Verification of hydrocarbon refining and petrochemical facilities

Transcription

1 SERVICE SPECIFICATION DNVGL-SE-0469 Edition August 2017 Verification of hydrocarbon refining and petrochemical facilities The electronic pdf version of this document, available free of charge from is the officially binding version.

2 FOREWORD DNV GL service specifications contain procedural requirements for obtaining and retaining certificates and other conformity statements to the objects, personnel, organisations and/or operations in question. August 2017 Any comments may be sent by to This service document has been prepared based on available knowledge, technology and/or information at the time of issuance of this document. 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 responsibility for loss or damages resulting from any use of this document.

3 CHANGES CURRENT General This document supersedes the October 2010 edition of DNV-DSS-314. 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 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 corrections Changes - current In addition to the above stated changes, editorial corrections may have been made. Service specification DNVGL-SE Edition August 2017 Page 3

4 CONTENTS Changes current... 3 Section 1 Introduction to risk based verification Introduction Risk based verification Definitions Abbreviations References Contents Section 2 Principles of risk based verification Purpose of section Verification principles Selection of level of verification Communications...19 Section 3 Service overview Purpose of section Service process Front end engineering design Project design, construction and commissioning Operations Facility modifications Appendix A Selection of verification level...35 A.1 Introduction...35 A.2 Quantitative risk assessment A.3 Trigger questions...39 Appendix B Verification documents...41 B.1 Purpose of appendix...41 B.2 DNV GL certificate of conformity B.3 Statement of conformity...42 B.4 Other verification documents B.5 Use of quality management systems B.6 Verification forms Appendix C Generic detailed verification scopes of work tables...50 C.1 Purpose of appendix...50 Service specification DNVGL-SE Edition August 2017 Page 4

5 C.2 of terms used in the scope of work tables...50 C.3 Overall project management C.4 Design...52 C.5 Construction...76 C.6 Commissioning...91 C.7 Operations C.8 Modifications or upgrades Contents Appendix D Major accident hazards versus safety-critical elements D.1 Purpose of appendix Appendix E Guidance on the development of verification plans E.1 Purpose of appendix E.2 The verification plan s part in facility risk management E.3 Independent third-party verification E.4 Verification plan E.5 Verification reporting E.6 Review and revision of the verification plan Changes historic Service specification DNVGL-SE Edition August 2017 Page 5

6 SECTION 1 INTRODUCTION TO RISK BASED VERIFICATION 1 Introduction 1 Function of this document 1 This service specification gives criteria for and guidance on third-party verification of the safety and integrity of hydrocarbon refineries and petrochemical facilities during new developments, operations and during modifications to existing facilities. 2 The experience gained from past projects specific to an oil refinery and a petrochemical plant is incorporated in this service specification. This service specification: describes DNV GL's verification services for oil refineries and petrochemical facilities, provides guidance for facility owners and others for the selection of the level of involvement of those carrying out the certification and verification activities, whether by simple trigger questions or as a result of a quantitative risk assessment provides a common platform for describing the scope and extent of verification activities. identifies typical risk critical equipment and the appropriate level of verification activities recommended to meet the verification objective and requirements. 3 This document is an object-specific service specification conforming to the philosophy defined in DNVGL-SE-0474 Risk based verification, see [5]. 2 Objectives 1 The objectives of this document are to: describe DNV GL s verification services for hydrocarbon refineries and petrochemical facilities during: design construction commissioning operations modification provide guidance for facility owners and other parties for the selection of the level of involvement of those carrying out verification activities, whether quantitatively as a result of a quantitative risk assessment or qualitatively by simple trigger questions provide a common platform for describing the scope and extent of verification activities. 3 Scope of application for verification 3.1 This SE may be adopted for the verification of all parts of all hydrocarbon refineries or types of petrochemical facilities or selected project phases. 3.2 This SE describes the principle of a levelled verification involvement, where the extent of verification involvement is linked to the risks associated with part or all of the facility. 3.3 The primary scope of DNV GL s verification work is the verification of the integrity of hydrocarbon facilities and the safety of its personnel and those in close proximity to it. Other aspects, such as the verification of the environmental impact of the facility, or its ability to meet the owner s business objectives, may be included in DNV s scope of work if desired by the owner. Service specification DNVGL-SE Edition August 2017 Page 6

7 3.4 Statutory verification (or certification) of hydrocarbon facilities to the requirements of national authorities is not included specifically in the scope of application of this SE. Such verification (or certification) shall be governed by the regulations of the relevant Authority. However, if detailed procedures are not given by these Authorities, this SE will be used by DNV GL as a guideline for its work. 4 Structure of this document 4.1 This document consists of three sections and five appendices: Sec.1, this section, explains the relationship between this document and DNV GL s overall risk based verification process. Sec.2 explains the principles of DNV GL s verification process with its risk based levels of involvement, and how the level of involvement for a particular project is defined. Sec.3 describes the verification process and the activities for each of the project phases. App.A gives guidance on the selection of verification level, preferably as the result from a quantitative risk assessment or alternatively, qualitatively as a result of the posing of trigger questions. App.B gives examples of verification documents. The use of quality management systems is addressed here. App.C gives a generic detailed scope of work tables for all phases and all levels of involvement. These tables are the basis for the development of project-specific scopes of work tables. App.D gives typical refinery hazards and their interface with safety-critical elements and risk mitigation measures. App.E gives guidance on the formulation of plans for the verification of the design, construction and commissioning of hydrocarbon facilities. 2 Risk based verification 1 General 1 This SE describes the principles of verification of the safety and integrity of hydrocarbon facilities for all phases. 2 The risk based verification concept is described in DNVGL-SE-0474 and visualized in Figure 1-1 overleaf. 3 The verification plan is the pivot element, with the asset specification, risk assessment and definition of verification involvement as input and the verification execution being the implementation. 2 Verification s role in hazard management 1 Major accident hazards are identified in a formal safety assessment by an analysis of the risks to the facility s personnel using suitable definitions of such accidents. 2 Safety-critical elements are those hardware-related measures, including computer software, designed to reduce the risk to the facility s personnel. 3 Performance standards are the definitions of how these safety-critical elements perform their risk reduction functions. 4 Verification plan is how an independent examination of these safety-critical elements is planned to confirm that they are suitable and fulfil the safety and integrity requirements of the facility s owner. A graphical representation of this process is shown in Figure 1-2 overleaf. Service specification DNVGL-SE Edition August 2017 Page 7

8 Guidance note: Further details of these terms are given in [E.2]. ---e-n-d---o-f---g-u-i-d-a-n-c-e---n-o-t-e--- Figure 1-1 DNV GL risk based verification flow chart Service specification DNVGL-SE Edition August 2017 Page 8

9 Figure 1-2 Verification as part of hazard management 3 Risk based verification planning 3.1 The selection of the level of verification shall depend on the level of risk a particular item adds to the overall risk to the facility. The planning can be simplified or detailed. This is further described in DNVGL- SE This service specification addresses both approaches as input into the preparation of a verification plan. Guidance note: Risk may be evaluated based on safety, environmental impact, business, schedule, public relations, reputation or other criteria set by the owner. The generic scopes of work tables are generated based on safety and integrity risks. Where other risks, such as environment or business, are required by the owner to be considered during the verification process, the principles set out in this document may be used to modify the generic scopes of work tables given in App.C. ---e-n-d---o-f---g-u-i-d-a-n-c-e---n-o-t-e In view of the complexity of most hydrocarbon facilities, DNV GL recommends strongly that the verification level be derived from the results of a quantitative risk assessment of the facility. Guidance note: Only in the simplest of hydrocarbon facilities, with consequently lower levels of risk would DNV GL consider that simplified qualitative verification planning using the trigger questions set out in App.A be justifiable. For novel technology for which there are no applicable standards to verify against, technology qualification according to procedures as defined in DNVGL-RP-A203 Technology qualification may be used as input for verification. ---e-n-d---o-f---g-u-i-d-a-n-c-e---n-o-t-e--- 4 Certificate of conformity 4.1 A certificate of conformity may be issued by DNV GL to confirm compliance according to the scope of work. An example is given in App.B. 4.2 The DNV GL certificate of conformity confirms that, after performing verification according to a DNV GL defined scope of work, DNV GL has found the hydrocarbon facility to conform to a given DNV GL standard or acceptable international standard. Service specification DNVGL-SE Edition August 2017 Page 9

10 4.3 Usually DNV GL performs the complete scope of work. However, in some circumstances, DNV GL may accept external independent review certificates, for example for pressure vessels. This shall be reflected in the certificate text. 4.4 A statement of conformity is issued in all instances where certificate of conformity is not applicable., see App.B for further details. 3 Definitions 3.1 Verbal forms Table 1-1 Definitions of verbal forms Terms shall should may Definition verbal form used to indicate requirements strictly to be followed in order to conform to the document verbal form used to indicate that among several possibilities one is recommended as particularly suitable, without mentioning or excluding others, or that a certain course of action is preferred but not necessarily required verbal form used to indicate a course of action permissible within the limits of the document 3.2 Terms Table 1-2 Definitions of terms Terms certificate of conformity Definition a document signed by a qualified party affirming that, at the time of assessment, the product or service met the stated requirements (BS 4778: Part 2), see [5] Guidance note: For this SE, a certificate is a short document (often a single page) stating compliance with specified requirements. The results from the associated verification activities shall be contained in a separate (single or multiple volumes) report. ---e-n-d---o-f---g-u-i-d-a-n-c-e---n-o-t-e--- commissioning (phase) commissioning completion construction (phase) design design (phase) the phase, after mechanical completion, where the facility is made ready for operation, this phase includes any contractual performance trials is the completion of the commissioning phase where the hydrocarbon facility is capable of performing to its design specification, this may include contractual performance trials all activities during construction, including fabrication, installation and testing up to mechanical completion all related engineering to design the facility including process, structural, mechanical, electrical and instrumentation disciplines as well as materials and corrosion an initial project phase that takes a systematic approach to the production of specifications, drawings and other documents to ensure that the facility meets specified requirements (including design reviews to ensure that design output is verified against design input requirements) Service specification DNVGL-SE Edition August 2017 Page 10

11 Terms fabrication hazard hazard and operability study (HAZOP) manufacture mechanical completion modifications Definition activities related to the assembly of objects such as structural assemblies, pressure vessels, piping or tanks. These may be built fully on-site or built offsite in parts and transferred to site for assembly or integration a physical situation with the potential to cause harm, such as injury or death to workers, damage to property, disruption of business or pollution of the environment the application of a formal systematic detailed examination of the process and engineering intention of new or existing facilities to assess the hazard potential of operation outside the design intention or malfunction of individual items of equipment and their consequential effects on the facility as a whole. is the making of articles or materials for the facility. In relation to hydrocarbon facilities, this typically refers to activities for the production of various components under contracts from one or more contractor or supplier is the completion of the construction phase (qv) where all equipment, such as pumps and compressors, may be energised and pressure vessels may be filled with their contents to enable commissioning to take place alterations to an existing hydrocarbon facility by modifying an existing part of the facility or adding new parts Guidance note: In hydrocarbon facilities, this is referred to frequently as upgrading. ---e-n-d---o-f---g-u-i-d-a-n-c-e---n-o-t-e--- operations (phase) risk risk reduction measures the phase when the facility is being used for the purpose for which it was designed the qualitative or quantitative likelihood of an accident or unplanned event occurring, considered in conjunction with the potential consequences of such a failure: in quantitative terms, risk is proportional to the quantified probability of a defined failure mode times its quantified consequence those measures taken to reduce the risks to the operation of the hydrocarbon facility and to the health and safety of 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: inherent safety prevention detection control mitigation emergency response. ---e-n-d---o-f---g-u-i-d-a-n-c-e---n-o-t-e--- safety objectives the safety goals in terms of functionality, reliability/availability and survivability for the design, construction and operation of the hydrocarbon facility including acceptance criteria for the level of risk acceptable to the owner Service specification DNVGL-SE Edition August 2017 Page 11

12 Terms verification Definition an examination to confirm that an activity, a product or a service is in accordance with specified requirements. Guidance note: The examination shall be based on information, which can be proved true, based on facts obtained through observation, measurement, test or other means. It should be noted that there is a distinct difference between verification and certification. The scope of work for verification is ultimately decided by the customer, while the scope of work for certification is ultimately decided by DNV GL (or the national authorities when DNV GL issues certificates on their behalf). ---e-n-d---o-f---g-u-i-d-a-n-c-e---n-o-t-e--- verification plan a plan, which defines the scope of the work for verification; it includes verification objectives, acceptance criteria, elements to be verified, level of involvement by party and type of verification activity 4 Abbreviations Table 1-3 Abbreviations Abbreviation CCTV D&ID D&ID ESD ESDV FEED FERA FGS FMEA HAZID HAZOP HVAC ICS NDT P&ID PCS PFD PFP PLEM closed circuit television ducting and instrumentation diagram ducting and instrumentation diagram emergency shutdown emergency shutdown valve front end engineering design fire and explosion risk assessment fire and gas system failure mode and effect analysis hazard identification hard and operability study heating, ventilation and air conditioning integrated control system non-destructive testing piping and instrumentation diagram process control system process flow diagram passive fire protection pipeline end manifold Service specification DNVGL-SE Edition August 2017 Page 12

13 Abbreviation PS PSD QRA SCE SIL SPM UFD UPS VAR VCE performance standard process shutdown quantitative risk assessment safety-critical element safety integrity level single point mooring utility flow diagram uninterruptible power supply verification activity report vapour cloud explosion 5 References Table 1-4 References Document code BS 4778 DNVGL-SE-0474 EN ISO 8402 ISO 9000 ISO 9001 ISO ISO TR Title Quality Vocabulary, Part 2 Quality Concepts and Related Definitions, 1991, British Standards Institute, London Health and Safety at Work etc Act 1974, HMSO London, ISBN The Offshore Installations (Safety Case) Regulations 2005, Statutory Instrument 2005 number 3117, HMSO London, ISBN A Guide to the Offshore Installations (Safety Case) Regulations 2005, HSE Books London, ISBN Council Decision 93/465/EEC of 22 July 1993 Concerning the Modules for the Various Phases of the Conformity Assessment Procedures and the Rules for the Affixing and Use of the CE Conformity Marking, which are Intended to be Used in the Technical Harmonisation Directives, Official Journal L 282 of 17/11/93. Risk based verification Metallic Products - Types of Inspection Documents, 2004, European Committee for Standardization, Brussels Quality -Vocabulary, 1994 (withdrawn), International Organization for Standardization, Geneva Quality Management Systems - Fundamentals and Vocabulary, 2005, International Organization for Standardization, Geneva Quality Management Systems - Requirements, 2008, International Organization for Standardization, Geneva Quality Management Systems Guidelines for Quality Plans, 2005, International Organization for Standardization, Geneva Guidelines for Quality Management System Documentation, 2001, International Organization for Standardization, Geneva Service specification DNVGL-SE Edition August 2017 Page 13

14 SECTION 2 PRINCIPLES OF RISK BASED VERIFICATION 1 Purpose of section 1 Objectives 1 The objectives of this section are to provide: an introduction to the principles of verification the safety and integrity of hydrocarbon refineries and petrochemical facilities, an introduction to the principles of risk based levels of verification activity and guidance on the selection of levels of verification. 2 Verification principles 1 Purpose of verification 1 Verification constitutes a systematic and independent examination of the various phases in the life of a hydrocarbon facility to determine whether it has sufficient integrity to meet its safety objectives. 2 Verification activities are expected to identify errors or failures in the safety and integrity-related work associated with the hydrocarbon facility and to contribute to reducing the risks to its operation and to the health and safety of personnel associated with it or in its vicinity. 3 Verification is primarily focused on integrity and human safety, but business risk (cost and schedule) may be addressed also if required by the owner. 2 Verification as a complementary activity 1 Verification shall be complementary to routine design, construction and operations activities and not a substitute for them. Therefore, although verification will take into account the work, and the assurance of that work, carried out by the owner and its contractors, it is possible that verification will duplicate some work that has been carried out previously by other parties involved in the hydrocarbon facility. 2 The verification plan shall be developed and implemented in such a way as to minimise additional work and cost, and to maximise its effectiveness. The development of the verification plan shall depend on the findings from the examination of quality management systems, the examination of documents and the examination of project activities. 3 Risk based levels of verification 3.1 To achieve a DNV GL certificate of conformity for a hydrocarbon facility a verification of the activities described by the scope of work defined within this SE first shall take place. 3.2 The level of verification activity is differentiated according to the overall risk to the facility and to individual parts of it. If the risk to the facility (or a particular part) is higher, the level of verification involvement is higher. Conversely, if the risk to the facility (or a particular part) is lower, the level of verification activities can be reduced, without any reduction in their effectiveness. Service specification DNVGL-SE Edition August 2017 Page 14

15 3.3 Verification of hydrocarbon facilities is categorised into low, medium and high. A summary of the levels of involvement is given in Table It is the prerogative of the owner of the hydrocarbon facility to choose the level of verification. The selection should consider the factors given in Sec.2 [3]. The selection of the most suitable verification level may be guided by using the information gained from a quantitative risk assessment, or alternatively qualitatively by trigger questions, as described in App.A. Further guidance is provided in DNVGL-SE-0474 Risk based verification. 3.5 Where DNV GL is issuing the certificate of conformity for the facility, DNV GL will decide on the appropriate scope and use the same type of questions to evaluate the suitability of the selected level. 3.6 Different levels of verification can be chosen for different phases of the hydrocarbon facility s design, construction or commissioning, or even within the same phase if necessary. For example, the design of a particular component or unit may be innovative and considered high risk whereas the construction and installation methods are well-known and considered low risk. The converse might be true also. 3.7 The level of verification can be reduced or increased during a phase if the originally chosen level is considered too rigorous or too lenient, as new information on the risks to the hydrocarbon facility becomes available. 3.8 Verification should be planned in close co-operation with the owner and each of its contractors, to provide a scope of work that is tailor-made to the schedule of each production process or activity, i.e. to make the verification activities, surveillance and hold points, an integrated activity and not a delaying activity. Guidance note: Many contractors have adequate quality control systems and quality control departments, with competent personnel to perform, for example, inspection at pressure vessel manufacturers. In that case, not all verification work need be done by DNV GL personnel. Where applicable, the various inspections may be carried out by competent persons other than DNV GL personnel. In that situation DNV GL s verification activities may comprise: reviewing the competence of the contractor s personnel, auditing their working methods and their performance of that work, and reviewing the documents produced by them. ---e-n-d---o-f---g-u-i-d-a-n-c-e---n-o-t-e Verification will direct greatest effort at those elements of the hydrocarbon facility whose failure or reduced performance will have the most significant impact on safety and integrity The degree of confidence placed in a certificate by its users depends on their degree of confidence in the verification carried out. Therefore, the level of verification will be stated on the certificate of conformity for the facility If more than one verification level has been used for a phase, then the lowest level will be reported on the facility s certificate, and the additional verification activities will be identified and described in the verification report. Service specification DNVGL-SE Edition August 2017 Page 15

16 3 Selection of level of verification 3.1 Selection factors 3.1 The selection of the level of verification shall depend on the criticality of each of the elements that have an impact on the management of hazards and associated risk levels of the facility. This is illustrated by Figure 2-1 below. 3.2 The contribution of each element shall be judged qualitatively and/or quantitatively and shall use, where possible, quantified risk assessment data to provide a justifiable basis for any decisions made. Table 2-1 s of verification - summary of involvement Low Medium High of involvement Review of general principles and production systems during design, construction and commissioning Review of principal design documents, construction and commissioning procedures and qualification reports Site attendance only during system testing Less comprehensive involvement than level medium Review of general principles and production systems during design, construction and commissioning Detailed review of principal and other selected design documents with support of simplified independent analyses Detailed review of construction and commissioning procedures Full time attendance during (procedure) qualification and review of the resulting reports Audit-based or intermittent presence at site Review of general principles and production systems during design, construction and commissioning Detailed review of most design documents with support of simplified and advanced independent analyses Detailed review of construction and commissioning procedures Full-time attendance during (procedure) qualification and review of the resulting reports Full time presence at site for most activities More comprehensive involvement than level medium Guidance for application on the level of involvement Proven facility designs with relatively harmless contents and/or installed in benign environmental conditions Established design; manufacturing and installation by experienced contractors Low consequences of failure from a safety point of view (or environmental or commercial, if required) Relaxed to normal completion schedule Facilities in moderate or well-controlled environmental conditions Facilities with a moderate degree of novelty Medium consequences of failure from a safety point of view, (or environmental or commercial, if required Ordinary completion schedule Facilities with a high degree of novelty or large leaps in technology Extreme environmental conditions Inexperienced contractors or exceptionally tight completion schedule Very high consequences of failure from a safety point of view (or environmental or commercial, if required Service specification DNVGL-SE Edition August 2017 Page 16

17 of involvement Guidance for application on the level of involvement Guidance note: Completion schedules affect verification involvement in an indirect but important way. The effect of a tight completion schedule is pressure on the project team to take less time to carry out the various tasks. Tight completion schedules are more prone to run late, thus adding more pressure on the project team. Problems which have been encountered in this situation in the past have included: design reviews not carried out incomplete welding non-destructive testing incomplete missing structural members commissioning incomplete. ---e-n-d---o-f---g-u-i-d-a-n-c-e---n-o-t-e Selection factors are the: overall safety objectives for the facility, assessment of the risks associated with the facility and the measures taken to reduce these risks, degree of technical innovation in the facility, experience of the contractors in carrying out similar work, quality management systems of the owner and its contractors. Figure 2-1 Selection of the required level of verification 3.2 Overall safety objective 3.1 An overall safety objective covering all phases of the hydrocarbon facility from design to operation shall be defined by the owner. The safety objective should address the main safety goals as well as establishing acceptance criteria for the level of risk acceptable to the owner. Depending on the facility and its location, the risk could be measured in terms of human injuries as well as environmental, political and economic consequences. Service specification DNVGL-SE Edition August 2017 Page 17

18 3.3 Assessment of risk A systematic review should be carried out to identify and evaluate the probabilities and consequences of failures in the hydrocarbon facility. The extent of the review shall reflect the criticality of the facility, the planned operation and previous experience with similar facilities. This review shall identify the risk to the operation of the facility and to the health and safety of personnel associated with it or in its vicinity Once the risks have been identified, their extent can be 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. Guidance note: Reasonable practicability The term as low as reasonably practicable (ALARP) has come into use through the United Kingdom s The Health and Safety at Work etc. Act See sec. E109. Reasonable Practicability is not defined in the Act but has acquired meaning by interpretations in the courts. It has been interpreted to mean that the degree of risk from any particular activity can be balanced against the cost, time and trouble of the measures to be taken to reduce the risk. Therefore, it follows that the greater the risk the more reasonable it would be to incur substantial cost, time and effort in reducing that risk. Similarly, if the risk were very small it would not be reasonable to expect great expense or effort to be incurred in reducing it. Further guidance on the principles and application of ALARP may be obtained from the United Kingdom s Heath and Safety Executive web-site at (July 2009). ---e-n-d---o-f---g-u-i-d-a-n-c-e---n-o-t-e The result of the systematic review of these risks is measured against the safety objectives and used in the selection of the appropriate verification activity level. 3.4 Technical innovation and contractor experience The degree of technical innovation in the hydrocarbon facility system shall be considered. Risks to the facility are likely to be greater for a facility with a high degree of technical innovation than with a facility designed, manufactured and installed to well-known criteria in well-known locations Similarly, the degree of risk to the facility should be considered where contractors are inexperienced or the work schedule is tight Factors to be considered in the selection of the appropriate verification level include: degree of difficulty in achieving technical requirements knowledge of similar facilities knowledge of contractors general experience knowledge of contractors experience in similar work. 3.5 Quality management systems Adequate quality management systems shall be implemented to ensure that gross errors in the work for facility design, construction and operations are limited. Service specification DNVGL-SE Edition August 2017 Page 18

19 3.5.2 Factors to be considered when evaluating the adequacy of the quality management system include: whether or not an ISO 9001, see [5] 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, e.g. has there been a rapid expansion of the work force or are all parties of a joint venture familiar with the same system. 4 Communications 4.1 Notification of verification level 4.1 An assessment of the required level of verification for a project should be made by the owner before preparing tender documents for design and construction activities. The owner can then specify this level in invitations to tender. This will give contractors clear guidance and reference when estimating the extent and cost of efforts associated with verification activities. 4.2 The required level of verification can be assessed by the owner using this SE. However, if the owner requires the contractor to carry out this assessment as part of his response to an invitation to tender the owner should provide the necessary information to enable the contractor to carry out this work. This information should include overall safety objectives for the hydrocarbon facility as well as particulars, such as temperatures, pressures, contents and environmental criteria, commonly contained in a design brief. 4.2 Obligations 4.1 To achieve the purpose and benefits of verification the involved parties shall be mutually obliged to share and act upon all relevant information pertaining to the verification scope. 4.2 The owner shall be obliged to: Inform DNV GL about the basis for selecting the level of verification and the investigations and assumptions made in this context. Give DNV GL full access to all information concerning the verification scope for the hydrocarbon facility and ensure that clauses to this effect are included in contracts for parties acting on behalf of the owner and parties providing products, processes and services covered by the verification scope. If information is proprietary and not available, exclusion from verification shall be mutually agreed with DNV GL. Ensure that DNV GL is involved in the handling of deviations from specified requirements within the verification scope. Act upon information provided by DNV GL with respect to events or circumstances that may jeopardise the safety or integrity of the facility and/or the purpose and benefit of verification Ensure that the safety objective established for the facility is known and pursued by parties acting on behalf of the owner and parties providing products, processes and services covered by the verification scope. 4.3 Second parties shall be obliged to: Perform their assigned tasks in accordance with the safety objectives established for the project. Provide the owner and DNV GL with all relevant information pertaining to the verification scope. Service specification DNVGL-SE Edition August 2017 Page 19

20 4.4 DNV GL will be obliged to: Inform the owner if, in the opinion of DNV GL, the basis for selecting the level of verification or the assumptions made in this respect are found to be in error or assessed incorrectly. Inform the owner of events or circumstances that, in the opinion of DNV GL, may jeopardise the safety or integrity of the facility and/or the purpose and benefit of verification. Effectively perform all verification work and adjust the level of involvement according to the actual performance of parties providing products, processes and services covered by the verification scope. Service specification DNVGL-SE Edition August 2017 Page 20

21 SECTION 3 SERVICE OVERVIEW 3.1 Purpose of section 3.1 Objectives 3.1 The objectives of this section are to provide, for hydrocarbon refining and petrochemical facilities: an overview of verification activities details of DNV GL s verification activities for aspects of the facility s development, operation or modification. 3.2 Service process 3.1 General principles 3.1 The process of DNV GL s verification of hydrocarbon facilities is based on distinct project phases and the recognition of key milestones. 3.2 The risk based verification process follows the common project phases: FEED (optional): conceptual design. Project design and construction: project management detail design construction manufacturing and fabrication of components and assemblies site assembly and integration. Project completion: commissioning issue of as-built and as-installed documentation. Facility operations: operations, maintenance and inspection. Facility modifications: design, construction and commissioning of modifications and alterations. Verification tasks need not be performed as part of a complete verification (or certification) of a hydrocarbon facility but can be stand-alone service for all or part of a project. 3.2 Scopes of work 3.1 An overview of the scopes of work for verification, at the three levels of verification low (L), medium (M) and high (H), are given in the tables in this section. 3.2 Note that the activity audit of the quality management system may be omitted if there exists a quality management system in accordance with ISO 9001, certified by an accredited third party for the scope of work being carried out in the project. Service specification DNVGL-SE Edition August 2017 Page 21

22 3.3 Typical generic detailed scopes of work descriptions, which show all the activities to be verified, are given in App.C. 3.4 A specific scope of work description shall be made for each particular project. This description should be similar to the tables in App.C and will be part of the final DNV GL verification report. 3.5 For operations which are not mentioned specifically in the tables but which are still found critical for a particular project the same general levels will be described. 3.3 Front end engineering design Verification during front end engineering design Verification during front end engineering design (FEED), or the conceptual and/or feasibility studies of a project, is not a prerequisite for verification. However, verification of the early stages of a project can reduce the extent, depth and cost of verification required during the design, construction and commissioning phases or indicates areas where verification would be difficult to achieve without further work being undertaken Design verification during FEED can be combined with additional reviews, where required by the owner, of: environmental aspects project schedule cost The FEED design documents shall be reviewed on a sample basis to ensure that the requirements of the project s specifications and standards have been incorporated Verification during FEED is the examination of the assumptions, methods and results of the design process and is performed to ensure that the specified requirements of the project will be achieved FEED verification will consist of one, or more, of reviewing: specifications for design design reports and drawings calculations specifications for construction and operation, resulting from design Definition of the scope of work for verification of FEED will follow Table 3- Table 3-1 Scope of work for verification of FEED Verification activity L M H Review of reports and specifications for construction and operation 1) spot check of critical aspects x x x spot check review of main specifications and reports x x thorough review of main specifications and reports x Service specification DNVGL-SE Edition August 2017 Page 22

23 Verification activity L M H 1) Services related to safety and integrity risks only. However, optional verification services, relating to environmental, business or other risks, when requested by the owner, may be carried out in the same manner. 3.4 Project design, construction and commissioning General All design, construction and commissioning aspects, relevant to hydrocarbon facility safety and integrity, shall be covered by the verification process Verification describes the individual activities undertaken by DNV GL at the various stages of the design, construction and commissioning of the hydrocarbon facility to confirm that the safety and integrity requirements of the owner have been fulfilled Verification of overall project management Verification of the overall project management is the examination of the means of controlling the whole hydrocarbon facility project This verification is to ensure that the necessary controls are in place to ensure information flows between the various interfaces. This is especially important where separate contractors have been employed for different phases of the project Definition of the scope of work for verification of overall project management will follow Table 3- Table 3-2 Scope of work for verification of overall project management Verification activity L M H Review of the project management process review of project quality management documentation. x x x audit of the quality management system x x review of sub-contractor control x x review of interface controls x x review of methods of information flow including document control x x Service specification DNVGL-SE Edition August 2017 Page 23

24 3.4.3 Verification during design Design verification is the examination of the assumptions, methods and results of the design process and is performed at the specified level of verification to ensure that the specified requirements of the hydrocarbon facility will be achieved Design verification will consist of one or more, of the following: reviewing the design process reviewing specifications for design reviewing design reports and drawings review of technology qualification program and associated results (for new technology) performing independent parallel calculations audit of project quality management system reviewing specifications for construction and operation, resulting from design Typical design aspects that shall be verified during the design of hydrocarbon processing are: Civil and structural: geotechnical report civil works and foundations structures. Plant facilities: general plant layout and equipment process safety systems emergency shutdown and alarm systems hazardous area classification and ventilation. passive and active fire protection philosophy fire and gas detection and alarm system electrical system emergency lighting process and utility piping systems mechanical system material selection and corrosion management Definition of the scope of work for verification of design will follow Table 3-3. Table 3-3 Scope of work for verification of design Verification activity L M H Review of the design process review of design quality management documentation x x x audit of design quality management system x x Review of specifications for design review of the design basis with emphasis of the survey results and environmental data: evaluation of the design criteria x x x Service specification DNVGL-SE Edition August 2017 Page 24

25 Verification activity L M H Review of design reports and drawings review of the main documentation to ensure that the main criteria have been accounted for in design, that the governing conditions are identified, and that the chosen design philosophies are in accordance with specified codes and standards x x x evaluation of the main methods used and spot checks of the input data and the calculation results x x detail review of main design reports x Performing independent parallel calculations check of pressure containment or overall integrity x x x simplified independent analysis/ calculation(s) performed by spot checks x x advanced independent analysis/ calculation(s) performed by spot checks x Review of specifications for construction and operation spot check of critical aspects x x x review of main specifications x x thorough review of main specifications x Review of specific operational challenges general principles x x x review of main documents supported by simplified analyses x x Guidance note: Design verification activities may be split up between basic design and detailed design, or other sub-phase, depending on type of contract. ---e-n-d---o-f---g-u-i-d-a-n-c-e---n-o-t-e Verification during construction Verification during construction is carried out by means of full time attendance, audits, inspection or spot checks of the work, as appropriate, in sufficient detail to ensure that the specified requirements of the hydrocarbon facility will be achieved Verification of these activities relates not only to the contractor s work but also to the monitoring of this work carried out by the owner During construction verification shall consist of one, or more, of: reviewing the construction process reviewing construction procedures reviewing qualification processes and results surveillance during construction activities reviewing final documentation. Service specification DNVGL-SE Edition August 2017 Page 25

26 Typical site activities to be verified during construction and up to mechanical completion are: Civil and structural: civil and structural works equipment supports storage tank foundations structural fire protection. Mechanical: mechanical equipment installation process piping installation welding procedures qualification and control welders qualification and welders identification control welding quality records non-destructive testing methods and reports pressure and leak tests of process piping system set pressures for relief valves. Electrical and instrumentation: electrical equipment and instrumentation in hazardous areas insulation resistance and continuity tests on equipment and cables equipment earthing electrical installation work relevant tests of electrical and instrumentation equipment, especially calibration of instruments and setting of protective devices if any. Common: material control and identification system final inspection reports of procured items The documents that should be produced in the project and submitted for review typically are: construction procedures and method statements; including test requirements, test procedures and acceptance criteria, repairs, personnel qualification records, etc. material specifications and data sheets drawings quality plans including Inspection and test plans welding procedure specifications and welding procedure qualification record NDT procedures The final documentation to be submitted after construction that should reflect the as-built status of the facility, should include but not be limited to: construction test records; visual, NDT, test samples, dimensional, heat treatment, etc. hydrostatic test reports as-built drawings Definition of the scope of work for verification of construction shall follow Table 3-4 for manufacturing and fabrication of critical, high-risk, components, Table 3-5 for manufacturing and fabrication of components not considered to be high-risk and Table 3-6 for site construction activities Component risk of shall be defined preferably by a quantitative risk assessment but qualitative methods may be used for lower-risk facilities. Service specification DNVGL-SE Edition August 2017 Page 26

27 Table 3-4 Scope of work for verification of manufacturing and fabrication of HIGH-RISK components Verification activity L M H Review of the manufacturing and fabrication process Review of manufacturing and fabrication management systems x x x Audit of the quality management system x x Review of manufacturing and fabrication procedures Review manufacturing, fabrication and inspection procedures for confirmation of compliance with the manufacturing specification x x x Review method statements x x Review of qualification process Review the manufacturing procedure specification, (MPS), manufacturing procedure qualification test (MPQT), if applicable x x x Full time attendance during MPQT, if applicable, or first day production x x Surveillance during manufacturing and fabrication activities Visit-based attendance during testing, to ensure, based on spot checks, that the delivered products have been produced in accordance with the manufacturing specification x x x Visit-based or full-time attendance during manufacturing and fabrication to ensure, based on spot checks, that the delivered products have been produced in accordance with the manufacturing specification Full-time attendance during manufacturing and fabrication to ensure, based on spot checks, that the delivered products have been produced in accordance with the manufacturing specification x x x Review of final documentation x x x Guidance note: Materials may be ordered with certificates of independent third-party verification (e.g. 3.2 according to EN 10204, see [5]). This can this be integrated in the overall verification activities, so not to duplicate work. Additionally, credit may be given to components that are CE-marked, providing that the appropriate conformity assessment modules have been used, e.g. for equipment for which the verification plan requires verification of design, Module H is insufficient and Module H1 is required, irrespective of the requirement of the particular directive see [5]. ---e-n-d---o-f---g-u-i-d-a-n-c-e---n-o-t-e Verification during commissioning Verification during commissioning is carried out by means of full time attendance, audits, inspection or spot checks of the work, as appropriate, in sufficient detail to ensure that the specified requirements of the hydrocarbon facility will be achieved. Service specification DNVGL-SE Edition August 2017 Page 27