Guide on Offshore Wind Farm Project Certification (Based on IEC Series) BV-WFPC 100

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1 Guide on Offshore Wind Farm Project Certification (Based on IEC Series) BV-WFPC 100

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3 BUREAU VERITAS, Bureau Veritas Certification and the Bureau Veritas 1828 device are registered trademarks and are owned by BUREAU VERITAS SA. All information provided in the Guide for Offshore Wind Farm Project Certification for the purpose of clarification of the project certification process is protected by copyright and is the property of Bureau Veritas Certification unless otherwise stated. No part of the documents may be reproduced, copied, downloaded or transmitted, in any form and by any means, without the prior written consent of Bureau Veritas Certification. No express or implied licence or right of any kind is granted regarding any information contained in the documents, any trademarks or other intellectual property rights of Bureau Veritas Certification or any third party. In no event shall Bureau Veritas Certification, its agents, consultants, and subcontractors, be liable for special, indirect or consequential damages resulting from or arising out of the use of Guide for Offshore Wind Farm Project Certification, including, without limitation, loss of profit or business interruptions, however these may be caused. Every effort is made to provide general information. However, Bureau Veritas Certification does not guarantee the accuracy, completeness, adequacy or usefulness of the content of the documents, including but not limited to, any information, product, service or process disclosed herein. Bureau Veritas Certification hereby disclaims all warranties and guarantees, whether expressed or implied, including any warranty of merchantability, fitness for a particular purpose or use, or non-infringement of third party rights with respect to the documents provided. Copyright 2012 Bureau Veritas Certification, All rights reserved. Bureau Veritas Certification thanks the International Electrotechnical Commission (IEC) for permission to reproduce Information from its International Publication IEC ed.1.0 (2010). All such extracts are copyright of IEC, Geneva, Switzerland. All rights reserved. Further information on the IEC is available from IEC has no responsibility for the placement and context in which the extracts and contents are reproduced by the author, nor is IEC in any way responsible for the other content or accuracy therein.

4 Index I. Index 4 1. Introduction Purpose Scope Structure Definitions and acronyms Definitions IEC terms Terms specific to this document Verbal forms Acronyms References Normative references IEC ISO Other standards Informative references Generalities Description General description References Interaction with Type Certificate Project certification process Procedure Deliverables Validity Bureau Veritas Certification s approach General methodology: Risk-based verification Document review Independent analyses Inspections and surveillance Site Conditions Evaluation Introduction Methodology Wind and Other Environmental Conditions Measurement campaign Data analysis Marine Conditions and Weather Windows Soil and Earthquake Conditions General description Geophysical investigations Geotechnical investigations Electrical Power Network Conditions 36 4 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

5 6. Design Basis Evaluation Introduction Methodology Necessary information Integrated Load Analysis Introduction Methodology Requirements Site-specific Design Evaluation Introduction General requirements and methodology Design review Mechanical / Structural calculations Corrosion protection Site-specific wind turbine / RNA design evaluation Site-specific support structure design evaluation Other installations design evaluation General description Electrical substation Electrical cables Manufacturing Surveillance Introduction Quality system evaluation Manufacturing inspection and surveillance Methodology Wind turbine Support structure Other installations Transportation and Installation Surveillance Introduction Review of the transportation and installation procedures Transportation and installation surveillance Commissioning Surveillance Introduction Review of the commissioning instructions Commissioning surveillance Project Characteristics Measurements Introduction General methodology Specific requirements Grid connection compatibility according to grid codes Verification of power performance Verification of acoustic noise emission

6 13. Final Evaluation and Project Certificate Final evaluation Delivery of Project Certificate Operation and Maintenance Surveillance Introduction Review of the operation and maintenance manuals Operation and maintenance surveillance Appendix A 84 6 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

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9 1. Introduction 1

10 1.Introduction 1.1.Purpose This document describes the general process for the certification of a fixed offshore wind farm project by Bureau Veritas Certification. It is meant as a public guide for the potential third party certification Applicant and intends to clarify the project certification process by listing mandatory requirements and necessary steps to be undertaken by the Applicant, as well as explaining Bureau Veritas Certification s methodology for the evaluation. Complying with the requirements and recommendations mentioned in this document will make the certification a more efficient and effective process. This document shall not be understood as a contractual document planned to be referred to in the certification process. When a certification contract is signed, Bureau Veritas Certification will provide the Applicant with a detailed evaluation plan which describes in more detail the specific requirements and procedures to follow for a project certification. 1.2.Scope This guide refers to the certification process described in IEC and is thus based on the IEC series, which constitutes the international standard for wind turbines. This basis is completed by other widely recognized standards such as the ISO series or the API RP 2A-WSD. The inclusion of other standards in the certification references might be possible (see 4.1.2) but the additional requirements and procedures to consider are not described in this document. This document covers only the internationally recognized IEC certification scheme. National certification schemes such as the BSH in Germany, though generally similar to the IEC series, might impose different requirements on specific topics. These particularities are not covered in this guide and will be subject to later additions. This guide is limited to the certification of fixed offshore wind turbine projects. For the sake of conciseness, the discussion is focused on horizontal-axis wind turbines, though most sections remain valid for vertical-axis wind turbines with appropriate modifications. The process covers the whole lifecycle of the project with the exception of dismantling. Requirements for dismantling are usually specified by local regulations and are thus project-specific. 1.3.Structure In order to avoid any potential misguidance, the structure of this guide matches the project certification procedure described in IEC Following a few introductory chapters (chapters 1 to 4), each chapter (chapters 5 to 14) corresponds to an individual module of the certification process. When a module can be broken down into several sub-modules the relevant chapter is divided into several sections to cover these sub-modules. Typically, each section consists of the following three parts: a description of the module or sub-module content and objective a description of the methodology that Bureau Veritas Certification applies to the specific item a list of requirements and recommendations that the Applicant should strive to follow 10 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

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13 2. Definitions and acronyms 2

14 2.Definitions and acronyms In this guide efforts have been made to use the vocabulary from the IEC series, upon which the certification process is based, whenever possible. Additionally, those terms that are more specific to this document and have not been defined in the IEC standards are defined. 2.1.Definitions IEC terms All definitions from the IEC series (especially IEC ) apply in this document. For a better readability, some definitions are reproduced here 1. Certification Procedure by which a third party gives written assurance that a product, process or service conforms to specified requirements; also known as conformity assessment. Evaluation for conformity Systematic examination of the extent to which a product, process or service fulfils specified requirements. Inspection Systematic examination of the extent to which a product, process or service fulfils specified requirements by means of measuring, observing, testing or gauging the relevant characteristics. Surveillance Continued monitoring and verification of the status of procedures, products and services, and analysis of records in relation to referenced documents to ensure specified requirements are met Terms specific to this document Conservative A given standard is deemed more conservative than another one if fulfilling all requirements of the former implies compliance with all requirements from the latter. Criticality The level of risk associated with a given component or process. It is usually determined based on an objective assessment of several project-dependent risk factors. Design review A documented, comprehensive and systematic examination of a design to evaluate its capability to fulfil the requirements for quality, identify problems, if any, and propose the development of solutions. Other installations All auxiliary installations of a wind farm, such as electrical substations, meteorological mast, electrical cable arrays, etc. References Set of standards which forms the basis to which the certification body verifies the conformity of the project design. 1 IEC ed.1.0 Copyright 2010 IEC Geneva, Switzerland. 14 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

15 Standard List of requirements published by national or international public organizations, defining uniform methods, processes or practices. Verification The method used to ensure the quality of purchased materials, items or components or of in-process products at appropriate points in the process. Wind farm Group of wind turbines and their support structures. Depending on the agreed scope of the project certification it may or may not include other installations as well Verbal forms Might / may / can: When referring to the Applicant, indicates a possible action. When referring to Bureau Veritas Certification, indicates a non-mandatory action, whose actual realization will be decided by Bureau Veritas Certification on a case by case basis. Shall / must: Indicates a mandatory requirement to be followed by the Applicant. Should: Indicates a recommendation or preferred course of action, but does not exclude other possible options which would be examined on a case by case basis. Will: Indicates an action to be undertaken by Bureau Veritas Certification. 2.2.Acronyms API American Petroleum Institute BSH DLC FE HAWC IEA IEC ISO ISSMGE NDT O&M PC RNA TC T&I Bundesamt für Seeschifffahrt und Hydrographie (Federal Maritime and Hydrographic Agency of Germany) Design Load Case Finite Element Horizontal Axis Wind turbine Code International Energy Agency International Electrotechnical Commission International Organization for Standardization International Society for Soil Mechanics and Geotechnical Engineering Non-Destructive Testing Operation and Maintenance Project Certificate Rotor / Nacelle Assembly Type Certificate Transportation and Installation 15

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17 3. References 3

18 3. References For the sake of brevity, only the main standards are listed here. The complete certification references mentioned by Bureau Veritas Certification are available on request Normative references IEC Reference Title IEC Wind turbines Part 22: Conformity testing and certification IEC IEC IEC IEC IEC IEC IEC Wind turbines Part 1: Design requirements Wind turbines Part 3: Design requirements for offshore wind turbines Wind turbine generator systems Part 11: Acoustic noise measurement techniques Wind turbines Part 12-1: Power performance measurements of electricity producing wind turbines Wind turbines Part 21: Measurement and assessment of power quality characteristics of grid connected wind turbines Power cables with extruded insulation and their accessories for rated voltages from 1kV (Um = 1,2kV) up to 30kV (Um = 36kV) Mobile and fixed offshore units - Electrical installations ISO Reference ISO 9001 ISO ISO ISO/IEC ISO/IEC ISO/IEC ISO ISO ISO ISO ISO ISO ISO ISO ISO Title Quality management systems Requirements Paints and varnishes Corrosion protection of steel structures by protective paint systems Petroleum and natural gas industries Design and operation of subsea production systems Part 5: Subsea umbilicals Conformity assessment Requirements for the operation of various types of bodies performing inspection Conformity assessment Requirements for bodies providing audit and certification of management systems General requirements for the competence of testing and calibration laboratories Petroleum and natural gas industries General requirements for offshore structures Petroleum and natural gas industries Specific requirements for offshore structures Part 1: Metocean design and operating considerations Petroleum and natural gas industries Specific requirements for offshore structures Part 2: Seismic design procedures and criteria Petroleum and natural gas industries Specific requirements for offshore structures Part 3: Topsides structure Petroleum and natural gas industries Specific requirements for offshore structures Part 4: Geotechnical and foundation design considerations Petroleum and natural gas industries Specific requirements for offshore structures Part 6: Marine operations Petroleum and natural gas industries Fixed steel offshore structures Petroleum and natural gas industries Fixed concrete offshore structures Paints and varnishes - Performance requirements for protective paint systems for offshore and related structures 18 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

19 Other standards Reference API RP 2A-WSD EN Title API RP 2A-WSD, Recommended Practice for Planning, Designing, and Constructing Fixed Offshore Platforms Working Stress Design EN 12495, Cathodic Protection for Fixed Steel Offshore Structures 3.2. Informative references The conformity to these requirements is not mandatory, however, it is highly recommended as this will ease the certification process. Reference BV NI 423 BV NR 493 IEA Recommended Practice ISSMGE MEASNET Procedure Title Bureau Veritas Marine Division, Guidance Note NI 423, Corrosion Protection of Steel Offshore Units and Installations Bureau Veritas Marine Division, Rule Note NR 493, Classification of Mooring Systems for Permanent Offshore Units International Energy Agency, Recommended Practice for Wind Turbine Testing 11. Wind speed measurement and use of cup anemometry International Society for Soil Mechanics and Geotechnical Engineering, Geotechnical & geophysical investigations for offshore and near shore developments MEASNET Procedure: Evaluation of Site Specific Wind Conditions. Version 1, November

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21 4. Generalities 4

22 4. Generalities 4.1. Description General description The purpose of project certification is to evaluate whether a specific wind farm, including type-certified wind turbines and their support structures and possibly other auxiliary installations, is designed and built taking into account the external conditions at the intended location and in conformity with the applicable standards, construction and electrical codes and other relevant site-specific requirements. The Applicant for project certification is usually the developer of the wind farm. The completion of project certification might be required by law or by investors and insurance companies. It might also be the result of a voluntary initiative from the Applicant to ensure the quality of the project. The exact scope of the certification shall be clearly defined at the beginning of the procedure, and will be mentioned in the Project Certificate (PC). The PC shall at least cover the wind turbines and their support structures, but can, on the Applicant s request, also encompass other equipment from the wind farm, such as: Substations (e.g. transformer substation) and their support structures Meteorological masts and their support structures Helidecks and their support structures Electrical cable arrays from the wind turbines to the transformer substations The certification procedure involves document review, independent calculations and audits and inspections programs. It covers safety and quality References A third-party certification is always based upon a given, fixed certification scheme for which the certification body is accredited. Bureau Veritas Certification s certification scheme is based on the public, internationally recognized IEC series, including in particular IEC describing the general certification process, IEC related to general design and load cases, and IEC for offshore wind turbines. However, being specific to wind turbines, the IEC series does not cover all aspects of the design and construction of an offshore wind farm. References to other recognized standards are therefore made when necessary. For example, the ISO series or API standards may be used for the design of the support structures. As a general rule, the requirements of the IEC series standards supersede requirements from other international standards when applicable. Mixing different standards should be avoided when possible, as they might have different approaches. For example, if the ISO approach is used for the site condition evaluation, then the corresponding ISO standards should be used in the design phase as well. Other internationally recognized public standards might also be integrated in the certification references on the Applicant s request on a case-by-case basis. If they come as an addition to the referenced standards, it shall only be demonstrated that they do not contradict the other standards listed in the certification references. However, if they are to be substituted to a referenced normative standard, the Applicant shall provide evidence that the chosen methodology is at least as conservative as the IEC/ISO approach. Substitutions of referenced informative standards will be evaluated on a case-by-case basis. 22 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

23 Any modification to the certification references will be explicitly stated on the Project Certificate. It is also possible, again on a case-by-case basis, to perform the certification on the basis of older versions of standards, such as for example IEC :1999. In such a case, these specificities will also be explicitly mentioned on the PC. However, certification according to a certification scheme other than the IEC series, or integration of private guidelines in the certification references, is not possible. For specific topics that are not covered by the IEC , such as an evaluation of the maintainability or availability, it is possible to incorporate requirements specified by the Applicant on a case-by-case basis. These specifications should be considered as additions to the existing references and cannot be substituted to any referenced standard. The exact specifications shall be agreed beforehand between the Applicant and Bureau Veritas Certification. Conformity statements can be issued for such items and listed in the final PC. Finally, the certification references will have to be adapted on a case-by-case basis to incorporate relevant local regulations, such as local grid codes for example. Only those regulations directly related to the scope described in IEC (see section 4.2.1) will be considered. In the case of conflict with the references listed in section 3, local regulations supersede international standards. The scope of project certification is limited to the technical and health and safety related aspects described in IEC (see section 4.2.1). Compliance to local regulations out of this scope, such as fishing rights, environmental impact assessment, administrative questions, etc., is the Applicant s responsibility and will not be verified. It is highly recommended that an assessment of the applicable local regulations be performed prior to the start of the certification procedure and as soon as possible in the course of the wind farm project Interaction with Type Certificate All wind turbine types to be installed shall have been certified by an accredited certification body. Valid Type Certificates (TC) shall be provided. For new turbine models which have not yet been certified, at least the Conformity Statement for the module Design Evaluation shall be available in order to start the certification process. The final Project Certificate will then only be issued once the TC is completed. The TC should preferably have been issued by Bureau Veritas Certification, but TC from other certification bodies will also be accepted, on the condition that they are duly accredited according to ISO/IEC or EN by an accreditation body member of the Multilateral Recognition Arrangement. The TC certification scheme shall be based on the IEC series, and should ideally rely on the same revisions of the standards as those included in the project certification references. Otherwise, gap analyses shall be performed by the Applicant. Other TC, such as those according to national standards or to private guidelines, cannot be accepted as such. In such a case, the Applicant shall engage a conversion process in order to get a TC according to the IEC series. Bureau Veritas Certification may perform this gap analysis in complement to the certification process. In this case, the Applicant shall make arrangements to provide Bureau Veritas Certification with the necessary documents. 23

24 4.2. Project certification process Procedure The general project certification procedure is described in IEC and is illustrated in Figure1. It is divided into several modules that are evaluated individually, though not always independently from each other as some will use the results from previous modules as inputs. Type Certificate Site conditions assessment Design basis evaluation Integrated load analysis Wind turbine / RNA design evaluation Support structure design evaluation Other installations design evaluation Wind turbine / RNA manufacturing surveillance Support structure manufacturing surveillance Other installations manufacturing surveillance Transport and installation surveillance Commissioning surveillance Project characteristics measurements Final evaluation Project certificate Operation and maintenance surveillance Mandatory module Optional module Figure 1 Project certification procedure 2 Each module, once validated, is concluded by an evaluation report and a conformity statement. The Project Certificate, along with the final evaluation report, is issued at the end of the certification procedure given that all mandatory modules have been successfully completed. A PC attests to the conformity and correctness of all mandatory modules and, if applicable, of the optional modules. 2 IEC ed.1.0 Copyright 2010 IEC Geneva, Switzerland. 24 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

25 It is possible to evaluate only one or a few modules of the certification, providing that the previous modules they depend on have been verified. In such a case, evaluation reports and conformity statements will be delivered for the successfully evaluated modules. A PC can only be issued if all the mandatory modules are duly validated. If the Applicant chooses to split the certification work between different certification bodies, arrangements for interaction between Bureau Veritas Certification and other certification bodies and sharing of information shall be made prior to the start of the certification procedure. Acceptance of conformity statements from other certification bodies does not imply that Bureau Veritas Certification takes responsibility for their work. The PC will clearly identify the modules which were evaluated by another certification body as well as the certification bodies involved. Optional modules, displayed in light grey in Figure1, will only be evaluated upon the Applicant s request. This shall be determined before the start of the certification process. If one or more optional modules are successfully evaluated, the corresponding conformity statement(s) will be issued and incorporated in the final PC. Should an optional module be evaluated but deemed not conform to the required standards, a PC can still be delivered but without mentioning this module Deliverables An evaluation report will be provided for every evaluated module. This report summarizes the evaluations, analyses or inspections performed by Bureau Veritas Certification, the different findings that were pinpointed, and the final results of the investigations. It asserts Bureau Veritas Certification s conclusion on the conformity of the module under scrutiny. If the module is deemed to be compliant with the relevant requirements, a conformity statement will be issued. An example of conformity statement can be found in Appendix A. As a final step of the certification scheme, Bureau Veritas Certification will go through the different evaluation reports and conformity statements for all modules of the certification scheme and document all relevant findings and observations into a final evaluation report. This final evaluation report will also reference all the documents relevant to the Project Certificate. The Project Certificate, along with the final evaluation report, is issued at the end of the certification procedure given that conformity statements for all mandatory modules could be issued. An example of PC can be found in Appendix A. The Applicant will also be provided with review sheets for every submitted document, containing all findings and comments made by the reviewer. As the documentation review is performed via special software (see 4.3.2), these review sheets will normally only be accessible to the Applicant on this software Validity A Project Certificate attests that a given wind farm was designed and installed according to a given set of references. This set of standards is not subject to revision, and the evaluation results consequently do not have any period of validity, as mentioned in IEC However, the PC does not provide any guarantee regarding future operation and maintenance (O&M) of the wind farm. This is why the validity of the PC must still be restricted and depend on a regular surveillance of the O&M activities. As a consequence, a PC delivered by Bureau Veritas Certification has a limited period of validity of one year after 25

26 the date of issuance, which can be extended annually for one additional year at a time, up to the design life of the project, under the following conditions (mentioned in IEC ): Bureau Veritas Certification has performed O&M surveillance of the wind farm according to the corresponding module of IEC and as described in section 14, in order to verify that the wind farm is operated and maintained according to the procedures described in the certified O&M manuals and that these procedures are compliant with the IEC series standards. The corresponding conformity statement shall have been issued less than a year prior to the issuance of the updated PC The Applicant shall report all repairs and modifications performed, and all planned major modifications, in comparison to the certified design and provide the updated documentation for Bureau Veritas Certification to review The Applicant shall provide a report describing operating experience as well as any deviation from expected behaviour for both the wind turbines and all other installations included in the PC Applications for the extension of the PC validity on an annual basis is a good way to ensure that the operation and maintenance of the wind farm is performed correctly, that problems are detected early enough and that the latest updates of the standards are correctly implemented through adaptations of the wind farm design when possible, thus maximizing the wind farm lifetime and production Bureau Veritas Certification s approach General methodology: Risk-based verification A risk-based approach is adopted for the entire certification process. The principle of risk-based verification is to assess the risks related to relevant failure modes of safety critical equipment and systems in order to keep the risk below an acceptable limit. For this purpose, safety critical equipment and systems are to comply with relevant performance standards and this compliance is verified. In practice, Bureau Veritas Certification will assess the criticality of the different components and subsystems of the specific wind farm under consideration, which depends on various parameters such as the consequences of failure, particular design specificities, previous experience, etc. This assessment is based on various documents provided by the Applicant including a risk analysis and Bureau Veritas Certification s experience with similar components or processes. The estimated criticality might evolve during the certification process as more experience is acquired. Changes in the design or procedures will also affect this estimation. The extent of verifications (which may include document review, independent analyses or surveillance) will then be adapted according to the estimated criticality. For example, for the design evaluation of the most critical components, independent analysis is normally required, while a simple documentation review might be sufficient for the less critical parts. Regarding manufacturing surveillance, the inspection rate will be determined individually for each component depending on the results of the risk assessment Document review A large part of the evaluation consists in reviewing calculation notes, specifications, drawings, data sheets, reports, certificates, etc. 26 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

27 The evaluators will verify the completeness of the documentation sent by the Applicant and its conformity to the certification references. A typical document verification loop consists of two successive reviews. Upon completing the first review, Bureau Veritas Certification will issue a list of comments to be considered by the Applicant. A second review is then performed to confirm that all these remarks have been correctly implemented in the updated document. Bureau Veritas has developed a specific software tool for document review, called DRT (Design Review Tool). Based on the well-known Documentum software, it allows smart management of the complete documentation and effective communication between Bureau Veritas Certification and the Applicant. Each document submitted by the Applicant is recorded in this online tool and referenced according to the applicable modules. The software centralizes all the comments made by the reviewer and makes them available to the Applicant who may address them directly online. This reviewing process ensures transparency and efficiency. Bureau Veritas Certification has extensive experience of handling confidential data and permanently strives to ensure the security and confidentiality of the documentation provided for its scrutiny Independent analyses Bureau Veritas Certification may in some cases perform independent calculations based on its own assumptions and methods. The goal of these independent calculations is to verify some key characteristics of the project. They do not prevent the Applicant from performing its own sensitivity analyses. Independent analyses are usually performed for the most critical cases only and not as a standard basis. Typical application fields would be: Atmospheric modelling and statistical calculations based on environmental data from the local measurements in order to determine the site-specific environmental design parameters Aero-elastic simulations to determine the loads on the wind turbine structure Structural and mechanical calculations to evaluate the impact of these loads on the different components of the wind turbine and on the support structure In addition, Bureau Veritas Certification can also provide independent verification on other particular points of interest at the Applicant s request Inspections and surveillance As defined in the IEC , the surveillance of a specific process (manufacturing, transportation, installation, etc.) consists of verifying that the procedures in force meet specified requirements. This verification usually involves several methods: Evaluation of the quality system Verification of the compliance of the procedures with the specified requirements (if not covered by the Type Certificate) Verification of the effective application of the procedures 27

28 The quality system evaluation is normally limited to the verification that the quality systems of the different manufacturers or operators involved are certified according to The quality system evaluation is normally limited to the verification that the quality systems of the different manufacturers or operators involved are certified according to ISO This quality system certification shall have been carried out by an accredited certification body operating according to ISO/IEC In this case, no additional audit of the quality system will be needed. However, if the quality system is not properly certified, Bureau Veritas Certification will have to evaluate that it meets sufficient quality management requirements. The evaluation of the compliance of the procedures usually consists of reviewing the different documents related to the process under scrutiny (manuals, checklists, reports, etc.) and verifying their compliance to the specified requirements. Finally, the verification of the correct application of the procedures involves review of records and reports related to the process under scrutiny and several on-site inspections of the process. The exact scope and extent of the inspections depend on the process itself and particularly on its estimated criticality. Usually, on-site inspections will not cover all components under investigation, but will be performed on the basis of random sampling. The sampling rate will be determined based on various parameters such as: The type of process (e.g. manual or automatized) The testing procedures for quality control The maturity of the company quality management system The experience of the company, in particular with the specificities related to wind turbines The component criticality The results of the previous evaluations (especially those from the design review) The sampling rate for components produced as unique specimens or in very small quantities for the wind farm, such as the components of the electrical substation for example, might however be set to 100 %. 28 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

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31 5. Site conditions evaluation 5

32 5. Site conditions evaluation 5.1. Introduction The first step in a project certification consists in assessing the site-specific design parameters, which include the atmospheric, marine, soil and electrical power network conditions. This assessment relies on desk studies, on-site field measurements and laboratory testing, which are undertaken by the Applicant and verified by the certification body Methodology Bureau Veritas Certification will verify that the measurements were performed in compliance with the relevant standards and that the site-specific design parameters were correctly calculated by the Applicant on the basis of these measurements. This evaluation is mostly based on documentation review. The correctness and completeness of the submitted reports is checked, with particular attention to the following aspects: Quality of the testing laboratories and companies carrying out the measurements (ISO/IEC accreditation or experience in the selected fields in particular) Quality of the testing equipment (instrumentation, calibration, etc.) Conformity of the measurements or testing procedures to the relevant codes and standards and to the industry best practices Processing of the measured data (data filtering, correction of inconsistent data, etc.) Calculation of the design parameters, in particular extrapolation to determine extreme parameters Documentation and reporting If the testing laboratories are not accredited according to ISO/IEC 17025, then Bureau Veritas Certification will audit their quality management system towards specific ISO/ IEC requirements and be more deeply involved in the measurement campaign, in particular by witnessing the measurements. Therefore, it is highly recommended to engage the certification process prior to the measuring campaign. Bureau Veritas Certification may also perform independent analyses on some specific topics. This would mainly consist of the recalculation of some particular parameters from the measured data, such as the extreme wind speed Wind and Other Environmental Conditions Measurement campaign As a rule, the wind and other environmental conditions should be derived from sitespecific measurements and local long-term reference data. These measurements should comply with IEC , the MEASNET procedure and the IEA Recommended Practice. Otherwise, it shall be demonstrated that the chosen methodology is conservative. Any deviation from these requirements shall be properly justified, and the additional uncertainty on the final results shall be estimated and taken into account. Note that only some key points are highlighted in this section, rather than all requirements mentioned in these standards. 32 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

33 The measuring campaign should be conducted over a period of at least one year, in order to avoid missing seasonal specificities. The measurement campaign should not rely solely on remote-sensing devices such as Lidars and Sodars. The installation of at least one measurement mast at the site is highly recommended in order to measure the local turbulence intensity, which cannot be properly measured by remote-sensing devices. Data should be recorded at a frequency of 1 Hz and averaged over 10-min periods. It is recommended that the averages and the standard deviations, as well as the maximum and minimum values within each averaging period, for all measured parameters are recorded. At least the following parameters shall be measured: 10-min average wind speed at 2 different heights 10-min average wind direction 10-min standard deviation of the wind speed 1-s (or equivalent) maximum wind speed per 10-min period Additionally, it is highly advised to measure the temperature, the pressure and the air humidity in order to derive the air density and the icing risk Data analysis The measurement data cannot usually be used directly and some additional post-treatment is necessary to derive the required site-specific design-driving parameters. This includes: Data filtering and completion (correction or suppression of erroneous or disturbed data) Generation of an atmospheric wind model to extrapolate the measured data to all turbine positions and hub heights Calculations of the site-specific design parameters Use of a wake model to evaluate the increase in turbulence intensity (and more generally the perturbation of the wind flow) due to the presence of the neighbouring wind turbines As a rule, the data analysis shall be performed by an experienced wind analyst. The procedures for data processing and analyses shall be exhaustively documented and all assumptions justified. Particular attention shall be devoted to the description of the statistical methods and assumptions used for the long-term correction and for the extrapolation of extreme events with a long recurrence period. The following parameters, as a minimum, shall be determined by the Applicant at each turbine position, in accordance with the requirements specified in IEC section 12: Long-term average wind speed Probability distribution of the wind speed and direction Extreme wind speeds 33

34 Turbulence intensity (ambient and including wake effect) in relation to the wind speed Wind shear Flow inclination Air density Air temperature range (yearly mean, minimum, maximum) Bureau Veritas Certification will review all the documentation related to the meteorological measurements and calculations, as described in 5.2. Particular attention will be devoted to the verification of the data quality and of the statistical and numerical extrapolation methods Marine Conditions and Weather Windows The objective of the measurement campaign is to determine the marine characteristics relevant for a safe design of the substructure, such as: Waves Currents Water level Sea ice Marine growth Other marine parameters such as water temperature, salinity, etc. The following parameters, as a minimum, shall be determined by the Applicant, in accordance with the requirements specified in IEC section 12 and ISO : Various extreme and significant wave heights as specified in IEC section 12.4 Joint probability distributions of mean wind speed, wave height and peak spectral period Extreme current speeds and directions Water level range as specified in IEC section 12.6 Marine growth characteristics Water temperature range Salinity Weather windows The calculation of environmental data for the extreme conditions for waves, wind, current, and for water level when relevant, is to be based on return periods of 1 year and 50 years, as described in IEC Extremes may not always result from the same meteorological conditions, or from the same storm event, nor at the same time within the same event. It may therefore be necessary or 34 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

35 useful to take into account the directionality of wind, waves and currents for extreme events. Depending on the site-specific climate, several sets, in which one of these parameters is governing, can be defined for the evaluation of combinations of the direction and intensity of waves, wind, and current and of associated parameters. More information can be found in the Bureau Veritas Marine Division Rule Note NR 493, Appendix B. Bureau Veritas Certification will review all the documentation related to the oceanographic measurements and calculations, as described in 5.2. Particular attention will be devoted to the review of the statistical and numerical extrapolation methods Soil and Earthquake Conditions General description The objective of the measurement campaign is to determine the soil characteristics relevant for a safe design of the substructure, such as: Soil classification, description and stratigraphy Basic soil parameters Deformation properties Shear strength parameters Soil corrosivity Other specific parameters, such as settlement parameters, dynamic soil parameters, etc. These properties are determined during a 3-phase process, including: Initial desk studies A general site investigation, mainly based on geophysical studies, to obtain an accurate bathymetric and geological mapping of the site. A detailed investigation of the soil properties through various geotechnical studies (soil coring and sampling, laboratory testing, etc.) More information about offshore soil investigations can be found in the ISSMGE document listed as informative reference in Chapter 3. The soil conditions assessment shall as a rule comply with ISO For projects located in seismically active areas, an assessment of the seismic risk shall be performed according to ISO Bureau Veritas Certification will review all the documentation related to the geophysical and geotechnical studies, as described in 5.2, with particular attention to the test reports and procedures. The quality, scope and completeness of the on-site investigations and laboratory tests will be verified, as well as the methods used to derive the design parameters from the measured data Geophysical investigations The objective of the geophysical survey is to understand the local topography and the nature and characteristics of the seabed. It is based on the findings from the initial desk study and aims at refining this general knowledge for the specificities of the site under consideration. 35

36 Geophysical investigations usually cover the whole project area and may encompass: Bathymetric studies, typically by the means of echo sounding Topographic studies: identification of significant local features and obstructions. This can be performed using echo sounding or magnetometric techniques Stratigraphic studies: identification of the soil profile, typically with seismic systems Geotechnical investigations The objective of the geotechnical survey is to determine as much information relative to soil properties as necessary for the design of the support structure and foundations, for the whole area under consideration. The recommended geotechnical testing program should be in accordance with the standard practices of offshore industry (in particular the oil and gas industry). It is not possible to give detailed requirements about the investigations to be performed, as the extent of the investigation program is highly dependent on the soil characteristics, the proposed type of foundations and the results of the geological and geophysical studies. Nevertheless, soil investigation shall, as a rule, comprise penetration tests and soil borings with sampling for laboratory tests, and shall extend to a depth below which possible existence of weak formations will not influence the structural integrity of the structure. In soil it is recommended to perform one cone penetration test per wind turbine and one sample borehole per group of 5 wind turbines. The number of sample borings might be reduced if the first investigations show that the site presents a good homogeneity in soil profiles and characteristics. However, one boring at each extremity of the wind farm and one additional in the middle is the absolute minimum. In case coarser soil is encountered (coarse gravel, boulder, cobbles) cone penetration tests are generally replaced by standard penetration tests. In case rock is encountered, rock coring shall be performed instead of CPTs and sample borings. The planned route(s) for electrical cables should be investigated. For the geophysical survey, a corridor of about 500 to 1000 m, centered on the planned cable route, should be investigated. For the geotechnical survey, soil sampling might be performed every 300 to 1000 m, depending on the soil type and homogeneity. Penetration tests may be recommended depending on soil conditions. Remarkable features of seabed (channels, scars, sand waves ) are to be investigated. In general at least 3 samplings per feature are recommended Electrical Power Network Conditions The electrical network conditions at the wind farm connection point shall be determined to ensure compatibility with the wind turbine electrical design parameters. This includes in particular (but is not limited to): Nominal voltage, possible voltage range and rate of change Nominal frequency, possible frequency range and rate of change Type, number and duration of network outages Existing load and power generation at the connection point 36 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

37 Additionally, the locally applicable grid connection requirements shall be considered and the Applicant shall demonstrate that the wind farm meets the required capabilities, in particular in terms of: Power factor control Power quality (harmonics, flicker, etc.) Fault-ride-through capacities Bureau Veritas Certification will verify that the Applicant has identified the relevant requirements and has provided sufficient proof that the wind farm is able to meet them. 37

38

39 6. Design basis evaluation 6

40 6. Design basis evaluation 6.1. Introduction The design basis describes all design specifications, requirements, assumptions and methodologies that were used for the project design, or are to be used during the manufacturing, transport, installation, commissioning and operation phases. The purpose of the design basis evaluation is to verify that the design basis is sufficient for a safe design and execution of the project, i.e. that it is coherent, exhaustive, sufficiently documented and that it meets all requirements related to the certification references Methodology The evaluation is solely based on a documentation review Necessary information As described in IEC , the design basis shall identify all requirements, assumptions and methodologies essential for the design, including: Codes and standards used for the design Wind turbine type and design parameters Site-specific design parameters Design assumptions, methodologies and principles Requirements for manufacturing, transportation, installation and commissioning (in particular environmental conditions relevant for installation) Requirements for operation and maintenance, in particular the inspection scope and frequency Grid connection requirements Other requirements (e.g. local regulations) Special care shall be observed for all documentation related to the load calculations. It shall clearly refer to the IEC series or to the other applied codes and standards. Any deviation from the standards, or specific design aspects and parameters not covered in the standards, shall be clearly stated in the design basis. The documentation shall describe at least the following points: External design parameters Design load cases Load factors and load reduction factors Partial safety factors applied on loads and materials Duration of simulation as well as number of simulations Methods used for the calculation of extreme and fatigue design loads and for response analyses Design lifetime of components, systems and structures 40 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

41 41

42

43 7. Integrated load analysis 7

44 7. Integrated load analysis 7.1. Introduction If the site-specific design parameters measured during the site conditions assessment are more critical than those specified in the wind turbine TC, it is necessary to perform sitespecific load calculations in order to determine the loads caused by the more stringent conditions at the site and verify that they do not exceed the design loads of the wind turbine. If the support structure is not part of the wind turbine TC, the integrated load analysis will be necessary in order to take the whole structure into account. The wind turbine and its support structure are modelled in an aero-elastic code and various simulations are performed using the site-specific environmental conditions (wind, waves, etc.). The objective is to determine the load distribution on the different parts of the wind turbine in both normal and extreme conditions. The load calculations are performed by the Applicant (or the wind turbine and support structure designers) and reviewed by Bureau Veritas Certification, which may also perform some independent simulations if deemed necessary. The design load cases mentioned in IEC represent several thousand simulations and cover a large range of operating conditions: Power production under normal environmental conditions, or in combination with extreme events (turbulence, wind shear, etc.) Occurrence of fault during power production (loss of electrical network, control system fault, freezing of blades, etc.) Start-up and shut-down, under normal conditions or in combination with extreme events, and emergency shut-down Extreme events (extreme wind speed and turbulence) when the turbine is parked, possibly with additional fault conditions Transport, installation, maintenance and repair 7.2. Methodology Bureau Veritas Certification will verify the calculations provided by the Applicant by reviewing the load reports. In particular, the following issues will be addressed: Range of DLC in respect to IEC , especially the combination of external conditions and operating conditions Calculation methods (wind and wave models used, simulation characteristics, statistical extrapolation of extreme loads, etc.) Comparison between the site-specific loads and the design loads considered in the wind turbine TC Bureau Veritas Certification will also carry out independent analyses for the most critical load cases at a minimum. For the determination of the loading on the wind turbine, Bureau Veritas Certification uses the aero-elastic code HAWC2 (developed by Risoe DTU) intended for the calculation of the wind turbine response in time domain. The structural part of the code is based on a multi-body approach using beam elements. The turbine is modelled as an assembly of bodies connected with constraint equations (rigid coupling, bearing, prescribed fixed bearing angle, etc.). The aerodynamic part of the code is based on the blade element momentum theory, extended from the classic approach to handle dynamic inflow, dynamic stall, skew inflow, shear effects on the induction and effects from large deflections. 44 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

45 7.3. Requirements Bureau Veritas Certification will require the load reports to be presented in a practical format, allowing for ready identification and verification of the different DLCs. Additionally, the load values submitted shall be accompanied by a description of the assumptions and methods used for each DLC. The aero-elastic model and input data shall also be extensively described, including in particular: Aerodynamic parameters Structural characteristics Control and protection system parameters Environmental conditions and models used (turbulence model, soil properties, etc.) In order to perform independent analyses, Bureau Veritas Certification will require information on the wind turbine and support structure characteristics in order to model the integrated system in the aero-elastic code. The required information typically includes: Tower, sub-structure and foundations properties (structural) Blade properties (structural and aerodynamic) Nacelle geometry and masses Drive train details (geometry of shafts, gearbox schema, gearbox ratio) Generator characteristics, power curve Mechanical and electrical losses Parameter values related to the control system Pitch actuator details Yaw control details Modal analysis results (rotor and tower modes, Campbell diagram) Aerodynamic control conditions (tip loss correction, hub loss) Bureau Veritas Certification will also require the extreme and fatigue time series from the Applicant calculations for comparison with the results of the independent analyses. 45

46

47 8. Site-specific design evaluation 8

48 8. Site-specific design evaluation 8.1. Introduction The purpose of site-specific design evaluation is to examine whether the wind turbines, the support structures and any other installation covered by the project certification are designed and documented in conformity with the design basis and if the design is adapted to the actual site conditions. The design evaluation is mostly based on the review of the design documentation and calculation notes. Independent structural and mechanical calculations might also be performed for some major components of the wind turbine or support structure in order to verify that the fatigue and ultimate loads previously calculated for the complete structure do not endanger the structural stability of the component General requirements and methodology Design review The design evaluation will mainly consist in reviewing calculation notes, specifications, drawings, data sheets, reports and certificates, and verifying their conformity to the agreed certification references and the design basis for the site-specific conditions under consideration. A particularly important part of the process is the comparison of the site-specific loads, if calculated as part of the Integrated Load Analysis (see section 7) with the design loads specified in the wind turbine TC. If the loading on the machine implied by the actual site conditions is higher than the design loads, it shall be demonstrated that the increased loads do not endanger the structural integrity of the wind turbine. The additional calculations and analysis shall take into account the results from the module Site Conditions Evaluation (section 5). Similarly, any change in vibration modes or natural frequencies shall also be stated and carefully evaluated. Bureau Veritas Certification will also verify that all the relevant environmental conditions at the site, not only the metocean conditions, were duly taken into consideration, even though they may not directly impact the loads on the wind turbine. These include for example: Temperature (cold climate sites would necessitate appropriate mitigation measures) Humidity Solar radiation Rain, hail, snow and ice (in particular risk of icing on the rotor blades) Chemically active substances Mechanically active particles Salinity Electrical conditions Lightning In particular, the risk of corrosion shall be carefully assessed, and appropriate protection measures shall be enforced. In order to take into account the increased loading and those site-specific environmental conditions, some components may have to be modified or reinforced compared to the design evaluated for the TC. 48 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

49 In such cases, the complete design documentation shall be provided in order to carry out a thorough design evaluation of the modified component. This requirement also applies to those components which were not or only partially included in the Type Certification evaluation Mechanical / Structural calculations Independent analysis may be carried out by Bureau Veritas Certification on critical structures and components (including nacelle and bearing, hub, nacelle frame, bolting, tower, gearbox, blades, etc.), especially on those which are reinforced or modified compared to the versions certified as part of the wind turbine TC. The dynamical behaviour of the transmission chain may also be investigated. To carry out independent analyses, FE models covering mesh and element information, material properties and boundary conditions shall be made available to Bureau Veritas Certification; they could be exported from commercial software such as ANSYS, ABAQUS, etc. Independent analyses include modal analysis, extreme & fatigue analysis and stability analysis. The exact scope of the required independent mechanical / structural calculations will be determined on a case by case basis depending on the site conditions, on the TC characteristics and on relevant project specificities Corrosion protection Offshore installations operate in a very aggressive environment regarding corrosion. Therefore, extensive protection is needed to prevent or mitigate the effects of corrosion on the wind turbine components and the support structures. The wind turbines and other relevant installations such as the electrical substation should be sealed in order to maintain a dry, non-corrosive environment inside the installation. Additional protection can be provided by de-humidifying devices and special protective systems, in particular for the electrical components. In the atmospheric zone, which is normally not exposed to waves, corrosion protection shall be provided by adequate protective paints and coatings. ISO and ISO can be referred to for guidance in this regard. Additional protection systems, such as steel wear plates, might be required in the splash zone to complement the protective coatings. The effect of corrosion might also be taken into account by increasing the steel thickness. For the permanently submerged area of the support structure, cathodic protection systems shall be implemented. These cover sacrificial anodes or impressed current systems. Methods and requirements regarding cathodic protection are described in EN Protective coating may also be applied to complement the cathodic protection. Bureau Veritas Marine Division Guidance Note NI 423 gives more information about corrosion protection for offshore installations Site-specific wind turbine / RNA design evaluation As the wind turbine shall already be type-certified, there is no need for a detailed investigation of the stability of each component as long as both the following conditions are satisfied: 49

50 The design of the component to be installed is the same as the design that has been certified The calculated site-specific loads on the component are not higher than the design loads considered in the type certificate In this case, Bureau Veritas Certification will only verify the adequacy of the component design to the local environmental conditions, in particular in terms of corrosion protection. On the other hand, if these conditions are not verified, Bureau Veritas Certification will review the complete design documentation of the component in order to evaluate its conformity to the design basis and verify that its adaptation to the site-specific loading and environmental conditions. The documentation provided shall include a full description of all modifications and reinforcements compared to the original, type-certified design. Bureau Veritas Certification may also perform independent analyses to verify the structural integrity of the structure and confirm the results of the calculations performed by the Applicant. The following components will be considered: Safety and control systems, including the wind farm control system Rotor blades Gearbox Generator Bearings Brakes Structural components: nacelle frame, hub, etc Bolted connections Cooling and heating systems Pitch and yaw systems Electrical components 8.4. Site-specific support structure design evaluation The support structure encompasses the tower, the sub-structure and the foundation of a wind turbine. Typical sub-structures for offshore wind farms are: Gravity-based Monopile Multipod Jacket Since the support structure is commonly not type certified its design evaluation will require more attention than that of the RNA. Bureau Veritas Certification will therefore verify the conformity of the support structure design (both structural and geotechnical) with the approved design basis and the certification references, as well as the completeness and correctness of the design documentation. 50 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

51 As a rule, the support structure shall be designed according to the ISO series, which includes requirements for both steel structures (ISO 19902) and concrete structures (ISO 19903). API RP 2A-WSD will also be accepted. Other recognized standards might be accepted on a case-by-case basis as described in section For foundations, the requirements in ISO shall be met. The most important part of the support structure design evaluation is the structural strength and stability analyses based on the site-specific loads calculated as part of the integrated load analysis. Bureau Veritas Certification will review the calculation notes from the Applicant and may also perform independent analyses if necessary. In case the support structure was not designed specifically for the site, the design loads will be compared to the calculated site-specific loads and any excess will be carefully examined. Also, the geotechnical parameters used in the calculation notes will be compared to those measured on the site, and the consequences of important deviations will be evaluated. Finally, the proposed corrosion protection system will be evaluated in light of the sitespecific environmental conditions Other installations design evaluation General description This module of the project certification procedure is optional, which means it will only be evaluated on the Applicant s request. Also, as those other installations are not described in the IEC series, the Applicant can define its own reference standards for the design evaluation. Bureau Veritas Certification can recommend adequate and recognized standards if necessary. In any case, the resulting safety level shall at least comply with the corresponding requirements of the relevant IEC series standard. The installations to be evaluated as part of the certification procedure shall be clearly defined. The evaluations are normally based on document review but might also include independent analysis. For each installation, Bureau Veritas Certification will perform the following verifications, when applicable: Evaluation of the design documentation Evaluation of the structural and geotechnical design with respect to the sitespecific conditions Evaluation of the design of the other installations with respect to the results of the integrated load analysis, if relevant Evaluation of the proposed corrosion protection system in light of the site-specific environmental conditions The following sections give more information relative to two important parts of a wind farm, the electrical substation and the electrical power cables. For other installations the applicable standards will be defined on a case-by-case basis Electrical substation Regarding structural requirements, electrical substations can be treated as any other offshore platform. Bureau Veritas Certification recommends designing the platform 51

52 according to ISO or API RP 2A-WSD. The topside design shall follow the requirements of ISO The electrical installation shall as a rule comply with IEC Electrical cables Wind farms will typically comprise two types of electrical cables: Medium voltage (e.g. 30 kv) cables linking the individual wind turbines to the electrical substation High voltage (> 100 kv) from the electrical substation to the shore to transport the generated power and feed it into the power network There is no international standard specific to subsea power cables. Nonetheless, electrical cables shall meet the requirements of the relevant part of IEC 60502, depending on their voltage level. ISO , which applies to subsea umbilicals, can also be used for the design, material selection, manufacture, design verification, testing, installation and operation of the subsea power cables. 52 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

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55 9. Manufacturing surveillance 9

56 9. Manufacturing surveillance 9.1. Introduction The purpose of manufacturing evaluation is to assess that the wind turbines, the support structures and any other installation covered by the project certification are manufactured in conformity with the design, manufacturing and inspection documentation. This evaluation includes the following elements: Quality system evaluation Manufacturing inspection and surveillance This evaluation is not limited to the final assembly plant and will consider the complete supply chain, in particular the manufacturers of the main components. Lower-level subcontractors will normally not be subjected to the manufacturing surveillance. However, Bureau Veritas Certification reserves the right to extend the scope of inspection in case critical components, unusual materials or special processes are involved. Prior to the beginning of the manufacturing, the Applicant shall provide sufficient information about the suppliers involved and the manufacturing processes, so that Bureau Veritas Certification can set up a detailed inspection and test plan Quality system evaluation The quality system evaluation is normally limited to the verification that the quality systems of the different manufacturers involved are certified according to ISO This quality system certification shall have been carried out by an accredited certification body that operates according to ISO/IEC If the quality system is not already certified, Bureau Veritas Certification will have to ascertain that it meets sufficient quality management requirements. The following aspects will be evaluated: Responsibilities Control of documents Subcontracting Purchasing Process control Inspection and testing Measuring equipment control Treatment of non-conforming products Corrective measures Management of change Quality recordings Personnel qualification, competency and training Product identification and traceability 56 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

57 9.3. Manufacturing inspection and surveillance Methodology The exact extent and scope of the inspections to be carried out will be defined on a case by case basis according to the project specificities, as described in section As a general rule, the manufacturing inspection of a given component will include: A survey of the manufacturing of a certain number of units, depending on the component criticality. This survey will cover all the phases of the fabrication process, including the non-destructive testing (NDT) when applicable The verification that design specifications are properly documented in workshop drawings, workshop instructions, purchase specifications, fabrication methods and procedures, including in particular special processes, and welding and NDT procedures when applicable A review of the personnel qualifications, in particular for welders, NDT operators and quality inspectors A review of the material certificates Verification of the inspection and test plan and effectiveness of its application Random checks of the effectiveness of acceptance procedures for purchased components Random checks of manufacturing and testing processes The necessary documentation of manufacturing processes, testing procedures, quality control, plans of the fabrication plants, etc., shall be provided to Bureau Veritas Certification beforehand. Bureau Veritas Certification will then submit a detailed inspection plan prior to the inspection for the manufacturer to take adequate measures to allow access to the necessary premises. Each inspection will be reported in a detailed inspection report listing all observations and comments raised by the inspectors Wind turbine The manufacturers involved in the fabrication of the main wind turbine components shall undergo the quality system evaluation described in 9.2. The suppliers of the following components might be considered for inspection: Rotor blades Rotor hub Rotor shaft Main, pitch and yaw bearings Gearbox Locking devices and mechanical brakes Generator Power converter Transformer Main frame, generator frame 57

58 Normally, those suppliers should have been evaluated as part of the type certification process. However, the manufacturing inspection during type certification is based on one specimen only. For project certification, additional surveillance activities are included in order to verify that the manufacturing of wind turbines for the specific project is carried out according to the approved design and with the intended quality, in particular with regards to modified or reinforced components. As most components are usually produced as serial products, it might be difficult to identify the products which will be allocated to a specific project. In such a case, visual inspections will be reduced and the evaluation will rather be focused on a documentation review. Additionally, the complete RNA will also be subjected to inspections based on random sampling. These inspections will cover both the assembly process and the final assembled RNA. They will focus in particular on the welded and bolted connections and the electrical installations. These inspections will take place at the wind turbine assembly plant. The sampling rate for inspections will be determined individually for each component and each manufacturer depending on the different criteria described in section Modified or reinforced components will be targeted in priority. On the contrary, if the manufacturer holds a valid Component Certificate according to IEC , the corresponding criticality will be reduced. If necessary, several inspections will be performed in order to witness all phases of the manufacturing process Support structure The manufacturers involved in the fabrication of the support structure will be submitted to the quality system evaluation described in 9.2. The manufacturing inspection of the support structure covers the following components: Tower Sub-structure Foundations The exact extent of the inspections will depend on the type of the support structure. In addition to the inspection description listed in 9.3.1, special attention will be devoted to the following items: Material quality For steel structures: Welding personnel qualifications Welding procedures For concrete structures: Preparations for concrete casting (reinforcement bars, embedment, etc.) Curing conditions 58 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

59 Construction joints, grouting Corrosion protection systems Non-destructive testing and other testing procedures Visual inspection of finished products Other installations If other installations are to be included in the Project Certificate, they shall be submitted to a manufacturing inspection as well. As this module is optional, the exact scope of the inspections will be determined on a case-by-case basis and in collaboration with the Applicant. If the manufacturing surveillance does not cover the complete installation, the limited scope will be mentioned on the corresponding Conformity Statement and on the final Project Certificate. For electrical substations, meteorological masts or any installation involving a support structure, the manufacturing inspection of the support structure will be carried out as mentioned in the previous section. The topsides however will necessitate a specific inspection plan, which will be determined on a case-by-case basis depending on the type of installation and the installation design. A specific inspection and testing plan will be set up for electrical cables as well. 59

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61 10. Transportation and installation surveillance 10

62 10. Transportation and installation surveillance Introduction The objective of the transportation and installation (T&I) surveillance is to make sure that no excessive loading is sustained by the wind turbines and their support structures during the transportation and the installation, and to prevent any damage on the components. Both the transportation of single components from the manufacturing plant to the harbour and the final sea transportation from the harbour to the site are considered. It consists of: Review of the intended T&I procedures, prior to their implementation Surveillance of the transportation and installation phases Review of the transportation and installation procedures Bureau Veritas Certification will assess the transportation procedures documented in the transportation manual. The description of the transportation process shall include: Technical specifications for the transportation Limiting environmental conditions Safety instructions Transportation arrangement including required fixtures, tooling and equipment Transportation loads and load conditions Bureau Veritas Certification will also verify that the installation process is documented with sufficient details and that it is compatible with the site conditions and the wind turbine design. The documentation shall include at least: Identification of personnel qualifications and skills Identification of interface points and any required technical specifications for civil and electrical construction works including earthing system Identification of specialized tooling and required lifting fixtures or equipment Quality control check points, measurements and inspections, required by the design Description of safety instructions and planned environmental protection measures Quality recording and record keeping processes In both cases, the conformity of the procedures with the design basis and the IEC series (in particular IEC and IEC ) will be evaluated. The Applicant may also refer to the ISO series (in particular ISO ) or API RP 2A-WSD for guidance regarding transport and installation procedures Transportation and installation surveillance Bureau Veritas Certification may perform surveillance of the T&I processes by audit or inspections to verify that the T&I procedures are correctly implemented. Surveillance may cover in particular the following phases: Monitoring of the loading and fastening at the manufacturer premises Surveillance of the transportation from the manufacturer premises to the harbour 62 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

63 Verification that no damage occurred, in particular to the corrosion protection system Monitoring of the loading and fastening of the different components on the installation boat in the harbour Compliance with the requirements for acceptable weather conditions during sea transportation and installation Surveillance of the complete installation process on site, especially the welding, bolting, non-destructive testing, etc Final visual inspection after installation Follow-up procedure on transportation or installation damages Bureau Veritas Certification will usually perform a full inspection of the first transports and installations, after which the T&I surveillance will not be systematic but based on random sampling. The exact sampling rate will be determined on a case-by-case basis, depending among other parameters on the findings from the first inspections, and might differ between the several steps mentioned above. Typical sampling rates would be around 10% for the first transportation (manufacturing plant to harbour), around 20% for the sea transportation (harbour to site) and 10 to 30% for the installation. These sampling rates could be reconsidered for projects involving a Marine Warranty Survey. In any case, Bureau Veritas Certification will review relevant transportation documentation and special care will be devoted to products shipped from overseas. Installation documentation will be controlled as well. Any deviation from the intended handling procedures shall be immediately reported to Bureau Veritas Certification, and an evaluation of the potential risks involved shall be performed. Bureau Veritas Certification may require special inspection for damages if deemed necessary. Bureau Veritas Certification will also review the Applicant s procedure for acceptability of damages. It shall cover damages potentially occurring during both the transportation (handling damages) and the installation. In particular, potential issues related to the foundations shall be considered: erroneous geotechnical assessment, lower than expected concrete strength, etc. In the event of damages, Bureau Veritas Certification will verify that this procedure is appropriately followed and that the persons taking the final acceptance decision are adequately qualified. 63

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65 11. Commissioning surveillance 11

66 11. Commissioning surveillance Introduction The purpose of the commissioning surveillance is to ensure that the procedures described in the commissioning manual are in conformance with the design basis and the IEC series (in particular IEC and IEC ), and that the final commissioning of the wind farm is actually carried out according to these procedures. It consists of two successive steps: Review of the commissioning instructions submitted by the manufacturer, prior to the commissioning of the wind farm (if not already covered by the TC) Surveillance of the commissioning, through both witnessing of the commissioning of a random sample of wind turbines and review of the final commissioning reports Review of the commissioning instructions This part is only necessary if the commissioning manual has not already been approved as part of the Type certification of the wind turbine. The intended commissioning instructions shall be submitted to Bureau Veritas Certification prior to the commissioning for review and approval. The commissioning manual shall include: The procedures to carry out in order to initialize the wind turbine The test plans to follow in order to verify that all components of the wind turbine operate properly and safely Bureau Veritas Certification will verify that the proposed procedures and test plans are documented in sufficient details and that they comply with the design basis and IEC series requirements. In particular, the following tests shall be planned as a minimum: Normal start-up Normal shutdown Emergency shutdown Shutdown from overspeed or representative simulation thereof Function test of the protection system 11.3.Commissioning surveillance Bureau Veritas Certification will witness the commissioning of some wind turbines in order to verify that the procedures described in the commissioning manual are correctly and fully implemented. The inspections will, in particular, cover: Witnessing of the connection to the grid Witnessing of the commissioning tests Bureau Veritas Certification will usually inspect the first wind turbines to be commissioned, after which the commissioning surveillance will not be systematic but based on random sampling. 66 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

67 The exact sampling rate will be determined on a case by case basis, depending among other parameters on the findings from the first round of inspections. Typical sampling rates would be approximately 10%. Bureau Veritas Certification will in addition to these inspections review all commissioning reports for the wind turbines whose commissioning has not been witnessed. Any deviation from the intended procedures shall be justified, and may involve subsequent inspections. 67

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69 12. Project characteristics measurements 12

70 12. Project characteristics measurements Introduction Project characteristics measurements constitute an optional module of the project certification and aim at verifying particular performance-related characteristics of the wind turbines at the specific site. They complement the measurements carried out for the type certification of the wind turbine. They can include the following measurements: Grid connection compatibility according to the local grid codes Verification of the power performance Verification of acoustic noise emission This module will only be evaluated if requested by the Applicant. Bureau Veritas Certification will review the test plan and the measurement reports in order to verify their conformity to the IEC series or other applicable standards. As this module is optional, the Applicant is not obliged to perform all tests within the module and may select only one or two of them. The conformity statement for this module will then naturally only mention those measurements that were verified by Bureau Veritas Certification. Additionally, when no IEC standards are available, the reference standards applied for the measurements as well as the compliance criteria will also be clearly identified in the final conformity statement General methodology The measurements should be carried out by recognized test laboratories or measurement institutes accredited according to ISO If this criterion is not verified, Bureau Veritas Certification will have to audit the measuring or testing body to verify that its quality management system meets these requirements. Bureau Veritas Certification may also witness the measurements to verify their compliance with the applicable standards. The wind turbines covered by the measurements shall be clearly identified in the reports. Any anomaly or unexpected behaviour during the measurements shall be reported and evaluated in the measurement report. Bureau Veritas Certification will verify that the measurement procedures comply with the applicable standards of the IEC series and any other agreed codes and standards (in particular the grid connection requirements). In order to avoid any problem, the test plan shall be agreed between Bureau Veritas Certification and the Applicant beforehand. Bureau Veritas Certification will also assess the completeness and correctness of the final test reports describing the measurement conditions, instrumentation, calibrations and analyses, as well as their conformity to the relevant standards Specific requirements Grid connection compatibility according to grid codes The purpose of these measurements is to document the capacity of the wind farm, or of one or more wind turbines within the wind farm, to meet the technical grid connection requirements specified in the local grid code applicable to the specific site. These measurements include the behaviour of the wind farm or the wind turbines during network faults such as low voltage ride through capabilities for example. 70 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

71 The exact scope and extent of the measurements depends on the local grid code requirements. If required, Bureau Veritas Certification can recommend relevant standards, such as IEC Verification of power performance The purpose of power performance measurements is to establish a measured power curve and refine the predicted annual energy production for one or more wind turbines within the wind farm. The results can then be compared to the guaranteed power curve for one individual turbine as provided by the manufacturer. The power performance measurements shall comply with IEC when applicable Verification of acoustic noise emission The purpose of these measurements is to document the acoustic emission characteristics of the wind farm, or of one or more wind turbines within the wind farm, and verify their compliance to local codes or any acoustic noise emission criteria defined by the Applicant. The acoustic noise emission measurements shall comply with IEC when applicable. 71

72

73 13. Final evaluation and project certificate 13

74 13. Final evaluation and project certificate Final evaluation As a final step of the certification scheme, Bureau Veritas Certification will go through the different evaluation reports and conformity statements for all modules of the certification scheme and document all relevant findings and observations into a final evaluation report. This final evaluation report will also reference all the documents relevant to the Project Certificate. A final assessment will be carried out on this basis and the decision whether or not to issue a Project Certificate will be made. In all cases, the final evaluation report will be delivered to the Applicant Delivery of Project Certificate If conformity statements were successfully delivered for all mandatory modules of the certification scheme, Bureau Veritas Certification will issue a Project Certificate to the Applicant on this basis. Any optional module evaluated during the course of the certification will also be referenced in the Project Certificate. The Project Certificate will list the standards composing the certification references, as well as all other regulatory requirements that may have been used as part of the conformity assessment of specific modules. 74 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

75 75

76

77 14. Operation and maintenance surveillance 14

78 14. Operation and maintenance surveillance Introduction Operation and maintenance (O&M) surveillance constitutes an optional module of the project certification. Its purpose is to ensure that the procedures described in the O&M manuals are in conformance with the design basis and the IEC series (in particular IEC and IEC ), and that the wind farm is actually operated and maintained according to these procedures. It consists of two successive steps: Review of the O&M instructions documented in the corresponding manuals, prior to the operation of the wind farm (if not already verified as part of the Type Certification of the wind turbine) Surveillance of the operation and maintenance of the wind farm, through both review of the O&M records and reports and periodic inspections of the wind farm This module will only be evaluated if requested by the Applicant. As this module is optional, the exact extent and scope of Bureau Veritas Certification s activities shall be agreed beforehand. In particular, it shall be determined whether the O&M surveillance will cover only the wind turbines and their support structures, or also other installations at the site. The agreed scope will be clearly identified in the corresponding conformity statement. The validation of the O&M surveillance module is mandatory in order to extend the validity of a Project Certificate Review of the operation and maintenance manuals Bureau Veritas Certification will assess the completeness of the operation manual, its compliance to the IEC series (in particular section 14.4 of IEC ) and its adequacy to the site conditions and the wind turbine design. This part is only necessary if the operation manual has not already been approved as part of the Type certification of the wind turbine. The manual shall at least include: Identification of personnel qualifications and skills Identification of required specialized tooling and personal protection equipment Description of access procedures Identification of limiting environmental conditions Description of the wind turbine and of its major components Description of start-up and shutdown procedures Alarms action list Description of emergency procedures Description of normal working procedures Description of planned environmental protection measures Description of quality recording and record keeping processes 78 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

79 Bureau Veritas Certification will assess the completeness of the maintenance manual, its compliance to the IEC series (in particular section 14.5 of IEC ) and its adequacy to the site conditions and the wind turbine design, including: Identification of scheduled maintenance actions including inspection intervals and routine actions Identification of personnel qualifications and skills Identification of required specialized tooling, spare parts and personal protection equipment Description of access procedures Identification of limiting environmental conditions Description of the wind turbine and of its major components Start-up, shutdown and re-commissioning procedures Diagnostic procedures and trouble-shooting guide Repair instructions Inspection for marine growth and its removal Maintenance of the scour protection system Maintenance of the corrosion protection system Description of emergency procedures Description of planned environmental protection measures Description of quality recording and record keeping processes The Applicant shall also develop a site-specific inspection and test plan, which will be verified by Bureau Veritas Certification. It shall at least include: The components to be inspected The type of inspection (visual inspection, NDT, inspection of the submerged structures, etc.) The sampling rate The recurrence of the inspection The qualification of the personnel performing the inspection Along the life of the project, the operation and maintenance manuals as well as the inspection and test plan might be updated in order to take into account the accumulated field experience. All revisions of these procedures shall be submitted to Bureau Veritas Certification for verification Operation and maintenance surveillance Bureau Veritas Certification will periodically inspect the wind farm in order to verify that the procedures described in the O&M manuals and in the inspection and test plan are correctly followed. These inspections are not meant to directly verify the integrity of the wind turbines and thus do not replace the inspections planned in the inspection and test plan. 79

80 They will cover in particular: Witnessing of regular maintenance operations, if possible Witnessing of function tests, if possible Verification that the repairs and replacements comply with the design basis Check of the settings of the control system Visual inspection of the general condition of the wind turbines and its main components: check for external cracks, deformations, dents, leakages (lubricant, cooling medium, etc.), etc. The components covered by inspection may include: Rotor blades Drive train, including the gearbox if applicable Generator Electrical installations Safety and control systems Locking devices and mechanical brakes Main structural components (tower, nacelle frame, etc.) Lightning protection system Corrosion protection system Submerged structures (support structure and foundations) Scour protection system, if applicable The inspections will be performed by random sampling. The exact sampling rate will be determined on a case by case basis depending on the evaluation of the O&M procedures and the inspection and test plan and on the results from previous inspections. Turbines that are underperforming or that have been subject to anomalies will be investigated as a priority. The interval between inspections will be determined on a case-by-case basis depending in particular on the wind turbine design, previous experiences with similar wind turbines and the results of previous inspections. Typically, inspections would be performed on an annual basis. In addition to these inspections, Bureau Veritas Certification will review O&M reports and records of damage and repairs that may have occurred. Any outstanding issue shall be properly documented as well as the actions undertaken to resolve it. All modifications of the original design shall be reported without delay to Bureau Veritas Certification for evaluation. 80 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

81 81

82

83 15. Appendix A 15

84 15. Appendix A CERTIFICATION DOCUMENTS TEMPLATES A.1 Conformity statement template 84 Offshore Wind Farm Project Certification - BV-WFPC Version 1 - December 2012

85 A.2 Project Certificate template 85

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