dnvgl-se-0480 verification of lifting appliances for the ... · service specification —...

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DNV GL AS

SERVICE SPECIFICATION

DNVGL-SE-0480 Edition July 2017

Verification of lifting appliances for the oiland gas industry

FOREWORD

DNV GL service specifications contain procedural requirements for obtaining and retainingcertificates and other conformity statements to the objects, personnel, organisations and/oroperations in question.

© DNV GL AS July 2017

Any comments may be sent by e-mail to [email protected]

This service document has been prepared based on available knowledge, technology and/or information at the time of issuance of thisdocument. The use of this document by others than DNV GL is at the user's sole risk. DNV GL does not accept any liability or responsibilityfor loss or damages resulting from any use of this document.

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Service specification — DNVGL-SE-0480. Edition July 2017 Verification of lifting appliances for the oil and gas industry

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CHANGES – CURRENT

GeneralThis document supersedes the October 2010 edition of DNV-OSS-308.The purpose of the revision of this service document is to comply with the new DNV GL document reference code system and profile requirements following the merger between DNV and GL in 2013. Changes mainly consist of updated company name and references to other documents within the DNV GL portfolio.

Some references in this service document may refer to documents in the DNV GL portfolio not yet published (planned published within 2017). In such cases please see the relevant legacy DNV or GL document. References to external documents (non-DNV GL) have not been updated.

Editorial correctionsIn addition to the above stated changes, editorial corrections may have been made.

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CONTENTS

Changes – current.................................................................................................. 3

Section 1 General....................................................................................................61.1 General............................................................................................. 61.2 Risk based verification..................................................................... 81.3 Defining a verification plan...............................................................91.4 DNV GL lifting reports and certificates........................................... 101.5 Definitions/abbreviations............................................................... 10

Section 2 Service overview................................................................................... 152.1 General........................................................................................... 152.2 Service process...............................................................................152.3 Project initiation............................................................................. 162.4 Project realization.......................................................................... 172.5 Verification documents................................................................... 24

Appendix A Selection of verification level.............................................................25A.1 General........................................................................................... 25A.2 Trigger questions............................................................................25

Appendix B Detailed example scope of work tables for verification...................... 28B.1 General........................................................................................... 28B.2 Description of terms used in the scope of work tables....................28B.3 Overall project management.......................................................... 30B.4 Design.............................................................................................30B.5 Construction and factory acceptance test.......................................40B.6 Installation and commissioning......................................................49

Appendix C Examples of verification documents...................................................60C.1 Verification documents................................................................... 60C.2 Use of quality management systems.............................................. 62C.3 Document forms............................................................................. 64

Appendix D Lifting appliance life cycle................................................................. 71D.1 Lifting appliance life cycle..............................................................71

Appendix E Informative documents...................................................................... 72E.1 Technical terminology.....................................................................72E.2 Guide for selection of verification level.......................................... 73

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Changes – historic................................................................................................74


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SECTION 1 GENERAL

1.1 General

1.1.1 Introduction

1.1.1.1 This DNV GL service specification gives criteria for and guidance on verification of lifting appliancesfor the oil and gas industry within the European Economic Area (EEA).

1.1.1.2 This specification falls under the top level document DNVGL-SE-0474 Risk based verification.

1.1.1.3 The descriptions in this specification directly support a simplified verification planning as described inDNVGL-SE-0474. When using the advanced or combined planning, the descriptions will give good referencesand starting points.

Guidance note:The latest revision of all DNV GL documents may be found in the publications list in the DNV GL web site www.dnvgl.com.

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1.1.2 Objectives

1.1.2.1 The objectives of this specification are to describe the following for a lifting appliance:

— preparation of a verification plan using DNV GL’s risk differentiated levels of verification activities anddetailed example scope of work tables

— DNV GL’s implementation and reporting of the verification plan

1.1.3 Scope of application for verification

1.1.3.1 This specification may be adopted for the verification of lifting appliances throughout the projectphases conceptual design, detailed design, construction, installation and commissioning.

1.1.3.2 Lifting appliances for offshore applications typically comprise the following objects:Cranes:

— mobile cranes— tower cranes— slewing jib cranes— bridge and gantry cranes— offshore cranes— floating cranes— winches and hoists— loader cranes— cable cranes— hand powered cranes.

Lifting accessories:

— chain slings— fibre slings— wire rope slings— spreader beams

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— lifting magnets— vacuum lifters— lifting forks— trollies— beam clamps— hooks— blocks— shackles— other loose gear.

Lifting appliances for life saving equipment:

— life boat winches— rescue boat davits— davits for life rafts— lifting appliances for rescue chutes— stretchers— lifting capsules— medical baskets.

Lifting person devices:

— lifting tables— mobile elevating work platforms— personnel baskets— manrider winches— access platforms— case stabbing baskets— cherry pickers— climbing platforms.

Drilling hoisting equipment:

— draw work— ram rigs— BOP cranes— pipe handling cranes— swivels— crown block— travelling block— dead line anchor.

Robots:

— manipulator arms— manually controlled load manipulating devices— production lines.

which are applied in various configurations and tailored to each particular project’s specific requirements.

1.1.3.3 This specification describes the principles of a levelled verification involvement. These principles maybe applied both for planning of any need or obligations for independent external verification (third party) aswell as internal company verification (second party).


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1.1.4 Structure of this documentThis section explains the relationship between this document and DNV GL’s overall risk based verificationsystematics.Sec.2 describes the activities for each project and the project phases for lifting appliances for offshoreapplications.App.A poses trigger questions to assist in the selection of verification levelApp.B gives detailed example scope of work tables for the different phases and levels of involvement. Thesetables are the basis for the development of project specific scope of work tables.App.C gives example verification documents and describes the documents issued during and as a result ofthe verification process. The use of quality management systems is addressed here also.App.D is a separate appendix for lifting appliances which includes figures for information.

1.2 Risk based verification

1.2.1 Elements of the service

1.2.1.1 The risk based verification concept is described in DNVGL-SE-0474 and shown in Figure 1-1.

1.2.1.2 The verification plan is the pivot element, with the asset specification, risk sssessment and definitionof involvement level as input and the verification execution being the implementation.


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Figure 1-1 The DNV GL risk based verification flow chart

1.3 Defining a verification plan

1.3.1 Risk based verification planning

1.3.1.1 The selection of the level of verification shall depend on the risk level of each of the elements thathave an impact on the management of hazards and associated risk levels of the asset. The planning may besimplified or detailed. This is further described in DNVGL-SE-0474.

1.3.1.2 This specification mainly aids in a simplified preparation of the Verification Plan.


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1.4 DNV GL lifting reports and certificates

1.4.1 General on verification

1.4.1.1 Verification describes the individual activities undertaken by DNV GL at the various stages of design,construction and operation of the facility. The scope of the verification plan is ultimately determined by theclient. A statement of conformity may be issued by DNV GL to confirm compliance according to the scope ofwork.

1.4.2 General on certification

1.4.2.1 Certification describes the totality of verification activities leading up to the issue of a certificate ofconformity. The scope of work and verification plan, called a certification plan, is set by DNV GL. All designand construction aspects, related to process facility safety and integrity, shall be covered by the certificationplan.

1.4.3 DNV GL certificate of lifting appliance

1.4.3.1 In the event that DNV GL does not define the scope of work necessary to achieve certification, acertificate of lifting appliance shall not be issued.

1.5 Definitions/abbreviations

1.5.1 General

1.5.1.1 Relevant definitions in ISO also apply to this service specification.

1.5.2 AbbreviationsTable 1-1 Abbreviations

Term Definition

ISO International Standardisation Organisation

ILO International Labour Organisation

CEN European Standardisation Organisation

FAT factory acceptance test

NB notified body

CE Communauté Européenne

EMC electromagnetic compatibility

FE finite element analysis

FLS fatigue element state

HAZID hazard identification


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Term Definition

HAZOP hazard and operability review

MPQT manufacturing procedure qualification test

MPS manufacturing procedure specification

NDE non-destructive examination

QRA quantitative risk analysis

RP recommended practice

SCF stress concentration factor

SHE safety, healt, environment

TCF technical construction file

ULS ultimate limit state

WPS welding procedure specifications

WPQR welding procedur qualification record

EEA European Economic Area (EU and EFTA countries)

1.5.3 Verbal FormsTable 1-2 Definitions of verbal forms

Term Definition

shall indicates requirements strictly to be followed in order to conform to this service specification and fromwhich no deviation is permitted

should indicates that among several possibilities, one is recommended as particularly suitable, without mentioningor excluding others, or that a certain course of action is preferred but not necessarily requiredOther possibilities may be applied subject to agreement.

may verbal form used to indicate a course of action permissible within the limits of the service specification

1.5.4 DefinitionsTable 1-3 Definitions

Term Definition

client DNV GL's contractual partnerIt may be the manufacturer, purchaser, operator (User), the owner or the contractor.

construction all activities during purchase, manufacturing, assembly, and erection at the manufacturers site. until thelifting appliance is ready factory acceptance test

factoryacceptance test(FAT)

final testing at the manufacturers site prior to shipment


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Term Definition

design engineering activities related to planning and preparation of the technical documentation of a liftingappliance and its components to enable its construction

installation activities related to the assembly and erection of the lifting appliance on the working location

commissioning ctivity after installation, including review, survey and testing in the presence of the client in order toassess compliance with the requirements

decommissioning activity to bring a lifting appliance out of operation after it has served its purpose

removal de-install the lifting appliance from its operating location

hazard a deviation (departure from the design and operating intention) which could cause damage, injury or otherform of loss (Chemical Industries Association HAZOP Guide)

hazop the application of a formal systematic critical examination to the process and engineering intentions ofnew or existing facilities to assess the hazard potential of mal-operation or mal-function of individual itemsof equipment and their consequential effects on the facility as a whole (Chemical Industries AssociationHAZOP Guide)

manufacture making of articles or materials, often in large volumesIn relation to process facilities, this typically refers to activities for the production of various componentsunder contracts from one or more contractor or supplier.

operations(phase)

the phase when the lifting appliance is being used for the purpose for which it was designed. Use includesstart-up, stopping, transport, operation, monitoring, inspection, repair, maintenance, service and cleaning

lifting appliance machine or deviceused for the purpose of vertical movement of a load with or without horizontalmovement

crane machine for cyclic lifting or cyclic lifting and handling of loads suspended on hooks or other load handlingdevices, whether manufactured to an individual design, in series or from prefabricated components

Guidance note:Suspended includes any additional means fitted to prevent swinging, rotation of load etc.


machine an assembly of linked parts or components, at least one of which moves, with the appropriate machineactuators, control and power circuits, etc., joined together for a specific application, in particular for theprocessing, treatment, moving or packing of a material

The term machinery also covers an assembly of machines which, in order to achieve one and the sameend, are arranged and controlled so that they function as an integral whole.

certificate ofconformity

a document signed by a qualified party affirming that, at the time of assessment, the product or servicemet the stated requirements (BS 4778: Part 2)

liftingaccessory

component or equipment not attached to the machine and placed between the machinery and the load oron the load in order to attach it

liftingcomponent

parts of a lifting accessory

certificate oflifting appliance

a document based on the ILO convention no. 152, issued by the competent person, which confirm that thelifting appliance is in compliance with the requirements and is designed, fabricated, assembled, erected,tested, documented and maintained, and can be safely used


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Term Definition

risk the qualitative or quantitative likelihood of an accident or unplanned event occurring, considered inconjunction with the potential consequences of such a failureIn quantitative terms, risk is the quantified probability of a defined failure mode times its quantifiedconsequence.

risk reductionmeasures

those measures taken to reduce the risks to the operation of process facilities and to the health and safetyof personnel associated with it or in its vicinity by:

— reduction in the probability of failure— mitigation of the consequences of failure.

Guidance note:The usual order of preference of risk reduction measures is:

a) inherent safety

b) prevention

c) detection

d) control

e) mitigation

f) emergency response


safetyobjectives

the safety goals for the design, construction, installation operation and abandonment the fixed offshorestructure including acceptance criteria for the level of risk acceptable to the owner

statement ofconformity

a statement or report signed by a qualified party affirming that, at the time of assessment, the definedfacility, phase, or collection of activities, met the requirements stated by the owner

verification an examination to confirm that an activity, a product or a service is in accordance with specifiedrequirements

Guidance note:The examination should be based on information, which can be proved true, based on facts obtained throughobservation, measurement, test or other means.ISO 8402: 1994: Verification: Confirmation by examination and provision of objective evidence that specifiedrequirements has been fulfilled.


competentperson

person, organisation or unit who has sufficient theoretical knowledge and practical experience to examineand judge the technical safety of lifting appliances, in order to issue reports and certificates

Guidance note:The term competent person corresponds to the term Enterprice of Competence (EOC) used by The OffshoreMechanical Handling Committee (OMHEC). In some countries the Authorities require that the Competent personshall be certified, authorised or accredited.


assessmentcodes

codes used in this document to describe the type and extent of assessment during risk based verification


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1.5.4.1

Table 1-4 Assessment codes

Code Legend

I For information only

R1 review of principles and general aspects

R2 Review of principles, general aspects and spot check of calculations

S1 Surveillance on a visit basis, e.g. once per week or sample review 10-20%

S2 Surveillance frequency minimum once per day or review of 50-60%

S3 Surveillance frequency minimum once per shift or review of 100% of items

A Audit

H Hold point

1.5.5 References— CEN standards— Norsok standards— ISO standards— API codes.


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SECTION 2 SERVICE OVERVIEW

2.1 General

2.1.1 Objectives

2.1.1.1 The objectives of this section are to provide:

— an overview all verification activities relating to lifting appliances— details of DNV GL’s verification services for lifting appliances.

2.2 Service process

2.2.1 General principles

2.2.1.1 The description of the process of DNV GL’s verification of lifting appliances is based on distinctproject phases and the recognition of key milestones.

2.2.1.2 Verification performed by DNV GL normally progresses through one or more of these project phasesand may include all or selected aspects of the project.

2.2.1.3 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.

2.2.2 Simplified verification planning

2.2.2.1 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 involvementshall be low, medium or high.

— Use the example detailed scope of work tables in App.B to make a first draft of a verification plan


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— Generate the project specific verification plan by including a project specific engineering judgment or riskanalysis to adjust the table to suit the project.

— Perform the verification execution according to the verification plan, making revision to the plan if andwhen necessary.

— Report the verification.

2.2.2.2 The trigger questions are included in App.A.

2.2.2.3 Generic scopes of work for verification at the three levels of verification; low (L), medium (M) andhigh (H), are given in the tables in this section.

2.2.2.4 Project specific detailed scope of work descriptions, based on the generic scopes of work tables andshowing all the activities to be verified, should be made. Examples of the level of detail are given in App.B.

2.2.2.5 Tables in this section give the principle differences between the levels of verification involvement.The detailed example tables should be treated as examples only. They shall not be used without a projectspecific confirmation of their completeness.

2.2.2.6 The project specific scope of work definition, derived from the tables in App.B (or similar), shall bepart of the final DNV GL verification report.

2.2.3 Selection of level of verification

2.2.3.1 The selection of the level of verification for the simplified verification planning is facilitated by thetrigger questions included in App.A.

2.2.4 Codes, standards and reference documents

2.2.4.1 The verification process described in this DNVGL-SE-0480 is not tailored to a specific technicalstandard, code or reference document.

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

2.2.4.3 It is recommended strongly not to mix standards due to the possible differences in safetyphilosophies.

Guidance note:Most standards are a coherent collection of requirements for all the relevant aspects of a lifting appliance. These aspects, e.g. loadand resistance, are normally among themselves adjusted to give an overall acceptable safety level. To pick requirements fromdifferent standards can then easily result in unpredictable and non-uniform levels of safety.


2.3 Project initiation

2.3.1 Verification during conceptual design

2.3.1.1 Verification during the conceptual and/or feasibility studies of a project and in the early stages of aproject may reduce the need for verification during the design, construction and installation phases, and canreduce costs during the long term operation, inspection and maintenance phases.


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2.3.1.2 It is recommended to combine the design verification during project initiation phase with additionalreview of:

— project schedule— cost impacts— business risks.

2.3.1.3 During this phase it may be beneficial to make an initial verification plan. Risk evaluations are carriedout during this phase and should be used to get an indication of the general verification level; Low, Mediumor High.

2.4 Project realization

2.4.1 General

2.4.1.1 All design, construction and installation aspects, relevant to a lifting appliance, may be covered bythe life cycle verification.

2.4.1.2 In this specification the split in the scope of work between design, construction and installation ismade between sets of requirements (specifications) developed during the various phases.

Guidance note:The split between design, construction and installation may vary, but it is useful to spend some time on the definition to reduceinterface problems later.


2.4.2 Verification of overall project management

2.4.2.1 Verification of the overall project management is the examination of the means of controlling theentire process leading up to an operational lifting appliance.

2.4.2.2 This verification should confirm that the necessary controls are in place to ensure information flowacross the various interfaces. It is especially important where separate contractors have been employed fordifferent phases of the project such as design, construction and installation.

2.4.2.3 Typically the documentation is expected to be in line with ISO 9000 requirements.

2.4.2.4 Definition of scope of work for verification of overall project management shall follow Table 2-1.

Table 2-1 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 X X

— audit of project quality management system X

— review of sub-contractor control X


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2.4.2.5 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.

2.4.3 Verification during design

2.4.3.1 Design verification is the examination of the assumptions, methods and results of the design processand is performed at the specified level of verification to ensure that the specified performance requirementsof the lifting appliance will be achieved.

2.4.3.2 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.

2.4.3.3 The documents that shall be produced in the project should as a minimum satisfy the requirementsof the selected code.

2.4.3.4 Definition of scope of work for verification of design should follow Table 2-2.

2.4.3.5 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.

2.4.3.6 The documents that shall be produced in the project and handed over to DNV GL shall enable for theselected level of verification, see Table 2-2 and should as a minimum satisfy the requirements of the selectedcode.

2.4.3.7 Definition of scope of work for verification of design should follow Table 2-2.


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Table 2-2 Scope of work for verification of design

Level


Review of the design process by

— review of design quality management documentation X

Review of specifications for design by

— review of the design specifications, i.e. regulations, standards, codes and clientspecifications (optional)

— review of the design basis with emphasis on the design criteria and classifications

X

X

X

X

X

X

Review of design risk assessment

— review of the risk assessment reports, including acceptance requirements andresults

X X

— spot check of critical aspects X X

— evaluation of critical aspects, including SHE as identified in the risk assessmentreports

X

Review of drawings, diagrams and documentation by

— review of the formal documentation to ensure that the requirements have beenaccounted for in design and that the chosen design philosophies are in accordancewith specified codes and standards

X X X

— evaluation of the main methods used and spot checks of the input data and thecalculation results

X X

— detailed review of main design reports X

— detailed review of the foundation reaction forces X X X

— detailed review of the user manual X X X

Guidance note:Design verification activities may be split up between basic design and detailed design, or other sub-phases, depending on type ofcontract.


2.4.4 Verification during construction and factory acceptance test

2.4.4.1 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 purchasedocumentation, and that correct materials, components and proper testing procedures are applied such thatit meets the requirements as per approved specifications and procedures. It is recommended that relevantpreparations for this is started as early as possible, e.g. by the appointment of a vendor supply verificationco-ordinator.

2.4.4.2 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.


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2.4.4.3 Verification of these activities relates not only to the manufacturers work but also to the monitoringof this work carried out by vendors and contractors others.

2.4.4.4 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.

2.4.4.5 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.

2.4.4.6 Particularly for the factory acceptance test it is highly recommended to prepare a formal testprocedure be verified prior to commencement.

2.4.4.7 Scope of work for verification of construction should follow Table 2-3 for manufacturing andfabrication and Table 2-4 for FAT.

Table 2-3 Scope of work for verification of manufacturing and fabrication

Level


Review of the manufacturing and fabrication process

— Review of manufacturing and fabrication quality management systems X X

— Audit of the quality management system X

Review of manufacturing and fabrication procedures

— Review of the design verification report X X

— Review manufacturing, fabrication and inspection procedures for confirmation ofcompliance with the manufacturing specification

X

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 inaccordance with the manufacturing specification

X X

Review of fabrication records


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Level


— Review the manufacturing data book, as applicable X X

— Review of formal documentation X X

Guidance note:Materials and components may be ordered with certificates of varying degrees of independent 3rd party verification This may beintegrated in the overall verification activities, so not to duplicate work.


Table 2-4 Scope of work for verification of factory acceptance tests

Level


Review of test programme and preparations for testing

— Review the FAT programme for confirmation of compliance with the requirementsand specifications

X X

Surveillance during testing

— Surveillance to ensure that the assembly, erection, rigging and configuration,complies with the test procedure requirements

X X

— Survey of the main elements to verify compliance with the constructionrequirements

X X

— Survey of testing to ensure that the results comply with the test procedurerequirements regarding safety aspects

X X

— Survey of testing to ensure that the results comply with the test procedurerequirements regarding performance, endurance and SHE aspects

X

2.4.5 Verification during installation and commisioning

2.4.5.1 This phase comprises shipment, installation, testing and commissioning in conjunction with handover of the lifting appliance to the user and to bring the lifting appliance into use for the first time.

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

2.4.5.3 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.

2.4.5.4 Verification of these activities relates not only to the manufacturers work but also to the monitoringof the work carried out by vendors installation contractors and others.

2.4.5.5 Installation and commissioning test verification shall consist of one, or some, of the following:


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— 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.

2.4.5.6 The documents that should be produced in the project and submitted for review prior to installationand 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.

2.4.5.7 Particularly for the commisioning acceptance test it is highly recommended to prepare a formal testprocedure be verified prior to commencement.

2.4.5.8 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.

2.4.5.9 Definition of scope of work for verification of installation and commissioning should follow Table 2-5for testing and completion.

Table 2-5 Scope of work for verification during installation and commissioning

Level


Initial activities

— Review of quality system documentation X X

— Review of previous verification reports X X X

— Review of qualification records X

Surveillance during installation activities

— Part time attendance during installation to verify that the foundation, interfaceconnection, access and escape routes are properly installed

X X

Review of installation documentation

— Review of foundation design report X X X


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Level


— Review of installation records and reports X X X

— Surveillance during test activities

— Witnessing of installation and commissioning testing regarding safety and integrity X X X

— Witnessing of SHE aspects, performance and endurance testing X

Review of final documentation

— Spot check of as-built documentation X X

— Review of as-built documentation X

— Review of formal documentation, i.e. EC Declaration of Conformity, if applicable X X X

— Review of user instructions X X X

— Review of former ILO certificates, if applicable X X X

2.4.6 Verification at issuance of certificate of lifting appliance

2.4.6.1 This phase comprises final issuance of the certificate of lifting appliance which is required to bringthe lifting appliance into use for the first time.

2.4.6.2 The scope of this verification is to summarise all previous verification activities and issue therequired certification documents as competent person.

2.4.6.3 Verification at issuance of the certificate of lifting appliance shall consist of some or all of thefollowing 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.

2.4.6.4 The scope of work for verification at issuance of certificate of lifting appliance shall follow Table 2-6.If a certain verification level is aimed for to be stated on the certificate, this verification level as a minimumhas to be followed in the previous verification phases.

Table 2-6 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 H

— Design verification report L/M/H 1) M/H H

— Construction and FAT report L/M/H 2) M/H H


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Level

Verification level applied stated on the certificate Low Med High

— Installation and commissioning report L/M/H M/H 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 GL.

2.5 Verification documents

2.5.1 General

2.5.1.1 The hierarchy of verification document is given in DNVGL-SE-0474. The descriptions of the content ofthese documents as well as examples of document forms are given in App.C to this specification.


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APPENDIX A SELECTION OF VERIFICATION LEVEL

A.1 General

A.1.1 General principles

A.1.1.1 The selection of the level of verification depends on the risk level of each of the elements that havean impact on the management of risks to the asset.

A.1.1.2 Verification shall direct greatest effort at those elements of the asset where the risk is highest andwhose failure or reduced performance will have the most significant impact on the project objective andgoals, e.g.:

— safety risks,— environmental risks,— economic/business risks.

A.1.1.3 Suitable selection factors include, but are not limited to, the:

— overall safety and other objectives for the asset— assessment of the risks associated with the asset and the measures taken to reduce these risks— degree of technical innovation in the asset— experience of the contractors in carrying out the work— quality management systems of the owner and its contractors— business risk associated with schedule impact and rework.

A.1.1.4 Due to the diversity of various lifting appliances, their contents, their degree of innovation,the geographic location, etc., it is not possible to give precise guidelines on how to decide what level ofverification is appropriate for each particular structure.

A.1.1.5 Therefore, guidance is given in the form of a series of questions that should be answered whendeciding the appropriate level of verification for a process facility. This list is not exhaustive and otherquestions should be added to the list if appropriate for a particular process facility.

A.1.1.6 It is emphasised that the contribution of each element should be judged qualitatively and/orquantitatively. Wherever possible quantified risk assessment data should use to provide a justifiable basis forany decisions made.

A.1.1.7 Depending on the stage of the project, the activities may not have taken place yet in which case thequestions should also be posed in another form, i.e. “Is …. planned to be?”

A.2 Trigger questions

A.2.1 Overall project objective and goals— Does the safety objective address the main safety goals?— Does the safety objective establish acceptance criteria for the level of risk acceptable to the owner?— Is this risk (depending on the type of appliance and its location) also measured in terms of environmental,

economic and political consequences?— In terms of scope of work is the project schedule realistic?— Does the contract place severe financial penalties if target dates for commissioning are not met?


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Guidance note:Substitute safety objective with other relevant objectives for the project, and go through all of them.


A.2.2 Assessment of risk— Has a systematic review been carried out to identify and evaluate the probabilities and consequences of

failures in the lifting appliance?— Has this review judged the contribution of each element qualitatively and/or quantitatively and used,

where possible, quantified risk assessment data to provide a justifiable basis for any decisions made?— Does the extent of the review reflect the risk level of the lifting appliance, the planned operation and

previous experience with similar appliances?— Does this review identify the risk to the operation of the lifting appliance and to the health and safety of

personnel associated with it or in its vicinity?— Has the extent of the identified risks been reduced to a level as low as reasonably practicable by means of

one or both of:

— reduction in the probability of failure?— mitigation of the consequences of failure?

— Has the result of the systematic review of the risks been measured against the owner’s safety (or other)objective?

— Has the result of this review been used in the selection of the appropriate verification activity level?

— In terms of schedule which are the items which have a significant impact?

A.2.3 Technical innovation— Has the degree of technical innovation in the lifting appliance design been considered?— Has it been considered that risks to the structure are likely to be greater with a high degree of technical

innovation than with an appliance designed, fabricated and installed to usual/typical criteria?— Have factors been considered in the selection of the appropriate verification level such as:

— degree of difficulty in achieving technical requirements?— knowledge of similar solutions?

A.2.4 Contractors’ experience— Has the degree of risk to the design/fabrication and installation been considered with respect to the

experience of the manufacturer/contractor?— Has the degree of risk been considered where the manufacturers/contractors are experienced but not in

similar work?— Has the degree of risk been considered where the work schedule is tight?

A.2.5 Quality management systems— Have all parties involved in the project implemented an adequate quality management system to ensure

that gross errors in the work are limited?— Do these parties include the:

— owner— design contractor


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— construction contractors— vendors— installation contractor— operator.

— Do the factors being considered when evaluating the adequacy of the quality management systeminclude:

— whether or not an ISO 9000 or equivalent certified system is in place?— results from external audits?— results from internal audits?— experience with contractors’ previous work?— project work force familiarity with the quality management system?

A.2.6 Simplified assessment and verification levelSee Table E-2.


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APPENDIX B DETAILED EXAMPLE SCOPE OF WORK TABLES FORVERIFICATION

B.1 General

B.1.1 General introduction

B.1.1.1 This appendix provides the format of the detailed verification lists (tables), generated for typicalsystems comprising a lifting facility:

1) cranes2) lifting accessories3) lifting appliances for life saving equipment4) lifting person devices5) drilling hoisting equipment6) robots.

which shall be made for each particular project.

B.1.1.2 The detailed project specific verification lists for the chosen level of verification shall be based onthese tables.

B.1.1.3 For project scenarios or components not covered in this appendix, similar lists with the same degreeof detail shall be made.

B.1.1.4 If any of the activities are moved from one phase to another, then this should be clearly identified onthe list where it is removed. Similarly, the detailed list for the phase to where it is moved shall be amended.

Guidance note:Typically, contractual boundaries may give natural splits of activities between phases. However, then it is even more important toensure that there is a traceably as to which phases what activity belong and that this is also conveyed to the contractors also.


B.2 Description of terms used in the scope of work tables

B.2.1 General

B.2.1.1 The following abbreviations have been used. The definitions of which are given subsequently:

— A is audit— S is surveillance— H is hold point— R is review— I is for information.

B.2.1.2 These abbreviations are DNV GL’s preferred terms and normally will be used in DNV GL generateddocuments. However, other terms, for example monitoring or witnessing, will be used by DNV GL if theseare the terms commonly used in documents, such as inspection and test plans, generated by others. In thatcase, it is expected that these other terms are defined in these documents.


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B.2.2 Audit

B.2.2.1 Systematic and independent examination to determine whether quality activities and related resultscomply with planned arrangements and whether these arrangements are implemented effectively and aresuitable to achieve objectives (ISO 8402:1994).

Guidance note:This activity differs from the surveillance by being focused on the adherence to and completeness and robustness of theprocedures and not on the actual result of the procedure (although this is not ignored). Further, the audit is normally a ‘one-off’activity as opposed to the continuity in monitoring.


B.2.3 Surveillance

B.2.3.1 Continual monitoring and verification of the status of an entity and analysis of records to ensure thatspecified requirements are being fulfilled (ISO 8402:1994).

Guidance note:Other commonly used terms for surveillance are monitoring or witnessing.


B.2.3.2 The amount of work involved in surveillance is not described in detail in the tables. This shall be partof the final contractual scope of work which shall define the frequency of surveillance based on the overallsurveillance and the quality control performed by other parties as well as DNV GL’s experience.

B.2.3.3 The following shall be used to describe the frequency if nothing else is specifically defined:

S1 = surveillance on a visit basis, e.g. once per week or sample review 10-20%S2 = surveillance frequency minimum once per day or review of 50-60%S3 = surveillance frequency minimum once per shift or review of 100% of items

Guidance note:These surveillance frequencies may be modified to correspond with production work flow.


B.2.4 Review

B.2.4.1 Systematic examination of reports and documentation against a project defined verification basis.The depth of review will depend both on the type of document and the level of involvement.

B.2.4.2 The following shall be used to describe the extent of the review if nothing else is specifically defined:

I = for information onlyR1 = review of principles and general aspectsR2 = Review of principles, general aspects and spot check of calculations

Guidance note:Review of production records does not guarantee their correctness. It is a confirmation to DNV GL that the manufacturer and/orsub-contractor has preformed the required activity and issued a report.



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B.2.4.3 Reports that are reviewed by DNV GL will, unless otherwise agreed, not be signed and stamped.

Table B-1 Assessment codes

Code Legend

I For information only

R1 Review of principles and general aspects

R2 Review of principles, general aspects and spot check of calculations

S1 Surveillance on a visit basis, e.g. once per week or sample review 10-20%

S2 Surveillance frequency minimum once per day or review of 50-60%

S3 Surveillance frequency minimum once per shift or review of 100% of items

A Audit

H Hold point

B.3 Overall project management

B.3.1 General

B.3.1.1 The project quality management documentation, if part of scope, should be available for review atthe early stages of the project, preferably before design is underway, to ensure that the necessary controlsare in place.

Table B-2 Overall project management

LevelItem Description

Low Med High

1 review of project quality management documentation R2 R2

2 audit of project quality management system A

3 review of sub-contractor control R2

4 review of interface controls R1 R2

5 review of methods of information flow R1

B.4 Design

B.4.1 General

B.4.1.1 Design consists of conceptual and detailed design and their associated documentation.

B.4.1.2 The scope of work for design verification is shown in tables listed in this chapter, for various typesof lifting appliances. The tables states a recommended scope of work for low, medium and high level


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verification, and may be changed upon an agreement between the client and DNV GL based on the methodlisted in App.A.

B.4.1.3 For manufacturers and vendors who have established a DNV GL approved ISO9000 quality systemcovering design of lifting appliances, this may reduce the scope of work accordingly, upon agreement withDNV GL. App.B describes the issues to be reviewed and the extent of verification included in the threeverification levels.

B.4.2 Verification during design

B.4.2.1 For verification of lifting appliances during design the following activities are considered:

— initial activities— review activities— final activities.

The initial activities includes a review of basic project information, design criteria and the design qualitymanagement system of the designer. The review activities include evaluation of documentation related to thedesign of the lifting appliance. The final activities include issuance of a design verification report.

B.4.3 Low level design verification

B.4.3.1 The low level design verification consists of a minimum verification involvement in order for DNVGL to issue a design verification report. Provided that the proceeding verification activities are performedduring construction, FAT, installation and commissioning, a DNV GL certificate of lifting appliance may finallybe issued. The ow level verification scheme is based that the risks associated with potential faulty design isconsidered to be low, typically for smaller, low capacity lifting appliances. The client may find internal controlmeasures sufficient and choose a low level design verification based on formal requirements towards thedesigner, such as quality assurance requirement, internal verification or EC Declaration of Conformity issuedby the manufacturer. Low level design verification will imply that the manufacturer is the sole responsible forthe technical construction file, and that a very limited extent of documentation is subject for design review.

B.4.4 Medium level design verification

B.4.4.1 Medium level design verification consists of a review of main design documents related to safetyand integrity. Critical aspects will be spot checked with focus on strength and integrity. The review will bedetailed for high risk aspects and independent checks will be performed. The medium level design verificationcorresponds to the ILO certification scheme applied world wide in the maritime area. See DNVGL-ST-0377Standard for shipboard lifting appliances or DNVGL-ST-0378 Standard for offshore and platform liftingappliances.

B.4.5 High level design verification

B.4.5.1 High level design verification consists of a full review of most of the produced documents related tosafety and integrity, including SHE aspects, performance and endurance of the lifting appliance. The mainspecifications are also checked. The review will be detailed for all high risk aspects and independent checkswill be performed. Less critical aspects will be spot checked. High level design verification is recommendedfor lifting appliances representing high risks, such as high capacity cranes, cranes lifting over process areas,cranes lifting persons, etc.


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Table B-3 Crane verification during design


Low Med High

Initial activities

1 Review of basic information, name of address of designer, manufacturer,vendors, user and intended location, if known

I I I

2 Review of design specifications, i.e. regulations, standards, codes and clientspecifications, if applicable

I R1 R2

3 Review of design criteria, including design temperature, environmentalinfluences, area classifications, design classifications of structures, mechanismsand systems

R1 R1 R2

4 Review of design quality management system - R1 R2

5 Review of technical risk assessment report - - R2

6 Technical design verification kick-off meeting - - H

Review activities

7 Review of general arrangement, rigging and reeving plan R1 R2 R2

8 Review of ratings, load charts and lifting tables, speeds and operationallimitations

R1 R2 R2

9 Review info on personnel lifting, if applicable R1 R2 R2

10 Review of detailed construction drawings and design calculations on all structuralelements essential for strength and safety

- R1 R2

11 Review of diagrams and calculations for sequence of failure, if applicable - R1 R2

12 Review of detailed drawings, calculations and documentation on all machineryelements and components essential for strength and safety

- R1 R2

13 Review of performance capacity and endurance calculations - - R1

14 Review of detailed drawings, diagrams and calculations on all system elementsessential for technical safety

- R1 R2

15 Review of control and work position including all SHE aspects - R1 R2

16 Review of control system documentation, including PLC programs if applicable - R1 R2

17 Review of safety system documentation including PLC programs if applicable - R1 R2

8 Review of communication and utility systems documentation - R1 R1

19 Review of fire and explosion protection drawings and descriptions - R1 R2

20 Review of noise and vibration protection drawings and descriptions - R1 R2

21 Review of electrical drawings and diagrams including EMC - R1 R2

22 Review of cabling and termination specification and arrangement drawings - - R1

23 Review of piping specification and arrangement drawings - - R1

24 Review of access and escape routes arrangement drawings - R1 R2


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Low Med High

25 Review of control station and work positions arrangement drawings - R1 R2

26 Review of FAT test programmes and commissioning test programmes - R1 R2

27 Review of labelling and marking documentation - R1 R1

28 Review of corrosion protection documentation - - R1

29 Review of vendor documentation, including product certificates - R2 R2

30 Review of foundation reaction forces R2 R2 R2

31 Review of fabrication specifications, plans and schedules - I I

32 Review of user manual including operating instructions, emergency proceduresand maintenance instructions

R2 R2 R2

33 Review of EC declaration of conformity, if applicable R2 R2 R2

34 Review of notified body certificates or statements, if applicable R2 R2 R2

Final activities

35 Issue design verification report H H H

Table B-4 Lifting accessories verification during design


Low Med High

Initial activities

1 Review of basic information, name of address of designer, manufacturer, vendors,user and intended location, if known

I I I


I R1 R2

3 Review of design criteria, including design temperature, environmentalinfluences, area classifications, design classifications of structures, mechanismsand systems, if applicable

R1 R1 R2




Review activities


8 Review of ratings, load charts and lifting tables and operational limitations R1 R2 R2



- R1 R2


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Low Med High


- R1 R2



- R1 R2





18 Review of electrical drawings and diagrams, including EMC - R1 R2







25 Review of suspension reaction forces R2 R2 R2



R2 R1 R2



Final activities:


Table B-5 Lifting appliances for life saving equipment verification during design


Low Med High

Initial activities


I I I


I R1 R2


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Low Med High


R1 R1 R2




Review activities



R1 R2 R2



- R1 R2


- R1 R2



- R1 R2



16 Review of safety system documentation, including PLC programs if applicable - R1 R2















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Low Med High



R2 R2 R2



Final activities:


Table B-6 Lifting person devices verification during design


Low Med High

Initial activities


I I I


I R1 R2


R1 R1 R2




Review activities



R1 R2 R2

9 Review info on personnel lifting R1 R2 R2

10 Review of detailed construction drawings and design calculations on allstructural elements essential for strength and safety

- R1 R2


- R1 R2



- R1 R2




DNV GL AS


Low Med High

















R2 R2 R2



Final activities:


Table B-7 Drilling hoisting equipment verification during design


Low Med High

Initial activities


I I I


I R1 R2


R1 R1 R2

4 Review of design quality management system documentation - R1 R2


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Low Med High



Review activities



R1 R2 R2



- R1 R2


- R1 R2



- R1 R2



















R2 R2 R2



DNV GL AS


Low Med High


Final activities:


Table B-8 Robots verification during design


Low Med High

Initial activities


I I I


I R1 R2


R1 R1 R2




Review activities



R1 R2 R2


- R1 R2


- R1 R2


- R1 R2




- R1 R2






DNV GL AS


Low Med High











R2 R2 R2



Final activities:


B.5 Construction and factory acceptance test

B.5.1 General

B.5.1.1 Construction and factory acceptance test (FAT) consists of fabrication site activities and theirassociated documentation.

B.5.1.2 The scope of work for verification during construction and FAT is shown in tables listed in thischapter, for various types of lifting appliances. The tables states a recommended scope of work for low,medium and high level verification, and may be changed upon an agreement between the client and DNV GLbased on the method listed in App.A.

B.5.1.3 For manufacturers and vendors who have established a DNV GL approved ISO9000 quality systemcovering construction and FAT of lifting appliances, this may reduce the scope of work accordingly, uponagreement with DNV GL.

B.5.1.4 For manufacturers who have established a manufacturing survey agreement (MSA) with DNV GL, inorder to systematically survey the construction and FAT activities, this arrangement may be used instead ofthe verification scheme listed in this chapter, upon further agreement.

B.5.2 Construction and factory acceptance test verification

B.5.2.1 For verification of lifting appliances the following activities are considered:

— initial activities


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— surveillance, review and test activities, and— final activities.

B.5.2.2 The initial activities include the review of procedures, attendance during qualification of procedures(e.g. MPQT) and personnel (e.g. welders) and other start-up activities. The surveillance, review and testactivities are the site attendance and the final activities are the review of production results/records, and thecompletion of documentation and reports.

B.5.3 Low level construction and factory acceptance test verification

B.5.3.1 For low level verification, no verification activities are stated. For this verification level, it is assumedthat construction and FAT of the lifting appliance in question is associated with low risk. This may be causedby the type and nature of the particular lifting appliance, or due to extensive internal quality assurancemeasures taken by the manufacturer or the client to ensure that all requirements are met.

B.5.3.2 Some of the potential verification activities during construction and FAT for low level verification willhowever be covered by verification during installation and commissioning.

B.5.4 Medium level construction and factory acceptance test verification

B.5.4.1 For medium level verification, the procedure review consists of a review of principles and generalaspects of the construction quality system, design review reports and procedures for construction and FAT.

B.5.4.2 During construction, DNV GL’s verification will be performed by part time attendance at the mainsite. The verification will mainly be spot check survey of structural parts and their assembly. Further, reviewof the construction records and the manufacturing record book will be reviewed by spot check.

B.5.4.3 Verification of the final activities will be carried out witnessing of safety critical parts of the FAT. Aninspection release note will then be issued.

B.5.5 High level construction verification

B.5.5.1 For high level verification, the initial activities consist of a detailed review of constructionmanagement system and procedures. A quality audit will be performed. Design verification reports and theFAT procedure will be reviewed. Any design changes will be required to be verified before construction.

B.5.5.2 Survey activity will include all main elements, SHE aspects, performance, endurance propertiesand marking. Depending on the fabrication schedule, part or full time attendance during construction will berequired. Verification will focus on the critical items and or aspects as identified in the detailed scope of worktables.

B.5.5.3 Verification of the final activities will be by detailed review of the production records and witnessingof FAT during testing of safety critical aspects as well as performance and endurance tests.

B.5.5.4 Finally an inspection release note and a FAT verification report will be issued.


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Table B-9 Crane verification during construction and FAT


Low Med High

Initial activities

1 Review construction quality management system - R1 R2

2 Quality system audit of relevant manufacturers - - A

3 Review of design verification reports - R1 R2

4 Review of construction specifications and procedures - I R2

5 Review of FAT procedure - R1 R2

6 Technical kick-off meeting and review of construction plans - - R1

7 Verify personnel qualification records - - R1

Surveillance activities

8 Confirm prefabricated items and vendor deliveries acc. to requirements - - S

9 Survey of interface to foundation and critical bolt connections - S W

10 Survey of main structural elements - S S

11 Survey of main machinery elements - S S

12 Survey of main system elements - - S

13 Survey of control station and work positions, internal access and escape routes - - S

14 Survey of SHE aspects for operation and maintenance - - S

15 Survey of marking, load tables, manufacturer plates and signboards - S S

Review activities

16 Review of documentation for prefabricated items and vendor deliveries - R1 R2

17 Review of main structural elements fabrication documentation - R2 R2

18 Review of main machinery elements fabrication documentation - R1 R2

19 Review of main system elements fabrication documentation - - R2

20 Review component certificates for wire ropes, hooks, blocks, other accessories - R2 R2

21 Review of manufacturing record book including NDE records, dimensionalmeasurement records, flatness measurement test records, pressure testrecords, instrumentation test records, noise test records, electrical test records,communication system test records, lubrication reports and lubrication samplingtest records, corrosion protection and preservation records, as applicable

- R1 R2

22 Review EC Declaration of Conformity acc. to the Machinery Directive, if applicable - R2 R2

23 Review EC Declaration of Conformity acc. to other EU Directives, if applicable - R1 R2

24 Review EC Type examination certificates or other notified body statements, ifapplicable

- R1 R2

Test activities


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Low Med High

25 Witness FAT, safety critical parts - H H

26 Witness FAT, performance and endurance tests etc. - - S

Final activities

27 Issue inspection release note and FAT verification report - H H

Table B-10 Lifting accessories verification during construction and FAT


Low Med High

Initial activities






6 Technical/kick-off meeting and review of construction plans - - R1









Review activities





19 Review integral component certificates for wire ropes, hooks, blocks, otheraccessories

- R2 R2


DNV GL AS


Low Med High

20 Review of manufacturing record book including NDE records, dimensionalmeasurement records, flatness measurement test records, pressure test records,instrumentation test records, electrical test records, lubrication reports, corrosionprotection and preservation records, as applicable

- R1 R2




- R1 R2

Test activities



Final activities


Table B-11 Lifting appliances for life saving equipment verification during construction and FAT


Low Med High

Initial activities


















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Low Med High

Review activities







- R1 R2




- R1 R2

Test activities



Final activities


Table B-12 Lifting person devices verification during construction and FAT


Low Med High

Initial activities











DNV GL AS


Low Med High








Review activities







- R1 R2




- R1 R2

Test activities



Final activities

27 Issue inspection release note and FAT verification report -- H H

Table B-13 Drilling hoisting equipment verification during construction and FAT


Low Med High

Initial activities




DNV GL AS


Low Med High















Review activities







- R1 R2




- R1 R2

Test activities



Final activities



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Table B-14 Robot verification during construction and FAT


Low Med High

Initial activities
















Review activities







- R1 R2




- R1 R2

Test activities



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Low Med High


Final activities


B.6 Installation and commissioning

B.6.1 General

B.6.1.1 Installation and commissioning consists of a number of different activities at the installation siteincluding reviews, surveys and witnessing of testing.

B.6.1.2 The scope of work for verification during installation and commissioning is shown in tables listed inthis chapter, for various types of lifting appliances. The tables states a recommended scope of work for low,medium and high level verification, and may be changed upon an agreement between the client and DNV GLbased on the method listed in App.A.

B.6.1.3 For manufacturers and vendors who have established a DNV GL approved ISO9000 quality systemcovering installation and commissioning of lifting appliances, this may reduce the scope of work accordingly,upon agreement with DNV GL.

B.6.2 Verification during installation and commissioning

B.6.2.1 For verification of lifting appliances during installation and commissioning the following activities areconsidered:

— initial activities— surveillance— review activities— test activities— final activities.

B.6.2.2 The initial activities include review of the quality management system for installation andcommissioning and other start-up activities. The surveillance activities are the site attendance, the reviewactivities may be carried out prior to or at site and the test and final activities are the (continuous) review ofinstallation and commissioning results/records and the completion of documentation and reports.

B.6.3 Low level installation and commissioning verification

B.6.3.1 For low level verification, the initial activities consist of a limited review of the documentation fromthe previous phases.

B.6.3.2 During the surveillance activities, main focus will be on the installation of the lifting appliance andthe foundation and the interface between the foundation and the lifting appliance. Also access and escaperoutes, signs and marking will be surveyed. The verification will be performed during site visits.

B.6.3.3 The subsequent review activities will focus on the documentation for the foundation structureand the manufacturing record book, including construction and FAT but also from the installation and


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commissioning phase. The review will also cover the final user instructions including maintenanceand operation manual. The formal documentation such as EC Declarations of Conformity and EC Typeexamination certificates if applicable will also be reviewed.

B.6.3.4 The verification during testing includes witnessing of test activities for safety critical elements andoverload tests according to the installation and commissioning test programme.

B.6.3.5 The final activities include issuance of an installation and commissioning verification report includingthe certificate of lifting appliance.

B.6.4 Medium level construction verification

B.6.4.1 For medium level verification, the initial activities consists of a general review of the installation andcommissioning quality management system in addition to a detailed review of the documentation from theprevious phases. Also installation specifications and procedures will be reviewed in general.

B.6.4.2 During the surveillance activities, main focus will be on the installation of the lifting appliance andon the foundation and the interface between the foundation and the lifting appliance. Control stations, workpositions, access and escape routes, signs and marking will be surveyed. The verification will be performedduring site visits.

B.6.4.3 The subsequent review activities will focus on the documentation for the foundation structure,upgrading/repair reports and the manufacturing record book, including construction and FAT but also fromthe installation and commissioning phase. The review will also cover the final user instructions includingmaintenance and operation manual. Test records for safety critical elements, fire and explosion alarmsare reviewed if applicable. The formal documentation such as EC Declarations of Conformity and EC Typeexamination certificates if applicable, will also be reviewed.

B.6.4.4 The verification during testing includes witnessing of test activities for safety critical elements andoverload tests according to the installation and commissioning test programme.

B.6.4.5 The final activities include issuance of an installation and commissioning verification report includingthe certificate of lifting appliance.

B.6.5 High level construction verification

B.6.5.1 For high level verification, the initial activities consists of a detailed review of the installation andcommissioning quality management system in addition to a detailed review of the documentation from theprevious phases. Also installation specifications and procedures will be reviewed in general.

B.6.5.2 During the surveillance activities, main focus will be on the installation of the lifting appliance andon the foundation and the interface between the foundation and the lifting appliance. Control stations,work positions, access and escape routes, signs and marking and other SHE aspects will be surveyed. Theverification will be performed during site visits.

B.6.5.3 The subsequent review activities will focus on the documentation for the foundation structure,upgrading/repair reports and the manufacturing record book, including construction and FAT but also fromthe installation and commissioning phase. The review will also cover the final user instructions includingmaintenance and operation manual. Test records for safety critical elements, fire and explosion alarmsare reviewed if applicable. The formal documentation such as EC Declarations of Conformity and EC Typeexamination certificates if applicable, will also be reviewed.

B.6.5.4 The verification during testing includes witnessing of test activities for safety critical and otherelements and overload tests according to the installation and commissioning test programme.


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B.6.5.5 The final activities include issuance of an installation and commissioning verification report includingthe certificate of lifting appliance. This item is not related to the installation and commissioning processas a normal hold point would be. This item is intended as a reminder to the DNV GL (or others) inspectionpersonnel that a final report of their verification activities is required to finish the work and issue thecertificate of lifting appliance which is needed to bring the lifting appliance into use.

Table B-15 Crane verification during installation and commissioning


Low Med High

Initial activities

1 Review installation and commissioning quality management system - R1 R2

2 Quality system audit of relevant installation - - A

3 Review of design verification report R1 R2 R2

4 Review of inspection release note and FAT verification report, or alternatively themanufacturers documentation from construction and FAT

R1 R1 R2

5 Review of installation specifications and procedures I R1 R2

6 Technical/kick-off meeting and review of installer’s documents - R1 R2

7 Verify personnel qualification test records - - R1


8 Survey of the installation to confirm correct installation and equipment hook-up H H H

9 Survey of the foundation S S S

10 Survey of interface to foundation and critical bolt connections S S W

11 Survey of access and escape routes S S S

12 Survey of control station and work positions - S S


14 Survey of marking, load tables, manufacturer plates and signboards S S S

Review activities

15 Review of foundation design and fabrication report, or ILO certificate R1 R1 R2

16 Review of noise measurement report, if applicable - - R1

17 Review of upgrading/repair report, if applicable - R2 R2

18 Review of weight reports - R1 R2

19 Review of ILO certificates, if applicable R2 R2 R2

20 Review installation records and equipment hook-up, incl. non-conformance logs - R1 R2

21 Review component certificates for wire ropes, hooks, blocks, other accessories R2 R2 R2


DNV GL AS


Low Med High

22 Review of installation and commissioning manufacturing records including NDErecords, dimensional measurement records, flatness measurement test records,pressure test records, instrumentation test records, electrical test records,communication system test records, lubrication reports and lubrication samplingtest records, as applicable

- R2 R2

23 Review of fire and gas alarms and shut downs test records, if applicable - R1 R2

24 Review of commissioning records for testing of all safety critical functions - R1 R2

25 Review the final user instructions including maintenance and operation manual R1 R2 R2

26 Review EC Declaration of Conformity acc. to the Machinery Directive, if applicable R1 R2 R2

27 Review EC Declaration of Conformity acc. to other EU Directives, if applicable R1 R1 R2


R1 R1 R2

Test activities

29 Witness testing according to commissioning functional test programme, safetycritical elements including emergency stop, emergency procedures, shut downs,etc.

H H H

30 Witness testing according to commissioning functional test programme, otherelements

- - H

31 Witness overload tests H H H

32 Witness testing of installation fire and gas warning and alarm systems, if applicable W W W

33 Witness testing of installation emergency evacuation warning and alarm systems, ifapplicable

W W W

Final activities

34 Issue installation and commissioning close-out report incl. certificate of liftingappliance

H H H

Table B-16 Lifting accessories during installation and commissioning


Low Med High

Initial activities




4 Review of inspection release note and FAT verification report R1 R1 R2




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Low Med High






Review activities








- R2 R2






R1 R1 R2

Test activities

23 Witness testing according to commissioning functional test programme H H H


Final activities


H H H


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Table B-17 Lifting appliances for life saving equipment verification during installation andcommissioning


Low Med High

Initial activities
















Review activities





19 Review of life saving equipment documentation and certificates, if applicable R2 R2 R2



22 Review of manufacturing record book including NDE records, dimensionalmeasurement records, flatness measurement test records, pressure testrecords, instrumentation test records, noise test records, electrical test records,communication system test records, lubrication reports and lubrication samplingtest records, as applicable

- R2 R2





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Low Med High



R1 R1 R2

Test activities


H H H


- - H


Final activities


H H H

Table B-18 Lifting person devices verification during installation and commissioning


Low Med High

Initial activities










9 Survey of the foundation and machine on which the lifting person device isconnected to, if applicable

S S S

10 Survey of interface to foundation, machine and critical bolt connections S S W





Review activities


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Low Med High

15 Review of foundation design and fabrication report, or ILO certificate for thefoundation

R1 R1 R2

16 Review of certificates for the machine on which the lifting person device isconnected to, if applicable

- R1 R2




20 Review of former ILO certificates, if applicable R2 R2 R2




- R2 R2






R1 R1 R2

Test activities


H H H


- - H


Final activities


H H H


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Table B-19 Drilling hoisting equipment verification during installation and commissioning


Low Med High

Initial activities
















Review activities

15 Review of foundation design and fabrication report, or ILO certificate for thefoundation

R1 R1 R2




19 Review of former ILO certificates, if applicable R2 R2 R2




- R2 R2





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Low Med High




R1 R1 R2

Test activities


H H H


- - H

31 Witness overload tests as applicable H H H



W W W

Final activities


H H H

Table B-20 Robot verification during installation and commissioning


Low Med High

Initial activities















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Low Med High



Review activities


16 Review of EMC measurement report, if applicable - - R1








- R2 R2







R1 R1 R2

Test activities


H H H


- - H




W W W

Final activities


H H H


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APPENDIX C EXAMPLES OF VERIFICATION DOCUMENTS

C.1 Verification documents

C.1.1 Validity of verification documents

C.1.1.1 Verification documents are, in principle, documents confirming that an examination has been carriedout, and are valid only at the date of issue.

C.1.2 Certificate of lifting appliance

C.1.2.1 A statement of conformity may be issued on completion of each particular project phase, or naturalpart thereof, and shall be based on a dedicated verification report.

C.1.2.2 A certificate of lifting appliance, however, shall be issued as a formal statement confirming thatverification of a lifting appliance complies with the minimum requirements applicable for 3rd party verificationof that particular product.

C.1.2.3 The certificate of lifting appliance is based on the international form recommended by ILO conventionno.152.

C.1.2.4 The technical information on a certificate of lifting appliance shall contain:

— certificate no. and date, replacing cert.no.— verification level applied (tick off boxes)— product description— standardised type of lifting appliance— name of owner— client reference— location (name of ship, installation, site, etc.— certified for the lifting of persons yes or no— regulation reference— cdode/standard reference— situation and description of lifting appliance (with distinguishing marks, if any) which has been testes and

thoroughly examined— angle to the horizontal or radius at which test load is applied— test load (tonnes)— safe working load (SWL) at angle or radius shown in column 2 (tonnes)— reference documents (tick off boxes)— signatures— application (operational limitations and conditions of use) for which the facility is intended— codes and standards with which the fixed structure has been found to comply— reason for issuing the certificate (tick off boxes)— DNV GL report reference— level of verification— an appendix containing the accompanying dedicated verification report.

C.1.2.5 An example of a typical statement of conformity is shown at the end of this appendix.


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C.1.3 Verification reports

C.1.3.1 Verification reports are issued to confirm that the relevant product or service has been completed inaccordance with specified requirements.

C.1.3.2 The report shall include information such as:

— product or service description and item number, if relevant— application (operational limitations and conditions of use) for which the product or service is intended— codes and standards with which the product or service has been verified against— clear statement of the conclusion from the verification (does it or does it not meet the specified

requirements)— codes and standards used as reference— documentation on which the verification report is based (documents, drawings, correspondence, including

revision numbers)— project-specific scope of work tables— any comments— identification of any non-conformances.

C.1.3.3 The verification report shall always be dated and have two signatures, the originator and the DNV GLinternal verifier.

C.1.4 Verification comments

C.1.4.1 Reviews of documents shall be reported using verification comment sheets (often called VerComs).These documents give details to the client of aspects of the fixed offshore structure facilities design andconstruction that DNV GL:

— considers does not meet the specified requirements— does not have enough information to make a decision— offers advice based on its own experience.

C.1.4.2 Only in the first two instances does DNV GL expect a response from the owner or its contractors.

C.1.4.3 An example of a typical verification comment sheet is shown at the end of this appendix.

C.1.5 Audit report

C.1.5.1 Audit reports are issued to confirm that a company’s quality management system has been reviewedto confirm compliance (or not) with the nominated standard and project requirements. In addition, the auditreports confirm compliance with the documented procedures and that these procedures are effective.

C.1.5.2 Audit reports shall contain information such as whether:

— the company has a documented quality system— this quality system has been certified by an accredited certification body for the product (or service) in

question— the quality system covers the following quality assurance elements adequately for the product:

— organisation— authority/responsibility— job descriptions for key persons— internal quality audits


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— documentation change control— job instructions/procedures— non-conformance/corrective action

— there are adequate procedures for activities such as:

— calibration of equipment— material identification and marking— control of special processes such as welding, NDT, PWHT— non-conformance identification and handling— inspection status— final inspection

— the company’s facilities are, in general, considered adequate for the scope of supply

— a quality plan has been prepared for the order concerned

— the purchaser or their appointed inspection agency are planned to attend the works

— there are any problem areas identified.

C.1.5.3 An example of a typical audit report is shown at the end of this appendix.

C.1.6 Visit reports

C.1.6.1 Visit reports are documentation/recording of attendance activity by DNV GL.Guidance note:Visit reports are and may be called by different names. Examples are inspection release note, survey report, inspection certificate,site report, etc.


C.1.6.2 A visit report shall contain enough information to identify clearly the product or service that hasbeen examined, the operating conditions or specifications to which it has been examined and the conclusionreached by DNV GL.

C.1.6.3 The visit report shall be printed on the relevant form and shall contain as much information aspossible in accordance with the standard headings in the form. In addition, the report number shall beshown.

C.1.6.4 An example of a typical visit report is shown at the end of this appendix.

C.2 Use of quality management systems

C.2.1 General

C.2.1.1 The assurance of structural integrity requires that gross errors during design, construction andoperation be minimised. The likelihood of gross errors shall be reduced in a systematic manner by theoperation of a quality management system adequate for the work being carried out.

C.2.1.2 Quality management systems frequently are documented at three levels:

— the quality manual and related procedures document how the organisation, as a whole, manages thequality of all its products and services

— the quality plan documents the specific procedures related to a particular project


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— the inspection and test plan documents how the quality control activities for a particular project shall becarried out and recorded.

C.2.2 Quality plans

C.2.2.1 The basic function of a quality plan is as an aide in the management of a project. In an organisationwith many quality procedures for a variety of functions the quality plan states those that are applicable tothat particular project. The quality plan acts as a route map through the complexities of management of theproject and highlights those activities relevant to quality management.

C.2.2.2 The project quality plan normally consists of two parts; firstly, a narrative description of the meansof controlling the project, and secondly, a tabular description of the inspections and tests to be carried outduring the work.

C.2.2.3 The quality plan should address:

— organisational details of the project— authorities and responsibilities of key personnel— interfaces between, the client, contractors, sub-contractors and third parties— quality assurance activities placed on sub-contractors— cross references to existing company procedures.

C.2.2.4 The narrative part of the quality plan should include a description of:

— the applicable standards— project organisation and responsibilities— review of the contractual requirements— project planning and progress reporting— procedures for such activities as design control, purchasing, construction, installation, commissioning,

interface control and auditing— procedures for inspection and maintenance as well as normal operation— emergency response issues.

C.2.2.5 Additionally, the narrative part of the plan should describe the documentation requirements. Itshould be specified:

— what documents are required— at what stage these documents are required— who is responsible for preparing the documents— relevant parties to whom documents are submitted— how any necessary approvals are acquired— who has originals and who has copies— if copies have to be certified copies— the length of time documents shall be retained and by whom.

C.2.3 Inspection and test plans

C.2.3.1 The tabular description of the inspections and tests to be carried out during the work is frequentlyknown as the inspection and test plan.

C.2.3.2 The following items should be checked for inclusion within the inspection and test plan:

— each inspection and test point and its relative location in the production cycle should be shown— the characteristics to be inspected and tested at each point should be identified


DNV GL AS

— the use of sub-contractors should be indicated and details of how the verification of sub-contractor’squality shall be carried out should be shown

— hold points established by the constructor, the operator or a third party, where witness or review of theselected inspection or test is required, should be shown.

C.2.4 Review of quality management programme

C.2.4.1 The contractor’s quality manual shall be reviewed for compliance with ISO 9001 or 9002 asappropriate. The contractor’s operations should be audited to establish compliance with the documentedsystem.

C.2.4.2 If the contractor has a quality system certified by an accredited third party certification body,this may be taken as evidence of a satisfactory quality system provided the certificate is relevant to thecontractor’s scope of work for the project. However, the last two years’ periodical audit reports shall bereviewed to identify if any recurring non-conformities have been revealed.

C.2.4.3 Any weaknesses revealed during this audit, or review of periodical audit reports, shall be consideredwhen planning the contractor monitoring activities.

C.2.4.4 Surveillance of the continuing acceptability of the contractor’s quality management system is carriedout by observing a selection of audits carried out by the contractor as part of its internal audit system. Theaudits to be observed should be selected over the length of the project at suitable intervals and should coveras wide a selection of activities as possible.

C.2.4.5 Contractors’ inspection and test plans for the various activities undertaken during their scope of workfor the pipeline shall be reviewed and accepted, if adequate.

C.3 Document forms

C.3.1 Introduction

C.3.1.1 The end of this appendix includes example forms for use by DNV GL in verification.

C.3.1.2 The following forms are included:

— certificate of lifting appliance— verification comments sheet— audit report— visit report.


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C.3.2 Certificate of lifting appliance

EXAMPLE


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EXAMPLE


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C.3.3 Verification comments sheet


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C.3.4 Audit report

EXAMPLE


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EXAMPLE


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C.3.5 Visit report

EXAMPLE


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APPENDIX D LIFTING APPLIANCE LIFE CYCLE

D.1 Lifting appliance life cycleTable D-1 DNV GL services and documentation within lifting appliance life cycle

Project phases Type of verificationdocuments

Certificate of liftingappliance application Application of DNVGL-SE-0480

Design Design verification report

Construction and FAT Inspection reports

Installation andcommissioning

Installation andcommissioning report

Operation Inspection reports

De-commissioningand removal Inspection reports

Reference for certification

— Authority regulations— International standards— DNV GL standards


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APPENDIX E INFORMATIVE DOCUMENTS

E.1 Technical terminologyTable E-1 Technical terminology used in this document

Lifting appliances are grouped into the following sub-systems and components

Structure Machinery Systems

Pedestal Prime mover Valve

Adaptor Motor Pipe

Beam Pump Cable

Boom Gearbox Switch

A-frame Transmission Fuse

Column Shaft Bus

Travers Spline Computer

Davit Pin Logic unit

Post Bolt Solenoid

Gantry Nut Program

Supports Sheave Indicator

Frame Brake Alarm

Mast Cylinder Warning

Suspension Winch Control

Plate Wire rope Monitor

Box Hook Terminal

Lattice Block Sensor

Gangway Bearing Display

Ladder Integral accessories Relays

Platform Component Light

Handrail Mechanisms Instrument


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E.2 Guide for selection of verification levelTable E-2 Critical elements, status and verification level

Element Status

Design Proven Unproven

Construction Proven Unproven

Utilisation Low High

Delivery schedule Slack Tight

Environment Mild Harsh

Location Open Compact

Operator skills High Low

Failure tolerance High Low

Downtime tolerance High Low

Verification level

Cha

nges

– h

isto

ric


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CHANGES – HISTORICThere are currently no historical changes for this document.

About DNV GLDriven by our purpose of safeguarding life, property and the environment, DNV GL enablesorganizations to advance the safety and sustainability of their business. We provide classification,technical assurance, software and independent expert advisory services to the maritime, oil & gasand energy industries. We also provide certification services to customers across a wide rangeof industries. Operating in more than 100 countries, our experts are dedicated to helping ourcustomers make the world safer, smarter and greener.

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