PURCHASING SPECIFICATION
Item: Seamless flange in S355NL
1.0
Validity
1.1
Extent of delivery
The specification describes requirements for forged seamless flanges in the steel grade
S355NL-EN 10113.
The purchase order (PO) states the part number and number of products to be delivered together
with information about the delivery condition (forged raw rings eras final machined flanges).
1.1.1 Delivery of forged raw rings
When the PO describes a delivery of forged raw rings, the delivery must fulfill all requirements
given in this specification, including the requirements which are given to the final machined
product. The final machining and the dimensional inspection of the final machined ring Will be
carried out later on after the product has been receivedThe supplier of the raw rings must carry through and document the inspection and testing given in
section 5.4 and 7.1.1.
1.1.2 Delivery of final machined rings
When the PO describes delivery of final machined products the extent of the delivery must fulfill all
requirements given in this specification.
1.2 References
This specification incorporates European Standards end other documents. These
normative references are cited at the appropriate places in the text. For undated references, it is
the latest edition of the publication, to which a reference is made, that applies (including
amendments).
2.0 Definition
2.1 Nominal product thickness
The term "Nominal product thickness' is defined as:
The smallest value of A or B, where A is the nominal height of the final machined flange
(measured on the outer circular side) and B is nominal width of finished, machined surface
(plane side).
2.2 Batch
The term “batch” is defined as:
A quantity, which contains products of the same nominal product thickness manufactured from
a single material cast (or charge), and which are heat treated together in the same heat
treatment cycle (in a furnace).
For products with dissimilar geometry of the forged rings the range of approvals given in table 1
shall apply. Any product within one group give approval for all products from the same group
provided that the products are manufactured from the same single material cast (or charge),
and which are heal treated In the same heat treatment cycle (in a furnace).
Nominal product thickness “t” of the
product from which the sample is cut
out
mm
t<63
63 < t < 100
100 < t < 150
150 < t < 200
Range of approval for “t”
mm
t<63
63 < t < 100
100 < t < 150
150 < t < 200
Table 1 - Range of approval for parts with dissimilar nominal product thickness
2.3 Sample
The term "sample” is defined as:
A piece, which is cut out of the product after rolling and all required heat treatments have been
carried out. The sample must represent the properties of the final machined product
Test specimens machined out of sample must be used for verification of chemical composition,
mechanical properties and impact properties.
2.4 Serial Number
The tam "Serial-number is defined as:
A unique number for each product, which must be the key to traceability in the workshop and
afterwards, when tile product is included in a complete wind turbine.
4.0 Manufacturing process
4.1
Seamless hot rolled ring
4.1.1 Manufacturing of the raw ring
The products must be seamless hot rolled rings manufactured by a forging and rolling process,
with subsequent normalizing in a furnace.
The forging rate must be a minimum of 3.5:1. The forging rate must be documented on request
4.1.2 Machining
When the PO describes a delivery of final, machined products, the product must be machined
in accordance with the requirements given on the drawing.
4.1.3 Preparing of surfaces before ultrasonic inspection
The surface of the product shall be prepared with shot blasting, sand blasting, surface grinding
and/or proof machining to ensure that the acoustic coupling will be maintained during the
ultrasonic inspection.
4.1.0 Welding
Repair by welding is not allowed.
5.0 Material
5.1
General
The grade and quality of the used material must be in accordance with EN 10113, together
with additions and clarification described in section 5.2 to 5.4.
5.2 Chemical composition
5.2.1 General
The chemical composition must comply with the values in EN 10113, together with the
additions and clarification described in section 5.2.2.
5.2.2 Carbon equivalent (CEV)
The maximum carbon equivalent value must be determined by using the following formula.
CEV=C + Mn/6+(Cr+Mo+V)/5 + (Ni + Cu)/15. The carbon equivalent value based on
the ladle analysis must be a maximum of 0.41% and the carbon equivalent value based
on the product analysis must be maximum of 0.43%.
5.3 Mechanical properties
5.3.1 General
The required verification test temperature, the chemical composition, mechanical
properties and the impact properties must comply with the relevant requirements of EN
10113, together with the additions and clarification described in section 5.3.2 to 5.3.5.
5.3.2 Tensile properties - product with a nominal product thickness <150 mm
The tensile strength, upper yield strength and elongation from the verification of test
specimens must be in accordance with the requirements given in EN 10113 for the
relevant product thickness.
5.3.3 Tensile properties - product with a nominal product thickness > 150 mm
The tensile strength, upper yield strength and elongation from the verification of test
specimens must be in accordance with the requirements given in table 1.
5.4 Inspection and testing
5.4.1 General
The product must be submitted to 'specific inspection and testingg in accordance with EN
10113 with the modification that the tensile test pieces and impact test pieces must be placed
as described in 5.4, 1.2 - 5.4.1.3 instead of the requirements given in EURONORM 18. Also
the additions and clarification described in section 5.4.2 - 5.4.5 must be met.
5.4.1.1
Placement of test specimens
Longitudinal, transverse and axial directions are defined in appendix 1.
5.4.1.2
Square cress section
For raw rings, which are forged with square cross section, it is required that the centre of the
test specimens is placed in a minimum distance of 15 mm from all forged surfaces.
5.4.1.3 Other cross sections
Vestas requires that it must be proven by performing a number of destructive tests that the
placement of the test pieces is representative of the product(s) which must be qualified.
5.4.2 Chemical composition
Each batch must be submitted to inspection and testing and the chemical composition and
carbon equivalent value (CEV) based on the results from the ladle analysis and the product
analysis must be documented.
5.4.3 Tensile properties
5.4.3.1
Products with a nominal product thickness <150 mm
Each batch must be submitted to inspection and testing for the verification of the tensile
strength, upper yield strength and elongation in accordance with the line of direction given in
EN 10113.
The properties in the longitudinal direction must be verified on the basis of a minimum of one
sample from each batch.
5.4.3.2 Product with a nominal product thickness >150 mm
Each batch must be submitted to inspection and testing for the verification of the tensile
strength, upper yield strength and elongation in accordance with the line of direction given in
EN 10113.
The properties in the longitudinal and transverse direction must be verified on the basis of
minimum one sample from each batch.
5.4.4 Impact properties
5.4.4.1
Product with a nominal product thickness <150 mm
Each batch must be submitted to inspection and testing for the verification of impact
properties in accordance with the line of direction given in EN 10113. The properties in the
longitudinal direction must be verified on the basis of a minimum of one sample from each
batch.
5.4.4.2 Product with a nominal product thickness > 150 mm
Each batch must be submitted to inspection and testing for the verification of impact properties
in accordance with the line of direction given in EN 10113. The properties in
the longitudinal and the transverse direction must be verified on the basis of a minimum of one
sample from each batch.
5.4.5 Material Inspection document
5.4.5.1
General
The result from the required verifications given in section 5.4.2 - 5.4.4, together with additions
described in 54.5.2 must be documented in a EN 10204 inspection document. The requirement
to the type of inspection document (3.1B or 3.1A) isolated on the drawing. If nothing is stated
on the drawing the product shall be supplier with a 3.1B inspection certificate.
5.4.5.2 Additional issues which must be documented
The inspection document must include the following additional information,
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Part number + rev. no.
Serial number.
Technical purchase specification no. + rev. no.
Charge number + Test number of specimens.
Nominal product thickness
U-Sign (if applicable).
6.0 Marking
6.1 General
When the forging of the raw ring and the final machining of the product are performed by the
same supplier, the marking of a product must be in accordance with section 6.1.2.
Otherwise, the forging shop must mark each product in accordance with section 6.1.1
before the product is shipped to the machining shop. Subsequently, when final machining
is carried out the product must be marked in accordance with section 6.1.2 before it is
shipped to Saba Niroo.
6.1.1 Marking of the raw ring
Each product must be marked with the following information:
Information which must be written on the product with ink
Part number, including the revision number.
The grade, quality of the materiel.
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Information which must be hard stamped into the product
The manufacturer's name or trademark.
Material heat number, including the test number.
Saba Niroo PO number.
Serial number.
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6.1.2 Marking of the final, machined product
Each product must be marked with the following information:
Information which must be hard stamped into the product
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The manufacturer's name or trademark.
Part number including the revision number.
Saba Niroo PO number.
The grade, quality of the material.
Material heat number including the test number.
Carbon equivalent values from the product analysis.
Serial number.
The making must be placed in accordance with the drawing.
7.0
Non-destructive inspection
7.1
Extent of examination
7.1.1 Internal discontinuities
The product must be examined 100% around 360 for internal discontinuities on minimum
two perpendicular surfaces "in accordance with the requirements given in the required
testing
standard. Also, indications regardless of the size must be recorded if it seems probable
that the indication will be visible in the surface after machining.
1)
It can be necessary to do the scanning on some more surfaces (dead zones) depending
on the chosen sound beam probes and the profile of the product.
7.1.2 Surface discontinuities
When the supplier assesses that the final, machined product meets the requirements in
7.2.2 it is not required theta magnetic particle inspection is carried out and documented.
7.1.3 Dimensional inspection
Dimensional inspection of the product delivered must be performed in accordance with the
line of direction given in the quality specification in question.
7.2 Acceptance criteria
7.2.1 Internal discontinuities
The final, machined product must meet the recording and acceptance level Crass E2)/e3).
SEP 1921.
2)
In case of doubt for classification of reflectors into those of measurable extension or
those with no measurable extension and dimensions of the area of a discontinuity, a 2
MHz probe with the optimal focus length for longitudinal waves must be used.
3)
The allowed number of indications with measurable extension and no measurable
extension are per random meter measured on the ring (reference area) on the outside
diameter of the product, when the reference area is placed in the most unsuitable place.
7.2.2 Surface discontinuities
Only surface discontinuities, which are fulfilling the acceptance level class 3:EN 10228-1 will
be permitted on the surfaces of the final, machined product.
Other types of surface discontinuities , e.g. shrinkages, sand and slag inclusions, etc. will
not be permitted in final, machined surfaces. It is allowed to remove eventual surface
discontinuities by grinding, and the grinding area is smaller than 2 cm2 and not deeper than
1 mm.
7.2.3 Dimensional inspection
The product must meet the requirements given on the drawing in question.
7.3 Formalized requirements to the registrations
The required examination given in 7.1.1 and 7.1.3 must be documented. The registrations
must meet the formalized requirements to a 3.1.B-EN 10204 inspection document and
additional requirements given in the quality specification in question.
8.0 Complaints after delivery
8.1
General
Saba Niroo reserves the right to carry out inspections on own costs after delivery in
order to ensure that the delivered products meets the specified requirements.
The inspection will be performed in accordance with section 8.2- 8.8 and must show that
the mentioned requirements are met.
8.2 Chemical composition
Tests to verity the chemical composition may be carried out to ensure that the sample Is
representative of the product
The following procedure will be used:
'A product analysis on an area located randomly on the product or on a sample cut out of
the product will be made."
The result of the verification must show that when a comparison between the test result
and values from the ladle analysis stated on the material certificate for the product in
question is made, it must be documented that the allowed deviations given in table 1:EN
10113-1 not are exceeded and the calculated carbon equivalent values meet the
requirements given in 5.2.2.
8.3 Grain size
Non-destructive test to verify grain size may be carried out to ensure that the sample is
representative of the flange.
The following procedure will be used:
'A replica test will be made on an area located randomly on the product."
The result of the verification must show that the equivalent index of ferritic grain size
“>6", when the grain size is determined in accordance with EURONORM 103.
8.4 Tensile properties
Destructive test to verify the mechanical properties may be carried out to ensure that
the sample Is representative for the flange.
The following procedure will be used:
Test samples will be cut out in a distance of maximum 20 mm below the foal machined
surface of the flange. Subsequently test specimens located in the longitudinal, transverse
or axial direction will be machined out of the sample and tensile tested."
The result of the verification must show that the requirements given in section 5.3 are
fulfilled.
8.5 Impact properties
Destructive test to verify the impact properties may be carried out to ensure that the sample
is representative for the flange.
The following procedure will be used:
"Test samples will be cut out at a distance of a maximum of 20 mm below the final,
machined surface. Subsequently, Charpy-V test specimens located in the longitudinal,
transverse or axial direction end to end or aside will be machined out of the sample and
tested.
The result of the verification must show that:
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The average value of impact energy is a minimum of 27 J. and the value from each test
must not be below 19 J, when three Charpy-V test specimens located in the longitudinal
direction placed end to end or aside are tested at a test temperature of-50 oC.
The average value of impact energy is a minimum 01163. and the value from each test
must not be below 11 J when three Charpy-V test specimens located in the transverse
or axial direction placed end to end or aside are tested at a test temperature 01 .50 T.
8.6
Internal discontinuities
An ultrasonic inspection may be carried out on the final, machined product. The
inspection must show that all requirements given in section 72.1 are met.
8.7 Surface discontinuities
A magnetic particle inspection may be carried out on the final, machined product. The
inspection must show that all requirements given in section 7.2.2 are met
8.8 Dimensional inspection
A dimensional inspection may be carried out on the final, machined product. The
inspection must show that all requirements given in section 7.2.3 are met.
Appendix 1 Location of samples and test pieces
The test paces must be taken from the sample as indicated in figure la —1f, where
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figure 1a and 1d show specimens placed In the longitudinal direction
figure 1b and 1e show specimens pieced in the transverse direction
figure 1c and 1f show specimens placed in the axial direction
also the placement of the specimens' notch for the impact test is indicated in figure 1d-1f.
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2)
The hatch area illustrates the cross section of the test specimens.
The axis of the notch must be perpendicular to the surface of the product.