base material used by SWP:
Consumables • The filler metal alloy shall be EN AW 5356
• Shielding gas shall be an argon/ helium mixture for all multi-pass
welds. Single pass welds can be either 100% argon or an
argon/helium mixture.
1.1.1.4. Preheat and Preheat and interpass temperatures shall be in accordance with DS/EN
interpass 1011-4, Table 1. These values shall be recorded on the WPQR and
temperatures monitored during production.
1.1.1.5. pWPS A pWPS acc. to DS/EN ISO 15609-1 must be made with use of ISO/TR
17671-1 and ISO/TR 17671-4 before performing the weld test.
1.1.1.6. Base material The base material used for testing shall be supplied with a 3.1 inspection
used for test. document.
1.1.1.7. Re-qualifying of The WPQR shall be re-qualified by making a new weld test if one of the
WPQR following parameters is changed:
• Wire (type, trade name, diameter).
• Gas mixture.
• Preheat.
1.1.1.8. Restriction of the A WPQR made as a multi-pass joint, with different processes being used
WPQR for the number of passes, only qualifies a WPS for this combination.

The WPQR can not be split up into the used processes, and then qualify a
WPS on each process.
1.1.1.9. Verification of The welding of the welding procedure test pieces must be verified by an
welding WPQR. external third party that will be responsible for ensuring that the correct
welding parameters used during the welding are transferred to the WPQR
– documentation. Furthermore, the third party must verify that all non-
destructive and destructive tests are performed in accordance with the
relevant standards, and conclude whether the test results are in
accordance with the requirements stated in this section.

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Appendix 2 - Welding procedure specification

1.1.2. Producing a A WPS shall be produced in accordance with 15609-1, with the additional
WPS requirements given in 1.1.2.1 to 1.1.2.2
1.1.2.1. Restriction of Calculation and restriction of the heat input shall be as given:
heat input • The upper and lower limit for heat input is ±25% of the average
heat input used for welding the test piece (WPQR). Heat input
average shall be calculated for:
o root passes
o filler passes
o cover passes
1.1.2.2. Maximum angle For all welding positions, which are specified in the standard as horizontal
of down slope in the welding direction, a maximum of 15 degrees down slope is
permitted.

Appendix 3 - Material defined by different standards

List of corresponding base material.
Standards EN AW ASTM W. no. DIN Old drawing Indications on the
AA from SWP surface pattern
Plates 5754 (H111) 5754 (H111) 3.3535.10 AlMg3 AlMg3 No pattern
(W19)
5083 (H111) 5083 3.3347.10 AlMg4,5Mn N/A No pattern
(O) (W28)

5754 (H114) 5754 (H114) 3.3535.26 AlMg3 five bar Quintet 5/7 alu
(F24)

Tubes 6060 T6 6060 T6 3.3206.26 AlMg0,5 EN 6060 *1 No pattern

6063 T6 6063 T6 AlMg0,5 EN 6063 *1

*1 on the drawings where material is written as EN 6060/63, bought base materials can be use.

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