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Sec.1: General [Table of Contents] App.A: Selection of Verification Level

DNV-OSS-308 Verification of Lifting Appliances for the Oil and Gas Industry

[-] Sec.2: Service Overview

SECTION 2
Service Overview

Sec.2
A. General

Sec.2
A 100   Objectives

Sec.2 A
101
   The objectives of this section are to provide:
an overview all verification activities relating to lifting appliances
details of DNV's verification services for lifting appliances.

Sec.2
B. Service Process

Sec.2
B 100   General principles

Sec.2 B
101
   The description of the process of DNV's verification of lifting appliances is based on distinct project phases and the recognition of key milestones.

Sec.2 B
102
   Verification performed by DNV normally progresses through one or more of these project phases and may include all or selected aspects of the project.

Sec.2 B
103
   The risk based verification process is described in relation to the normal project phases:

Project initiation:
conceptual design.


 Project realisation:
detail design
construction and factory acceptance test
installation and commissioning
issue of certificates enabling for operation.


 Project operation:
operation
maintenance
repair.

Project abandonment:
decommissioning
removal.

Sec.2
B 200   Simplified verification planning

Sec.2 B
201
   The steps in the simplified verification planning are as follows:
Use trigger questions to assess the overall risk level of the project (or manageable elements thereof).
Evaluate the risk against the relevant owner or project acceptance criteria (often this can be directly tied to the owner core values or a sub-set of these) and decide whether the general verification involvement shall be Low, Medium or High.
Use the example detailed scope of work tables in Appendix B to make a first draft of a Verification Plan
Generate the project specific Verification Plan by including a project specific engineering judgment or risk analysis to adjust the table to suit the project.
Perform the verification execution according to the Verification Plan, making revision to the plan if and when necessary.
Report the verification.


Sec.2 B
202
   The trigger questions are included in Appendix A.

Sec.2 B
203
   Generic scopes of work for verification at the three levels of verification; Low (L), Medium (M) and High (H), are given in the tables in this section.

Sec.2 B
204
   Project specific detailed scope of work descriptions, based on the generic scopes of work tables and showing all the activities to be verified, should be made. Examples of the level of detail are given in Appendix B.

Sec.2 B
205
   Tables in this section 2 give the principle differences between the levels of verification involvement. The detailed example tables are to be treated as examples only. They shall not be used without a project specific confirmation of their completeness.

Sec.2 B
206
   The project specific scope of work definition, derived from the tables in Appendix B (or similar), shall be part of the final DNV verification report.

Sec.2
B 300   Selection of level of verification

Sec.2 B
301
   The selection of the level of verification for the simplified verification planning is facilitated by the trigger questions included in Appendix A.

Sec.2
B 400   Codes, standards and reference documents

Sec.2 B
401
   The verification process described in this DNV-OSS is not tailored to a specific technical standard, code or reference document.

Sec.2 B
402
   It is recommended to use internationally recognised codes or standards. Where combinations of standards and external criteria are used the exact terms of reference and documents to be issued shall be agreed at the beginning of the project and formally defined in the contract.

Sec.2 B
403
   It is recommended strongly not to mix standards due to the possible differences in safety philosophies.

Sec.2
C. Project Initiation

Sec.2
C 100    Verification during conceptual design

Sec.2 C
101
   Verification during the conceptual and/or feasibility studies of a project and in the early stages of a project can reduce the need for verification during the design, construction and installation phases, and can reduce costs during the long term operation, inspection and maintenance phases.

Sec.2 C
102
   It is recommended to combine the design verification during project initiation phase with additional review of:
project schedule
cost impacts
business risks.


Sec.2 C
103
   During this phase it may be beneficial to make an initial verification plan. Risk evaluations are carried out during this phase and should be used to get an indication of the general verification level; Low, Medium or High.

Sec.2
D. Project Realization

Sec.2
D 100   General

Sec.2 D
101
   All design, construction and installation aspects, relevant to a lifting appliance, may be covered by the life cycle verification.

Sec.2 D
102
   In this specification the split in the scope of work between design, construction and installation is made between sets of requirements (specifications) developed during the various phases.

Sec.2
D 200   Verification of overall project management

Sec.2 D
201
   Verification of the overall project management is the examination of the means of controlling the entire process leading up to an operational lifting appliance.

Sec.2 D
202
   This verification should confirm that the necessary controls are in place to ensure information flow across the various interfaces. It is especially important where separate contractors have been employed for different phases of the project such as design, construction and installation.

Sec.2 D
203
   Typically the documentation is expected to be in line with ISO 9000 requirements.

Sec.2 D
204
   Definition of scope of work for verification of overall project management shall follow Table D1.

Sec.2 D
Table D1 Scope of work for verification of overall project management  
 Level 
Verification activity Low Med High 
Review of the project management process by    
review of project quality management
documentation
 
 
audit of project quality management
system
 
  
review of sub-contractor control
 
  



Sec.2 D
205
   The verification of the overall project management quality system and documentation is optional. The reviews and audits should typically be performed if an extensive verification of a project is performed, while might be omitted for smaller sub-phase verifications.

Sec.2
D 300   Verification during design

Sec.2 D
301
   Design verification is the examination of the assumptions, methods and results of the design process and is performed at the specified level of verification to ensure that the specified performance requirements of the lifting appliance will be achieved.

Sec.2 D
302
   Design verification should consist of one, or some, of the following:
review of the design process
review of specifications for design (asset specifications)
review of design reports and drawings
review of diagrams and descriptions
review of specifications for construction, installation and operation, resulting from design.


Sec.2 D
303
   The documents that shall be produced in the project should as a minimum satisfy the requirements of the selected code.

Sec.2 D
304
   Definition of scope of work for verification of design should follow Table D2.

Sec.2 D
305
   Design documentation may depend on the complexity of the lifting appliance consist of the following:
name and address of the manufacturer, vendors, client, crane owner and intended location (if known)
specifications for design, i.e. regulations, standards, codes, and client specifications (optional)
design criteria including design temperature, environmental influences, and area classifications
load ratings
classification of structures, mechanisms and systems
general arrangement of the lifting appliance including rigging/reeving plans
info regarding personnel lifting, if applicable
detailed construction drawings on all elements concerning technical safety
structural design calculations, including failure curves, if applicable
machinery design calculations
system design calculations
fire and gas protection drawings and descriptions
noise protection plans and drawings
drawings and specifications for electrical components
cable and piping specifications
prime and secondary movers, such as diesel engines, el. motors, hydraulic pumps etc.
operational limitations including overload protection system calculations if applicable
specifications for construction including material specifications, welding specifications, NDE-extent
programme for functional and load tests
fabrication plans and schedules
drawings of marking
operation and maintenance manual.


Sec.2 D
306
   The documents that shall be produced in the project and handed over to DNV shall enable for the selected level of verification, ref. Table D2 and should as a minimum satisfy the requirements of the selected code.

Sec.2 D
307
   Definition of scope of work for verification of design should follow Table D2.

 

Sec.2 D
Table D2 Scope of work for verification of design  
 Level 
Verification activity Low Med High 
Review of the design process by    
review of design quality management
documentation
 
  
Review of specifications for design by    
review of the design specifications, i.e.
regulations, standards, codes and client
specifications (optional)
review of the design basis with emphasis on the design criteria and classifications
 
X
X
X
Review of design risk assessment    
review of the risk assessment reports,
including acceptance requirements and results
 
 
spot check of critical aspects
 
 
evaluation of critical aspects, including SHE as identified in the risk assessment reports
 
  
Review of drawings, diagrams and
documentation by
 
   
review of the formal documentation to ensure that the requirements have been accounted for in design and that the
chosen design philosophies are in
accordance with specified codes and standards
 
evaluation of the main methods used and spot checks of the input data and the
calculation results
 
 
detailed review of main design reports
 
  
detailed review of the foundation
reaction forces
 
detailed review of the user manual
 

Sec.2
D 400   Verification during construction and factory acceptance test

Sec.2 D
401
   This phase comprises prefabrication, fabrication, assembly, erection and Factory acceptance Test. An important element is to ensure that the contractual design requirements are incorporated in the purchase documentation, and that correct materials, components and proper testing procedures are applied such that it meets the requirements as per approved specifications and procedures. It is recommended that relevant preparations for this is started as early as possible, e.g. by the appointment of a vendor supply verification co-ordinator.

Sec.2 D
402
   Verification during construction and factory acceptance test is carried out by means of attendance, audits, inspection or spot checks of the work as well as witnessing of factory acceptance test, as appropriate, in sufficient detail to ensure that the specified requirements of the lifting appliance will be achieved.

Sec.2 D
403
   Verification of these activities relates not only to the manufacturers work but also to the monitoring of this work carried out by vendors and contractors others.

Sec.2 D
404
   Construction and factory acceptance test verification may consist of one, or some, of the following:
reviewing the quality assurance system documentation adopted by the manufacturer and vendors
reviewing the construction process
reviewing construction procedures
reviewing qualification process
reviewing manufacturer survey arrangements, if applicable
surveillance during construction activities
witnessing during factory acceptance test
reviewing final documentation.


Sec.2 D
405
   The documentation that should be submitted for review are typically:
manufacturing quality system documentation
manufacturing procedures, including test requirements and acceptance criteria, repairs, personnel qualification records etc.
material certificates
test and calibration records
dimensional measurement reports
welding documentation incl. NDE reports
noise and vibration records.


Sec.2 D
406
   Particularly for the Factory Acceptance Test it is highly recommended to prepare a formal test procedure be verified prior to commencement.

Sec.2 D
407
   Scope of work for verification of construction should follow Table D3 for manufacturing and fabrication and Table D4 for FAT.

Sec.2 D
Table D3 Scope of work for verification of manufacturing and fabrication  
 Level 
Verification activity Low Med High 
Review of the manufacturing and fabrication process    
Review of manufacturing and fabrication quality management systems
 
 
Audit of the quality management system
 
  
Review of manufacturing and fabrication
procedures
 
   
Review of the design verification report
 
 
Review manufacturing, fabrication and
inspection procedures for confirmation of
compliance with the manufacturing
specification
 
  
Surveillance during manufacturing and
fabrication activities
 
   
Visit-based or full-time attendance
during manufacturing and fabrication to ensure, based on spot checks, that the
components and assemblies have been produced in accordance with the
manufacturing specification
 
 
Review of fabrication records    
Review the Manufacturing Data Book, as
applicable
 
 
Review of formal documentation
 
 

Sec.2 D
Table D4 Scope of work for verification of Factory Acceptance Tests 
 Level 
Verification activity Low Med High 
Review of test programme and preparations for
testing
 
   
Review the FAT programme for confirmation of compliance with the requirements and specifications
 
 
Surveillance during testing    
Surveillance to ensure that the assembly,
erection, rigging and configuration, complies with the test procedure requirements
 
 
Survey of the main elements to verify
compliance with the construction
requirements
 
 
Survey of testing to ensure that the results
comply with the test procedure requirements regarding safety aspects
 
 
Survey of testing to ensure that the results
comply with the test procedure requirements regarding performance, endurance and SHE aspects
 
  

Sec.2
D 500   Verification during installation and
commisioning

Sec.2 D
501
   This phase comprises shipment, installation, testing and commissioning in conjunction with hand over of the lifting appliance to the user and to bring the lifting appliance into use for the first time.

Sec.2 D
502
    An important element is to ensure that the lifting appliance as installed on its final location meets the requirements in the regulations and as per approved specifications and procedures. It is imperative that relevant preparations for this is started as early as possible, e.g. by the appointment of a installation and commissioning responsible co-ordinator.

Sec.2 D
503
   Verification during installation and commissioning is carried out by means of attendance, audits, inspection or spot checks of the work as well as witnessing of function and overload testing, as appropriate, in sufficient detail to ensure that the specified requirements of the lifting appliance will be achieved.

Sec.2 D
504
   Verification of these activities relates not only to the manufacturers work but also to the monitoring of the work carried out by vendors installation contractors and others.

Sec.2 D
505
   Installation and commissioning test verification shall consist of one, or some, of the following:
reviewing the installation and commissioning plans
reviewing installation and commissioning procedures
reviewing qualification process
surveillance during installation activities
witnessing during function and overload test
reviewing final documentation.


Sec.2 D
506
   The documents that should be produced in the project and submitted for review prior to installation and commissioning are typically:
Quality plans
Installation procedures, including test requirements and acceptance criteria, repairs, personnel qualification records etc
Welding documentation including NDT reports
Pressure testing procedures
Pretensioning procedures
Piping and cabling hook up procedures
Access and maintenance plans and
Manufacturer's / installers quality system manual.


Sec.2 D
507
   Particularly for the Commisioning Acceptance Test it is highly recommended to prepare a formal test procedure be verified prior to commencement.

Sec.2 D
508
   The "as-built" documentation to be submitted after installation include but not be limited to:
Installation records, i.e. dimensional reports, hook up test reports, personnel qualification records etc
Material certificates
Welding records, oil test samples, heat treatment etc.
Vibration and noise reports
Commissioning report.


Sec.2 D
509
   Definition of scope of work for verification of installation and commissioning should follow Table D5 for testing and completion.

Sec.2 D
Table D5 Scope of work for verification during installation and commissioning 
 Level 
Verification activity Low Med High  
Initial activities     
Review of quality system documentation
 
  
Review of previous verification reports
 
 
Review of qualification records
 
   
Surveillance during installation activities     
Part time attendance during installation to verify that the foundation, interface
connection, access and escape routes are properly installed
 
  
Review of installation documentation     
Review of foundation design report
 
 
Review of installation records and reports
 
 
Surveillance during test activities
 
    
Witnessing of installation and
commissioning testing regarding safety and integrity
 
 
Witnessing of SHE aspects, performance and endurance testing
 
   
Review of final documentation     
Spot check of as-built documentation
 
  
Review of as-built documentation
 
   
Review of formal documentation, i.e. EC
Declaration of Conformity, if applicable
 
 
Review of user instructions
 
 
Review of former ILO certificates, if
applicable
 
 

Sec.2
D 600   Verification at issuance of Certificate of Lifting Appliance

Sec.2 D
601
   This phase comprises final issuance of the certificate of Lifting Appliance which is required to bring the lifting appliance into use for the first time.

Sec.2 D
602
   The scope of this verification is to summarise all previous verification activities and issue the required certification documents as competent person.

Sec.2 D
603
   Verification at issuance of the Certificate of Lifting Appliance shall consist of some or all of the following activities:
reviewing the design verification reports
reviewing the construction and FAT reports, including
component and product certificates and former ILO certificates
reviewing installation and commissioning reports, including modification/repair reports, and upgrading documentation, if relevant.


Sec.2 D
604
   The scope of work for verification at issuance of Certificate of Lifting Appliance shall follow Table D6. If a certain verification level is aimed for to be stated on the certificate, this verification level as a minimum has to be followed in the previous verification phases.

Sec.2 D
Table D6 Scope of work for final issuance of Certificate of Lifting Appliance 
 Level 
Verification level applied stated on the certificate Low Med High  
Verification of project
management
 
 M/H  
Design verification report
 
L/M/H 1) M/H  
Construction and FAT report
 
L/M/H 2) M/H  
Installation and commissioning
report
 
L/M/H M/H  

  1. The design verification activity may be carried out during installation and commissioning.
  2. The low level verification during construction and FAT does not involve DNV.

Sec.2
E. Verification Documents

Sec.2
E 100   General

Sec.2 E
101
   The hierarchy of verification document is given in DNV-OSS-300 Appendix B. The descriptions of the content of these documents as well as examples of document forms are given in Appendix C to this specification.
Sec.1: General [Table of Contents] App.A: Selection of Verification Level