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GPR25001_R0[1]

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GPR25001_R0[1]

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    1 INTRODUCTION ................................................................................................................. 2 1.1 Scope ................................................................................................................................. 2 2 DEFINITION AND ACRONYMS ............................................................................................. 2 3 REFERENCES...................................................................................................................... 2 3.1 Normative references ............................................................................................................ 2 4 GENERAL REQUIREMENTS .................................................................................................. 3 4.1 Qualification ........................................................................................................................ 3 4.2 Qualified Products, Product changes and Requalification ........................................................... 3 4.3 Batch .................................................................................................................................. 3 4.4 Traceability .......................................................................................................................... 3 4.5 Hazardous constituents ......................................................................................................... 3 4.6 Written Communication ......................................................................................................... 3 5 COMPONENT APPROVAL PACKAGE (CAP) REQUIREMENTS .................................................... 3 5.1 Destructive Testing Report .................................................................................................... 3 5.2 Non-destructive Testing Report .............................................................................................. 5 5.3 Salvage Report .................................................................................................................... 7 5.4 Controlled Cooling Cycle Report ............................................................................................. 7 5.5 Heat Treatment Report ......................................................................................................... 7 5.6 Surface Treatment Report ..................................................................................................... 8 5.7 Dimensional Inspection Report............................................................................................... 8 5.8 Machining Process Report...................................................................................................... 8 6 INSPECTION REQUIREMENTS: SERIAL PRODUCTION ............................................................ 8 6.1 Destructive Testing Report .................................................................................................... 8 6.2 Non-destructive Testing Report .............................................................................................. 9 6.3 Salvage Report .................................................................................................................. 10 6.4 Heat Treatment Report ....................................................................................................... 10 6.5 Surface Treatment Report ................................................................................................... 10 6.6 Reduced Dimensional Inspection REPORT ............................................................................. 10 6.7 Machining Process Report.................................................................................................... 10

RECORD OF CHANGES

    Rev. Date Author Description

    00 05/02/2010 IBL The present document replaces EQ410001.

    Casting general requirements (GPS83001) added.

    GD015388/ GD014928/EM009001 replaced by new codification (GPS92003/

    GPS91001/ GMS71010).

    Section 1.1: Present specification is applicable for standard and reinforced

    blade plate G5X.

    Section 4 added.

    Section 5/6:

    - CAP test level application in one part after 150 batches.

    - Non destructive and Destructive testing defined per batch

    Section 5.1/6.1:

    - A complete definition of Destructive testing Report included

    - Cut-up testing added in homologation.

    Section 5.2/6.2:

    - NDT levels updated according to GPS92003/GPS91001. Levels

    defined for two areas (CA and rest of areas).

    - “Dross is not accepted” paragraph added

    Section 5.3: Specific reparation conditions updated.

    Section 5.8/6.7: Machining Process Report added.

    Reduced Dimensional Inspection Report references removed from the

    present specification.

    ICA-TEC-001-R06 (en) Edition 1

    Confidentiality: 2 / SUPPLIER INFORMATION

    Code: GPR25001-en Rev: 00

    GAMESA PART REQUIREMENTS Date: 05/02/10 Pg. 2 of 10

    Title: BLADE PLATE CASTING G5X

1 INTRODUCTION

1.1 SCOPE

    This specification describes the documentation to be given by the supplier of G5X wind turbine standard and reinforced casting blade plates and it is applicable to all parts when called out in design and manufacturing drawings. It also comprises the minimum requirements for part validation. The component referred to in this specification is manufactured in EN-GJS-400-18U-LT.

    During manufacturing process validation documentation shall be given in a CAP (Component Approval Package)

    Once First Article Validation has been completed, then reduced inspection level shall be applied (less documentation shall be required), provided manufacturing process is within its limits.

2 DEFINITION AND ACRONYMS

GCT: Gamesa Corporación Tecnológica

    MP: Magnetic Particles

    UT: Ultrasonic Testing

    CAP: Component approval package

    SQA: Supplier Quality Assurance

    CA: Critical Areas

    NDT: Non Destructive Testing

3 REFERENCES

3.1 NORMATIVE REFERENCES

    The following documents are invoked as part of this specification and must be fulfilled to the extent defined. Unless specifically over-ruled by the inclusion of a date, or an issue letter or code, the latest issue shall always apply.

Number Title

    GPS90001 Non destructive testing.

    GPS92003 Ultrasonic inspection in Spheroidal cast iron

    GPS91001 Magnetic Particles Inspection in Cast Iron.

    ISO 11971 Visual examination of surface quality of steel castings

    ASTM A802 Standard Practice for Steel Castings, Surface Acceptance Standards, Visual Examination

    EN 1563 Founding- Spheroidal graphite cast irons

    Preparation of steel substrates before application of paints and related product- Visual assessment ISO 8501-1 of surface cleanliness-

    GMS71010 Spheroidal Graphite Cast Iron EN-GJS-400-18-LT

    GPS83001 Casting process specification

    GTS92501 Blade plate Casting G5X Cut-up

    ICA-TEC-001-R06 (en) Edition 1

    Confidentiality: 2 / SUPPLIER INFORMATION

    Code: GPR25001-en Rev: 00

    GAMESA PART REQUIREMENTS Date: 05/02/10 Pg. 3 of 10

    Title: BLADE PLATE CASTING G5X

4 GENERAL REQUIREMENTS

4.1 QUALIFICATION

    The manufacturing requirements to be fulfilled by any casting supplier to obtain GCT full approval shall be according to GPS83001.

    The material covered by this specification shall be a product which has been tested and comply with the characteristics specified herein.

4.2 QUALIFIED PRODUCTS, PRODUCT CHANGES AND REQUALIFICATION

    No deviation from approved method of manufacture is permitted without prior written approval from Gamesa Materials & Processes Directorate. Any change by the manufacturer may be cause for requalification. A change is defined as, but not limited to: material specification or manufacturing process changes, raw material source or supply changes product and/or manufacture location.

4.3 BATCH

    Batch is defined as the final product following the same manufacturing processes, melted at the same time (same box, ladle and heat treated in the same furnace).

4.4 TRACEABILITY

    Each individual product shall be traceable to the raw materials source at all stages of manufacture and delivery.

    Material for re-testing and specimens tested in CAP must be stored for 2 years. Component Approval Package and Serial production documents must be kept for 20 years.

4.5 HAZARDOUS CONSTITUENTS

Not applicable.

4.6 WRITTEN COMMUNICATION

    All communication in regard to this specification which could impact an existing purchase order shall be directed through Gamesa Purchasing Department. Communications regarding specification technical interpretation, alternative proposal, revision, special process approval or where specifically required by the specification during the development phase before homologation, shall be directed to Gamesa Materials & Processes Directorate.

During the serial phase all communications shall be directed to SQA.

5 COMPONENT APPROVAL PACKAGE (CAP) REQUIREMENTS

    Non-destructive and destructive tests shall be carried out per batch, unless otherwise required in point 5.1 and 5.2.

The minimum requirement for CAP approval is 2 batches.

G5X Blade plate casting CAP must contain the following reports:

5.1 DESTRUCTIVE TESTING REPORT

A destructive testing report, covering following issues, shall be generated.

    ICA-TEC-001-R06 (en) Edition 1

    Confidentiality: 2 / SUPPLIER INFORMATION

    Code: GPR25001-en Rev: 00

    GAMESA PART REQUIREMENTS Date: 05/02/10 Pg. 4 of 10

    Title: BLADE PLATE CASTING G5X

5.1.1 Sampling

; Integrally cast-on test specimens. 2 cast test specimens per batch according to GMS71010. One of these

    specimens must be delivered to GCT for retesting.

    ; 1 cut-up of a real part per CAP. Cut-up scheme must be defined by Gamesa Materials & Processes

    Directorate. Cut-up test specification is according to GTS92501.

Specimen identification shall provide full traceability.

The number and type of tests and conformity criteria shall be in accordance with Table 1.

     Test method Clause Nº of tests Conformity criteria

    Chemical composition 5.1.2 1 per ladle

    Metallographic tests 5.1.3 1 per cast sample Cast-on test

    specimens Tensile test (R, R, mp0.2 (2 per batch) 5.1.4.1 1 per cast sample A%)

    Impact 5.1.4.2 3 per cast sample

    GMS71010 Metallographic tests 5.1.3

    Cut-up test part Tensile test according to 5.1.4.1 * number of cut test sample GTS92501 (R, R, A%) mp0.2 according to Cut-up Scheme

    Impact 5.1.4.2

    Test on part Hardness test 5.1.5 2 per part* (Each unit of the batch)

    *2 measurements per part (1 set per location) according to Figure 1.

    Table 1. Frequency of destructive testing in a CAP

5.1.2 Chemical analysis test

    One chemical analysis per ladle shall be reported according to GMS71010.

Chemical elements to be reported are according to GMS71010.

5.1.3 Metallographic test

    One metallographic test shall be carried out per separately cast test specimens.

    Graphite and microstructure shall be evaluated conforming to GMS71010.

Evaluation shall be carried out in integrally cast test samples and cut-up test samples according to GMS71010.

5.1.4 Mechanical properties tests

Mechanical tests shall be reported and documented including failures, though re-testing results are

    satisfactory.

    In all mechanical testing distance from test area (fracture) to surface must be reported.

Mechanical properties shall comply with GMS71010 for a relevant thickness of 35 mm.

    ICA-TEC-001-R06 (en) Edition 1

    Confidentiality: 2 / SUPPLIER INFORMATION

    Code: GPR25001-en Rev: 00

    GAMESA PART REQUIREMENTS Date: 05/02/10 Pg. 5 of 10

    Title: BLADE PLATE CASTING G5X

5.1.4.1. Tensile test

Tests shall be performed in accordance with GMS71010.

Nº of tests on integrally cast test specimens, 1.

5.1.4.2. Impact test

    The tests shall be performed in accordance with GMS71010 (ISO V, -20ºC).

    Nº tests on integrally cast test specimens: 3 per integrally cast test specimen.

5.1.5 Hardness test

Hardness measurements as per GMS71010, carried out on part and in location shown in Figure 1. Total

    measurements, 2 (1 set per location).

    Figure 1. Hardness test location

5.2 NON-DESTRUCTIVE TESTING REPORT

Applicable non-destructive testing specification shall be GPS92003 and GPS91001 in those aspects relative to

    inspection procedure and defect acceptance limits.

Dross is not accepted and shall be removed by mechanical means in accordance with point 5.3 (Salvage

    Report).

    5.2.1 Visual Inspection

    ICA-TEC-001-R06 (en) Edition 1

    Confidentiality: 2 / SUPPLIER INFORMATION

    Code: GPR25001-en Rev: 00

    GAMESA PART REQUIREMENTS Date: 05/02/10 Pg. 6 of 10

    Title: BLADE PLATE CASTING G5X

The surface of the castings after blasting must meet the grade Sa 2 ? in accordance with ISO 8501-1.

    Quality levels described in Table 2 (according to ISO 11971) must be complied for all significant areas and

    final casting roughness R in critical areas must be between 60-100μm before surface treatment. z

Extent of inspection: 100% all parts and surfaces.

    Quality Levels Surface Feature C.A. Rest of Areas

    Surface roughness A2 A3

    Non metallic inclusions B2 B4

    Gas porosity C2 90% C1 and 10% C3

    Mechanical dressing H1 H1

    Table 2. Visual inspection acceptance criteria for defined areas in Figure 2

    Figure 2. Description of Critical Areas (C.A)

For the evaluation of the surface quality of castings (complying with ASTM A802), SCRATA (Steel Casting

    Research and Trade Association) Comparators shall be used.

Inspection must be carried out on finished casting.

Surfaces that shall not be machined, must be smoothed with gradual transitions and without visible “brush

    strokes”.

5.2.2 Ultrasonic Inspection

    Part shall be 100% UT inspected in all surfaces according to GPS92003.

    ICA-TEC-001-R06 (en) Edition 1

    Confidentiality: 2 / SUPPLIER INFORMATION

    Code: GPR25001-en Rev: 00

    GAMESA PART REQUIREMENTS Date: 05/02/10 Pg. 7 of 10

    Title: BLADE PLATE CASTING G5X

    Inspection shall be carried out according to Table 3 requirements.

Sound velocity must be measured in critical areas with maximum thickness and must be reported to GCT.

    Material Requirements Visual inspection Ultrasonic Inspection

     Area in Figure 2 CA Rest of Areas CA Rest of Areas

    Extent of inspection per batch 100% 100%

    Extent of inspection per casting 100 % 100 % 100 % 100% part

    Severity level 2 Severity level 3

    Acceptance level See Table 2 See Table 2

    Wall section: Type B Wall section: Type B

    Note: The wall sections are related to the dimensions of the finished part once machined.

    Table 3. Extent and acceptance criteria of non-destructive testing in a CAP

5.3 SALVAGE REPORT

Salvage welding is NOT allowed under any circumstance.

If quality requirements are not met, parts can be repaired by grinding, except machining areas, which must

    be submitted to GCT approval.

    100% of repaired area must be Magnetic Particles Inspected again after repairing.

    The allowed depth of surface defects and the maximum allowed grinding depth must be established in accordance with Table 4 .

    1)Areas (See Figure 2) Type of repair action

    Critical areas To be evaluated individually in each case.

    2)Rest of areas According to GPS90001

    Note 1: All reparations are susceptible to be rejected by Quality Inspector. Note 2: Repairing outer surface excludes repairing on inner surface of the same area.

    Table 4: Repair criteria

    Surface roughness, after repairing by grinding, must comply with H1 according to ISO 11971, SCRATA Comparators.

5.4 CONTROLLED COOLING CYCLE REPORT

Supplier must document a controlled cooling cycle guaranteeing proper microstructure and mechanical

    properties.

5.5 HEAT TREATMENT REPORT

Heat treatment cycle shall be documented if applicable.

    ICA-TEC-001-R06 (en) Edition 1

    Confidentiality: 2 / SUPPLIER INFORMATION

    Code: GPR25001-en Rev: 00

    GAMESA PART REQUIREMENTS Date: 05/02/10 Pg. 8 of 10

    Title: BLADE PLATE CASTING G5X

5.6 SURFACE TREATMENT REPORT

    A surface treatment report, which will be available for GCT, indicating compliance with requirements specified in design drawing shall be issued.

5.7 DIMENSIONAL INSPECTION REPORT

    A dimensional report covering values obtained from measurements carried out of all the casting drawing dimensions will be supplied.

5.8 MACHINING PROCESS REPORT

5.8.1 Non Destructive Testing Report

    Applicable non-destructive testing specification shall be GPS91001 in those aspects relative to inspection procedure and defect acceptance limits.

Cut shrinkage is not allowed after machining.

5.8.1.1. Magnetic Particle Inspection

    All (100%) machined areas, as well as grinded surfaces must be inspected by magnetic particle. Severity level 2 according to GPS91001.

5.8.2 Salvage Report

As per point 5.3 in case it is necessary.

5.8.3 Dimensional Inspection report

    A dimensional report covering values obtained from measurements carried out of all dimensions in machining drawing will be supplied.

6 INSPECTION REQUIREMENTS: SERIAL PRODUCTION

    Once manufacturing process has been validated in supplier by means of a CAP, reduced inspection level shall be applied in which it shall be required the following documentation:

    Non-destructive and destructive tests shall be carried out per batch, unless otherwise required in point 6.1 and 6.2.

    When the production process is modified as a result of a non-conformity (rejected parts) or as a control measure after 150 batches manufactured, CAP test level must be applied in one batch.

6.1 DESTRUCTIVE TESTING REPORT

A destructive testing report, covering following issues, shall be generated:

6.1.1 Sampling

Integrally cast-on test specimen. 1 cast test specimens per batch.

Specimen identification shall provide full traceability.

The number and type of tests and conformity criteria shall be in accordance with Table 5.

    ICA-TEC-001-R06 (en) Edition 1

    Confidentiality: 2 / SUPPLIER INFORMATION

    Code: GPR25001-en Rev: 00

    GAMESA PART REQUIREMENTS Date: 05/02/10 Pg. 9 of 10

    Title: BLADE PLATE CASTING G5X

     Conformity Test method Clause Nº of tests criteria

    Chemical Analysis 6.1.2 1 per ladle

    Metallographic Test 6.1.3 1 per cast test specimens Cast-on test specimen

    Tensile test (R, R, A%) 6.1.4 1 per cast test specimens (1 per batch) mp0.2GMS71010

    Impact test (ISO V, -20ºC) 6.1.4 3 per cast test specimens

    Test on part Hardness 6.1.5 2 per part* (1 part per batch)

    *2 measurements per part (1 set per location) according to Figure 1.

    Table 5. Frequency of destructive testing for serial production

6.1.2 Chemical analysis test

As per point 5.1.2

6.1.3 Metallographic test

    One metallographic test shall be carried out per cast-on test specimens.

    Graphite and microstructure shall be evaluated conforming to GMS71010.

6.1.4 Mechanical properties tests

One tensile specimen and three ISO-V impact specimens per cast-on test specimens, according to GMS71010.

Mechanical properties shall comply with GMS71010 for a relevant thickness of 35 mm.

6.1.5 Hardness test

As per point 5.1.5

6.2 NON-DESTRUCTIVE TESTING REPORT

Extent and acceptance criteria of non-destructive testing for serial production are shown in Table 6.

Material Requirements Visual inspection Ultrasonic Inspection

     Area in Figure 2 CA Rest of Areas CA Rest of Areas

    Extent of inspection per batch 100% >20%

    Extent of inspection per casting 100 % 100 % 100 % 100% part

    See Severity level 2 Severity level 3 Acceptance level See Table 2 Table 2 Type B Type B

    Note: The wall sections are related to the dimensions of the finished part once machined.

    Table 6. Extent and acceptance criteria of non-destructive testing for serial production

    ICA-TEC-001-R06 (en) Edition 1

    Confidentiality: 2 / SUPPLIER INFORMATION

    Code: GPR25001-en Rev: 00

    GAMESA PART REQUIREMENTS Date: 05/02/10 Pg. 10 of 10

    Title: BLADE PLATE CASTING G5X

    Applicable non-destructive testing specification shall be GPS92003 and GPS91001 in those aspects relative to inspection procedure and defect acceptance limits.

    Dross is not accepted and shall be removed by mechanical means in accordance with point 5.3 (Salvage Report).

6.2.1 Visual Inspection

Extent and acceptance criteria of inspection are showed in Table 6.

6.2.2 Ultrasonic Inspection

    All surfaces must be inspected by UT within the limits of GPS92003 and severity level shown in Table 6.

6.3 SALVAGE REPORT

As per point 5.3

6.4 HEAT TREATMENT REPORT

Heat treatment cycle shall be documented if applicable.

6.5 SURFACE TREATMENT REPORT

As per point 5.6

6.6 REDUCED DIMENSIONAL INSPECTION REPORT

    A dimensional report covering values of dimensions specified by means of symbols in casting drawing will be supplied.

6.7 MACHINING PROCESS REPORT

    Applicable non-destructive testing specification shall be GPS91001 in those aspects relative to inspection procedure and defect acceptance limits.

Cut shrinkage is not allowed after machining.

6.7.1 Non Destructive Testing Report

100% of the parts as indicated in point 5.8.1.

Cut shrinkage is not allowed after machining.

6.7.2 Salvage Report

As per point 5.3 in case it is necessary.

6.7.3 Reduced Dimensional Inspection report

    A dimensional report covering values of dimensions specified by means of symbols in machining drawing will be supplied.

    ICA-TEC-001-R06 (en) Edition 1

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