Confidential Page 1 of 33 WTG Foundations Supply

Employer's Requirements Appendix B01

Copyright 2012 RWE Npower Renewables Limited
All pre-existing rights reserved.
This document is supplied on and subject to the terms and conditions of the Contractual Agreement relating
to this work, under which this document has been supplied, in particular:
Confidentiality
This document is confidential.
Liability
n preparation of this document RWE npower renewables has made reasonable efforts to ensure that the
content is accurate, up to date and complete for the purpose for which it was contracted. RWE npower
renewables makes no warranty as to the accuracy or completeness of material supplied by the client or their
agent.
Other than any liability on RWE npower renewables detailed in the contracts between the parties for this
work RWE npower renewables shall have no liability for any loss, damage, injury, claim, expense, cost or
other consequence arising as a result of use or reliance upon any information contained in or omitted from
this document.
Any persons intending to use this document should satisfy themselves as to its applicability for their intended
purpose.
The user of this document has the obligation to employ safe working practices for any activities referred to
and to adopt specific practices appropriate to local conditions.













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Employer's Requirements Appendix B01

CONTENTS


1. General Requirements ...................................................................................................................................... 4
1.1. Scope ....................................................................................................................................................... 4
1.2. Definitions of structural parts .................................................................................................................... 4
1.3. Terminology ............................................................................................................................................. 5
1.4. Standards ................................................................................................................................................. 6
2. Materials .......................................................................................................................................................... 10
2.1. General Requirements ........................................................................................................................... 10
2.2. Steel Grades .......................................................................................................................................... 10
2.3. Castings and Forgings ........................................................................................................................... 14
2.4. Requirements for Supply of nterface Flange ......................................................................................... 14
2.5. Surface Condition ................................................................................................................................... 15
2.6. Steel Certification ................................................................................................................................... 15
3. Manufacturing, workmanship and quality control ....................................................................................... 16
3.1. General requirements ............................................................................................................................ 16
3.2. Special and Primary Steel Fabrication ................................................................................................... 17
3.3. Secondary Structure Fabrication ............................................................................................................ 17
3.4. Execution of Welds ................................................................................................................................ 18
3.5. Post Weld heat Treatment ..................................................................................................................... 18
3.6. Weld mprovement ................................................................................................................................. 18
3.7. Welding Personnel ................................................................................................................................. 19
3.8. Control and Quality of Welds ................................................................................................................. 19
3.9. Non-Destructive Testing ......................................................................................................................... 20
3.9.1. Personnel .................................................................................................................................... 20
3.9.2. NDT Procedures, Technique Sheets and Reporting Proformas ................................................. 20
3.9.3. NDT nspection Extent of nspection ........................................................................................ 21
3.9.4. NDT nspection - General ............................................................................................................ 22
3.9.5. Requirements for Ultrasonic nspection ...................................................................................... 23
3.9.6. Visual nspection / MP Acceptance Criteria ............................................................................... 24
3.9.7. Ultrasonic Testing Acceptance Criteria ....................................................................................... 25
3.9.8. NDT nspection Report Documentation ....................................................................................... 25
3.10. Traceability ............................................................................................................................................. 26
3.11. Fabrication Tolerances ........................................................................................................................... 26
3.11.1. Flange Tolerances .................................................................................................................... 26
3.11.2. Structural Steelwork Tolerances ............................................................................................... 27
3.11.3. Dimensional Control ................................................................................................................. 28
3.12. Execution of Bolted Connections ........................................................................................................... 28
3.12.1. General ..................................................................................................................................... 28
3.12.2. Bolt tightening ........................................................................................................................... 28



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Employer's Requirements Appendix B01

3.13. Product Handling .................................................................................................................................... 29
4. Documentation ................................................................................................................................................ 30
4.1. Fabrication Drawings ............................................................................................................................. 30
4.2. Fabrication Procedures .......................................................................................................................... 30
4.3. Quality / As-Built Documentation ........................................................................................................... 31
5. Additional requirements ................................................................................................................................. 33
5.1. Departures & Non-Conformance ............................................................................................................ 33
5.2. nspection of manufacture and installation ............................................................................................. 33






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Employer's Requirements Appendix B01

1. General Requirements
1.1. Scope
These supplementary conditions shall apply to all parts of the Wind Turbine Generator sub-
structure and foundations, except proprietary machine components.
1.2. Definitions of structural parts
Steelwork, and the applicability of connections within steelwork, is categorised as special,
primary, secondary or tertiary steelwork, as defined in Table 1-1.
Special
Steelwork
Steelwork where failure will have substantial consequences and are subject to
a stress condition that may increase the probability of a brittle fracture. This
category includes steelwork which would be classed as Primary steelwork, but
is subject to through-thickness loading, which arises from complex biaxial or
triaxial loading e.g. complex joints on a jacket foundation, tower to
substructure interface flanges, padeyes etc.
Primary
Steelwork
Steelwork whose consequence of failure may lead to global structural failure
of the structure or to loss of function of the structure or other substantial
consequence. Primary structural members are members participating in the
overall integrity of the structure or which are important for operational safety
(e.g. padeyes or hook-on points).
Secondary
Steelwork
Steelwork whose consequence of failure will not lead to global structural
failure or other significant consequence. Secondary steelwork comprises all
appurtenances attached to the primary steelwork including boat landing
structures, internal and external access platforms, J-tubes, ladders, anode
supports, installation guides etc. Connections between primary and
Secondary Steelwork shall be classified as primary steelwork. Padeyes or
hook on points shall never be classed as secondary steel even when attached
to secondary steel.
Tertiary
Steelwork
Those steelwork elements attached to the Secondary Steelwork which
represent independent elements to the Secondary Steelwork, such as
brackets and supports for mounting of navigational aids and safety equipment.
Components connected to other secondary components but making up a
secondary structure, such as beams, handrails and the like, shall be classified
as Secondary Steelwork.
Table 1-1 Steelwork category definitions
The guidance notes in DNV-OS-J101 and shall be considered and followed when defining the
applicable structural category.



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Employer's Requirements Appendix B01

1.3. Terminology
The following terminology and abbreviations apply within this specification:
Carbon Equivalent See EN 10225 cl. 8.2.3
Hot-Rolled Rolled in the range 910C 1250C without any grain refining action
Manufacturer See EN 10225
NDT Procedure A written description of all essential parameters and precautions to be
applied when using a specific NDT method to inspect products in
accordance with standard(s), code(s) or specification(s)
NDT Technique Sheet A specific written description or instruction of the precise steps to be
followed in the testing of an individual component to an established
NDT procedure
Normalised Reheated above 910C and cooled in air, in order to produce a grain
refining action
Normalising Rolled See EN 10225
Supplier See EN 10225
Thermo-mechanically
Rolled
See EN 10225
Quenching and Tempering See EN 10225
CTOD Crack Tip Opening Displacement
MP Magnetic Particle nspection
NDT Non Destructive Testing
PWHT Post Weld Heat Treatment
RPS Radiation Protection Supervisor
WPQ Weld Procedure Qualifications
WPS Weld Procedure Specification
WPQR Weld Procedure Qualification Record
Table 1-2 Terminology and Abbreviations




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Employer's Requirements Appendix B01

1.4. Standards
Steel parts shall comply with legislation and the references listed in Table 1-3 below. (*ANS/AWS
D1.1 shall not be used). The Standards listed in Table 1-3 are key references. Normative
references and linked standards mentioned in these shall be respected. Standards appropriate to
offshore installations shall be applied; standards derived for onshore application shall not be
employed unless specifically approved for use by the Employer. Any proposed departures from
these standards must be notified to the Employer and shall only be used if accepted by the
Employer.
Unless agreed in writing by the Employer the latest revision of the following standards shall be
used at all times. n the case of discrepancies between the standards listed below or with the
Employer's Requirement the stricter shall apply.
1. Overall / Design Standards
No. Reference
1.1 DNV-OS-J101 Design of Offshore Wind Turbine Structures
2. Material Standards
No. Reference
2.1 EN 10025-1 Hot rolled products of structural steels. General technical delivery
conditions
2.2 EN 10025-2 Hot rolled products of structural steels. Technical delivery conditions for
non-alloy structural steels
2.3 EN 10025-3 Hot rolled products of structural steels. Technical delivery conditions for
normalized/normalized rolled weldable fine grain structural steels
2.4 EN 10025-4 Hot-rolled products of structural steels. Technical delivery conditions for
the thermo mechanical rolled weldable fine grain steels
2.5 EN 10163: Delivery requirements for surface condition of hot-rolled steel plates, wide
flats and sections.
2.6 EN 10164: Steel products with improved deformation properties perpendicular to the



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Employer's Requirements Appendix B01

surface of the product. Technical delivery conditions
2.7 EN 10204 Metallic products. Types of inspection documents
2.8 EN 10225 Weldable Structural Steels for Fixed Offshore Structures
2.9 EN 10210-1 Hot finished structural hollow sections of non-alloy and fine grain steels.
Technical delivery requirements
2.10 EN 10210-2 Hot finished structural hollow sections of non-alloy and fine grain steels.
Tolerances, dimensions and sectional properties
2.11 EN 10293: Steel castings for general engineering uses
2.12 EN 10340: Steel castings for structural uses
2.13 DNV-OS-B101: Metallic Materials
3. Bolt Standards
No. Reference
- To be defined by Foundation Design Contractor
4. Execution / Fabrication Standards
No. Reference
4.1 DNV-OS-C401 Fabrication and Testing of Offshore Structures (See Notes 1&2)
4.2 EN 287-1 Qualification test of welders. Fusion welding. Steels
4.3 EN 1011-2 Welding. Recommendations for welding of metallic materials. Arc welding of
ferritic steels
4.4 EN 1418 Welding personnel. Approval testing of welding operators for fusion welding
and resistance weld setters for fully mechanized and automatic welding of metallic
materials



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Employer's Requirements Appendix B01

4.5 EN SO 3834-1: Quality requirements for fusion welding of metallic materials. Criteria
for the selection of the appropriate level of quality requirements
4.6 EN SO 3834-2: Quality requirements for fusion welding of metallic materials.
Comprehensive quality requirements (see Note 4)
4.7 EN SO 3834-3: Quality requirements for fusion welding of metallic materials. Standard
quality requirements (see Note 4)
4.8 EN SO 3834-5: Quality requirements for fusion welding of metallic materials.
Documents with which it is necessary to conform to claim conformity to the quality
requirements of SO 3834-2, SO 3834-3 or SO 3834-4
4.9 EN SO 5817: Welding Fusion welded joints in steel, nickel, titanium and their alloys
Quality levels for imperfections
4.10 EN SO 9692: Welding and allied processes -- Types of joint preparation
4.11 EN SO 15609: Specification and qualification of welding procedures for metallic
materials - Welding procedure specification
4.12 EN SO 15614: Specification and qualification of welding procedures for metallic
materials - Welding procedure test
5. Other standards referred to in this document and which shall be complied with as
applicable (see Note 5)
No. Reference
5.1 EEMUA 197: Specification for the fabrication of non-primary structural steelwork for
offshore installations
5.2 EN 1090-2: Execution of steel structures and aluminium structures. Technical
requirements for steel structures
5.3 EN 1993: Eurocode 3. Design of steel structures
Table 1-3 Standards and References




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Employer's Requirements Appendix B01

NOTES to Table 1-3
1) ANS / AWS D1.1 shall not be used.
2) For the correct application of DNV-OS-C401 reference must be made to DNV-OS-J101
(e.g. definition of inspection categories).
3) As per section 3.8 EN SO 3834-2 shall apply for special and Primary Steelwork and EN
SO 3834-3 for Secondary Steelwork.
4) For standards relating to Non-Destructive Testing refer to Table 3-1 in section 3.9.2.
5) n the event of discrepancy with other standards listed in Table 1-3, the requirements of
those other standards shall take precedence.




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2. Materials
2.1. General Requirements
The operational life for all structural materials shall be a minimum of 27 years. All structural steel
shall be new and fit for this purpose.
All steel shall be fully killed and of low Sulphur low Carbon Equivalent practice. Steel shall be hot-
rolled (up to 25mm thick only), and above 25mm thick shall be normalised or normalising rolled or
thermo mechanically rolled. Quenched and tempered materials are not permitted.
2.2. Steel Grades
Steel grades shall be selected by the Contractor and shall conform to the requirements of the
standards listed in Table 1-3, as appropriate for the material selected. n particular the Contractor
shall demonstrate that his chosen grades comply with the requirements of the design standards
DNV-OS-J101 or other standards as agreed with the Employer and the Certifying Authority. n the
case of discrepancy between standards the stricter requirement shall apply.
Acceptable steel properties and examples of suitable steel grades for Primary and Secondary
Steelwork are provided in Table 2-1 to Table 2-2. The Contractor shall provide his proposed steel
grades within his tender return.
The steel strength class of the main members of the external working platform should possess a
yield strength of 355 N/mm or higher.



















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Employer's Requirements Appendix B01


Location
in
Structure
/ Use
Thickness
(mm)
Min
Tensile
Strength
(N/mm2)
Min
Yield
Strength
(N/mm2)
Suitable Steel Grades
Minimum avg
Charpy Test
results &
through
thickness
properties
Primary
below -2m
LAT
(design
temp 0C)
t16
16<t25
25<t40
40<t63
63<t70
70<t100
100<t
460
460
460
460
460
460
460
355
355
345
335
325
325
320
S355K2 or S355N or M
S355NL or S355ML
S355NL or S355ML
S355NL or S355ML
S355NL or S355ML
S355NL or S355ML
S355G7+N
34J at -20C
1

41J at -40C
2

41J at -40C
2

41J at -40C
2

41J at -40C
2

50J at -40C
2

50J at -60C
3

Primary
above
-2m LAT
(design
temp -
10C)
t16
16<t25
25<t40
40<t63
63<t70
70<t80
80<t100
460
460
460
460
460
460
460
355
355
345
335
325
325
325
S355K2 or S355N or M
S355NL or S355ML
S355NL or S355ML
S355NL or S355ML
S355NL or S355ML
S355NL or S355ML
S355G7+N or G7+M
34J at -20C
1

41J at -40C
2

41J at -40C
2

41J at -40C
2

41J at -40C
2

50J at -40C
2

50J at -60C
3

All
Through
Thickness
Loaded;
Nodes of
Jackets
25<t<40
40<t63
63<t100
460
460
460
345
335
325
S355G10+N*Z35| or
G10+M*Z35|
41J at -60C
3
+Z35

50J at -60C
3
+Z35

Decking,
plate
girders
t16
16<t40
460
460
355
345
S355G2+N, S355K2 or N
or M
S355G3+N, S355G6+M,
S355NL or ML
34J at -20C
1

41J at -40C
2


Secondary t20
20<t40
410
410
235
235
S235J0
S235J2
27J at 0.0C
4

27J at -20C
5

Table 2-1 Steel Grades for Plates

NOTES to Table 2-1
1) Plates delivered to EN 10025 Grade S355K2 will not automatically comply with DNV OS-
J101 since EN 10025 only requires 27J minimum avg. The Contractor shall ensure material
used complies with the above requirement and DNV-OS-J101.

2) Plates delivered to EN 10025 Grade S355NL will not automatically comply with DNV OS-
J101 since EN 10025 only requires 31J minimum avg. The Contractor shall ensure material
used complies with the above requirement and DNV-OS-J101.

3) Since -60C Charpy tested steel is not commonly available (except in AP 2H or 2W), -
40C/-50C Charpy tested steel will be accepted for this purpose where:- the joint is PWHT



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Employer's Requirements Appendix B01


Or the steel has been HAZ CTOD pre-qualified to EN 10225
Or the steel has been HAZ Drop-Weight Tear Test pre-qualified to AP 2H, 2W or 2Y
Or the steel has passed Z35 testing to EN 10164
n addition to passing the requirements for -40C/-50C Charpys. n such cases the Contractor
must show that PWHT is not necessary using ECA. Normally it has been found that material
with under 100J will not pass these additional tests.
4) This is met by EN 10025 Grade S235J0.

5) This is met by EN 10025 Grade S235J2.


STEEL
TYPE
Location
in
Structure /
Use
Thickness
(mm)
Min
Tensile
Strength
(N/mm2)
Min
Yield
Strength
(N/mm2)
Suitable Steel
Grades
Minimum
avg Charpy
Test
results
(Seamless
HS)
Tubes
Tube
stubs
Fenders
Fender
stubs

t16
16<t40

460
460

355
345

S355K2
S355NL or
S355ML

34J at -
20C
1

41J at -
40C
2


(Seamless
HS)
Secondary t16
16<t40

410
410

275
265

S275J0H
S275J2H

27J at 0C
3

27J at -
20C
4


(Rolled
Sections)

Primary /
Secondary
(inc
tubular)
t16
16<t40
460
460
355
345
S355K2
S355NL or ML
34J at -
20C
1

41J at -
40C
2


(Rolled
Sections)
Secondary t16
16<t40
410
410
275
265
S275J0H
S275J2H

27J at -
20C
3

27J at -
40C
4


- Handrails t<6 410 235 S235JR Not
Required
Table 2-2 Steel Grades for tubular sections.

NOTES to Table 2-2
1) Plates delivered to EN 10025 Grade S355K2 will not automatically comply with DNV OS-
J101 since EN 10025 only requires 27J minimum avg. The Contractor shall ensure
material used complies with the above requirement and DNV-OS-J101.



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Employer's Requirements Appendix B01


2) Plates delivered to EN 10025 Grade S355NL will not automatically comply with DNV OS-
J101 since EN 10025 only requires 31J minimum avg. The Contractor shall ensure
material used complies with the above requirement and DNV-OS-J101.

3) This is met by EN 10210 Grade S275J0H.

4) This is met by EN 10210 Grade S235J2H.
Other general requirements are as follows:
a) Through thickness tested grades shall be used for material over 25mm that are subject to
substantial through thickness loads e.g. plates that will have lifting pad eyes attached to
them. Steel required to have through thickness properties is required to meet the additional
testing requirements of EN 10225 Option13, level Z35.
b) The maximum Carbon Equivalent values of the DNV-OS-B101 must be adhered to as these
may have more stringent requirements than quoted in EN 10025 and EN 10225.
c) The steel grade selection against brittle failure shall be based upon the minimum ambient
temperature at the wind farm site as noted in environmental data provided by the Employer.
All lifting lugs and/or pad eyes shall be suitable for a minimum design temperature of -10C.
The following maximum material thicknesses for each level of impact testing shall be applied
in accordance with Table 2-3 for primary steel and Table 2-4 for secondary steel.
Charpy Impact Test
Temperature (C)
Maximum Material Thickness (mm)
0C Design Temp. -10C Design Temp.
- 20 25 20
- 40 50 (Special) 40 (Special)
- 40 100 (Primary) 80 (Primary)
- 40 + CTODs 100 (Special) 80 (Special)
- 60 150 (Primary) 150 (Primary)
- 60 100 (Special) 80 (Special)
Table 2-3 Primary Steelwork Charpy Requirements



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Employer's Requirements Appendix B01


Charpy Impact Test Temperature (C)
Maximum Material Thickness (mm)
+20 (nominal) 6
0 20
-20 40
Table 2-4 Secondary Steelwork Charpy Requirements
d) n general, the usage of higher strength steel for plates and sections is allowed. t is possible
to use a S460 N+NL, S460 M+ML, S420 N+NL, S420 M+ML according to EN 10025-3/-4. EN
10025-3/-4 is to be used in connection with EN 10025-1. Through thickness classes and
charpy test results minimum requirements are to be agreed with the Employer following the
philosophy of Table 2-1
e) n general, the usage of higher strength steel for tubes is allowed. t is possible to use a S460
NH+NLH, S460 MH+MLH, S420 M+ML according to EN 10219 and EN 10210. Through
thickness classes and charpy test results minimum requirements are to be agreed with the
Employer following the philosophy of Table 2-1.
f) Thickness limitations specified in DNV OS-J101 Section 6 Table A7 must be met if no
fracture mechanics or PWHT is carried out (see also section 3.5).
2.3. Castings and Forgings
Where cast steel items or forgings are used, these shall fulfil all technical requirements equivalent
to those specified herein and shall comply with relevant state of the art and current guidelines
including DNV OS-B101 and the applicable standards listed in Table 1-3.
2.4. Requirements for Supply of nterface Flange
The main transition piece interface flange between tower and substructure shall be provided by
the Contractor.
The flange shall be a forging meeting the chemical and mechanical requirements of EN 10025
S355NL+Z25 plate material. t should be noted that this may have a higher Carbon Equivalent
than the Contractor's selected grade for the adjoining steel part. The Contractor shall consider
this when determining the preheat for the welding to the adjacent steel part (i.e. a higher preheat
may be necessary). Reference is made to EN 1011-2 for the determination of preheat.
The design shall allow an additional 2-5mm thickness on the flange to allow for machining down
surface irregularities or enlarging of bolt holes. No hand held grinding shall be undertaken on the
flange.



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Employer's Requirements Appendix B01

2.5. Surface Condition
n general the surface condition of delivered plate materials shall as a minimum be in accordance
with EN 10163-2 Class A Subgroup 2. The surface condition of sections shall as a minimum be in
accordance with EN 10163-3 Class C Subgroup 2.The Foundation Design Contractor may
specify tighter surface condition requirements, depending on the design assumptions.
2.6. Steel Certification
All primary and secondary structural steel shall be supplied with certificates according to EN
10204.
Steel Certification

Material
Control
Steel strength and quality class Re.
EN 10025
Type of certificate Re. EN
10204
1 Normal SXXX H0, J2, and K2 nspection Certificate:3.1
2 Tightened up All qualities nspection Certificate:3.2
Table 2-5 Requirements for Certification of Structural Steel.
The adoption of 3.1 or 3.2 certification shall be the Employer's choice based upon the
Contractor's steel grade proposals. Where the Contractor adopts the steel grades given in Tables
2-1 and 2-2 and without modification Type 3.1 certification shall apply. For Tender purposes,
where the Contractor intends to modify steel grades from those provided, he shall assume that
Certification Type 3.2 will be required.
Steel certification shall consist of certified copies of mill reports covering the chemical and
physical properties, country and rolling mill of origin, and including a statement indicating that the
steel is new billet steel and that testing has been performed in accordance with EN standards.




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Employer's Requirements Appendix B01

3. Manufacturing, workmanship and quality control
3.1. General requirements
Manufacturing and workmanship shall comply with requirements of the DNV and relevant EN and
other standards included in Table 1-3, as well as the specific requirements listed in this section.
General requirements for manufacturing and workmanship are as follows:
a) All connections shall be detailed by the fabricator based on information shown on the
drawings and all considerations or shipment and erection. Detailing shall be performed using
rational engineering design and standard practice in accordance with standards listed in
Table 1-3.
b) All connections for shop or field connections or splicing shall be shown on the fabrication
drawings for review prior to fabrication.
c) Material shall be properly marked and match-marked where required for field assembly. The
sequence of shipments shall be such as to expedite erection and minimize the field handling
of material.
d) Milled surfaces shall be completely assembled or welded before milling.
e) All edges of exposed steel shall be rounded to a minimum radius of 2mm.
f) No combination of bolts and welds shall be used for stress transmission in the same faying
face of any connection.
g) Holes shall be drilled or punched at right angles to the surface of the metal and shall be not
more than 1.5 mm larger than the connector diameter. Burning shall not be used to make or
enlarge holes. Holes shall be clean-cut without torn or ragged edges. Outside burrs resulting
from drilling operations shall be removed.
h) The Contractor shall provide all holes, slots and openings required by other trades together
with necessary reinforcing. Suitable templates for proper location of holes and openings shall
be used. Where adjustment is required slotted hoes shall be provided. Where openings are
shown on the Drawings or shop drawings no change in location will be permitted without prior
approval of the Employer.
i) Manual oxygen cutting shall be done only with a mechanically guided torch. An unguided
torch may be used provided the cut is within 3 mm of the required line.
j) Thermally cut edges shall be ground back by 3mm to remove HAZ from thermal cutting.
k) Any jacket nodes shall be bevelled, using a CNC bevelling machine.
l) The Contractor shall include a cutting procedure, detailing pre-heat temperature and the
procedure for the cutting of any seafastenings.



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Employer's Requirements Appendix B01

m) No temporary attachments (e.g. temporary lift points, seafastenings etc.) shall be welded to
any part of the structure unless detailed on the design drawings.
n) Welding of any temporary attachments shall be in full accordance with this specification.
o) Any temporary attachments, such as gussets or pad eyes, shall be removed by grinding
followed by MP of the ground area. Hitting attachments with hammers to remove
attachments is not permitted.
p) All attachments shall be seam welded to avoid the ingress of moisture.
3.2. Special and Primary Steel Fabrication
a) All special and primary fabrication shall be in accordance with DNV-OS-C401 except as
modified by this specification.
b) Crack Tip Opening Displacement (CTOD) tests are not required providing consumables are
used which have been tested by the Contractor or the consumable manufacturer meeting
0.25mm at -10C and the designated steel properties are used. Departure from the properties
stated in Table 2-1 to Table 2-2 shall require the Contractor to develop his own CTOD test
proposals.
c) Preheat shall be extrapolated from the weld procedure qualifications (WPQ) and estimated
using EN 1011-2 to make allowance for extra thickness or restraint or cooling paths.
d) Special and Primary welds shall be held for 48 hours after completion before carrying out final
NDT.
e) The maximum material thicknesses for each level of impact testing shall be applied for
Primary Steelwork as stated in Section 2.2. Charpy tests are not required for steel < 6mm
thick. CTOD tests are not required except as stated above.
f) All welds of Primary Steelwork shall be full penetration.
3.3. Secondary Structure Fabrication
a) Secondary structure shall be fabricated in accordance with DNV-OS-C401 or other standard
approved by the Employer.
b) The maximum material thicknesses for each level of impact testing shall be applied for
secondary structures as stated in Section 2.2. The impact energy shall be 27J/19J
average/individual for steels up to grade S275 and 35J/25J for steels up to grade S355.
Charpy tests are not required for steel 10mm thick. Where these requirements meet or
exceed the requirements of DNV-OS-J101, Sec. 6, Table A6, CTOD tests are not required
except as stated above.
c) All fatigue critical welds of Secondary Steelwork shall be full penetration.



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Employer's Requirements Appendix B01

3.4. Execution of Welds
Welding shall comply with the standards stated above in Section 1.4 and their normative
references. n addition the following requirements shall be considered:
a) All welding sequences shall be such as to reduce the residual welding stresses to a
minimum. Balanced welding sequence shall be adopted to minimise distortion.
b) Welded connections shall be detailed and designed to minimize the accumulation of through-
thickness strains due to weld shrinkage.
c) The toughness and notch sensitivity of the steel shall be considered in the formation of all
welding procedures to prevent brittle and premature fracture during fabrication and erection.
d) Crossing of welds shall generally be avoided.
e) After welding all spatter shall be removed by grinding.
f) For field welds adequate measures shall be taken to ensure environmental conditions are
suitable (moisture, wind, temperature etc.).
3.5. Post Weld heat Treatment
The Contractor shall determine the requirements for undertaking post weld heat treatment
(PWHT) on any of the weldments associated with his material grade, thickness choices and
potential fabrication strains. However, it is recommended that material and thickness choices
should avoid the need for tests in the PWHT or strained aged conditions.
Where the steel will be post weld heat treated (PWHT) testing in the post weld heat treated
condition shall be undertaken by the manufacturer or supplier (Option 10 of EN 10225).
Attention is drawn to the requirements of DNV-OS-J101 Sec.6 A500.
3.6. Weld mprovement
mproved fatigue endurance of welds may be permitted by weld improvement methods such as
weld-grinding. To be effective, weld-grinding must completely remove all weld toes, stop-starts
and surface ripples. Where weld improvement is to be adopted it shall be subject to execution in
accordance with the methodology set out in DNV-OS-J101 and limited to locations where grinding
access is easy. The Contractor may submit proposals for alternative weld improvement
procedures to the Employer for consideration.
Weld-grinding is highly specialized and shall therefore be carried out only by suitably trained
personnel. f grinding or other weld improvement method is proposed, the Contractor shall
demonstrate, by tests to be agreed once the improvement method is known, that the execution
can be carried out to the satisfaction of the Employer by the trained personnel.



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Employer's Requirements Appendix B01

Where the design of Primary and Secondary Steelwork is dependent upon the application of weld
improvement of any kind, the weld improvement execution shall be subject also to the approval of
the Certifying Authority.
Compliance criteria for weld grinding shall be as stipulated in DNV-OS-J101. Defective weld
grinding shall require the complete replacement or repair of the parent material to the satisfaction
of the Employer and Certifying Body.
3.7. Welding Personnel
Welders and welding operators shall be certified in accordance with the provisions of EN287-1 or
EN 1418 as appropriate and retested at least every two years. Qualification documents shall be
made available for inspection by the Employer.
Welding of Primary structure shall be managed by an W qualified nternational Welding
Engineer with at least 5 years proven experience of this level of work.
A schedule of all approved welding inspection personnel who will be working on the Works shall
be supplied to the Employer. This schedule shall detail the formal Welding nspection and / or
Visual nspection qualifications for which each person is approved for consideration by the
Employer.
All welders and welding operators shall be qualified according to the requirements of the
fabrication standards listed in Table 1-3 and provided with an identity pass.
The Contractor shall provide the Employer with a schedule of welders and welding operators
employed on the agreement cross-referred to personnel number, the procedures and position to
which they are qualified and the dates for pre-qualification.
f requested by the Employer, the Contractor shall provide historical evidence of the satisfactory
previous performance of welders and welding operators for the type of work on which they are
engaged. When this is not available, the Employer reserves the right to require welders and
welding operators to be re-trained and re-tested at the Contractor's own expense.
3.8. Control and Quality of Welds
This section is applied for quality control of welds designed and calculated in accordance with the
Specification. All welding, non-destructive Testing of welds (NDT), and weld improvements such
as grinding shall comply with the requirements of the Certification Body.
a) The preparation of welds shall be carried out according to EN SO 9692. Prior to welding the
weld preparation shall be inspected.
b) All welding shall be carried out in accordance with SO 3834 Part 2 for Primary structure
including special steelwork and SO 3834 Part 3 for Secondary structure.
c) The Contractor shall submit weld procedures to the Employer to review at least 12 weeks
prior to the start of fabrication.



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d) Weld acceptance shall be as defined in section 3.9.6 and 3.9.7.
e) The Employer reserves the right to conduct regular audits and cross checks on production
weld joints.
f) The Contractor shall maintain records of weld repair and rejection rates throughout the
fabrication programme. Records shall reflect rejections on the basis of number of weld rejects
and on the basis of length of weld repaired per weld joint type. n addition to reporting repairs
as they occur analysis shall be conducted on a weekly basis to determine the cause of
rejections and to identify when there is the need to implement corrective actions.
g) The Contractor shall maintain records to enable traceability of welder and welder operators in
special and primary welds.
h) The Contractor shall maintain records to enable identification of welding consumables to
welds.
3.9. Non-Destructive Testing
3.9.1. Personnel
NDT personnel performing inspections shall be approved in accordance with BS EN SO 9712;
Non-Destructive Testing Qualification and certification of NDT personnel. The British Scheme;
Personnel Certification in Non-Destructive Testing (PCN) managed by the British nstitute of NDT
shall be the preferred certification body.
For overseas locations, National Schemes compliant with SO 9712 should generally be
acceptable, however advice should be sought from the Employer on the suitability of approval in
any particular method or application required.
f an internal certification scheme based upon ASNT-SNT-TC-1A is proposed as an alternative to
SO 9712 by the Contractor, the certification schemes written practice shall be made available to
the Employer for review and consideration.
For each NDT method, certification shall cover proficiency to Level 2 as a minimum. For
Ultrasonic Method, Level 2, Category 3.1 and 3.2 (PCN) shall be the minimum with additional
categories as appropriate (3.8, 3.9) to the inspection and joint configuration. Level 1 personnel
shall not be used.
The Contractor shall supply a schedule of all approved Welding nspection and Non-Destructive
Testing personnel who will be working on the Works to the Employer. This schedule shall detail
the experience, qualification, certification and the techniques/procedures to which each person is
approved.
3.9.2. NDT Procedures, Technique Sheets and Reporting Proformas
All NDT procedures shall meet the requirements of the following standards:




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Employer's Requirements Appendix B01

No Relevant Standard (BS EN ISO)

Related Inspection Method
1 BS EN SO 9712 Qualification and Certification of
NDT personnel
2 BS EN SO 17637 Visual Testing of Fusion Welded
Joints
3 BS EN SO 17640 / 11666 / 23279 Ultrasonic nspection
4 SO 17638 / BS EN SO 9934-1/2 Magnetic Particle nspection
5 BS EN 571-1/ SO 3452 Penetrant nspection
6 BS EN 1330 Parts 1 to 10 / BS EN SO 12706 Terminology
Table 3-1 Standards for NDT nspection
NDT Procedures and Technique Sheets shall be designed and approved by an appropriate NDT
Level 3 engineer to detect those defects that could occur as a consequence of the chosen
welding process and/or any inappropriate application of controls through the process.
Technique Sheets (based upon the appropriate NDT Method Procedure) shall be designed for
each specific joint type likely to be encountered during the works. Ultrasonic Technique Sheets
shall include scanning patterns to be used for individual weld geometries. Any restrictions to test
shall be clearly defined.
Proof of the NDT Procedure and/or Technique Sheet's ability to detect defects of a pre-
determined size and orientation as defined in the acceptance criteria may be required by the
Employer in the form of a NDT procedure performance validation test/report.
NDT reporting proformas shall include appropriate fields to record the inspection parameters
used so that a repeat inspection could be conducted if required. n addition, the reporting
proformas shall include fields to allow the accurate recording of any recordable indications
detected.
NDT Procedures, Technique Sheets and reporting proformas shall be made available to the
Employer for review and comment at least twelve weeks before the commencement of any
inspection activity.
3.9.3. NDT nspection Extent of nspection
The extent of nspection shall conform as a minimum to the requirements of DNV-OS-C401;
specific extent to this contract is detailed in Table 3-2.
Inspection Category

Visual Ultrasonic Magnetic
Special and Primary structure butt welds:
Longitudinal welds (within any
grouted connections)
100% 100% 100%
Longitudinal welds 100% 20% 20%



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Employer's Requirements Appendix B01

(remaining structure)
Circumferential welds
(non grinded)
100% 100% 100%
Circumferential welds
(flush grinded)
100% 100% 100%
TRF Flange weld 100% 100% 100%
Welded attachments:
Butt welds

100% 100% 100%
Fillet welds

100% 0% 100%
Secondary structure welds:
Butt Welds 100% 20%
1,2
20%
1,2

Cross and T-Joints, Full
penetration welds
100% 20%
1,2
20%
1,2

Cross and T-Joints, partial
penetration and fillet welds
100% 0% 20%
1,2

Table 3-2 Extent of inspection for Galloper Foundations
NOTES to Table 3-2
1) Percentage of NDT shall be carried out on each individual assembly and reflect the
proportion of workmanship of each individual welding operative.

2) For welds of individual length less than 300mm it is expected that NDT will be performed
on 100% of that weld.

3) t is highlighted that as per section 1.2 padeyes, lifting points and hook-on points shall
always be classed as either primary or special steelwork.

3.9.4. NDT nspection - General
All welds and components shall be clearly identified by the Contractor on the object under test
prior to any NDT inspection and referenced to an appropriate engineering drawing.
All welds shall be 100% visually inspected prior to carrying out NDT. The visual inspection shall
identify for corrective action prior to NDT any areas where welds do not have a regular finish or
merge smoothly into the base material.
Welds classified as Special or Primary shall be held for 48 hours after completion before carrying
out final NDT.
NDT reports shall identify the location and extent of any recordable indications present in the
weld area relative to a known or fixed datum.



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ndividual NDT reports shall be produced for all welds inspected. Reporting by "exception only or
the reporting of multiple welds onto one report shall not be permitted.
Where defects are removed, the excavated area shall be dressed by grinding to produce the
specified profile and surface condition for re-welding and surface inspection NDT. The completed
excavation shall be examined by magnetic particle inspection or other suitable methods to verify
complete removal of flaw(s) prior to re-welding.
For magnetic particle inspection, the use of permanent magnets or prods is not permitted.
Unless otherwise agreed by the Employer, volumetric inspection of welds shall be undertaken by
using the ultrasonic method. When applicable, ultrasonic volumetric inspection of welds shall
include testing for the presence of transverse indications.
For ultrasonic inspection, characterisation of planar indications shall be carried out in accordance
with BS EN SO 23279.
The Employer shall have the right at any time or place during the contract to undertake any form
of NDT audit or re-inspection by his representative on any weld or component associated with the
works.
3.9.5. Requirements for Ultrasonic nspection
The requirements for ultrasonic inspection shall comply with the requirements of DNV-OS-C401
Ch.2 Sec.3 Clause 2.4.12 2.4.21. n addition, the following shall also be applicable:-
t is recommended that the same ultrasonic probes are used for both the detection of, and for the
classification of indications. The frequency shall be between the range 2MHz 5 MHz and shall
be selected on the ability to improve range resolution when characterising indications at the
appropriate beam path lengths applicable to the individual weld under examination.
Reference sensitivity shall be established by constructing a Distance Amplitude Correction curve
with a reference block in accordance with Table 3-3.
The procedure shall include a measurement of correction for attenuation and transfer loss, which
shall be added to the reference sensitivity to establish the corrected primary gain.
f differences are <2dB, correction is not required.
f the differences are >2dB - <12dB, they shall be compensated for
f the difference is >12dB, the reason shall be referred for consideration
Evaluation of flaw(s) shall be made for any flaw that produces a response greater than 33% of the
constructed DAC reference curve. To aid flaw detection scanning sensitivity shall be increased by
at least 6dB; however, defect size evaluation shall be undertaken at the corrected primary gain
i.e. DAC Reference sensitivity plus transfer correction factor (if appropriate).



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n order to characterise and size large flaw responses it may be necessary to reduce the gain to
enable the top of the signal envelope to be seen on flaw detector screen.
For dimensional evaluation either the 20dB or 6dB drop methods shall be used.
Responses exceeding the recording level but are considered to be acceptable shall be recorded
on the ultrasonic NDT report for reference.
Ultrasonic inspection of welds shall include scanning for transverse defects in both the weld and
base material. For thin walled welds this may be achieved by using scans with skewed probe
angle from the parent material. On thick walled welds, to detect near surface mid weld transverse
flaws, scans made from the weld cap will normally be required. The Contractor shall evaluate
weld surface condition for cap scanning and determine whether surface preparation is required to
permit this.

Thickness of
material to be
examined (mm)
Thickness of
block (mm)
Diameter of
hole (mm)
Distance of
hole from one
surface (mm)
10 < t 50 40 or t
3 0.2
t/2 and t/4.
Additional
holes are
allowed and
recommended
50 < t 100 75 or t
100 < t 150 125 or t
6 0.2
150 < t 200 175 or t
200 < t 250 225 or t
t > 250 275 or t
Table 3-3 Calibration reference block requirements.

3.9.6. Visual nspection / MP Acceptance Criteria
For visual and MP defect acceptance criteria of Special and Primary classified welds, adopt BS
EN SO 5817, level B criteria plus the additional requirements given in (a) to (f) below.
For visual and MP defect acceptance criteria of Secondary classified welds, adopt BS EN SO
5817, level C criteria plus the additional requirements given in (a) to (f) below.
a) Undercut maximum depth shall be 0.5mm intermittent for Primary Steelwork, and 0.75mm for
Secondary Steelwork.
b) Undercut is not allowed for special steelwork.
c) ntermittent shall be defined as not more than 10mm per 100mm not more than a total of
100mm in 1m.
d) Shrinkage grooves or root concavity maximum 1.5mm, permitted intermittently.
e) Overlap is not permitted.



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Employer's Requirements Appendix B01

f) Porosity is not permitted
3.9.7. Ultrasonic Testing Acceptance Criteria
For ultrasonic defect acceptance criteria, adopt BS EN SO 5817, level B criteria for Special and
Primary classified welds.
For ultrasonic defect acceptance criteria, adopt BS EN SO 5817, level C criteria for Secondary
classified welds.
Table 3-4 gives detail of the relationship between Quality level, Testing level and Acceptance
level to be applied in assessing ultrasonic responses.

Weld
Classification
Quality level
in accordance
with BS EN
ISO 5817
Testing
technique and
level in
accordance with
BS EN ISO 17640
Non-planar
indications:-
Acceptance level
in accordance
with BS EN ISO
11666 [note 1]
Planar indications:-
Characterisation of
planar indications in
accordance with BS EN
ISO 23279 [note2]
Special /
Primary
B B 2 Not acceptable
Secondary C C 3 Not acceptable
Table 3-4 Quality level, Testing level and Acceptance level to be applied in assessing ultrasonic
responses
NOTES to Table 3-4
1) All imperfections from which the reflected echo amplitude exceeds the evaluation level
shall be characterised.

2) All imperfections that are characterised as planar (cracks, lack of fusion, incomplete
penetration) shall be rejected irrespective of through wall height or length.

3.9.8. NDT nspection Report Documentation
The Contractor shall submit documentation for welded parts comprising as a minimum:
a) Unequivocal identification of the inspected components
b) How the inspection was performed
c) By what means
d) Who performed the inspection and when
e) The result obtained
f) Evaluation of the result
g) Who evaluated the result



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3.10. Traceability
All welds shall be clearly marked in accordance with an established procedure during the
fabrication process. This procedure for identification shall define in detail how the Contractor
controls the identification and marking of welds and how weld history; non-destructive Testing
results and material placement are recorded.
To ensure material traceability on individual components, all steel used in Special and Primary
Steelwork shall have material specification with original heat and charge number marked on
them. This information shall be included in product documentation packs.
A system for identification (numbering) of all weldments including areas of weld repair shall be
established by the Contractor in order to maintain traceability.
All welds shall have D numbers cross-linked to referenced drawings, non-destructive Testing
number, accepted or reject codes, non-destructive testing interpretation records, repair code and
finally certified acceptance record. All these shall be interrelated to each other clearly and in a
manner to facilitate easy accessibility for reference.
dentification of the components and spots inspected shall be documented on drawings of the
object and may further be marked directly on the object.
Reference marking of the non-destructive testing inspection shall be included in the
documentation.
Marking shall not impair the characteristics of the object inspected. Marking by stamping of welds,
or other technique which may cause discontinuity to the weld from which fatigue cracking may
propagate, shall not be permitted.
The documentation shall be prepared concurrently with the welding and inspection work and be
issued to the Employer. All part documentation shall be summarised and compiled in a final
documentation report containing unequivocal references between welds inspected, inspection
batches and inspection documentation.
Documentation of weld inspection shall be provided for all welds inspected rather than by
exception.
3.11. Fabrication Tolerances
3.11.1. Flange Tolerances
This section applies to the main transition piece interface flange between tower and substructure
as well as any other flanges within the design which form part of the primary structure, e.g.
between a transition piece and Monopile.
Full dimensional requirements and tolerances for flanges shall be defined by the Foundation
Design Contractor during detailed design. The Contractor shall supply and fabricate the interface
flanges in accordance with these tolerances.



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Employer's Requirements Appendix B01

Each flange shall have a full dimensional survey before and after welding onto the primary
structure. The method of survey shall be agreed with the Employer. The Employer shall be
notified before each test. Survey results shall be made not later than two weeks after the survey.
The tolerance checking procedure for the main transition piece interface flange shall as a
minimum meet the requirements defined by the WTG Contractor.
3.11.2. Structural Steelwork Tolerances
Primary Steelwork shall be fabricated in accordance with the requirements for DNV-OS-C401. n
addition to the requirements noted within DNV-OS-C401 and its normative references the Primary
Steelwork shall meet the following requirements:
a) Within 610mm of any circumferential weld the measured circumference shall not exceed the
nominal circumference +/- 15% of the plate thickness.
b) Overall out of straightness shall be maximum 0.0015*L. Local out of straightness shall comply
with DNV-OS-C401.
c) Local out-of-roundness tolerances shall be defined by the Foundation Design Contractor. n
general they shall not exceed 0.002*D or 10% of the wall thickness.
d) Ovality and Out of Roundness tolerances shall be checked and reported at both pile ends
and either side of all circumferential welds. As a minimum 4 measurements shall be taken at
0, 45, 90 and 135 to determine D
max
and D
min
. The maximum allowable ovality (D
max

D
min
) shall be 0.5% of the nominal diameter. This shall be reported for each can.
e) The maximum allowable misalignment tolerance for Butt welds shall be the smaller of 4mm or
0.1t
1
where t
1
is the smaller of the two plate thicknesses. f justified by the Contractor, agreed
by the Employer, and explicitly included within the design, this tolerance may be increased to
a maximum of 0.15t
1
. Any agreed locations where this tolerance is relaxed shall be noted on
the drawings. All other locations shall meet the tighter tolerance.
f) Misalignment shall be measured at a minimum of 8 equally spaced locations around the
circumference of each circumferential weld.
g) Misalignment tolerance shall also be checked at highspots and flatspots where the signs
either side of the circumferential weld are opposite.
h) MP end perpendicularity and MP end flatness shall be defined by the Foundation Design
Contractor with regard to the requirements of the piling hammer being used.
Secondary Steelwork fabrication tolerances shall be in accordance with EEMUA 197 Secondary
Steelwork or Eurocode 3 using whichever is stricter, or in accordance with any specific tolerances
identified on the drawings.



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3.11.3. Dimensional Control
Methods of tolerance control, survey, monitoring and recording must be provided in the
Contractor's method statements.
Documentation shall be provided to show that the structures lie within the allowable fabrication
tolerances. Any items that fail to meet the required tolerances must be identified as a non-
conformity and where possible rectified. Corrective actions applied shall also be documented.
3.12. Execution of Bolted Connections
3.12.1. General
Bolts, nuts and washers shall comply with the standards contained in Table 1-3, as appropriate
for the material selected. Grades shall be exactly as specified by the Foundation Design
Contractor and higher grades will not be used as a substitute. Bolts nuts and washers shall be
supplied with certificates according to EN 10204.
The maximum hardness permitted for all bolts and studs used in the submerged or splash zones
is 35Rc (345Hv). This applies to threads also, and bolting with higher hardness may be subject to
Hydrogen cracking from cathodic protection. Studbolts shall be manufactured from bar with rolled
threads and must have certification to show that hardness complies with this requirement in the
finished condition; not just in the bar stock prior to thread rolling.
Joint ply contact (faying) surfaces shall be flat and make contact across the entire faying surface.
Where connections undergo significant deformation in assembly such that welds in close
proximity may be affected, said welds may be subject to further non-destructive testing post
assembly at the discretion of the Employer.
The contact surfaces for prestressed connections shall not be coated or surface treated in any
way that may impair the pre-tensioning of the connection in the short or long term.
No welding of bolts or nuts above grade 4.6 or equivalent shall be permitted.
Lock nuts shall be used on all bolts.
No bolt, washer or nut shall be re-used after dismantling or unloading post-assembly.
3.12.2. Bolt tightening
Bolted connections can either be: Non pre-stressed with no specific requirements to tightening
method, or Pre-stressed, with a prescribed tightening method and value.
Pre-stressed connections shall be used for all critical connections. Critical connections shall
include all connections to Primary and Special Steelwork and all connections subject to fatigue.



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Pre-tensioning of critical connections shall be by means of a proprietary pre-tensioning device
that applies tensile load directly to the bolted assembly. The torque method shall not be used for
critical connections. No lubrication shall be applied to pre-stressed bolt assemblies when used for
critical connections and all bolts shall have sufficient bolt over-length in order to allow the use of a
proprietary tool. Documentation for the tightening method shall be given which demonstrates that
the minimum pre-stressing force will be achieved without overstressing the bolt or other joint
component.
For non-critical connections (e.g. handrail connections, grating fixings etc.) the torque method of
pre-tensioning may be used. The torque method to be used shall be according to EN 1090-2. Due
to uncertainties associated with torque losses samples shall be produced to better determine
torque values.
Non pre-stressed connections shall be secured by minimum hand tightening method and lock
nuts.
Documentation in the form of check sheets or similar shall be provided to demonstrate that all
bolted connections have been tightened in line with requirements.
3.13. Product Handling
Structural steel shall not be handled until any paint has thoroughly dried. Care shall be exercised
to avoid abrasions and other damage during handling.
Materials shall be stored above ground level and out of mud and dirt. Storage areas shall have
adequate provisions for drainage. Adequate protection from damage or soiling by adjacent
fabrication operations shall be provided.
Material shall not be delivered to the project site/handover location until the proposed method and
sequence of transportation, handling at port and erection has been reviewed by the Employer.
Method and sequence shall be planned so as to avoid delay or damage to the work of other
trades.
Storage of fabricated steel at handover location site shall be coordinated with the Employer.
Material stored shall be protected against corrosion or deterioration.
The sequence of shipments shall be such as to expedite erection and minimize the offshore
handling of material.



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Employer's Requirements Appendix B01

4. Documentation
The Contractor shall submit to the Employer and to the Certifying Authority all documentation
identified in this section. He shall make available further documentation as requested by the
Employer or Certifying Authority at no additional cost and as required for quality control and
certification purposes.
Documentation shall be submitted in line with the requirements of the Document Release
Schedule.
4.1. Fabrication Drawings
Fabrication drawings shall show all information necessary for the fabrication of each member and
for the shop or field assembly of members /components of the structure. The following shall be
detailed on the drawings or associated method statements:
a) Type of material, size and weight of members.
b) Type, size, location and extent of all welds and bolts, with distinction made between shop and
field connections. Details of the WPS to be used at each location shall be shown.
c) Procedures and diagrams showing a step by step sequence of assembly.
d) Requirements for intermediate surveys and allowances for temperature.
e) Assembly equipment size and weight and additional elements which may be required to
support or stabilize elements during assembly.
f) Locations of shoring and how shoring is stabilized and controlled.
4.2. Fabrication Procedures
Written procedures covering the complete fabrication process and all quality documentation as
required by the Standards listed in Table 1-2 shall be submitted. Key documentation includes but
is not limited to:
a) Quality Plan and nspection and Test Plans (TPs) detailing the Contractors' quality control
measures.
b) WPQRs and WPSs in accordance with DNV-OS-C401 as applicable covering all welding
processes including repair procedures.
c) Schedule of welding inspection personnel to be used on the works.
d) Schedule of welders and welding operators to be used on the works.
e) Welders and welding operator's qualification documents.
f) Pre-heating procedures.
g) Procedures for storage and control of welding consumables.



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Employer's Requirements Appendix B01

h) Flame straightening procedures.
i) Traceability Procedures.
j) Risk Assessments.
k) NDT Procedures, technique sheets and reporting proformas.
l) NDT Operator Certification.
m) NDT Procedure performance validation reports (if applicable).
n) Dimensional control procedures.
o) Manufacturers' specifications, literature and installation instructions for the following products,
including laboratory test reports and such other data to show compliance with these
Specifications (including specified standards):
High strength bolts (each type) including nuts and washers.
Welding consumable (each type).
Shop coat primer paint, field touch-up paint.
Any specialist products used in the assembly, e.g. elastomeric bearings.
The procedures shall address the following key points: welding sequence, equipment to be used,
welding system (manual, semi-automatic or automatic), positions of welding, number of passes
for each weld size, preparation of surfaces prior to welding, accessibility of welders.
4.3. Quality / As-Built Documentation
Documentation shall be produced concurrently with the work and be issued to the Employer
within 4 weeks of completion of a component. Reporting of inspections by exception is not
permitted.
Separate documentation packs shall be produced for all major components. A separate
documentation pack will be produced for padeyes, lifting points, and hook-on points. These
documentation packs will include all test reports and certificates necessary to prove the SWL
(e.g. NDT reports as applicable, material certificates, weld maps, dimensional surveys etc.). The
format and layout of the documentation pack shall be proposed by the Contractor for the
Employer's acceptance prior to the start of fabrication.
Documentation packs shall include but not be limited to:
a) Handover certificates
b) Certificates of conformity for equipment and / or CE certificate where appropriate
c) Specific certificates of conformity for padeyes and lifting points
d) Traceability records for welds and welding consumables
e) Records of weld repair and rejection
f) Non-Destructive Testing reports for welds



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Employer's Requirements Appendix B01

g) Heat treatment records
h) Steel, welding consumable and other material certification
i) Material traceability records
j) As-built drawings
k) Dimensional survey reports
l) Bolted connection tightening documentation
m) Weight Control Report
n) List of Non-Conformance Reports and concessions, with copies of these. Both Employer
and Contractor documents shall be included
o) List of Technical Queries raised
p) Any instructions from the Employer which changed the specification
q) Snagging reports from the Employer and Contractor
r) Sub-contractor quality documentation
s) Mechanical testing reports
t) Electrical testing and commissioning reports
u) Any other fabrication records deemed appropriate by the Employer




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Employer's Requirements Appendix B01

5. Additional requirements
5.1. Departures & Non-Conformance
The Contractor shall provide details of any non-compliance with the following for review by the
Employer:
a) Design, manufacture and the execution
b) Departure from any standards specified in this document
c) Departure from any standards listed
d) Departure from any drawings and/or specifications

5.2. nspection of manufacture and installation
The Employer reserves the right to inspect the manufacture and fabrication at the Contractor's
premises or at his Subcontractor's premises at any time in the manufacturing and fabrication
process.