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WU, Qiang (John)

Shanghai, CHINA

24 Mar. 2010

IEC61400-22:2010 WTG Conformity Testing and Certificationby TÜVRheinland

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Time Schedule

Source: www.iec.ch

It is estimated that final version for IS (International Standard) is to be published in middle June 2010, however that will not deviate much from this FDIS (Final Draft International Standards).

This presentation is based on FDIS, which is subject to final tuning until IS is officially released and published.

Same as in IEC WT01, description in Introduction section of IEC61400-22:“In addition to design verification and testing, this standard provides information for the recognition of or assessment for approval of the supplier's qualityquality system, regular surveillance through inspection of the supplier's quality system and quality plans, and audit testing of samples…”

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Brief Review

IEC 61400-22: 2010 “Conformity Testing and Certification”

Developed from

IEC WT 01: 2001“IEC System for Conformity Testing and Certification of Wind Turbines”

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Application Scope

SWT

Source: Vestas

Application Scope

This International Standard defines rules and procedures for a certification system for windturbines (WT) that comprises both type certification and certification of wind turbine projects installed on land or off-shore

1. Evaluation of test for design data shall be considered;

2. For rotor blade, evaluation of static blade test is specified;

3. Duration test is specified in IEC61400-2.

Source: Enercon Source: Vestas Source: Multibrid

Source: Qingdao Anhua

Source: Enercon

Special rules and procedures apply for Small Wind Turbines (SWT):

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Normative StandardsIEC 61400 (all parts), Wind turbinesIEC 61400-1:2010, Wind turbines – Part 1: Design requirements*IEC 61400-2:2006, Wind turbines – Part 2: Design requirements for small wind turbinesIEC 61400-3:2009, Wind turbines – Part 3: Design requirements for offshore wind turbinesIEC 61400-4:2011, Wind turbines – Part 4: Design and specification of gearboxes**IEC 61400-5:2012, Wind turbines – Part 5: Rotor blades***IEC 61400-11:2002, Wind turbine generator systems – Part 11: Acoustic noise measurement techniquesIEC 61400-12-1:2005, Wind turbines – Part 12-1: Power performance measurements of electricity producing wind turbinesIEC/TS 61400-13:2001, Wind turbine generator systems – Part 13: Measurement of mechanical loadsIEC/TS 61400-14:2005, Wind turbine generator systems – Part 14: Declaration of apparent sound power level and tonalityvaluesIEC 61400-21:2001, Wind turbines – Part 21: Measurement and assessment of power quality characteristics of grid connected wind turbinesIEC/TS 61400-23:2001, Wind turbine generator systems – Part 23: Full-scale structural testing of rotor bladesIEC/TR 61400-24:2002, Wind turbines – Part 24: Lightning protectionIEC 61400-25- 1 -2 -3 -5:2006/ -4 2008, Wind turbines – Part 25: Communications for monitoring and control of wind power plantsIEC 61400-26:2010, Wind turbines – Part 26: Availability for wind turbines and wind turbine plants****IEC 61400-27:2012, Wind turbines – Part 27: Electrical simulation models for wind power generation *****

IEC 60034 (all parts), Rotating electrical machines

* Present version is published in 2005, revision is to be published in 2010.**Revision from ISO 81400-4:2005, Wind turbines – Part 4: Design and specification of gearboxes, plan to be published in 2011.***IEC61400-23 is the rule for full scale test of rotor blade, -5 is in work proposal phase, plan to be published in 2012.**** plan to be published in 2010.***** plan to be published in 2012.

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Type Certification

Source: IEC61400-22Source: IEC WT01

Type TestingType Testing

Design EvaluationDesign Evaluation

Modules inIEC WT01:2001

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Design Basis Evaluation

Source: Ninbo Tairui

Design basis evaluation is one of new modules which is stipulated in IEC61400-22.

According to standard description, the purpose of design basis evaluation is to examine that the design basis is properly documented and sufficient for safe design of the wind turbine type.

The design basis shall identify all requirements, assumptions and methodologies, which are essential for the design and the design documentation, including:

– codes and standards;

– design parameters, assumptions, methodologies and principles, and

– other requirements, e.g. for manufacture, transportation, installation and commissioning as well as for operation and maintenance.

Source: Wind Energy Handbook

Source: Wind Energy Explained– Theory, Design and Application

Source: DNV Guideline

Source: IEC61400-22

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Design Evaluation 1/2

Source: IEC61400-22

Design evaluation is regarded as part of type certification which specifies not only “virtual” (on paper or computer) but also whole “physical”processesprocesses . This is quite an explanation of the “begin with the end in mind” ideology.

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Design Evaluation 2/2

Source: IEC61400-22

In modules evaluation of “rotor blades”, “machine and structural components” and “electrical components”, there are relevant IEC standards besides general requirements as of in IEC61400-1, -2, -3:

IEC61400-5 -23 for rotor bladesIEC61400-4 for gearboxIEC61400-24 for lightening protectionIEC 60034 series for generator workshop tests etc.

Source: LM

Source: Bosch

Source: Enercon

Source: Lanzhou Electric

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Manufacturing Evaluation 1/3

Source: IEC61400-2

The purpose of manufacturing evaluation is to assess if a specific wind turbine type is manufacturedmanufactured in conformity with the documentation designdocumentation design verified during the design evaluation. This evaluation shall include the following elements:– quality system evaluation; and– manufacturing inspection.

Manufacturing evaluation “in practice” can be regard as challenge particularly under present global-sourcing tendency, because it co-exists different national standards i.e.- for materials.- for manufacturing processes.- for inspections. (for instance NDT, welding etc.)

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Manufacturing Evaluation 2/3

Source: IEC61400-2

In manufacturing, due to before-mentioned reasons, production equipment as well as regularly calibration by relevant local technical authorities also brings to topic for quality control in regard of global scale.

There are different focus points of wind turbine production in different phases as of in “prototype”, “0-serial production” and “regular mass production”. This lies not only on wind turbine manufacturers themselves, but more importantly their supply chain.

Machining workshop ZWZ bearingHeat treatment ZWZ bearing

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Manufacturing Evaluation 3/3

Source: IEC61400-2

Besides the factors in quality assurance as described before e.g. 1) material + production process, 2) equipment, skillful workers as usual, plays a crucial role.

Extra as stipulated in ISO quality management system i.e. 9001 requirements for training, education mechanism for employees, the training contents itself and recognition / accreditation in national level is in need of:- International harmonization;- Global presence of 3rd party for surveillance.

Source: Vestas TJ Source: Sinovel

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Source: IEC61400-22

Type Testing

Source: Baoding Huiteng

Source: NGC

Source: Tsinghua Uni.

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Type Characteristics Measurements

Source: IEC61400-22

Source: CEPRI

Source: DEWI

Source: CRESP

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Project Certification

Project certification shall confirm for a specific site that type-certified wind turbines and particular foundation designs meet requirements governed by site-specific external conditionsand are in conformity with applicable local codes and other requirements relevant to the site.

Project certification may also confirm conformity for other installations in relation to the turbine installations. The certification shall confirm that the wind conditions, other environmental and electrical network conditions, and soil properties at the site conform with those defined in the design documentation for the wind turbine type(s) and foundation(s).

Source: IEC61400-22

Modules inIEC WT01:2001

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Component CertificationThe procedures for component certification should be in line with the type certification procedures, specific content of a module depends on the actual component.

For components that are required to undergo specified type testing as partof the wind turbine type testing module, it is recommended that the type testing be included as part of any component certification.

IEC61400-22 keeps this component certification as in IEC WT01, it is estimated that other so far influential WT guideline is to take same revision, since from pragmatic point view, under present globalization trend, sub-supplier in supply chain has stronger will to appear on market and compete with each other. Certification is one of their demonstrations.

Source: IEC61400-22

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Source: Northwind

ConclusionTo enhance product quality and stimulate technology innovation impetus is the mission of 3rd party certification body for Wind Energy Industry.

This Value is fulfilled by updated requirements for 3rd party with “begin with the end in mind” ideology, as well as “comprehensive” methodology in whole cycle and processes, therefore:

- Accreditation is not only an authority but means more obligationobligation;

- Certification is not only done in office in HQs but more on sitessites in global scale;

- Verification and validation is done not only with in-house software and test labs, but more with updated technologyupdated technologydeveloped together with universities, R&D institutes, testing centers, independent engineering companies as well as data collected from condition monitoring of WTs in operation.

Manufacturing

Testing

Transportation

Installation

Commissioning

O&MCondition Monitoring

Designing

Global Technology Assessment (GTAC)

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GTAC ShanghaiGlobal Standards, International Capacity and Local Testing

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For Further Questions…

windenergytechnology@shg.chn.tuv.com

Source: Datang Corp.

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Thanks for your attention!