guideline for the certification__ of wind turbines edition 2003

7/30/2019 Guideline for the Certification__ of Wind Turbines Edition 2003

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Rules and GuidelinesRules and Guidelines

IV Industrial ServicesIV Industrial Services

1 Guideline for the Certification of Wind Turbines1 Guideline for the Certification of Wind Turbines

1 General Conditions for Approval1 General Conditions for Approval

2 Safety System, Protective and Monitoring Devices2 Safety System, Protective and Monitoring Devices

3 Requirements for Manufacturers, Quality Management,

Materials and Production

3 Requirements for Manufacturers, Quality Management,

Materials and Production4 Load Assumptions4 Load Assumptions

5 Strength Analyses5 Strength Analyses

6 Structures6 Structures

7 Machinery Components7 Machinery Components

8 Electrical Installations8 Electrical Installations

9 Manuals9 Manuals

10 Testing of Wind Turbines10 Testing of Wind Turbines11 Periodic Monitoring11 Periodic Monitoring

Edition 2003with Supplement 2004



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This Guideline was compiled by Germanischer Lloyd WindEnergie GmbH in cooperation

with the Wind Energy Committee. The Wind Energy Committee consists of representatives from

manufacturers, universities, insurance companies, associations, engineering offices, authorities and institutes.

The current members of the Wind Energy Committee are named on our website:

www.gl-wind.com

This Guideline comes into force on 1st

November 2003.

Interpretation of the Guideline is the exclusive prerogative of Germanischer Lloyd WindEnergie GmbH.

Any reference to the application of this Guideline is permitted only with the consent

of Germanischer Lloyd WindEnergie GmbH.

The latest edition of the General Terms and Conditions

of Germanischer Lloyd WindEnergie GmbH is applicable.

Reproduction by printing or other means, even of extracts, is only permissible with the consent

of Germanischer Lloyd WindEnergie GmbH.

Germanischer Lloyd WindEnergie GmbH

Steinhoeft 9, 20459 Hamburg / Germany

Phone: +49 40 31106-707 Fax: +49 40 31106-1720

E-mail: [email protected] Internet: http://www.gl-wind.com

Published by: Germanischer Lloyd WindEnergie GmbH

Printed by: Heydorn Druckerei und Verlag, Uetersen / Germany
http://www.gl-wind.com/http://www.gl-wind.com/


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IV Part 1 Table of Contents

GL Wind 2003 Page 3

Table of Contents

List of Abbreviations

Symbols and Units

Chapter 1 General Conditions for Approval

1.1 Scope ............................................................. .......................................................... ................................ 1-1

1.1.1 General.............................................. ........................................................... ............................................ 1-1

1.1.2 Transition periods ......................................................... ............................................................. .............. 1-1

1.1.3 Deviations ...................................................... ................................................................... ....................... 1-1

1.1.4 National requirements............................. ................................................................ ................................. 1-1

1.1.5 Assessment documents ................................................................ ....................................................... ..... 1-1

1.2 Extent of Certification ................................................................... ........................................................ 1-3

1.2.1 Subdivision of the certification................................................................. ............................................... 1-3

1.2.2 Assessment of prototypes (C Design Assessment) .................................................................. ............. 1-3

1.2.3 A and B Design Assessment.................................................................................................. ............. 1-4

1.2.4 Site-specific Design Assessment................................................................................ .............................. 1-6

1.2.5 Type Certificate.................................................... ............................................................. ....................... 1-6

1.2.6 Project Certificate ........................................................... ........................................................... .............. 1-8

1.2.7 Re-certification ............................................................ ................................................................ .......... 1-10

1.3 Basic Principles for Design and Construction ........................................................... ........................ 1-11

1.3.1 General.............................................. ........................................................... .......................................... 1-111.3.2 Definitions ............................................................ ............................................................ ..................... 1-11

1.3.3 Analysis procedure............................................................................ ..................................................... 1-12

1.3.4 Mathematical model....................................................................... ........................................................ 1-12

Appendix 1.A

1.A National Requirements in Germany........................................... ........................................................ 1-13

1.A.1 General............................................. ........................................................... ........................................... 1-13

1.A.2 Analysis concept ....................................................... ................................................................... .......... 1-13

1.A.3 Wind conditions ....................................................... .......................................................... .................... 1-14

Appendix 1.B

1.B National Requirements in Denmark............................................................ ....................................... 1-15

1.B.1 General.............................................. ................................................................ ..................................... 1-15

1.B.2 Regulations and standards................................................................. ..................................................... 1-15

Appendix 1.C

1.C National Requirements in France............... ...................................................................... .................. 1-17

1.C.1 General.............................................. ................................................................ ..................................... 1-17

1.C.2 Building permission procedure .............................................................. ................................................ 1-17

Appendix 1.D

1.D National Requirements in the Netherlands......................................................... ............................... 1-19

1.D.1 General............................................. ........................................................... ........................................... 1-19


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1.D.2 Preliminary standard NVN 11400-0 .................................................. .................................................... 1-19

Appendix 1.E

1.E National Requirements in India.................................................... ...................................................... 1-21

1.E.1 General.......................................................... ........................................................... .............................. 1-211.E.2 Certification categories .................................................................... ...................................................... 1-21

1.E.3 TAPS-2000 requirements.......................... ........................................................... .................................. 1-21

Appendix 1.F

1.F IEC and CENELEC Standards ........................................................... ............................................... 1-23

1.F.1 General...................................................... ........................................................... .................................. 1-23

1.F.2 List of normative documents in the area of wind energy.............................................................. ......... 1-23

1.F.3 Supply sources ...................................................... ............................................................ ..................... 1-23

Chapter 2 Safety System, Protective and Monitoring Devices

2.1 General............................................................ ................................................................ ........................ 2-1

2.1.1 Assessment documents ............................................................... ........................................................ ..... 2-1

2.1.2 Systematic consideration of possible faults ............................................................... .............................. 2-1

2.1.3 Description of the controller for approval of the load assumptions ......................................................... 2-2

2.2 Control and Safety System.................................................................. .................................................. 2-3

2.2.1 General....................................................... ............................................................. ................................. 2-3

2.2.2 Definitions ............................................................ ........................................................... ........................ 2-3

2.2.3 Requirements and design concept............... ..................................................................... ........................ 2-5

2.3 Protective and Monitoring Devices................................................................. ...................................... 2-9

2.3.1 General...................................................... .............................................................. ................................. 2-92.3.2 Limiting values, control system.................................................................. ............................................. 2-9

2.3.3 Safety equipment (locking devices) for maintenance .............................................................. .............. 2-15

Appendix 2.A

2.A Interaction of the Control and Safety Systems............................................................. ..................... 2-17

Chapter 3 Requirements for Manufacturers, Quality Management,

Materials and Production

3.1 Requirements for Manufacturers.................................................................... ..................................... 3-13.1.1 General....................................................... ............................................................. ................................. 3-1

3.1.2 Works equipment .......................................................... ............................................................ ............... 3-1

3.1.3 Personnel........................................................................... ........................................................ ............... 3-1

3.1.4 Shop approval ...................................................... ............................................................ ........................ 3-1

3.2 Quality Management ............................................................. .......................................................... ...... 3-3

3.2.1 General...................................................... .............................................................. ................................. 3-3

3.2.2 Definitions ........................................................... ............................................................ ........................ 3-3

3.2.3 Requirements for the quality management system ...................................................................... ............ 3-3

3.2.4 Certification of the QM system........................................................ ........................................................ 3-3

3.3 Materials ............................................................ .............................................................. ....................... 3-5

3.3.1 General requirements........... ................................................................ .................................................... 3-53.3.2 Metallic materials ............................................................ ......................................................... ............... 3-6

3.3.3 Fibre-reinforced plastics (FRP)........................................................................ ...................................... 3-11


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3.3.4 Wood.......................................................... .............................................................. .............................. 3-13

3.3.5 Reinforced concrete and prestressed concrete ................................................................... .................... 3-14

3.4 Production and Testing................................................................ ........................................................ 3-17

3.4.1 General.............................................. ........................................................... .......................................... 3-17

3.4.2 Welding...................................................... ........................................................... ................................. 3-173.4.3 Laminating fibre-reinforced plastics ................................................................... ................................... 3-19

3.4.4 Adhesive bonding ................................................................ .................................................................. 3-21

3.4.5 Manufacturing surveillance for FRP............................................................................ .......................... 3-22

3.4.6 Wood processing............................................................ ............................................................... ......... 3-23

3.4.7 Making and working the concrete............................................ .............................................................. 3-24

Chapter 4 Load Assumptions

4.1 Fundamentals ......................................................... .......................................................... ...................... 4-1

4.1.1 General.............................................. ........................................................... ............................................ 4-1


4.1.3 Design methods.................................................................... ............................................................... ..... 4-24.1.4 Safety classes ............................................................... .............................................................. .............. 4-2

4.2 External Conditions ...................................................... ............................................................ ............. 4-3

4.2.1 General.............................................. ........................................................... ............................................ 4-3

4.2.2 Wind turbine classes ................................................................ ........................................................... ..... 4-3

4.2.3 Wind conditions ....................................................... ......................................................... ....................... 4-4

4.2.4 Other environmental conditions.................................................................. ........................................... 4-11

4.2.5 Electrical power network conditions.................................... .................................................................. 4-12

4.3 Calculation of the Loads.................................. ................................................................ .................... 4-13

4.3.1 General............................................. ............................................................ .......................................... 4-13

4.3.2 Loads............................................................ ............................................................ .............................. 4-134.3.3 Design situations and load cases................................................................... ......................................... 4-13

4.3.4 Load calculations .......................................................... ............................................................... .......... 4-19

4.3.5 Partial safety factors for loads................................... ................................................................... .......... 4-20

4.4 Site-Specific Assessment ....................................................... ............................................................... 4-23

4.4.1 Site assessment ............................................................. ............................................................... .......... 4-23

4.4.2 Wind farm influence ...................................................... ............................................................... ......... 4-24

4.4.3 Influence of earthquakes ................................................................ ........................................................ 4-25

4.4.4 Complex terrain ......................................................... .................................................................. .......... 4-26

4.4.5 Extreme temperatures .................................................. ................................................................ .......... 4-26

4.4.6 Corrosion, erosion................................ ................................................................ .................................. 4-27

4.4.7 Assessment and comparison ...................................................................... ............................................ 4-27

Appendix 4.A

4.A Coordinate Systems ............................................................. ................................................................ 4-29

4.A.1 Blade coordinate system ............................................................. ........................................................... 4-29

4.A.2 Chord coordinate system............................................................. ........................................................... 4-29

4.A.3 Hub coordinate system................................................ ................................................................. .......... 4-30

4.A.4 Rotor coordinate system .............................................................. .......................................................... 4-30

4.A.5 Tower top coordinate system ............................................................... .................................................. 4-31

4.A.6 Tower bottom coordinate system ............................................................... ............................................ 4-31

Appendix 4.B

4.B Evaluation of the Loads........................ ................................................................ ............................... 4-33

4.B.1 Presentation of load case definitions.............................. ........................................................................ 4-33


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4.B.2 Presentation of the results ........................................................ .............................................................. 4-33

4.B.3 Further evaluations................................................................................ ................................................. 4-34

Appendix 4.C

4.C Fault in the Power System.................. ................................................................ ................................. 4-37

Appendix 4.D

4.D Design Parameters for Describing Wind Turbine Class S................................................................ 4-39

4.D.1 Plant parameters.............................................................................. ...................................................... . 4-39

4.D.2 Wind conditions ...................................................... .......................................................... ..................... 4-39

4.D.3 Conditions of the electrical power network .............................................................. ............................. 4-39

4.D.4 Other environmental conditions (where necessary)............................................................... ................ 4-40

Chapter 5 Strength Analyses

5.1 General............................................................ ................................................................ ........................ 5-1

5.2 Determination of the Stresses................. ..................................................................... .......................... 5-3

5.2.1 General notes on the loading of the structure.............................................................................. ............. 5-3

5.2.2 Method of analysis............. ................................................................ ...................................................... 5-3

5.2.3 Dynamic calculation ........................................................ .......................................................... .............. 5-4

5.2.4 Quasi-static calculation......................................................... ............................................................. ...... 5-4

5.3 Metallic Materials ................................................................ ............................................................ ...... 5-5

5.3.1 Material properties....................................................... ............................................................. ............... 5-5

5.3.2 General strength analysis ............................................................... .......................................................... 5-5

5.3.3 Fatigue analysis............................................................. ............................................................. .............. 5-5

5.3.4 Serviceability analysis ............................................................. .............................................................. 5-13

5.4 Concrete.................... ................................................................ ........................................................... . 5-15

5.4.1 Material properties....................................................... ............................................................... ........... 5-15

5.4.2 Ultimate limit states ............................................................... ............................................................... . 5-15

5.4.3 Serviceability Limit State.................................................................................. ..................................... 5-16

5.5 Fibre Reinforced Plastics (FRP) and Bonded Joints............................ ............................................. 5-17

5.5.1 General....................................................... .............................................................. .............................. 5-17

5.5.2 Materials .............................................................. .............................................................. .................... 5-17

5.5.3 Analyses....................................... ................................................................ .......................................... 5-18

5.5.4 Glass Fibre Reinforced Plastics (GRP)................................................................... ............................... 5-21

5.5.5 Carbon Fibre Reinforced Plastics (CRP) ............................................................ ................................... 5-22

5.5.6 Bonded joints ........................................................ ............................................................. .................... 5-23

5.6 Wood .......................................................... ........................................................... ................................ 5-25

Appendix 5.A

5.A Strength Analyses with the Finite Element Method.................................................. ........................ 5-27

5.A.1 General...................................................... ............................................................... .............................. 5-27

5.A.2 Modelling of the structure.................................................. ................................................................... . 5-29

5.A.3 Loading of the structure ................................................................... ...................................................... 5-32

5.A.4 Calculation and evaluation of the results ................................................................. .............................. 5-32

5.A.5 Documentation of FE analyses for the certification of wind turbines......... ........................................... 5-33


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Chapter 6 Structures

6.1 General........................................................ ............................................................ ................................ 6-1

6.2 Rotor Blades ......................................................... ............................................................ ...................... 6-3

6.2.1 General.............................................. ........................................................... ............................................ 6-36.2.2 Assessment documents ................................................................ ....................................................... ..... 6-3

6.2.3 Delivery checks.................................................................. ........................................................ .............. 6-3

6.2.4 Analyses........................................ ................................................................ ........................................... 6-4

6.2.5 Blade tests .......................................................... ............................................................... ....................... 6-4

6.3 Machinery Structures............................................................... ......................................................... .... 6-7

6.3.1 General.............................................. ........................................................... ............................................ 6-7


6.3.3 Analyses........................................ ................................................................ ........................................... 6-7

6.4 Nacelle Covers and Spinners...................................................... ........................................................... 6-9

6.4.1 General.............................................. ........................................................... ............................................ 6-96.4.2 Assessment documents ................................................................ ....................................................... ..... 6-9

6.4.3 Analyses........................................ ................................................................ ........................................... 6-9

6.5 Bolted Connections ......................................................... ........................................................... .......... 6-13

6.5.1 Assessment documents ................................................................ .......................................................... 6-13

6.5.2 Strength analyses of bolted connections ............................................................... ................................. 6-13

6.5.3 Inspection of bolted connections............................................................. ............................................... 6-13

6.6 Tower.......................................................... ........................................................... ................................ 6-15

6.6.1 General............................................. ............................................................ .......................................... 6-15


6.6.3 Analysis concept ....................................................... ................................................................... .......... 6-15

6.6.4 Loads to be applied ............................................................... ................................................................. 6-15

6.6.5 Determination of the internal design forces and moments....................................... .............................. 6-15

6.6.6 Verification for the tower ................................................................ ....................................................... 6-17

6.6.7 Design details.................................. ................................................................ ....................................... 6-19

6.6.8 Durability.......................................................... ................................................................. .................... 6-23

6.7 Foundation........................ ................................................................ .................................................... 6-25

6.7.1 General............................................. ............................................................ .......................................... 6-25


6.7.3 Analysis concept ....................................................... ................................................................... .......... 6-25


6.7.5 Foundation ........................................................ ................................................................. .................... 6-25

6.7.6 Soil....................................................... .............................................................. .................................... 6-26

Chapter 7 Machinery Components

7.1 General........................................................ ............................................................ ................................ 7-1


7.1.2 Materials ............................................................... ............................................................ ....................... 7-1

7.1.3 Drive train dynamics.................................... ........................................................... ................................. 7-1

7.2 Blade Pitching System .............................................................. ......................................................... .... 7-3

7.2.1 General.............................................. ........................................................... ............................................ 7-3


7.2.3 Loads to be applied ............................................................... .............................................................. ..... 7-3

7.2.4 Strength analysis ........................................................... ............................................................. .............. 7-3


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7.3 Bearings ............................................................ .............................................................. ........................ 7-5

7.3.1 General....................................................... ............................................................. ................................. 7-5

7.3.2 Assessment documents ............................................................... ........................................................ ..... 7-5

7.3.3 Assessment of materials....................................................... .............................................................. ...... 7-5

7.3.4 Loads to be applied .............................................................. .............................................................. ...... 7-5

7.3.5 Calculations ......................................................... ............................................................ ........................ 7-67.3.6 Miscellaneous .............................................................. ............................................................. ............... 7-7

7.4 Gearboxes ............................................................. ........................................................... ....................... 7-9

7.4.1 General....................................................... ............................................................. ................................. 7-9

7.4.2 Materials .............................................................. ............................................................ ........................ 7-9

7.4.3 Loads to be applied .............................................................. .............................................................. ...... 7-9

7.4.4 Calculation of load capacity of gears.............................................................. ....................................... 7-10

7.4.5 Strength analysis for shafts and connecting elements ............................................................... ............. 7-12

7.4.6 Additional verifications ....................................................... ................................................................. . 7-13

7.4.7 Equipment....... ................................................................ ............................................................ ........... 7-13

7.4.8 Inspection of gearboxes ........................................................... ............................................................. . 7-13

7.4.9 Running-in period........................................................ ................................................................ .......... 7-14

7.4.10 Manuals...................................................... .............................................................. .............................. 7-14

7.5 Mechanical Brakes and Locking Devices................................................. .......................................... 7-15

7.5.1 General....................................................... .............................................................. .............................. 7-15

7.5.2 Assessment documents ................................................................ ......................................................... . 7-15

7.5.3 Loads......................................................................... ......................................................... .................... 7-15

7.5.4 Calculations ......................................................... .............................................................. .................... 7-16

7.5.5 Miscellaneous .............................................................. ................................................................ .......... 7-16

7.6 Couplings ......................................................... ................................................................. .................... 7-17

7.6.1 General....................................................... .............................................................. .............................. 7-17

7.6.2 Assessment documents ................................................................ ......................................................... . 7-17

7.6.3 Materials .............................................................. .............................................................. .................... 7-177.6.4 Calculations ......................................................... .............................................................. .................... 7-17

7.6.5 Miscellaneous .............................................................. ................................................................ .......... 7-17

7.7 Elastomer Bushings ................................................................ ............................................................. 7-19

7.7.1 General....................................................... .............................................................. .............................. 7-19



7.7.4 Strength analysis .......................................................... ................................................................ .......... 7-20

7.7.5 Additional verifications ....................................................... .................................................................. 7-20

7.8 Yaw System........ ................................................................ ......................................................... .......... 7-21

7.8.1 General....................................................... .............................................................. .............................. 7-217.8.2 Assessment documents ................................................................ .......................................................... 7-21


7.8.4 Strength analysis .......................................................... ................................................................ .......... 7-21

7.9 Hydraulic Systems ........................................................... .......................................................... .......... 7-23

7.9.1 General....................................................... .............................................................. .............................. 7-23


7.9.3 Materials .............................................................. .............................................................. .................... 7-23

7.9.4 Design and construction............................................ ................................................................... .......... 7-23

Chapter 8 Electrical Installations

8.1 Area of Application ....................................................... ........................................................... .............. 8-1

8.1.1 Application................................................................... ............................................................. ............... 8-1


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8.1.2 Scope............................................................ ............................................................ ................................ 8-1

8.1.3 Standards................................................................. .......................................................... ....................... 8-1

8.1.4 Operating and environmental conditions .............................................................. ................................... 8-1

8.1.5 Parallel operation with public power supply networks .............................................................. .............. 8-1

8.1.6 Stand-alone operation .................................................................... .......................................................... 8-2


8.2 Electrical Machines........................................................ ........................................................... ............. 8-5

8.2.1 General.............................................. ........................................................... ............................................ 8-5

8.2.2 Materials ............................................................... ............................................................ ....................... 8-5

8.2.3 Ventilation and cooling ............................................................ ........................................................... ..... 8-5

8.2.4 Windings.............. ............................................................ ......................................................... ............... 8-5

8.2.5 Bearings ............................................................... ............................................................. ....................... 8-5

8.2.6 Duty cycles of electrical machines................................................................ ........................................... 8-5

8.3 Transformers........................................................ ............................................................ ...................... 8-7

8.3.1 General.............................................. ........................................................... ............................................ 8-7

8.3.2 Installation .................................................... ........................................................... ................................ 8-7

8.3.3 Dry-type transformers........................................ ................................................................ ...................... 8-7

8.3.4 Liquid-cooled transformers................................................................. ..................................................... 8-7

8.3.5 Converter transformers ............................................................. .......................................................... ..... 8-7

8.3.6 Protection........................................................ .................................................................. ....................... 8-7

8.4 Static Converters................. ................................................................ ................................................... 8-9

8.4.1 General.............................................. ........................................................... ............................................ 8-9

8.4.2 Installation of static converters .......................................................... ...................................................... 8-9

8.4.3 Protection equipment ....................................................... ........................................................... ............. 8-9

8.5 Medium Voltage .............................................................. ........................................................... .......... 8-11

8.5.1 General.......................................... ....................................................... .................................................. 8-11

8.5.2 Protective measures ................................................................ ............................................................. .. 8-118.5.3 Pressure relief ............................................................ ................................................................. ........... 8-11

8.5.4 SF6 switchgear...................................................... ............................................................. .................... 8-11

8.6 Charging Equipment and Storage Batteries...................... ................................................................ 8-13

8.6.1 General.............................................. ........................................................... .......................................... 8-13

8.6.2 Charging equipment......................... ................................................................ ...................................... 8-13

8.6.3 Storage batteries........................ ........................................................... .................................................. 8-13

8.6.4 Installation and operation of batteries ................................................................. ................................... 8-13

8.7 Switchgear and Protection Equipment ............................................................ .................................. 8-15

8.7.1 General.............................................. ........................................................... .......................................... 8-15

8.7.2 Short-circuit and overload protection devices................................................. ....................................... 8-158.7.3 Control circuits ....................................................... ........................................................... .................... 8-15

8.7.4 Measuring and indicating circuits ..................................................................... ..................................... 8-16

8.7.5 Earth fault detection and monitoring.............................................................................. ........................ 8-16

8.7.6 Design and rating of the switchgear................................................ ....................................................... 8-16

8.7.7 Switchboards and cabinets for low voltage..................... ....................................................................... 8-16

8.7.8 Synchronizing gear and equipment for smooth connection ............................................................... .... 8-16

8.7.9 Electrical / electronic components in the safety system......................... ................................................ 8-16

8.7.10 Circuits for safety-related parts of the controls............................................................... ....................... 8-17

8.8 Cables and Electrical Installation Equipment................ ................................................................... 8-19

8.8.1 Selection of cables and lines ................................................................. ................................................. 8-19

8.8.2 Loading, protection and laying of cables and lines ........................................................... ..................... 8-19

8.9 Lightning Protection............................................................... ............................................................. 8-21

8.9.1 General.............................................. ........................................................... .......................................... 8-21


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8.9.2 Protection concept.............................................. ............................................................... ..................... 8-21

8.9.3 Execution of measures ............................................................. .............................................................. 8-22

Chapter 9 Manuals

9.1 Erection Manual................................................................... ............................................................ ...... 9-1

9.1.1 General....................................................... ............................................................. ................................. 9-1

9.1.2 Format of the erection manual ................................................................... .............................................. 9-1

9.1.3 Scope of the erection manual..................................................................... .............................................. 9-1

9.2 Documents for Commissioning ....................................................... ...................................................... 9-3

9.2.1 Commissioning manual ........................................................ .............................................................. ..... 9-3

9.2.2 Commissioning record............................................................ ........................................................... ...... 9-3

9.2.3 Format of the documents ........................................................... ......................................................... ..... 9-3

9.2.4 Scope of the commissioning manual .................................................................. ..................................... 9-3

9.3 Operating Manual............................................... ........................................................... ........................ 9-5

9.3.1 Purpose of the operating manual..................................................... ......................................................... 9-59.3.2 Format of the operating manual............................................................... ................................................ 9-5

9.3.3 Scope of the operating manual............................. ...................................................................... .............. 9-5

9.4 Maintenance Manual ........................................................... ............................................................ ...... 9-7

9.4.1 General....................................................... ............................................................. ................................. 9-7

9.4.2 Purpose of the maintenance manual........................................................................... .............................. 9-7

9.4.3 Format of the maintenance manual.......................................................................... ................................ 9-7

9.4.4 Scope of the maintenance manual................................................... ......................................................... 9-7

Chapter 10 Testing of Wind Turbines

10.1 General......................................................... ..................................................................... .................... 10-1

10.1.1 Prototype test ....................................................... ............................................................... ................... 10-1

10.1.2 Tests within the scope of the Design Assessment ..................................................................... ............. 10-1

10.2 Power Curve............................................................. ........................................................ .................... 10-3

10.3 Noise Emission............................................................ ................................................................ .......... 10-5

10.4 Electrical Characteristics ............................................................ ........................................................ 10-7

10.5 Test of Turbine Behaviour................................................................ ................................................... 10-9

10.5.1 General................................................... .................................................................. .............................. 10-9

10.5.2 Test plan.............................................................. ................................................................ ................... 10-9

10.5.3 Test of the safety system.................................................................. ...................................................... 10-9

10.5.4 Test of the braking systems.............. ...................................................................... .............................. 10-10

10.5.5 Test of automatic operation................ ................................................................ .................................. 10-11

10.5.6 Test of the switching operations............................................................ ............................................... 10-12

10.5.7 Measurement of the natural frequencies ............................................................. ................................. 10-13

10.5.8 Hydraulic pressure at the mechanical brakes ........................................................... ............................ 10-13

10.6 Load Measurements............................................................................... ............................................ 10-15

10.7 Prototype Trial of Gearboxes................................................................. ........................................... 10-17

10.7.1 General.................................................... ................................................................. ............................ 10-17

10.7.2 Scope of the prototype trial...... ..................................................................... ....................................... 10-1710.7.3 Documentation of the prototype trial .................................................................... ............................... 10-17


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GL Wind 2003 Page 11

10.8 Witnessing of the Commissioning............ ................................................................ ......................... 10-19

10.8.1 General.................................................... ................................................................. ............................ 10-19

10.8.2 Procedure for witnessing........................................................ .............................................................. 10-19

Chapter 11 Periodic Monitoring11.1 Scope and Execution................................................................ ............................................................ 11-1

11.1.1 General............................................... ............................................................ ........................................ 11-1

11.1.2 Scope and execution ................................................................ .............................................................. 11-1

11.2 Technical Experts, Documentation and Actions.................................................................... ............ 11-3

11.2.1 Technical experts ...................................................... ................................................................... .......... 11-3

11.2.2 Documentation............................... ................................................................ ........................................ 11-3

11.2.3 Actions............................................................... ................................................................ .................... 11-3

References of the Guideline


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IV Part 1 List of Abbreviations

GL Wind 2003 Page 13

List of Abbreviations

Abbreviation MeaningA Abnormal (for partial safety factors)

C Condition of the serviceability

CRP Carbon Fibre Reinforced Plastic

Coh Coherence function

DLC Design Load Case

ECD Extreme Coherent gust with Direction change

ECG Extreme Coherent Gust

EDC Extreme Direction Change

EOG Extreme Operating Gust

EWM Extreme Wind speed Model

EWS Extreme Wind Shear

F Fatigue

FEM Finite Element Method

FRP Fibre Reinforced Plastic

GRP Glass Fibre Reinforced Plastic

GL Germanischer Lloyd

GL Wind Germanischer Lloyd WindEnergie GmbH

LDD Load Duration Distribution

N Normal and extreme (for partial safety factors)

NTM Normal Turbulence Model

NWP Normal Wind ProfileS Wind turbine class S (S for special)

TTransport, erection and maintenance (for partial safetyfactors and for the wind speed)

U Ultimate limit state


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IV Part 1 Symbols and UnitsGL Wind 2003 Page 15

Symbols and Units

Symbols and Units Used in the Guideline

Symbol Meaning Unit Remarks

A cross-section area (strength)reference surface (aerodynamics)

m-

A category for the higher turbulence intensity - (see Section 4.2.2)

AS stress cross-section m (see Section 5.3.3.4.1)

a slope parameter - (see Section 4.2.2)

B category for the lower turbulence intensity - (see Section 4.2.2)

b width (breadth) m

b1 opening width (arc measure) m (see Section 6.6.7.2)

C scale parameter of the Weibull function m/s (see Section 4.2.3.1.1)CA coefficient of aerodynamic lift -

CW coefficient of aerodynamic drag -

CM coefficient of aerodynamic moment -

Cia reduction factors for the material safetyfactor, short-term strength

- i from 1 to 4

Cib reduction factors for the material safetyfactor, fatigue strength

- i from 1 to 5

Cic reduction factors for the material safetyfactor, stability

- i from 1 to 2

Cid reduction factors for the material safety

factor, bonding

- i from 1 to 4

CIFF reduction factor for inter-fibre failure - (cf. Section 5.5.3)

cmax maximum blade depth m (cf. Section 4.2.4.2.3)

cmin parameter for calculating the ice formation onthe blade

m (see Section 4.2.4.2.3)

D damage -

D, d diameter m

DQ damage contribution from vortex-inducedtransverse vibrations

- (see Section 6.6.6.1.5)

DF damage contribution of the actions from theoperating conditions


d nominal bolt diameter m (see Section 5.3.3.4.1)E E-modulus (modulus of elasticity) MPa, N/mm

F force N

Fi force acting in the direction i = x, y or z N (see Chapter 4, Appendix B)

FSmax max. bolt force under extreme load N (see Section 5.3.3.4.1)

F0,2min bolt force at the 0.2 % elastic strain limit N (see Section 5.3.3.4.1)

f line force N/m

f frequency 1/s f = /(2)

f0,n n-th natural frequency 1/s n = 1, 2,

fR maximum rotating frequency of the rotor inthe normal operating range

1/s

fR,m transition frequency of the m rotor blades 1/sG gust reaction factor -


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Symbols and Units IV Part1Page 16 GL Wind 2003


G dead weight N

G shear modulus MPa, N/mm

g area load from dead weight N/m

g acceleration due to gravity (=9.81m/s) m/sh height m

h1 opening height m (see Section 6.6.7.2)

I moment of inertia m4

I15 characteristic value of the turbulence intensityfor a mean wind speed of 15 m/s

- (see Section 4.2.2)

j casting quality level - (see Section 5.3.3.4.3)

j0 constant - (see Section 5.3.3.4.3)

K modified Bessel function -

KA application factor - (see Section 7.4.4.3.1)

KF transverse load factor, root stress - (see Section 7.4.4.3.5)

KF face load factor, root stress - (see Section 7.4.4.3.4)KH transverse load factor, contact stress - (see Section 7.4.4.3.5)

KH face load factor, contact stress - (see Section 7.4.4.3.4)

KV dynamic load factor - (see Section 7.4.4.3.2)

K load distribution factor - (see Section 7.4.4.3.3)

k flange gaps m (see Section 6.6.7.1)

k shape parameter of the Weibull function - (see Section 4.2.3.1.1)

ks reduction factor for the design S/N curve oflarge bolts


L isotropic, integral turbulence scale parameter m

Le scale parameter of the coherence function m

Lk integral length parameter of the speedcomponent

m

l component length m

l statically effective span m

M moment Nm

MBmin minimum required braking moment kNm (see Section 7.5.1)

MBminAusl minimum design braking moment kNm (see Section 7.5.1)

MBmax maximum actual braking moment kNm (see Section 7.5.1)

Mi moment acting in the direction i = x, y or z Nm (see Chapter 4, Appendix 4.B)

Mk tilting moment of the induction generator Nm (see Chapter 4, Appendix 4.C)

Mn rated torque Nm (see Chapter 4, Appendix 4.C)m mass kg

m slope parameter of the S/N curve -

N permissible load cycle number -

N perpendicular force (axial force) N

N recurrence period for extreme conditions a

Ni tolerable number of stress cycles - (see Section 5.3.3.2.3)

ND limiting stress cycle number fatigue limit - (see Section 5.3.3.4)

n quantity (i.e. number of) -

n rotational speed 1/min

n1 minimum operating rotational speed 1/min (see Section 2.2.2.5)

n2 set value of the speed controller 1/min (see Section 2.2.2.5)

n3 maximum operating rotational speed 1/min (see Section 2.2.2.5)


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n4 cut-out speed 1/min (see Section 2.2.2.5)

nA activation speed 1/min (see Section 2.2.2.5)

n i number of existing stress cycles - (see Section 5.3.3.2.3)

nmax maximum overspeed 1/min (see Section 2.2.2.5)nr rated speed 1/min (see Section 2.2.2.5)

nref reference load cycle number - (see Chapter 4, Appendix 4.B)

P confidence level -

P live load N

P power W

P survival probability - (see Section 5.3.3.4.2)

PA activation power kW (see Section 2.2.2.6)

Pr rated power kW (see Section 2.2.2.6)

PR(Vhub) Rayleigh probability distribution, i.e. theprobability that V < Vo


PT over-power kW (see Section 2.2.2.6)PW(Vhub) Weibull probability distribution - (see Section 4.2.3.1.1)

p area live load N/m

Q total load N

q area loading N/m

R resistance N, Nm, MPa generic term, referring e.g. to atolerable bending moment

R stress or strain ratio - R= min/ max

R, r radius m

S action N, Nm, MPa generic term, referring e.g. to anacting bending moment

Sd reduction factor casting quality - (see Section 5.3.3.4.3)

SF safety against tooth root fracture -

SH safety against pitting -

S P reduction factor survival probability - >2/3 (see Section 5.3.3.4)

S1(f) power spectral density m2/s2 (see Section 4.2.3.1.3)

SS safety against scuffing

sK tilting slip of the induction generator - (see Chapter 4, Appendix 4.C)

T temperature C, K

T time interval s

T characteristic gust shape duration s

t component thickness mt time (as a variable) s

T1 time constant of the stator s (see Chapter 4, Appendix 4.C)

Ui i% fractile value of the normal distribution -

u displacement in the x direction m

V thrust N

V wind speed m/s

V(y, z, t) longitudinal component of the wind speed,describing the horizontal wind shear

m/s (EWS: see Section 4.2.3.2.6)

V(z) magnitude of the wind speed at the height z m/s (see Section 4.2.3.1.2)

V(z, t) longitudinal component of the wind speedin relation to height and time

m/s (EWS: see Section 4.2.3.2.6)

VA short-term cut-out wind speed m/s (see Section 2.2.2.7)


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Vave annual average wind speed at hub height m/s (see Section 4.2.3.1.1 und 4.2.2)

VB gust value m/s (see Section 2.2.3.3.2)

Vcg extreme value of the wind speed amplitude

for the coherent gust shape over the sweptrotor area, applying the extreme coherentgust

m/s (ECG: see Section 4.2.3.2.4)

VeN expected extreme wind speed (averagedover 3 s), with a recurrence period of

N years. Ve1 and Ve50 for 1 or 50 yearsrespectively, applying the steady-stateextreme wind speed model

m/s (EWM: see Section 4.2.3.2.1)

VgustN

maximum value of the wind speed for theextreme operating gust, with an expectedrecurrence period of N years

m/s (EOG: see Section 4.2.3.2.2)

Vhub

10-min mean of the wind speed at hub height m/s

Vin cut-in wind speed m/s (see Section 2.2.2.7)V

N expected extreme wind speed (averaged over

10 min), with a recurrence period of N years.V1 and V50 for 1 or 50 years respectively,applying the turbulent extreme wind speedmodel

m/s (EWM: see Section 4.2.3.2.1)

Vout

cut-out wind speed m/s (see Section 2.2.2.7)

Vr

rated wind speed m/s (see Section 2.2.2.7)

Vref

reference wind speed: fundamental parameterof the extreme wind speed, used for definitionof the type classes

m/s (see Section 4.2.2)

VT the 10-min mean of the wind speed at hubheight, specified by the manufacturer formaintenance, erection and transport. VT canconsist of several quantities.

m/s (cf. Section 4.3.4.8)

v coefficient of variation -

v displacement in the y direction m

W section modulus of a plane m

w displacement in the z direction m

Xd subtransient reactance - (see Chapter 4, Appendix 4.C)

x; x coordinates m

y parameter for the extreme wind shear model:

horizontal distance to the hub centreline

- (EWS: see Section 4.2.3.2.6)

y; y coordinates m

z height over terrain surface m (see Section 4.2.3.1.2)

zhub

hub height of the wind turbine over groundlevel

m (see Section 4.2.3.1.2)

z; z coordinates m

power law exponent for the normal windprofile


S inclination of the outer flange surfaces (see Section 6.6.7.1)

parameter for the models of extreme operating gust, extreme direction change and

extreme wind shear

- (EOG: see Section 4.2.3.2.2),(EDC: see Section 4.2.3.2.3),

(EWS: see Section 4.2.3.2.6) gamma function - (see Section 4.2.3.1.1)

slip - = /G


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F partial safety factor for the loads - (see Section 4.3.5)

Gr partial safety factor for the analysis of thesafety against bearing capacity failure

- (see Section 6.7.6.3)

M partial safety factor for the material - (see Sections 5.3.2.1, 5.3.3.2.2

and 5.4.1.2)

M0 material partial safety factor - = 1.35, see Section 5.5.2.4, para 1

Ma material partial safety factor for short-termstrength


Mb material partial safety factor for fatiguestrength


Mc material partial safety factor for stability - (see Section 5.5.3)

Md material partial safety factor for bonding,short-term strength


Me material partial safety factor for bonding,long-term strength


M,3 material partial safety factor for the analysisof shear-loaded connections


P partial safety factor for the analysis of pilefoundations


iT load partial safety factor for the rotor bladetest

- i from 1 to 2

opening angle (see Section 6.6.7.2)

B logarithmic decrement -

strain - = /E

nonlinear notch strain - (see Section 5.A.1.5)

cg greatest angular deviation during a gust

development from the direction of theaverage wind speed, applying the model forextreme coherent gust with direction change

(ECD: see Section 4.2.3.2.5)

( t ) time curve of the wind direction change

eN extreme direction change, with a recurrenceperiod of N years, applying the model of theextreme direction change

(EDC: see Section 4.2.3.2.3)

N( t ) time curve of the extreme direction changewith a recurrence period of N years, apply-ing the model of the extreme directionchange

(EDC: see Section 4.2.3.2.3)

temperature C

mean, year annual average temperature C (see Section 4.4.5.2)

1yearmin/max

extreme temperature with a recurrence periodof 1 year

C (see Section 4.4.5.2)

min/max,operation

extreme temperature for operation C (see Section 4.4.5.2)

1 turbulence scale parameter m (see Section 4.2.3.1.3)

friction coefficient / slip factor -

E parameter for calculating the ice formation onthe rotor blade

kg/m, (see Section 4.2.4.2.3)

density kg/m

E density of the ice kg/m3

(see Section 4.2.4.2.3) normal stress MPa, N/mm


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nonlinear notch stress MPa, N/mm (see Appendix 5.A, Section

5.A.1.5)

A reference value of the S/N curve MPa, N/mm (see Section 5.3.3.4.2)

A reference value of the S/N curve MPa, N/mm (see Section 5.3.3.4.2)

D fatigue limit MPa, N/mm (see Section 5.3.3.4.2)

k linear-elastic notch stress MPa, N/mm (see Appendix 5.A, Section5.A.1.5)

S structural or hot spot stress MPa, N/mm (see Appendix 5.A, Section5.A.1.5)

1 standard deviation of the longitudinal windspeed at hub height

m/s (see Section 4.2.3.1.3)

i stress range MPa, N/mm (see Section 5.3.3.2.3)

shear stress MPa, N/mm

inclination of the plane

yaw error (see Section 2.2.2.8) angle for two-phase short circuit (see Chapter 4, Appendix 4.C)

A cut-out yaw error (see Section 2.2.2.8)

angular velocity 1/s = 2f

g grid angular frequency 1/s (see Chapter 4, Appendix 4.C)

1P, 2P,3P...

excitation of the wind turbine through therotor speed multiplied by the factor 1, 2, 3...

1/s

Subscripts

Symbol Meaning Remarks

A amplitudec pressure separated by a comma (Sd,c)d design valueF load, actionF tooth rooti enumerationk characteristic quantityM material, mean value e.g. M, Mmax maximummin minimum

p prestress separated by a comma (Rd,p)R resisting preceding in combination with the sub-

scripts k and d, but without separation by acomma (e.g. Rd orRk)

res resultingS acting preceding in combination with the sub-

scripts k and d, but without separation by acomma (e.g. FSd or MSk)

t tension separated by a comma (Rd,t)x; x coordinate designationy; y coordinate designationz; z coordinate designation

Auxiliary symbols

Symbol Meaning

mean value of the overlined quantity


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Prefixes

Symbol Meaning

difference or part of the subsequent quanti-ties

product of the subsequent quantities sum of the subsequent quantities


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Rules and GuidelinesRules and Guidelines

IV Industrial ServicesIV Industrial Services1 Guideline for the Certification of Wind Turbines1 Guideline for the Certification of Wind Turbines

1 General Conditions for Approval1 General Conditions for Approval




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IV Part 1 Table of Contents Chapter 1

GL Wind 2003 Page 3

Table of Contents

1.1 Scope ........................................................... ........................................................... ................................. 1-11.1.1 General.....................................................................................................................................................1-1 1.1.2 Transition periods ....................................................... ................................................................ ............. 1-11.1.3 Deviations ....................................................... ................................................................... ...................... 1-11.1.4 National requirements............................................................. .............................................................. ... 1-11.1.4.1 International guidelines............................................................................................................................1-11.1.5 Assessment documents ......................................................... ............................................................... .... 1-1

1.2 Extent of Certification ............................................................... ............................................................ 1-31.2.1 Subdivision of the certification................................................................................................................1-31.2.1.1 C Design Assessment............................................................................................................................1-31.2.1.2 A and B Design Assessment of the type of a wind turbine ................................................................ 1-31.2.1.3 Site-specific Design Assessment..............................................................................................................1-31.2.1.4 Type Certificate for the type of a wind turbine............................................................ ............................ 1-31.2.1.5 Project Certificate ................................................... ........................................................... ...................... 1-31.2.2 Assessment of prototypes (C Design Assessment) .............................................................. ................. 1-31.2.2.1 General.....................................................................................................................................................1-3 1.2.2.2 Scope and validity....................................................................................................................................1-41.2.2.3 Documents to be submitted......................................................................................................................1-41.2.2.4 Scope of assessment.................................................................................................................................1-41.2.3 A and B Design Assessment...............................................................................................................1-41.2.3.1 Scope and validity....................................................................................................................................1-41.2.3.2 Assessment of the design documentation ........................................................ ........................................ 1-51.2.3.3 Witnessing and Tests................................................................................................................................1-61.2.4 Site-specific Design Assessment..............................................................................................................1-6

1.2.4.1 Scope........................................................................................................................................................1-6 1.2.4.2 Site-specific assessment...........................................................................................................................1-61.2.5 Type Certificate........................................................................................................................................1-61.2.5.1 Scope and validity....................................................................................................................................1-61.2.5.2 Quality management system.......................................................... .......................................................... 1-61.2.5.3 Implementation of the design-related requirements in production and erection...................................... 1-61.2.5.4 Prototype test ............................................................... ............................................................... ............. 1-71.2.6 Project Certificate ................................................... ........................................................... ...................... 1-81.2.6.1 Scope and validity....................................................................................................................................1-81.2.6.2 Surveillance during production................................................................................................................1-81.2.6.3 Surveillance during transport and erection ................................................................ .............................. 1-81.2.6.4 Surveillance of commissioning................................................................................................................1-9

1.2.6.5 Periodic Monitoring.................................................................................................................................1-91.2.7 Re-certification ........................................................ ...................................................................... ........ 1-10

1.3 Basic Principles for Design and Construction ............................................................ ....................... 1-111.3.1 General......................................................... ........................................................... ............................... 1-111.3.2 Definitions ........................................................ ........................................................... .......................... 1-111.3.2.1 Loads...................................................................... ............................................................ .................... 1-111.3.2.2 Limit states................................................. ................................................................ ............................ 1-111.3.2.3 Partial safety factors for loads.............................................. ................................................................ .. 1-111.3.2.4 Partial safety factors for materials ............................................................ ............................................. 1-121.3.3 Analysis procedure ............................................................ .................................................................... 1-121.3.4 Mathematical model ......................................................... ............................................................. ........ 1-12


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Chapter 1 Table of Contents IV Part 1

Page 4 GL Wind 2003

Appendix 1.A

1.A National Requirements in Germany...................................................... ............................................. 1-131.A.1 General........................................................ ........................................................... ................................ 1-131.A.1.1 Material requirements............................................................... ............................................................. 1-13

1.A.1.2 Requirements for manufacturers................................................... ......................................................... 1-131.A.1.3 Analysis ............................................................ .................................................................. ................... 1-131.A.1.4 Guidelines for measurements............................................................................... .................................. 1-131.A.2 Analysis concept....................................................... ................................................................... .......... 1-131.A.2.1 Towers...................................................................... .......................................................... .................... 1-131.A.2.2 Foundations................................................. ................................................................ ........................... 1-141.A.3 Wind conditions ...................................................... .......................................................... ..................... 1-141.A.3.1 General........................................................ ........................................................... ................................ 1-141.A.3.2 Wind zones.................................................................... ............................................................... .......... 1-141.A.3.3 Reference wind speeds................................................................. .......................................................... 1-141.A.3.4 Annual average and turbulence intensity ............................................................... ................................ 1-14

Appendix 1.B

1.B National Requirements in Denmark.......................................................... ......................................... 1-151.B.1 General........................................................ ........................................................... ................................ 1-151.B.2 Regulations and standards............................................................................. ......................................... 1-15

Appendix 1.C

1.C National Requirements in France.............. ..................................................................... .................... 1-171.C.1 General........................................................ ........................................................... ................................ 1-171.C.2 Building permission procedure .................................................................. ............................................ 1-17

Appendix 1.D

1.D National Requirements in the Netherlands........................................................ ................................ 1-191.D.1 General........................................................ ........................................................... ................................ 1-191.D.2 Preliminary standard NVN 11400-0 .......................................................... ............................................ 1-191.D.2.1 Scope................................................................. .................................................................. ................... 1-191.D.2.2 Load assumptions .......................................................... ................................................................ ........ 1-19

Appendix 1.E

1.E National Requirements in India.................................................... ...................................................... 1-211.E.1 General...................................