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GL风电规范，风电认证规范.pdf
Contents
List of Abbreviations
Symbols and Units
Symbols and Units Used in the Guideline
Subscripts
Auxiliary symbols
Prefixes
Chapter 1
Scope
General
Transition periods
Deviations
National requirements
International guidelines
Assessment documents
Extent of Certification
Subdivision of the certification
C – Design Assessment
A – and B – Design Assessment of the type of a wind turbine
Site-specific Design Assessment
Type Certificate for the type of a wind turbine
Project Certificate
Assessment of prototypes (C – Design Assessment)
General
Scope and validity
Documents to be submitted
Scope of assessment
A – and B – Design Assessment
Scope and validity
Assessment of the design documentation
Witnessing and Tests
Site-specific Design Assessment
Scope
Site-specific assessment
Type Certificate
Scope and validity
Quality management system
Implementation of the design-related requirements in production and erection
Prototype test
Project Certificate
Scope and validity
Surveillance during production
Surveillance during transport and erection
Surveillance of commissioning
Periodic Monitoring
Re-certification
Basic Principles for Design and Construction
General
Definitions
Loads
Limit states
Ultimate limit state
Serviceability limit state
Partial safety factors for loads
Partial safety factors for materials
Analysis procedure
Mathematical model
Appendix 1.A National Requirements in Germany
General
Material requirements
Requirements for manufacturers
Analysis
Guidelines for measurements
Analysis concept
Towers
Foundations
Wind conditions
General
Wind zones
Reference wind speeds
Annual average and turbulence intensity
Appendix 1.B National Requirements in Denmark
General
Regulations and standards
Appendix 1.C National Requirements in France
General
Building permission procedure
Appendix 1.D National Requirements in the Netherlands
General
Preliminary standard NVN 11400-0
Scope
Load assumptions
Appendix 1.E National Requirements in India
General
Certification categories
Category I
Category II
Category III
TAPS-2000 requirements
Category I and II
Category III
External conditions for India (corresponding to TAPS-2000, Appendix 2)
Appendix 1.F IEC and CENELEC Standards
General
List of normative documents in the area of wind energy
Supply sources
Chapter 2
General
Assessment documents
Systematic consideration of possible faults
Description of the controller for approval of the load assumptions
Control and Safety System
General
Definitions
Control concept and control system
Safety concept and safety system
Braking system
Clearance
Rotational speed of the rotor
Power
Wind speed
Wind direction and yaw error
External power supply, mains failure
Locking devices
Requirements and design concept
General safety concept
Single failure
Redundancy
Control and safety systems
Control system
Safety system
Braking systems
Braking system requirements
Wind turbine with mechanical brake and non-independent blade pitching system
Selection of the braking principle
External power supply
Torque-limiting components
Protective and Monitoring Devices
General
Limiting values, control system
General
Rotational speed
Measurement of rotational speed
Operational reliability of the measurement system
Excessive speed and the reaction of the control system
Rotational speed exceeding activation speed
Behaviour following activation of the safety system
Power
Measurement of power
Measurement of power for the control system
Monitoring the power for the safety system
Exceeding the over-power PT or the rated power Pr
Exceeding the activation power PA
Automatic start-up
Wind speed
Requirements
Measurement of wind speed
Exceeding the cut-out wind speed
Exceeding the short-term cut-out wind speed
Automatic start-up
Control during faulty wind speed measurements
Shock
General
Measurement of shock
Operational safety
Exceeding the limiting value
Operational vibration monitoring
General
Measurement of vibrations
Determination of the limiting values
Exceeding the limiting value
Automatic start-up
Mains failure/load shedding
General
Operation following mains failure
Operation after restoration of mains
Short circuit
Requirements
Operation following a short circuit
Monitoring the generator temperature
Requirements
Limiting values
Operation after excess temperature
Condition monitoring of the braking systems
General
Measurement parameters
Safety requirement
Operation after a fault is detected
Cable twisting
Requirements
Measurement parameter
Limiting value
Operation after excessive twisting
Yaw system
Measurement of wind direction
Operation for faulty wind direction measurements
Active yaw system
Passive yaw system
Frequency and voltage
Emergency push button
General
Requirements
Operation after activation of Emergency push button
Faults in machinery components
Operation of a cold plant
Operativeness of the control system and data storage
Automatic detection of icing-up
Ice sensor
Operation on detection of icing-up
Safety equipment (locking devices) for maintenance
Requirements
Design of the locking devices
Safety requirements
Activation of the locking device
Appendix 2.A Interaction of the Control and Safety Systems
Chapter 3
Requirements for Manufacturers
General
Works equipment
Personnel
Shop approval
General
Application for approval
Approval procedure, period of validity
Change in approval conditions
Quality Management
General
Definitions
Requirements for the quality management system
Certification of the QM system
Materials
General requirements
General
Material tests
Corrosion protection
General
Design for corrosion protection
Material selection
Coatings
Metallic materials
Structural steels
Cast steel
Stainless steels
Forging steels
Standards
Production processes
Delivery condition, heat treatment
General forging quality
Mechanico-technological testing
Non-destructive testing
Cast iron
Aluminium alloys
Wrought alloys
Cast alloys
Fibre-reinforced plastics (FRP)
Definitions
General
Reaction resin compounds
Reinforcing materials
Core materials
Prepregs
Adhesives
Approval of materials
Wood
Types of wood
Material testing and approval
Glues and adhesives
Surface protection
Wood preservatives
Mechanical fasteners
Reinforced concrete and prestressed concrete
General
Standards
Raw materials for concrete
Cement types
Concrete aggregate
Added water
Admixtures
Additives
Building materials
Concrete
Concrete-reinforcing steel
Prestressing steel and prestressing procedure
Grouting mortar
Steel for fixtures and prestressed high-tensile bolts
Durability of the concrete
Production and Testing
General
Welding
Prerequisites of the works
Welders, welding supervision
Welding method, welding procedure tests
Welding fillers and auxiliary materials
Weld joint design
Execution and testing
Laminating fibre-reinforced plastics
Requirements for manufacturers
Laminating workshops
Store-rooms
Processing requirements
Building-up the laminate
Curing and tempering
Sealing
Adhesive bonding
Adhesive joints
Assembly process
Manufacturing surveillance for FRP
General
Incoming inspection
Production surveillance
Component checks
Wood processing
Manufacture of wooden rotor blades
General
Mould requirements
Preparing the wood
Layer build-up and bonding
Wood preservation
Surface protection
Blade connections
Manufacturing surveillance of wooden rotor blades
General
Incoming inspection
Visual checks
Making and working the concrete
Proportioning and mixing the raw materials
Transport, pouring and compacting
Curing
Concreting in cool or hot weather
Formwork and its supports
Forms
Stripping
Quality control
General
Tests during construction
Conformity checks
Inspection and maintenance of the completed structure
Chapter 4
Fundamentals
General
Assessment documents
Design methods
Safety classes
External Conditions
General
Wind turbine classes
Wind conditions
Normal wind conditions
Wind speed distribution
Normal wind profile model (NWP)
Normal turbulence model (NTM)
Extreme wind conditions
Extreme wind speed model (EWM)
Extreme operating gust (EOG)
Extreme direction change (EDC)
Extreme coherent gust (ECG)
Extreme coherent gust with direction change (ECD)
Extreme wind shear (EWS)
Other environmental conditions
Other normal environmental conditions
Other extreme environmental conditions
Temperature
Lightning
Ice
Earthquakes
Electrical power network conditions
Calculation of the Loads
General
Loads
Inertial and gravitational loads
Aerodynamic loads
Operational loads
Other loads
Design situations and load cases
Power production (DLC 1.0 to 1.13)
Power production plus occurrence of fault (DLC 2.1 to 2.3)
Start-up (DLC 3.1 to 3.3)
Normal shut-down (DLC 4.1 to 4.2)
Emergency shut-down (DLC 5.1)
Parked (standstill or idling) (DLC 6.0 to 6.6)
Parked plus fault conditions (DLC 7.1)
Transport, erection, maintenance and repair (DLC 8.1 to 8.3)
Load calculations
General influences
Operational influences
Operation within the resonance range of the tower
Partial safety factors for loads
Partial safety factors for the loads in the analysis of the serviceability limit state
Partial safety factors for the loads in the analysis of the ultimate limit state
Partial safety factor for the loads in the analysis of the fatigue strength
Partial safety factor for the loads in the deflection analysis
Special partial safety factors
Site-Specific Assessment
Site assessment
General
Determination of the wind conditions
Determination of other environmental conditions
Determination of the electrical power network conditions
Assessment of the foundation / soil properties
Risk analysis
Wind farm influence
Documents required for determination of the wind farm influence
Calculation models for determination of the wind farm influence
Influence of earthquakes
General
Acceleration
Load case definition
Analysis
Complex terrain
General
Definition
Wind conditions
Extreme temperatures
Influence of extreme temperatures
Load assumptions
Corrosion, erosion
Assessment and comparison
Comparison through wind data
Comparison of the loads
Appendix 4.A Coordinate Systems
Blade coordinate system
Chord coordinate system
Hub coordinate system
Rotor coordinate system
Tower top coordinate system
Tower bottom coordinate system
Appendix 4.B Evaluation of the Loads
Presentation of load case definitions
Presentation of the results
General
Extreme loads
Fatigue loads
Further evaluations
Appendix 4.C Fault in the Power System
Appendix 4.D Design Parameters for Describing Wind Turbine Class S
Plant parameters
Wind conditions
Conditions of the electrical power network
Other environmental conditions (where necessary)
Chapter 5
General
Determination of the Stresses
General notes on the loading of the structure
Method of analysis
General
Nominal stress approach
Structural stress approach
Influences
Dynamic calculation
Quasi-static calculation
Metallic Materials
Material properties
General strength analysis
General
Method of analysis
Fatigue analysis
General
Methods for fatigue analysis
General
Simplified fatigue analysis
Damage calculation
Notes on the superposition of multi-axial stress conditions
Equivalent stress hypotheses
S/N curves for dimensioning
S/N curves for welded steel structures and bolted connections
S/N curves for the design of non-welded forged and rolled parts
S/N curves for the design of cast steel and spheroidal graphite cast iron
S/N curves for the design of aluminium parts
Serviceability analysis
Partial safety factors
Deformation analysis
Concrete
Material properties
Characteristic values
Partial safety factors gM
Ultimate limit states
Fracture and stability failure
Fatigue analysis
Serviceability Limit State
Partial safety factors
Deformation analysis
Stress Limit State
Crack width limitation
Fibre Reinforced Plastics (FRP) and Bonded Joints
General
Materials
Requirements for manufacturers
Requirements for the materials
Characteristic values
Partial safety factors for the material
Analyses
General
Analysis for fibre failure
Analysis for inter-fibre failure
Stability analysis
Glass Fibre Reinforced Plastics (GRP)
Carbon Fibre Reinforced Plastics (CRP)
Bonded joints
Wood
Appendix 5.A Strength Analyses with the Finite Element Method
General
Introduction
Determining the objective, type and extent of the strength analysis
Global deformations and stresses
Local deformations and stresses
Locally increased stresses
Modelling of the structure
Extent of the model
Selecting the elements
Element subdivision
Simplifications
Boundary conditions and supports
Checking the input data
Loading of the structure
General
Modelling the loads
Checking the load input
Calculation and evaluation of the results
Plausibility of the results
Deformations
Stresses
Fatigue strength
Presentation of the results
Documentation of FE analyses for the certification of wind turbines
General
General requirements for the documentation
Special requirements for the documentation
Results
General
Partial results
Final results
Chapter 6
General
Rotor Blades
General
Designs
Requirements for manufacturers
Requirements for materials
Assessment documents
Delivery checks
Final tests
Documentation
Defects
Analyses
Analysis concept
Actions
Structural member resistances
Blade tests
General
Test requirements
Documentation
Machinery Structures
General
Assessment documents
Analyses
Nacelle Covers and Spinners
General
Designs
Requirements for manufacturers
Requirements for the materials
Assessment documents
Analyses
Analysis concept
Actions
Dead weight
Live loads
Wind loads
Snow and ice loads
Load combinations
Component resistances
Bolted Connections
Assessment documents
Strength analyses of bolted connections
Inspection of bolted connections
Tower
General
Assessment documents
Calculation documents
Drawings
Description of erection
Analysis concept
Loads to be applied
Determination of the internal design forces and moments
General
Overall dynamic calculation
Simplified calculation
General
Wind-induced vibration of the tower in the wind direction
Wind-induced transverse vibrations
Internal forces and moments for the fatigue safety analysis
Interfaces
Verification for the tower
Ultimate limit states
Safety concept
Ultimate limit state for strength
Ultimate limit state for stability
Ultimate limit state for fatigue
Wind-induced transverse vibrations
Serviceability limit state
Design details
Ring flange connections
Openings in tubular steel towers
Shear-loaded bolted connections
Durability
Foundation
General
Assessment documents
Calculation documents
Drawings
Soil investigation report
Analysis concept
Loads to be applied
Foundation
Structural steel components
Reinforced concrete components
Design of piles
Soil
Safety concept
Nature of the soil
Slab foundations
Pile foundations
Chapter 7
General
Assessment documents
Materials
Drive train dynamics
Blade Pitching System
General
Assessment documents
Loads to be applied
Strength analysis
Verification of load capacity of gears
Shafts and connecting elements
Bearings
Additional verifications
Bearings
General
Assessment documents
Assessment of materials
Loads to be applied
Calculations
General
Analysis of the static load-bearing capacity under extreme load
Verification of rating life
Minimum loading
Miscellaneous
Gearboxes
General
Scope
Assessment documents
Materials
Approved materials
Assessment of materials
Loads to be applied
General
Fatigue loads
Extreme loads
Calculation of load capacity of gears
General
Input data for gear rating
Influence factors for the load calculations
Application factor KA
Dynamic load factor Kv
Load distribution factor Kg
Face load factors KHß and KFß
Transverse load factors KHa and KFa
Fatigue analysis
Requirements
Application of the load duration distribution (LDD) of the torque
Use of the equivalent torque
Analysis of the static strength
Analysis of the safety against scuffing
Strength analysis for shafts and connecting elements
General
Analysis of the fatigue strength
Analysis of the static strength
Additional verifications
Gearbox bearings
Bolted connections
Housing, torque arm and planet carrier
Analysis of the cooling
Equipment
Inspection of gearboxes
Running-in period
Manuals
Mechanical Brakes and Locking Devices
General
Assessment documents
Loads
Calculations
Miscellaneous
Couplings
General
Assessment documents
Materials
Calculations
Miscellaneous
Elastomer Bushings
General
Assessment documents
Loads to be applied
Strength analysis
Additional verifications
Yaw System
General
Assessment documents
Loads to be applied
Strength analysis
Verification of load capacity of gears
Shafts and connecting elements
Bearings
Yaw brake
Additional verifications
Hydraulic Systems
General
Assessment documents
Materials
Design and construction
Chapter 8
Area of Application
Application
Scope
Standards
Operating and environmental conditions
Parallel operation with public power supply networks
Stand-alone operation
Assessment documents
Electrical Machines
General
Materials
Ventilation and cooling
Windings
Bearings
Duty cycles of electrical machines
Transformers
General
Installation
Dry-type transformers
Liquid-cooled transformers
Converter transformers
Protection
Static Converters
General
Installation of static converters
Protection equipment
Medium Voltage
General
Protective measures
Pressure relief
SF6 switchgear
Charging Equipment and Storage Batteries
General
Charging equipment
Storage batteries
Installation and operation of batteries
Switchgear and Protection Equipment
General
Short-circuit and overload protection devices
Control circuits
Measuring and indicating circuits
Earth fault detection and monitoring
Design and rating of the switchgear
Switchboards and cabinets for low voltage
Synchronizing gear and equipment for smooth connection
Electrical / electronic components in the safety system
Circuits for safety-related parts of the controls
Cables and Electrical Installation Equipment
Selection of cables and lines
Loading, protection and laying of cables and lines
Lightning Protection
General
Protection concept
Requirements
Definition of protection levels
Definition of protection zones
Execution of measures
Foundation earth electrode for the tower
Design of the tower
Junction at the yaw bearing
Connection of the machine foundation to the earthing system
Connection of the generator and the gearbox to the earthing system
Connection of other components in the nacelle
Metallic housings of the nacelle
Non-metallic housings of the nacelle
Lightning conduction from rotor blades
Lightning conduction from the rotor hub
Lightning conduction from wind measurement sensors
Switchgear installations in the tower
Operation buildings and transformer substations separated from the wind turbine
Connections for laying cables between the tower and separate buildings
Switchgear installations inside separate buildings
Treatment of cables and lines at the interfaces of the lightning protection zones
Application of the protection facilities
Chapter 9
Erection Manual
General
Format of the erection manual
Scope of the erection manual
Type designation of the wind turbine
Prerequisites for erection
Working steps for erection
Warnings against hazardous situations
Form sheet for the erection record
Documents for Commissioning
Commissioning manual
Commissioning record
Format of the documents
Scope of the commissioning manual
Type designation of the wind turbine
Checks before commissioning
Working steps for commissioning
Checks to conclude commissioning
Form sheet for the commissioning record
Operating Manual
Purpose of the operating manual
Format of the operating manual
Scope of the operating manual
Description of the wind turbine
Notes for users
Help with fault-finding
Maintenance Manual
General
Purpose of the maintenance manual
Format of the maintenance manual
Scope of the maintenance manual
Chapter 10
General
Prototype test
General requirements
Requirements for the wind turbine to be tested
Tests within the scope of the Design Assessment
Power Curve
Noise Emission
Electrical Characteristics
Test of Turbine Behaviour
General
Test plan
Test of the safety system
Test of the braking systems
Test of automatic operation
Test of the switching operations
Measurement of the natural frequencies
Hydraulic pressure at the mechanical brakes
Load Measurements
Prototype Trial of Gearboxes
General
Scope of the prototype trial
Documentation of the prototype trial
Witnessing of the Commissioning
General
Procedure for witnessing
Chapter 11
Scope and Execution
General
Objective of Periodic Monitoring
Requirements for the technical expert
Scope and execution
Execution of Periodic Monitoring
Basis of assessment for Periodic Monitoring
Documentation of the wind turbine to be inspected
Scope of Periodic Monitoring
Technical Experts, Documentation and Actions
Technical experts
Documentation
Actions
Repairs
Decommissioning and recommissioning
References of the Guideline
IV
IV
1
1
Rules and Guidelines
Rules and Guidelines
Industrial Services
Industrial Services
Guideline for the Certification of Wind Turbines
Guideline for the Certification of Wind Turbines
1 General Conditions for Approval
1 General Conditions for Approval
2 Safety System, Protective and Monitoring Devices
2 Safety System, Protective and Monitoring Devices
3 Requirements for Manufacturers, Quality Management,
3 Requirements for Manufacturers, Quality Management,
Materials and Production
Materials and Production
4 Load Assumptions
4 Load Assumptions
5 Strength Analyses
5 Strength Analyses
6 Structures
6 Structures
7 Machinery Components
7 Machinery Components
8 Electrical Installations
8 Electrical Installations
9 Manuals
9 Manuals
10 Testing of Wind Turbines
10 Testing of Wind Turbines
11 Periodic Monitoring
11 Periodic Monitoring
Edition 2003
Edition 2003
with Supplement 2004
with Supplement 2004
This Guideline was compiled by Germanischer Lloyd WindEnergie GmbH in cooperation
with the Wind Energy Committee. The Wind Energy Committee consists of representatives from
manufacturers, universities, insurance companies, associations, engineering offices, authorities and institutes.
The current members of the Wind Energy Committee are named on our website:
www.gl-wind.com
This Guideline comes into force on 1st November 2003.
Interpretation of the Guideline is the exclusive prerogative of Germanischer Lloyd WindEnergie GmbH.
Any reference to the application of this Guideline is permitted only with the consent
of Germanischer Lloyd WindEnergie GmbH.
The latest edition of the General Terms and Conditions
of Germanischer Lloyd WindEnergie GmbH is applicable.
Reproduction by printing or other means, even of extracts, is only permissible with the consent
of Germanischer Lloyd WindEnergie GmbH.
Germanischer Lloyd WindEnergie GmbH
Steinhoeft 9, 20459 Hamburg / Germany
Phone: +49 40 31106-707 Fax: +49 40 31106-1720
E-mail: WindEnergie@gl-group.com Internet: http://www.gl-wind.com
Published by: Germanischer Lloyd WindEnergie GmbH
Printed by: Heydorn Druckerei und Verlag, Uetersen / Germany
Table of Contents
Page 3
Table of Contents
IV – Part 1
GL Wind 2003
List of Abbreviations
Symbols and Units
Chapter 1 General Conditions for Approval
1.1
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.2
1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
1.2.6
1.2.7
1.3
1.3.1
1.3.2
1.3.3
1.3.4
Scope .......................................................................................................................................................1-1
General..................................................................................................................................................... 1-1
Transition periods .................................................................................................................................... 1-1
Deviations ................................................................................................................................................ 1-1
National requirements.............................................................................................................................. 1-1
Assessment documents ............................................................................................................................ 1-1
Extent of Certification ...........................................................................................................................1-3
Subdivision of the certification................................................................................................................ 1-3
Assessment of prototypes (C – Design Assessment) ............................................................................... 1-3
A – and B – Design Assessment............................................................................................................... 1-4
Site-specific Design Assessment.............................................................................................................. 1-6
Type Certificate........................................................................................................................................ 1-6
Project Certificate .................................................................................................................................... 1-8
Re-certification ...................................................................................................................................... 1-10
Basic Principles for Design and Construction ................................................................................... 1-11
General................................................................................................................................................... 1-11
Definitions ............................................................................................................................................. 1-11
Analysis procedure................................................................................................................................. 1-12
Mathematical model............................................................................................................................... 1-12
Appendix 1.A
1.A
1.A.1
1.A.2
1.A.3
National Requirements in Germany...................................................................................................1-13
General................................................................................................................................................... 1-13
Analysis concept.................................................................................................................................... 1-13
Wind conditions ..................................................................................................................................... 1-14
Appendix 1.B
1.B
1.B.1
1.B.2
National Requirements in Denmark...................................................................................................1-15
General................................................................................................................................................... 1-15
Regulations and standards...................................................................................................................... 1-15
Appendix 1.C
1.C
1.C.1
1.C.2
National Requirements in France.......................................................................................................1-17
General................................................................................................................................................... 1-17
Building permission procedure .............................................................................................................. 1-17
Appendix 1.D
1.D
1.D.1
National Requirements in the Netherlands........................................................................................1-19
General................................................................................................................................................... 1-19
Page 4
Table of Contents
IV – Part 1
GL Wind 2003
1.D.2
Preliminary standard NVN 11400-0 ...................................................................................................... 1-19
Appendix 1.E
1.E
1.E.1
1.E.2
1.E.3
National Requirements in India.......................................................................................................... 1-21
General................................................................................................................................................... 1-21
Certification categories .......................................................................................................................... 1-21
TAPS-2000 requirements....................................................................................................................... 1-21
Appendix 1.F
1.F
1.F.1
1.F.2
1.F.3
IEC and CENELEC Standards .......................................................................................................... 1-23
General................................................................................................................................................... 1-23
List of normative documents in the area of wind energy....................................................................... 1-23
Supply sources ....................................................................................................................................... 1-23
Chapter 2 Safety System, Protective and Monitoring Devices
2.1
2.1.1
2.1.2
2.1.3
2.2
2.2.1
2.2.2
2.2.3
2.3
2.3.1
2.3.2
2.3.3
General....................................................................................................................................................2-1
Assessment documents ............................................................................................................................ 2-1
Systematic consideration of possible faults ............................................................................................. 2-1
Description of the controller for approval of the load assumptions ......................................................... 2-2
Control and Safety System....................................................................................................................2-3
General..................................................................................................................................................... 2-3
Definitions ............................................................................................................................................... 2-3
Requirements and design concept............................................................................................................ 2-5
Protective and Monitoring Devices.......................................................................................................2-9
General..................................................................................................................................................... 2-9
Limiting values, control system............................................................................................................... 2-9
Safety equipment (locking devices) for maintenance ............................................................................ 2-15
Appendix 2.A
2.A
Interaction of the Control and Safety Systems.................................................................................. 2-17
Chapter 3 Requirements for Manufacturers, Quality Management,
Materials and Production
3.1
3.1.1
3.1.2
3.1.3
3.1.4
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.3
3.3.1
3.3.2
3.3.3
Requirements for Manufacturers.........................................................................................................3-1
General..................................................................................................................................................... 3-1
Works equipment ..................................................................................................................................... 3-1
Personnel.................................................................................................................................................. 3-1
Shop approval .......................................................................................................................................... 3-1
Quality Management .............................................................................................................................3-3
General..................................................................................................................................................... 3-3
Definitions ............................................................................................................................................... 3-3
Requirements for the quality management system .................................................................................. 3-3
Certification of the QM system................................................................................................................ 3-3
Materials.................................................................................................................................................3-5
General requirements............................................................................................................................... 3-5
Metallic materials .................................................................................................................................... 3-6
Fibre-reinforced plastics (FRP).............................................................................................................. 3-11
IV – Part 1
GL Wind 2003
Table of Contents
Page 5
3.3.4
3.3.5
3.4
3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
3.4.6
3.4.7
Wood...................................................................................................................................................... 3-13
Reinforced concrete and prestressed concrete ....................................................................................... 3-14
Production and Testing........................................................................................................................3-17
General................................................................................................................................................... 3-17
Welding.................................................................................................................................................. 3-17
Laminating fibre-reinforced plastics...................................................................................................... 3-19
Adhesive bonding .................................................................................................................................. 3-21
Manufacturing surveillance for FRP...................................................................................................... 3-22
Wood processing.................................................................................................................................... 3-23
Making and working the concrete.......................................................................................................... 3-24
Chapter 4 Load Assumptions
4.1
4.1.1
4.1.2
4.1.3
4.1.4
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.4
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
4.4.6
4.4.7
Fundamentals.........................................................................................................................................4-1
General..................................................................................................................................................... 4-1
Assessment documents ............................................................................................................................ 4-1
Design methods........................................................................................................................................ 4-2
Safety classes ........................................................................................................................................... 4-2
External Conditions...............................................................................................................................4-3
General..................................................................................................................................................... 4-3
Wind turbine classes ................................................................................................................................ 4-3
Wind conditions ....................................................................................................................................... 4-4
Other environmental conditions............................................................................................................. 4-11
Electrical power network conditions...................................................................................................... 4-12
Calculation of the Loads......................................................................................................................4-13
General................................................................................................................................................... 4-13
Loads...................................................................................................................................................... 4-13
Design situations and load cases............................................................................................................ 4-13
Load calculations ................................................................................................................................... 4-19
Partial safety factors for loads................................................................................................................ 4-20
Site-Specific Assessment ......................................................................................................................4-23
Site assessment ...................................................................................................................................... 4-23
Wind farm influence .............................................................................................................................. 4-24
Influence of earthquakes ........................................................................................................................ 4-25
Complex terrain ..................................................................................................................................... 4-26
Extreme temperatures ............................................................................................................................ 4-26
Corrosion, erosion.................................................................................................................................. 4-27
Assessment and comparison .................................................................................................................. 4-27
Appendix 4.A
4.A
4.A.1
4.A.2
4.A.3
4.A.4
4.A.5
4.A.6
Coordinate Systems .............................................................................................................................4-29
Blade coordinate system ........................................................................................................................ 4-29
Chord coordinate system........................................................................................................................ 4-29
Hub coordinate system........................................................................................................................... 4-30
Rotor coordinate system ........................................................................................................................ 4-30
Tower top coordinate system ................................................................................................................. 4-31
Tower bottom coordinate system ........................................................................................................... 4-31
Appendix 4.B
4.B
4.B.1
Evaluation of the Loads.......................................................................................................................4-33
Presentation of load case definitions...................................................................................................... 4-33
Page 6
Table of Contents
IV – Part 1
GL Wind 2003
4.B.2
4.B.3
Presentation of the results ...................................................................................................................... 4-33
Further evaluations................................................................................................................................. 4-34
Appendix 4.C
4.C
Fault in the Power System................................................................................................................... 4-37
Appendix 4.D
4.D
4.D.1
4.D.2
4.D.3
4.D.4
Design Parameters for Describing Wind Turbine Class S................................................................4-39
Plant parameters..................................................................................................................................... 4-39
Wind conditions ..................................................................................................................................... 4-39
Conditions of the electrical power network ........................................................................................... 4-39
Other environmental conditions (where necessary)............................................................................... 4-40
Chapter 5 Strength Analyses
5.1
5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.3
5.3.1
5.3.2
5.3.3
5.3.4
5.4
5.4.1
5.4.2
5.4.3
5.5
5.5.1
5.5.2
5.5.3
5.5.4
5.5.5
5.5.6
5.6
General....................................................................................................................................................5-1
Determination of the Stresses................................................................................................................5-3
General notes on the loading of the structure........................................................................................... 5-3
Method of analysis................................................................................................................................... 5-3
Dynamic calculation ................................................................................................................................ 5-4
Quasi-static calculation............................................................................................................................ 5-4
Metallic Materials..................................................................................................................................5-5
Material properties................................................................................................................................... 5-5
General strength analysis ......................................................................................................................... 5-5
Fatigue analysis........................................................................................................................................ 5-5
Serviceability analysis ........................................................................................................................... 5-13
Concrete................................................................................................................................................ 5-15
Material properties................................................................................................................................. 5-15
Ultimate limit states ............................................................................................................................... 5-15
Serviceability Limit State....................................................................................................................... 5-16
Fibre Reinforced Plastics (FRP) and Bonded Joints......................................................................... 5-17
General................................................................................................................................................... 5-17
Materials ................................................................................................................................................ 5-17
Analyses................................................................................................................................................. 5-18
Glass Fibre Reinforced Plastics (GRP).................................................................................................. 5-21
Carbon Fibre Reinforced Plastics (CRP) ............................................................................................... 5-22
Bonded joints ......................................................................................................................................... 5-23
Wood ..................................................................................................................................................... 5-25
Appendix 5.A
5.A
5.A.1
5.A.2
5.A.3
5.A.4
5.A.5
Strength Analyses with the Finite Element Method.......................................................................... 5-27
General................................................................................................................................................... 5-27
Modelling of the structure...................................................................................................................... 5-29
Loading of the structure......................................................................................................................... 5-32
Calculation and evaluation of the results ............................................................................................... 5-32
Documentation of FE analyses for the certification of wind turbines.................................................... 5-33
IV – Part 1
GL Wind 2003
Table of Contents
Page 7
Chapter 6 Structures
6.1
6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
6.3
6.3.1
6.3.2
6.3.3
6.4
6.4.1
6.4.2
6.4.3
6.5
6.5.1
6.5.2
6.5.3
6.6
6.6.1
6.6.2
6.6.3
6.6.4
6.6.5
6.6.6
6.6.7
6.6.8
6.7
6.7.1
6.7.2
6.7.3
6.7.4
6.7.5
6.7.6
General....................................................................................................................................................6-1
Rotor Blades ...........................................................................................................................................6-3
General..................................................................................................................................................... 6-3
Assessment documents ............................................................................................................................ 6-3
Delivery checks........................................................................................................................................ 6-3
Analyses................................................................................................................................................... 6-4
Blade tests................................................................................................................................................ 6-4
Machinery Structures ............................................................................................................................6-7
General..................................................................................................................................................... 6-7
Assessment documents ............................................................................................................................ 6-7
Analyses................................................................................................................................................... 6-7
Nacelle Covers and Spinners.................................................................................................................6-9
General..................................................................................................................................................... 6-9
Assessment documents ............................................................................................................................ 6-9
Analyses................................................................................................................................................... 6-9
Bolted Connections ..............................................................................................................................6-13
Assessment documents .......................................................................................................................... 6-13
Strength analyses of bolted connections ................................................................................................ 6-13
Inspection of bolted connections............................................................................................................ 6-13
Tower.....................................................................................................................................................6-15
General................................................................................................................................................... 6-15
Assessment documents .......................................................................................................................... 6-15
Analysis concept.................................................................................................................................... 6-15
Loads to be applied ................................................................................................................................ 6-15
Determination of the internal design forces and moments..................................................................... 6-15
Verification for the tower ....................................................................................................................... 6-17
Design details......................................................................................................................................... 6-19
Durability............................................................................................................................................... 6-23
Foundation............................................................................................................................................6-25
General................................................................................................................................................... 6-25
Assessment documents .......................................................................................................................... 6-25
Analysis concept.................................................................................................................................... 6-25
Loads to be applied ................................................................................................................................ 6-25
Foundation ............................................................................................................................................. 6-25
Soil......................................................................................................................................................... 6-26
Chapter 7 Machinery Components
7.1
7.1.1
7.1.2
7.1.3
7.2
7.2.1
7.2.2
7.2.3
7.2.4
General....................................................................................................................................................7-1
Assessment documents ............................................................................................................................ 7-1
Materials .................................................................................................................................................. 7-1
Drive train dynamics................................................................................................................................ 7-1
Blade Pitching System ...........................................................................................................................7-3
General..................................................................................................................................................... 7-3
Assessment documents ............................................................................................................................ 7-3
Loads to be applied .................................................................................................................................. 7-3
Strength analysis ...................................................................................................................................... 7-3
Page 8
7.3
7.3.1
7.3.2
7.3.3
7.3.4
7.3.5
7.3.6
7.4
7.4.1
7.4.2
7.4.3
7.4.4
7.4.5
7.4.6
7.4.7
7.4.8
7.4.9
7.4.10
7.5
7.5.1
7.5.2
7.5.3
7.5.4
7.5.5
7.6
7.6.1
7.6.2
7.6.3
7.6.4
7.6.5
7.7
7.7.1
7.7.2
7.7.3
7.7.4
7.7.5
7.8
7.8.1
7.8.2
7.8.3
7.8.4
7.9
7.9.1
7.9.2
7.9.3
7.9.4
Table of Contents
IV – Part 1
GL Wind 2003
Bearings ..................................................................................................................................................7-5
General..................................................................................................................................................... 7-5
Assessment documents ............................................................................................................................ 7-5
Assessment of materials........................................................................................................................... 7-5
Loads to be applied .................................................................................................................................. 7-5
Calculations ............................................................................................................................................. 7-6
Miscellaneous .......................................................................................................................................... 7-7
Gearboxes ...............................................................................................................................................7-9
General..................................................................................................................................................... 7-9
Materials .................................................................................................................................................. 7-9
Loads to be applied .................................................................................................................................. 7-9
Calculation of load capacity of gears..................................................................................................... 7-10
Strength analysis for shafts and connecting elements............................................................................ 7-12
Additional verifications ......................................................................................................................... 7-13
Equipment.............................................................................................................................................. 7-13
Inspection of gearboxes ......................................................................................................................... 7-13
Running-in period.................................................................................................................................. 7-14
Manuals.................................................................................................................................................. 7-14
Mechanical Brakes and Locking Devices........................................................................................... 7-15
General................................................................................................................................................... 7-15
Assessment documents .......................................................................................................................... 7-15
Loads...................................................................................................................................................... 7-15
Calculations ........................................................................................................................................... 7-16
Miscellaneous ........................................................................................................................................ 7-16
Couplings.............................................................................................................................................. 7-17
General................................................................................................................................................... 7-17
Assessment documents .......................................................................................................................... 7-17
Materials ................................................................................................................................................ 7-17
Calculations ........................................................................................................................................... 7-17
Miscellaneous ........................................................................................................................................ 7-17
Elastomer Bushings ............................................................................................................................. 7-19
General................................................................................................................................................... 7-19
Assessment documents .......................................................................................................................... 7-19
Loads to be applied ................................................................................................................................ 7-20
Strength analysis .................................................................................................................................... 7-20
Additional verifications ......................................................................................................................... 7-20
Yaw System........................................................................................................................................... 7-21
General................................................................................................................................................... 7-21
Assessment documents .......................................................................................................................... 7-21
Loads to be applied ................................................................................................................................ 7-21
Strength analysis .................................................................................................................................... 7-21
Hydraulic Systems ............................................................................................................................... 7-23
General................................................................................................................................................... 7-23
Assessment documents .......................................................................................................................... 7-23
Materials ................................................................................................................................................ 7-23
Design and construction......................................................................................................................... 7-23
Chapter 8 Electrical Installations
8.1
8.1.1
Area of Application................................................................................................................................8-1
Application............................................................................................................................................... 8-1
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