DNVGL-SE-0441 Type And Component Certification Of Wind .
SERVICE SPECIFICATIONDNVGL-SE-0441Edition June 2016Type and component certification of windturbinesThe electronic pdf version of this document found through http://www.dnvgl.com is the officially binding version.The documents are available free of charge in PDF format.DNV GL AS
FOREWORDDNV GL service specifications contain procedural requirements for obtaining and retaining certificates andother conformity statements to the objects, personnel, organisations and/or operations in question. DNV GL AS June 2016Any comments may be sent by e-mail to rules@dnvgl.comThis service document has been prepared based on available knowledge, technology and/or information at the time of issuance of this document. The use of thisdocument by others than DNV GL is at the user's sole risk. DNV GL does not accept any liability or responsibility for loss or damages resulting from any use ofthis document.
Changes – currentCHANGES – CURRENTGeneralThis is a new document.Service specification, DNVGL-SE-0441 – Edition June 2016DNV GL ASPage 3
CHANGES – CURRENT . 3Sec.1Sec.2Introduction . 71.1General.71.2Objective 1.3.91.3.101.3.111.4Definitions.111.4.1 Terminology and definitions. 111.4.2 Abbreviations and symbols . 121.5References .131.5.1 General . 131.5.2 DNV GL service documents. 131.5.3 International standards and other referenced publications . 141.6General procedures .141.6.1 Wind turbine development phases . 141.6.2 Applicant . 151.6.3 Certification body . 151.6.4 Deliverables . 151.6.5 Customer - DNV GL interaction . 161.6.6 Certification requirements - quality management . 171.6.7 Standards, codes and additional requirements . 171.6.8 Surveillance/inspection general requirements . 17of application .9General .9Occupational health and safety .9Extreme temperature conditions .9Condition monitoring systems.9Fire protection systems.9Electromagnetic compatibility .9Lifetime extension. 10Grid code compliance . 10Service and maintenance activities . 10Training systems . 10Shop approvals . 10Service overview . 182.1General.182.2Assessment documents .182.3Deviations .182.4Certification modules .182.5D level certification .192.6C level certification.202.6.1 General . 202.6.2 Prototype certificate . 202.6.3 Design certification module - level C . 202.6.4 Test certification module - level C . 202.6.5 Manufacturing certification module - level C. 212.7A and2.7.12.7.22.7.32.7.4B level certification .21General . 21Provisional type certificate. 21Type certificate. 21Design certification module - level A or B . 22Service specification, DNVGL-SE-0441 – Edition June 2016DNV GL ASPage 4ContentsContents
Sec.3Test certification module - level A or B . 22Manufacturing certification module - level A and B. 232.8Site level certification.252.8.1 General . 252.8.2 Site specific type certificate . 252.8.3 Design certification module - site level . 252.8.4 Test certification module - site level . 262.8.5 Manufacturing certification module - site level. 262.9Component certificates.26Detailed service description . 273.1General.273.2Design basis .273.3Design certification module for levels A, B or site .283.3.1 General . 283.3.2 Control and protection system . 283.3.3 Loads and site conditions . 293.3.4 Rotor blades. 303.3.5 Machinery and housings . 303.3.6 Support structures . 313.3.7 Electrical installations . 313.3.8 Manuals. 313.4Design certification module for C level .323.4.1 General . 323.4.2 Documents to be submitted. 323.5Design certification module for D level .333.5.1 General . 333.5.2 Documents to be submitted. 333.6Test certification module .343.6.1 General . 343.6.2 Type inspection . 343.6.3 Test of wind turbine behaviour. 353.6.4 Load measurements . 353.6.5 Rotor blade tests . 353.6.6 Gearbox and other component tests . 363.6.7 Noise emission measurements (optional) . 363.6.8 Power performance measurements (optional) . 373.6.9 Electrical characteristics measurements (optional) . 373.6.10 Electromagnetic compatibility measurements (optional) . 373.7Manufacturing certification module .383.7.1 General . 383.7.2 Quality management system . 383.7.3 Shop approval . 383.7.4 Rotor blade manufacturing . 403.7.5 Gearbox manufacturing . 413.7.6 Hub and Nacelle assembly. 423.7.7 Tower manufacturing. 433.7.8 Manufacturing of other critical components. 44Service specification, DNVGL-SE-0441 – Edition June 2016DNV GL ASPage 5Contents2.7.52.7.6
Certificates and statements . 464.1General.464.2Modifications and recertification .464.3Integration of component certificates .474.4Customer obligations .474.5Rules for the use of the certificate .48App. A Certification mark and sample certificate . 49A.1 Certification mark . 49A.2 Sample certificate and statement of compliance . 50App. B Manuals. 52B.1General. 52B.2Transport and installation manual. 52B.3Commissioning manual . 54B.4Operating manual. 56B.5Maintenance manual . 58Service specification, DNVGL-SE-0441 – Edition June 2016DNV GL ASPage 6ContentsSec.4
SECTION 1 INTRODUCTION1.1 GeneralLessons learned from certification projects specifically component and type certification of onshore andoffshore wind turbines realised over the last years were taken into account during the development of thisservice specification.The pressure on the reduction of cost of energy is high in the renewable energy sector. Focusing on reducingcosts increases the risk of reducing safety, quality and reliability. Hence, the independent evaluationbecomes a higher importance to ensure a state-of-the-art level of safety, quality and reliability.Thus DNV GL’s type and component certification scheme has been adapted to meet market needs andexpectations.This service specification (SE) specifies DNV GL’s services for type and component certification of onshoreand offshore wind turbines. It serves as a— facilitator to identify and apply relevant technical standards— guidance for engineers from concept to serial production— description to meet the state-of-the-art for wind turbines, and to go beyond— common communication platform for describing the scope and extent of activities performed forcertification of a wind turbine and its components— contractual basis for the certification of wind turbines.This certification scheme and the IEC 61400-22 scheme are aligned with respect to the technicalrequirements and the certificates, however, this scheme is adjusted to reflect the actual productdevelopment sequence. For example, the test certification modules also include the test part of the finalevaluation according to IEC 61400-22.The conceptual and prototype stages of the development process are covered considering technologyqualification and risk analysis.The interface to project certification is addressed through the introduction of a new type certificate whichshall be site/product specific, see [2.8].The wind farm design lifetime is typically 20 years. The cost reduction pressure in the power sector makesit necessary to consider also increasing the design lifetime for example to 25 or 30 years. The wind farmdesign lifetime may be chosen and shall be taken into consideration from the project beginning through allrelevant phases.The certification services are adjusted to follow the wind turbine or component development phases fromconcept to serial production, see Figure 1-1.Statement rtificateTypeCertificateSite imeExtensionDecommissioningFigure 1-1 Certification services aligned with the development processThese development phases may be supported during the wind turbine development by respectivecertification deliverables. The overview in Figure 1-1 provides guidance in selecting the appropriatecertification deliverables.This service specification is divided into four main sections:Sec.1Sec.2Sec.3Sec.4gives an introduction to the service specification.gives an overview of the certification scheme and its certification modules.gives a detailed description of the certification scheme and its modules.describes the final deliverables as well as the maintenance of the certificates.Sec.1 covers type and component certification. Sec.2 to Sec.4 (as well as the appendices) focus on typecertification to ease reading; component certification may be performed analogously by application of theelements and modules as listed in Sec.2 to Sec.4 (as well as appendices).Service specification, DNVGL-SE-0441 – Edition June 2016DNV GL ASPage 7
The DNV GL document system is organized according to a three-level document hierarchy, with these mainfeatures:— Principles and procedures related to DNV GL’s certification and verification services are separated fromtechnical requirements and are presented in DNV GL service specifications (SE). Service specificationspresent the scope and extent of DNV GL’s services.— Technical requirements are issued as self-contained DNV GL standards (ST). Standards are issued asneutral technical standards to enable their use by national authorities, as international codes and ascompany or project specifications without reference to DNV GL’s services.— Associated product documents are issued as DNV GL recommended practices (RP). Recommendedpractices provide DNV GL’s interpretation of safe engineering practice for general use by industry.Guidance note:The latest revision of all DNV GL documents may be found in the ”rules and standards” pages on the DNV GL website o-t-e---1.2 ObjectiveThis document has a dual objective: it serves as a publicly available description of DNV GL’s services relatedto type and component certification of wind turbines and secondly it shall be referred to as a contractualdocument in the certification contract between the manufacturer and DNV GL.The document specifies the obligations of the customer, usually the manufacturer, when his wind turbineor wind turbine component/system shall be certified. The document also specifies the obligations of DNV GLand the tasks carried out by DNV GL for certification.The aim of this document is to provide a certification scheme which addresses individual needs in thevarious wind turbine development phases, reduce the costs over the lifetime and at the same time to notcompromise the added value and quality delivered by certification. Additional certification services may bechosen to enhance the functionality, reliability and value even more. The service specification serves alsoto detail and clarify the certification activities and facilitate achieving compliance.The main differentiators of the DNV GL certification scheme to other existing schemes are:— more guidance and descriptions to facilitate application— all wind turbine relevant topics addressed in one service specification— all wind turbine development phases are supported by the certification scheme— certification may be tailored by adding multiple optional services.Depending on the specific individual interests and agreed scope the benefits by applying this servicespecification may be among others:— independent approval of the wind turbine and/or component(s) to reduce the own risk in developing anddesigning— building of trust in the design and construction— reducing costs by early detection of non-conformities— confidence in technical integrity— confirmation of requirements as stated by project developers, investors, operators, manufacturers,governmental and non-governmental organisations— prove by an independent body to meet the national and international acknowledged state-of-the-art andto ease market entry— utilise statements and certificates for authorisation by governmental bodies— prove to investors or insurer that third party approval was successfully performed— securing sustainable energy production throughout life-cycle— minimising technical risks— document stepwise the maturity of the wind turbine development project— mitigate the risks to environment and people.Service specification, DNVGL-SE-0441 – Edition June 2016DNV GL ASPage 8
1.3 Scope of application1.3.1 GeneralThis specification applies to type certification of wind turbines as well as for component certification.Component certification as a term used in this service specification covers e.g. major and minorcomponents, systems, single parts or assemblies used in a wind turbine or attached to it. The mandatorycertification modules comprise design, manufacturing and testing at different stages of the wind turbinedevelopment process. An overview of the certification modules is given in Sec.2 and a more detaileddescription is given in Sec.3.This specification together with referred DNV GL standards and recommended practices represents acompletely revised and expanded version of GL-IV-1 and GL-IV-2; both with a history of 30 years.The services described in [1.3.2] - [1.3.11] below are optional services related to type and componentcertification. They may be added to component or type certification to extend the use of respectivecertificates by e.g. adding more options or markets.1.3.2 Occupational health and safetyThe DNV GL certification according to this service specification does not cover compliance with internationalor national occupational health and safety requirements. The verification of compliance with health andsafety requirements such as EN 50308 and or national requirements may optionally be included in thecertification scope.Guidance note:The compliance with European Directives including CE marking requirements is not covered by this certification -1.3.3 Extreme temperature conditionsFor site conditions including altitude outside the standard site conditions as defined in DNVGL-ST-0437,there shall be additional considerations for design and operation of wind turbines. DNVGL-RP-0363 coversthe main aspects influenced by extreme temperature including air density, material properties andlubrication. It may be used to extend the normal temperature range of a component or wind turbine to verylow and/or very high temperatures.1.3.4 Condition monitoring systemsThe certification of condition monitoring systems may be included in the type or component certification orit may be delivered as an independent service. The DNV GL certification service is described in the DNV GLservice specification DNVGL-SE-0439.1.3.5 Fire protection systemsThe certification of fire protection system may be included as part of the type certification for a wind turbineor it may be offered as an independent service, i.e. certification of the fire protection. The service isdescribed in detail in DNVGL-SE-0077.1.3.6 Electromagnetic compatibilityThe wind turbine control and protection system shall in general be immune against the electromagneticemission levels within the wind turbine, see also DNVGL-ST-0438.The certification of electromagnetic compatibility (EMC), i.e. immunity and emission may be included in thetype certification of a wind turbine or delivered as a separate certification service. The DNV GLrecommended practice DNVGL-RP-0440 may be used as reference.Service specification, DNVGL-SE-0441 – Edition June 2016DNV GL ASPage 9
1.3.7 Lifetime extensionWind turbines are designed for a finite service life. Usually a design lifetime of 20, 25 or 30 years is takenas a basis for the design.If a wind turbine or wind farm shall be operated beyond its design lifetime, the wind turbine shall beassessed with regard to its potential for lifetime extension for the specific site conditions.Different approaches may be taken to provide the necessary verification and shall preferably utilise theexistence of a Type Certificate. Further information is available in the DNVGL-SE-0263.Figure 1-2 Lifetime extension1.3.8 Grid code complianceThe certification of grid code compliance for a wind turbine shall be based on measurements of electricalcharacteristics including fault ride-through (FRT) as well as verification of the wind turbine model for use ingrid simulations by validation against test results. The outcome shall be a type certificate for the windturbine or an additional component or equipment certificate.The DNV GL service for grid code compliance certification is delivered independently of the wind turbine typeand component certification as described in this service specification. Further information about grid codecompliance (GCC) is given in DNVGL-SE-0124.1.3.9 Service and maintenance activitiesDNV GL provides certification services for service and maintenance activities for the wind energy industry.The service is delivered independently of other services and is described in DNVGL-SE-0448.1.3.10 Training systemsDNV GL provides certification of training system established within the renewable energy sector e.g.covering rescue training programs. The service is described in the GL Technical Note for Certification ofTraining Programs and Training Systems in the Renewable Energy Industry.1.3.11 Shop approvalsThe DNV GL shop approval is providing third party verification of a workshop and/or single fabricationprocedure. It may be applied for manufacturing of components, repair procedures and single manufacturingprocedures. Desired target is time and cost reduction during the certification process. The service isdescribed in DNVGL-SE-0436.Service specification, DNVGL-SE-0441 – Edition June 2016DNV GL ASPage 10
1.4 Definitions1.4.1 Terminology and definitionsTable 1-1 Definitions of verbal formsVerbal formsDefinitionshallverbal form used to indicate requirements strictly to be followed in order to conform with the documentshouldverbal form used to indicate that among several possibilities one is recommended as particularlysuitable, without mentioning or excluding others, or that a certain course of action is preferred but notnecessarily requiredmayverbal form used to indicate a course of action permissible within the limits of the documentTable 1-2 Definitions of termsTermDefinitioncertificationaction by a certifying body, providing written assurance that adequate confidence is provided thatthe subject of the certification, i.e. the wind turbine, is demonstrably in conformity with a specificstandard or other normative documentThe term designates all the activities associated with the process leading to the issue of acertificate. The scope of work is defined by the certifying body or by a regulatory body.certificationschemecertification scheme, i.e. a sequence of phases or modules to be completed prior to the issue of acertificatecomponentcertificate (CC)a certificate issued by a certifying body, here DNV GL, when it has been demonstrated that aproduct type in question, here a wind turbine component, assembly or system, complies with theapplicable regulationsThe component certificate shall allow the customer to manufacture certified wind turbinecomponents or systems during the period of validity of the certificate.componentcertificationcertification of specific wind turbine components such as rotor blade, generator, gearbox, brake,coupling, pitch system, yaw system, nacelle frame, tower and rotor–nacelle assemblyComponent certification covers relevant modules of type certification with the extent dependingon the component/system in question.customerDNV GL’s contractual partner, usually the certification applicantfinal certificationreportfinal report, issued as reference document for the type or component certificate, and providingdocumentation of the evaluation of the elements and modules in the type or componentcertificationThe report includes a reference list of all supporting product documentation, an evaluation ofwhether the detailed documentation is complete and all relevant requirements are confirmed bytype test results, and a review of the final product documentation.manufacturerthe manufacturer of the wind turbine or of any wind turbine component or system in questionoutstanding issuethe term outstanding issue is used to denote a deviation from standards and technicalrequirements specified in the certification agreement, and which needs to be completed for fullcomplianceprototypecertificate (PT)the prototype certificate shall allow the customer to manufacture, install and operate a prototypewind turbine during the period of validity of the certificaterotor nacelleassembly (RNA)the rotor nacelle assembly includes all components/systems located above the tower top flangestatement ofcompliance (SoC)a statement signed by a qualified party affirming that, at the time of assessment, a product or aservice meets specified requirementsstatement offeasibility (SoF)a statement signed by a qualified party affirming that, at the time of assessment, a new productunder development was considered conceptually feasible and suited for further development andqualificationsubstructurethe structure connecting the tower with the foundation structure for an offshore wind turbine e.g.jacket structuresupport structurethe support structure comprising the tower, the substructure and the foundation structuretype certificate(TC)a certificate issued by a certifying body, here DNV GL, when it has been demonstrated that aproduct type in question, here a wind turbine type, complies with the applicable regulationsThe type certificate shall allow the customer to manufacture certified wind turbines during theperiod of validity of the certificate.Service specification, DNVGL-SE-0441 – Edition June 2016DNV GL ASPage 11
Table 1-2 Definitions of terms (Continued)TermDefinitiontype certificate –level A (TC A)a certificate issued upon successful completion of the certification modules for level Atype certificate –level B (TC B)a certificate issued upon successful completion of the certification modules for level Btype certificate –site level (TC site)a certificate issued upon successful completion of the certification modules for the site levelverificationan evaluation or assessment to confirm that an activity, a product or a service is in accordancewith specified requirementsThe type certificate – level B shall have outstanding issues with no safety implication during thevalidity period.The site specific type certificate shall list the wind turbines covered by the certificate.Upon confirmation according to an agreed scope of work for the verification service, DNV GL shallissue a statement of compliance or a certificate.wind turbinesystem which converts kinetic energy in the wind into electrical energyThe wind turbine comprises of the rotor nacelle assembly, the tower and the electrical systemincluding the wind turbine electrical terminals.Figure 1-3 Definition of offshore and onshore wind turbines1.4.2 Abbreviations and symbolsAbbreviations and symbols used in this servi
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