Shipboard incinerators with capacities up to 4000 kw

Transcription

1 STANDARD FOR CERTIFICATION No. 2.9 Approval Programmes Type Approval Programmes for Marine Equipment Directive (MED) No MED A.1/2.7 Shipboard incinerators with capacities up to 4000 kw JANUARY 2015 The electronic pdf version of this document found through is the officially binding version The content of this service document is the subject of intellectual property rights reserved by Det Norske Veritas AS (DNV). The user accepts that it is prohibited by anyone else but DNV and/or its licensees to offer and/or perform classification, certification and/or verification services, including the issuance of certificates and/or declarations of conformity, wholly or partly, on the basis of and/or pursuant to this document whether free of charge or chargeable, without DNV's prior written consent. DNV is not responsible for the consequences arising from any use of this document by others.

2 FOREWORD DNV is a global provider of knowledge for managing risk. Today, safe and responsible business conduct is both a license to operate and a competitive advantage. Our core competence is to identify, assess, and advise on risk management. From our leading position in certification, classification, verification, and training, we develop and apply standards and best practices. This helps our customers safely and responsibly improve their business performance. DNV is an independent organisation with dedicated risk professionals in more than 100 countries, with the purpose of safeguarding life, property and the environment. Standards for Certification Standards for Certification (previously Certification Notes) are publications that contain principles, acceptance criteria and practical information related to the Society's consideration of objects, personnel, organisations, services and operations. Standards for Certification also apply as the basis for the issue of certificates and/or declarations that may not necessarily be related to classification. Det Norske Veritas AS January 2015 Any comments may be sent by to rules@dnv.com This service document has been prepared based on available knowledge, technology and/or information at the time of issuance of this document, and is believed to reflect the best of contemporary technology. The use of this document by others than DNV is at the user's sole risk. DNV does not accept any liability or responsibility for loss or damages resulting from any use of this document.

3 CHANGES CURRENT Page 3 CHANGES CURRENT General This is a new document. Det Norske Veritas AS, company registration number , has on 27 th November 2013 changed its name to DNV GL AS. For further information, see Any reference in this document to Det Norske Veritas AS or DNV shall therefore also be a reference to DNV GL AS.

4 Contents Page 4 CONTENTS CHANGES CURRENT Scope Conformity assessment of design of product type Procedure Documents to be submitted Design requirements Requirements to product marking Elements of type approval Design assessment Type testing Type approval certificate EC conformity assessment procedure EU certification scheme Definitions Entry into force of EU directive on marine equipment CE marking - Wheel marking Certification of shipboard incinerators according to the EU directive on marine equipment Design phase Module B - Type-examination Production phase Module D - Production quality assurance Module E - Product quality assurance Module F - Product verification Module G - Unit verification... 9 App. A Test specification App. B EU Marine equipment - Application form 43.44a... 12

5 Sec.1 Scope Page 5 1 Scope This type approval programme gives the requirements on which DNV bases its type approval for issuance of certificates according to the Marine Equipment Directive, 96/98/EC, as amended, for shipboard incinerators, listed as A.1/2.7 in the Annex A.1.2 Marine Pollution Prevention. The conditions outlined in this programme shall be fulfilled before the EC Type-Examination certificates are issued. The procedure for assessment of conformity of manufactured products (production) is not part of the scope for the type approval programme. 2 Conformity assessment of design of product type 2.1 Procedure Type approval procedure consists of the following elements: design assessment type testing 2.2 Documents to be submitted The following documentation is to be submitted electronically: EU Marine Equipment - Application Form (see App.B for example form): 43.44a Test proposal for capacity and emission test, according to App.A, including laboratory accreditation certificate Test proposal for safety and control test, according to App.A Test proposal for visual inspection, according to App.A Functional description of all essential parts of the equipment Assembly drawings showing main dimensions and equipment arrangement Piping diagrams with material list Mechanical drawings with material lists of all mechanical components and with material list Electrical system and instrumentation layout and diagrams and list of components Drawings of warning plates and instruction plate(s) for incinerator Operation, installation and maintenance manual with drawings, electric diagrams, spare-part lists etc. and including routine maintenance Hardware, firmware and software revision information, as applicable, necessary to identify the equipment under test. Specification if the incinerator is batch or continuous loaded. Special operational limitations, if any. Reports with results from capacity and emission test, prototype safety and control test and visual inspection according to App.A. The test proposals are to be approved well in advance before testing. The submitted documentation will be evaluated in accordance with this type approval programme and other applicable rules. The documentation to be submitted by the manufacturer shall be clearly labelled and divided in such a way that all elements below can be easily identified. All drawings and descriptions are to be marked with drawing number, item name, revision no. and/or issue date, etc. The documentation shall be generic drawings suitable for a type approval. Guidance note: Where a range of incinerators of the same design, but of different capacities, are to be type approved in accordance with these specifications, full documentation according to the above list is required for each capacity and will be listed on the certificate. If identical drawings with the same drawing numbers applies to several capacities, this should be clearly indicated by the manufacturer. ---e-n-d---of---g-u-i-d-a-n-c-e---n-o-t-e Design requirements The shipboard incinerator is to comply with relevant requirements of the following publication as amended: IMO Resolution MEPC.244(66) (2014 Standard Specification for Shipboard Incinerators).

6 Sec.2 Conformity assessment of design of product type Page Requirements to product marking The final product shall be provided with visible marking, which completely identifies the product and its components according to drawings/equipment specification. The marking shall give at least the following information: identification of manufacturer equipment type designation or model identification capacity (net design heat release) serial number revision information, as applicable, for all firmware or software modules installed per hardware unit, necessary to identify the equipment, permanently marked somewhere on the final product. 2.5 Elements of type approval Design assessment Design assessment based on the documentation requested in [2.2] is to assess that the design of the product conforms with the rules and standards as described in [2.3] Type testing The type testing (TT) comprises: capacity and emission test safety and control test visual inspection. As test site the following may be accepted: A European Laboratory accredited by an EA (European Accreditation) member. A non-european laboratory accredited by an organization who has signed an MLA (multilateral agreement) with EA. A laboratory having the quality system approved by DNV based on EN ISO/IEC A Statement of Recognition shall be issued. A laboratory recognized/certified by his country Marine Administration provided acceptance by the responsible approval unit. Testing at a non-recognized/certified laboratory providing the testing is witnessed by a branch expert DNV surveyor and such arrangement is to be approved by the responsible approval unit prior to testing. Testing carried out on site or at the manufacturer s premises providing the test set-up is approved and the testing is witnessed by a branch expert DNV surveyor. Such arrangement is to be approved by the responsible approval unit before testing. The above tests shall be documented by a test report issued by the laboratory, or by the manufacturer if testing is carried out at the manufacturer s premises. If the testing is witnessed by DNV, the reports shall be signed and stamped by the DNV representative. All test reports shall include the type designation or model identification of the equipment tested. The test reports from the capacity and emission test and the safety and control test shall include hardware, firmware and software revision information, as applicable, necessary to identify the equipment under test. It is the manufacturer s responsibility to ensure that the testing/inspection is performed according to the requirements. Note: Where a range of incinerators of the same design, but of different capacities, are to be type approved in accordance with these specifications, full type testing of minimum two capacities within the range may be accepted, on the condition that the two tests performed are from the lowest quarter and highest quarter of the capacity range. This applies to the capacity and emission test and the safety and control test. The visual inspection may be performed on only one capacity. ---e-n-d---of---n-o-t-e Capacity and emission test Tests are to be carried out to verify that the capacity and emission of the test sample conforms with capacity specifications and with the requirements of the IMO standards, see test specification in App.A. Note: As specified in MEPC.244(66) Annex 1.3, the requirement for duration of the test operation is 6-8 hours for burning of both sludge oil and solid waste. The requirements to the contents of sludge oil and solid waste are specified in

7 Sec.3 EC conformity assessment procedure Page 7 MEPC.244(66) Annex 1.4. The test report shall specify the duration of the test operation and the fuel/waste contents specification applied in the test. ---e-n-d---of---n-o-t-e Safety and control test Tests are to be carried out to verify that the test sample conforms with the control and safety requirements of the IMO standards, see test specification in App.A. Testing may be carried out on site or at the manufacturer s premises providing the test set-up is approved by, the test is witnessed by, and the test report is signed and stamped by, a branch expert DNV surveyor. Note: The safety and control test is a requirement in MEPC.244(66) Sec. 7.1 (prototype test), and the test requirements in 7.1 are identical to those listed in 7.3 (installation test). The safety and control test is conducted to ensure that all of the control components have been properly installed and that all parts of the incinerator, including safety and control devices, are in satisfactory operating condition. ---e-n-d---of---n-o-t-e Visual inspection Visual inspection is to be carried out to verify the items listed in the table of Visual inspection in App.A conform with the IMO requirements. The visual inspection is to be performed by a branch expert DNV surveyor. The test report is to be signed and stamped by the DNV surveyor. The visual inspection may be carried out on site or at the manufacturer s premises providing the test set-up is approved by the DNV surveyor Type approval certificate When the design assessment and type testing are successfully completed, a type approval certificate will be issued to the manufacturer for the conformity of the design of the product type. 3 EC conformity assessment procedure 3.1 EU certification scheme 3.2 Definitions Notified Body (NB): means an organisation designated by the competent national administration of a Member State to undertake conformity assessment procedures of equipment specified in the EU directive on marine equipment. Such equipment may then be used on board ships registered in any Member State within the European Economic Area (EEA). Conformity Assessment Procedures: means those procedures necessary to obtain an EC Type-Examination Certificate, QS-Certificate of Assessment - EC, Certificate of Conformity - EC and the manufacturer s Declaration of Conformity necessary for affixing the mark of conformity. The conformity assessment is subdivided into modules which relate to the design and production phases. Modules: The certification scheme specifies different modules to be followed. There is a variety of modules covering the design and production phases, and the manufacturer may choose between different modules, dependent on type of product, the nature of the risk involved etc. 3.3 Entry into force of EU directive on marine equipment The EU Council Directive 96/98/EC on Marine Equipment (in force from and mandatory from ) includes the above product, and detailed testing standards in International instruments have already been worked out. The standards are specified in [2.3]. 3.4 CE marking - Wheel marking CE marking (mark of conformity, a ship wheel) of this product may be carried out by DNV as Notified Body. The Directive is mandatory for the products when they are put on board new or existing ships not previously carrying such equipment, or where it replaces equipment previously carried on board, when the ship is flying the flag of any EEA (EU + EFTA) member state. The manufacturer or its authorised representative established within the community shall affix the wheel mark to each product and draw up a written declaration of conformity at the end of the production phase. The wheel shall be followed by the DNV identification number as Notified Body when involved in the

8 Sec.4 Certification of shipboard incinerators according to the EU directive on marine equipment Page 8 production control phase, and by the last two digits of the number of the year in which the mark is affixed (XX). See example below: 0575/XX 4 Certification of shipboard incinerators according to the EU directive on marine equipment For certification of such equipment the EU Directive will require compliance with Modules B + D, or Modules B + E, or Modules B + F or Module G. The DNV type approval will satisfy the EC type-examination required in Module B. A summary of Modules B, D, E, F and G is also made below. On request, further details of these EU Modules will be given by the local DNV surveyor. 4.1 Design phase Module B - Type-examination DNV s type approval procedure is equal to Module B (EC type-examination) referred to in the EU Council Directive on Marine Equipment. Renewal of an EC type-examination certificate (validity 5 years) will be based on a statement from the manufacturer confirming that no change has been made to the design of the product. If the manufacturer wants to change the design, the manufacturer shall apply for approval of the change. New/ updated documentation shall be submitted to the responsible approval unit. The revised design shall be approved prior to selling any products based on the revised design. 4.2 Production phase For the production phase the manufacturer may choose between modules D, E, F and G. If modules D and E are chosen, DNV as the Notified Body may approve his quality system (QS) and will then arrange with the necessary details, making it possible to affix wheel mark. For all modules, the manufacturer shall draw up a declaration of conformity and affix the mark of conformity. 4.3 Module D - Production quality assurance If the manufacturer operates an approved QS for production and testing equivalent to the requirements in EN ISO 9001 (e.g. approved by DNV as the Notified Body), Module D may be used. DNV shall issue a QS Certificate of Assessment - EC Module E - Product quality assurance If the manufacturer operates an approved QS for inspection and testing equivalent to the requirements in EN ISO 9001 (e.g. approved by DNV as the Notified Body), Module E may be used. DNV shall issue a QS Certificate of Assessment - EC Module F - Product verification Necessary measures shall be taken by the manufacturer, in order that the manufacturing process ensures conformity of the products with the type as described in the EC type-examination certificate (Module B). DNV as the Notified Body shall carry out the appropriate examinations and tests in order to check the conformity of the product with the requirements of the International instruments either by examination and testing of every product, or by examination and testing of products on a statistical basis. DNV shall issue a Certificate of Conformity - EC.

9 Sec.4 Certification of shipboard incinerators according to the EU directive on marine equipment Page Module G - Unit verification This Module is used for equipment being produced in small quantities. The unit verification consists of two elements: assessment of technical documentation examination and test of the equipment concerned Examination of technical documents by DNV Examination of technical documents to ensure that the design of a product or system conforms with the specified requirements will be carried out by branch experts Examination and test of equipment The notified body shall examine the individual product and carry out appropriate tests to ensure that it complies with the relevant requirements of the International requirements specified in Annex B to the directive, Module G Certificate of conformity/ CE marking DNV will issue a certificate of conformity.

10 App.A Test specification Page 10 Appendix A Test specification The manufacturer shall, unless otherwise agreed, set up the equipment and ensure that it is operating normally before type testing commences. Please see the full specification of the test requirement in the MEPC.244(66) references. Tests/inspections to be carried out C. Capacity and emission test No TEST Specification of test Status Comments C.1 Max capacity sludge oil burning MEPC.244(66) Annex 1.2 C.2 Max capacity solid waste burning MEPC.244(66) Annex 1.2 C.3 Pilot fuel consumption per burner MEPC.244(66) Annex 1.2 C.4 O2 average in combustion chamber MEPC.244(66) Annex 1.2 C.5 CO average in flue gas MEPC.244(66) Annex 1.2 C.6 Soot number average MEPC.244(66) Annex 1.2 C.7 Combustion chamber flue gas outlet temperature average MEPC.244(66) Annex 1.2 C.8 Amount of unburned components in ashes MEPC.244(66) Annex 1.2 Solid waste only S. Safety and control test No TEST Specification of test Status Comments S.1 Flame failure MEPC.244(66) , , S.2 Ignition failure MEPC.244(66) , , S.3 Trial-for-ignition period MEPC.244(66) S.4 Number of possible automatic restarts after flame safeguard control has operated MEPC.244(66) S.5 Type of flame detector MEPC.244(66) S.6 Lower the fuel oil pressure MEPC.244(66) , S.7 Charging lock MEPC.244(66) 3.10, S.8 Interlock to prevent the charging door from opening MEPC.244(66) 3.10, S.9 Interlock on ash removal doors MEPC.244(66) 3.12, S.10 Other interlocks (specify) MEPC.244(66) S.11 Flue gas temperature controller MEPC.244(66) , S.12 Combustion temperature controller MEPC.244(66) , S.13 Preheat temperature of combustion chamber MEPC.244(66) 4.1, For continuous-loaded incinerator only S.14 Temperature in the actual combustion space within 5 minutes after start MEPC.244(66) 4.1, For batch-loaded incinerator only S.15 Prepurge requirements MEPC.244(66) 4.1, S.16 Time between restarts requirements MEPC.244(66) 4.1, S.17 Postpurge requirements MEPC.244(66) 4.1, S.18 Shock-cooling of flue gas MEPC.244(66) 4.7, 7.3.4

11 App.A Test specification Page 11 S. Safety and control test (Continued) No TEST Specification of test Status Comments S.19 Fuel supply controls MEPC.244(66) S.20 Low-voltage test MEPC.244(66) 7.3.6, DNV rules Pt.4 Ch.8 Sec.2 B204 S.21 Disconnection switch MEPC.244(66) , 5.1, S.22 Emergency stop switch MEPC.244(66) 5.2, S.23 Negative pressure switch MEPC.244(66) 3.9, 4.4, , S.24 Other switches (specify) MEPC.244(66) S.25 Wall temperature protection and outside MEPC.244(66) surface temperature 3.4, 4.3 S.26 Outlet for audible alarm MEPC.244(66) S.27 Visible indicators MEPC.244(66) S.28 Manual reset of visible indicators MEPC.244(66) S.29 Cooling of fire box MEPC.244(66) 5.6 S.30 Safety shutdown if loss of power MEPC.244(66) Either the incinerator is unaffected by voltage variations in the range of -15% to +20%, or the incinerator undergoes a safety shutdown Also verify that flue gas fan can restart independently V. Visual inspection No TEST Specification of test Status Comments V.1 Protection from rotating/moving and MEPC.244(66) 3.3 electrical parts V.2 Easy internal maintenance MEPC.244(66) 3.8 V.3 Feeding system is not dangerous MEPC.244(66) 3.10, 3.11 V.4 Feeding sluice/system ensures that material charged moves to the combustion chamber MEPC.244(66) 3.11 V.5 Safe observation port MEPC.244(66) 3.13 V.6 Terminal leads/screws MEPC.244(66) V.7 Grounding MEPC.244(66) , V.8 Colour of insulated conductor MEPC.244(66) V.9 Warning plates against unauthorized opening of doors and against overloading MEPC.244(66) 4.5 V.10 Instruction plates addressing cleaning ashes/ slag, combustion air openings, operating procedures including those for start-up, normal shut-down, emergency shut-down, and loading of garbage V.11 Revision information, as applicable, for all firmware or software modules are installed per hardware unit, necessary to identify the equipment, permanently marked somewhere on the final product MEPC.244(66) 4.6, 4.6.1, 4.6.2

12 App.B EU Marine equipment - Application form 43.44a Page 12 Appendix B EU Marine equipment - Application form 43.44a EU MARINE EQUIPMENT APPLICATION FORM Notified Body No Council Directive 96/98/EC on Marine Equipment, as amended Applicant: Manufacturer: Place where manufactured: Applicant is to be authorised by the manufacturer to act on his behalf. Authorisation: Enclosed Conformity Assessment Module(s): GN EC Type-Examination (Module B) Approval of Quality System: module D or module E Certificate of conformity: module F or module G US Coast Guard approval according cording to the US/EEA EFTA Mutual Recognition Agreement (if applicable) Documentation submitted: MED Item No.: Equipment: Technical documentation (module B, D, E, F and G) Quality system documentation (module D and E) ILLUSTRATION T N ONLY Type designation: Standards to which the equipment is to be certified: This picture is provided solely for illustration. It may deviate somewhat from the e current version of the illustrated form The undersigned agrees to comply with the requirements for assessment and to supply any information needed for evaluation of the product/system to be assessed. It is understood that DNV GL has the right to charge for its services including cases where the equipment proves not to be in accordance with the requirements. The undersigned hereby declares that the information given in this document is correct, and that the same application has not been lodged with any other body. DNV GL DNV GL AND THE HORIZON GRAPHIC ARE TRADEMARKS OF DNV GL AS. Form No.: 43.44a Issue: May 2014 Page 1 of 2

13 App.B EU Marine equipment - Application form 43.44a Page 13 EU MARINE EQUIPMENT APPLICATION FORM Place: Date: for the applicant (name) (title) ILLUSTRATION ONLY This picture is provided solely for illustration. It may deviate somewhat from the current version of the illustrated form Form No.: 43.44a Issue: May 2014 Page 2 of 2