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SERVICE SPECIFICATION DET NORSKE VERITAS DNV-DSS-314 VERIFICATION OF HYDROCARBON REFINING AND PETROCHEMICAL FACILITIES OCTOBER 2010
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Page 1: DNV DSS-314 (2010) - Verification of Hydrocarbon Refining and Petrochemical Facilities

SERVICE SPECIFICATION

DET NORSKE VERITAS

DNV-DSS-314

VERIFICATION OF HYDROCARBON REFINING

AND PETROCHEMICAL FACILITIES

OCTOBER 2010

Page 2: DNV DSS-314 (2010) - Verification of Hydrocarbon Refining and Petrochemical Facilities

FOREWORD

DET NORSKE VERITAS (DNV) is an autonomous and independent foundation with the objectives of safeguarding life,property and the environment, at sea and onshore. DNV undertakes classification, certification, and other verification andconsultancy services relating to quality of ships, offshore units and installations, and onshore industries worldwide, andcarries out research in relation to these functions.

DNV service documents consist of amongst other the following types of documents:— Service Specifications. Procedual requirements.— Standards. Technical requirements.— Recommended Practices. Guidance.

The Standards and Recommended Practices are offered within the following areas:A) Qualification, Quality and Safety MethodologyB) Materials TechnologyC) StructuresD) SystemsE) Special FacilitiesF) Pipelines and RisersG) Asset OperationH) Marine OperationsJ) Cleaner EnergyO) Subsea Systems

The electronic pdf version of this document found through http://www.dnv.com is the officially binding version© Det Norske Veritas

Any comments may be sent by e-mail to [email protected] subscription orders or information about subscription terms, please use [email protected] Typesetting (Adobe Frame Maker) by Det Norske Veritas

If any person suffers loss or damage which is proved to have been caused by any negligent act or omission of Det Norske Veritas, then Det Norske Veritas shall pay compensation tosuch person for his proved direct loss or damage. However, the compensation shall not exceed an amount equal to ten times the fee charged for the service in question, provided thatthe maximum compensation shall never exceed USD 2 million.In this provision "Det Norske Veritas" shall mean the Foundation Det Norske Veritas as well as all its subsidiaries, directors, officers, employees, agents and any other acting on behalfof Det Norske Veritas.

Page 3: DNV DSS-314 (2010) - Verification of Hydrocarbon Refining and Petrochemical Facilities

Service Specification DNV-DSS-314, October 2010Changes – Page 3

BackgroundThe experience gained from past projects specific to an oil refinery and a petrochemical plant is incorporatedin this Service Specification.

Scope of documentThis Service Specification:

— describes DNV'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 quantitativerisk 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.

Changes Two new DNV service document types have been introduced as from October 2010 to be used for services thatare not limited to offshore and/or not to be considered as DNV Rules for classification of Ships or HSLC/NSC.The documents have been named; DNV Service Specifications (DSS) and DNV Standards (DS).This service specification; DSS-314: “Verification of Hydrocarbon Refining and Petrochemical Facilities”replaces the previous version of the document with short name; DNV-OSS-314. There are no changes incontent, only how the document is referred to, as OSS now will be used for Service Specifications intended forOffshore use.

DET NORSKE VERITAS

Page 4: DNV DSS-314 (2010) - Verification of Hydrocarbon Refining and Petrochemical Facilities

Service Specification DNV-DSS-314, October 2010 Page 4 – Contents

CONTENTS

Sec. 1 Introduction To Risk-based Verification ......................................................................................... 8

A. Introduction..................................................................................................................................................................... 8A 100 Function of this Document ................................................................................................................................... 8A 200 Objectives ............................................................................................................................................................. 8A 300 Scope of Application for Verification................................................................................................................... 8A 400 Structure of this Document ................................................................................................................................... 8

B. Risk-based Verification................................................................................................................................................... 9B 100 General.................................................................................................................................................................. 9B 200 Verification’s Role in Hazard Management ......................................................................................................... 9B 300 Risk-based Verification Planning ....................................................................................................................... 10B 400 Certificate of Conformity.................................................................................................................................... 10

C. Definitions..................................................................................................................................................................... 10C 100 Verbal Forms ...................................................................................................................................................... 10C 200 Definitions .......................................................................................................................................................... 11

D. Abbreviations ................................................................................................................................................................ 12

E. References ..................................................................................................................................................................... 13

Sec. 2 Principles of Risk-based Verification ............................................................................................. 14

A. Purpose of Section ........................................................................................................................................................ 14A 100 Objectives ........................................................................................................................................................... 14

B. Verification Principles .................................................................................................................................................. 14B 100 Purpose of Verification ....................................................................................................................................... 14B 200 Verification as a Complementary Activity ......................................................................................................... 14B 300 Risk-based Levels of Verification ...................................................................................................................... 14

C. Selection of Level of Verification ................................................................................................................................ 15C 100 Selection Factors................................................................................................................................................. 15C 200 Overall Safety Objective..................................................................................................................................... 16C 300 Assessment of Risk ............................................................................................................................................. 16C 400 Technical Innovation and Contractor Experience............................................................................................... 17C 500 Quality Management Systems ............................................................................................................................ 17

D. Communications ........................................................................................................................................................... 17D 100 Notification of Verification Level ...................................................................................................................... 17D 200 Obligations.......................................................................................................................................................... 17

Sec. 3 Service Overview .............................................................................................................................. 19

A. Purpose of Section ........................................................................................................................................................ 19A 100 Objectives ........................................................................................................................................................... 19

B. Service Process ............................................................................................................................................................. 19B 100 General Principles............................................................................................................................................... 19B 200 Scopes of Work................................................................................................................................................... 19

C. FEED............................................................................................................................................................................. 20C 100 Verification During FEED.................................................................................................................................. 20

D. Project Design, Construction and Commissioning ....................................................................................................... 20D 100 General................................................................................................................................................................ 20D 200 Verification of Overall Project Management...................................................................................................... 20D 300 Verification during Design ................................................................................................................................. 21D 400 Verification During Construction ....................................................................................................................... 22D 500 Verification During Commissioning .................................................................................................................. 23

E. Operations ..................................................................................................................................................................... 25E 100 General................................................................................................................................................................ 25E 200 Verification of Overall Operations Management ............................................................................................... 25E 300 Verification During Operations .......................................................................................................................... 25

F. Facility Modifications ................................................................................................................................................... 26F 100 Reasons for Modifications .................................................................................................................................. 26F 200 Particular Aspects of Modifications to Hydrocarbon Facilities.......................................................................... 26F 300 Verification During the Design of Modifications............................................................................................... 27F 400 Verification During the Construction of Modifications...................................................................................... 27

DET NORSKE VERITAS

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Service Specification DNV-DSS-314, October 2010 Contents – Page 5

F 500 Verification During the Commissioning of Modifications................................................................................. 27

App. A Selection of Verification Level ........................................................................................................ 29

A. Introduction................................................................................................................................................................... 29A 100 General Principles............................................................................................................................................... 29

B. Quantitative Risk Assessment....................................................................................................................................... 29B 100 Use of a Quantitative Risk Assessment .............................................................................................................. 29B 200 Scope of a QRA .................................................................................................................................................. 30B 300 Risk Assessment ................................................................................................................................................. 30B 400 Hazard Identification .......................................................................................................................................... 30B 500 Frequency Estimation ......................................................................................................................................... 30B 600 Consequence Criteria .......................................................................................................................................... 31B 700 Consequence Analysis ........................................................................................................................................ 31B 800 Domino Effect Analysis ..................................................................................................................................... 31B 900 Risk Summation and Evaluation......................................................................................................................... 31B 1000 Sensitivity Analysis ............................................................................................................................................ 31B 1100 Assessment of Risk Mitigation Measures........................................................................................................... 31

C. Trigger Questions.......................................................................................................................................................... 31C 100 Use of Trigger Questions .................................................................................................................................... 31C 200 Overall Safety Objective..................................................................................................................................... 32C 300 Assessment of Risk ............................................................................................................................................. 32C 400 Technical Innovation .......................................................................................................................................... 32C 500 Contractors’ Experience...................................................................................................................................... 32C 600 Quality Management Systems ............................................................................................................................ 32

App. B Verification Documents ................................................................................................................... 34

A. Purpose of Appendix..................................................................................................................................................... 34A 100 Introduction......................................................................................................................................................... 34A 200 Issue and Filing of Certificates ........................................................................................................................... 34A 300 Validity of Verification Documents.................................................................................................................... 34

B. DNV Certificate of Conformity .................................................................................................................................... 34B 100 Definition ............................................................................................................................................................ 34B 200 Scope of Verification to Obtain a DNV Certificate of Conformity.................................................................... 34

C. Statement of Compliance ............................................................................................................................................. 35C 100 Definition ............................................................................................................................................................ 35C 200 Scope of Verification to Obtain a Statement of Compliance.............................................................................. 35

D. Other Verification Documents ...................................................................................................................................... 35D 100 Verification Reports............................................................................................................................................ 35D 200 Verification Comments Sheets ........................................................................................................................... 35D 300 Visit Reports ....................................................................................................................................................... 36

E. Use of Quality Management Systems .......................................................................................................................... 36E 100 General................................................................................................................................................................ 36E 200 Quality Plans....................................................................................................................................................... 36E 300 Inspection and Test Plans ................................................................................................................................... 37E 400 Review of Quality Management Programme ..................................................................................................... 37

F. Verification Forms ........................................................................................................................................................ 37F 100 Specimen Forms ................................................................................................................................................. 37F 200 Certificate of Conformity.................................................................................................................................... 38F 300 Statement of Compliance.................................................................................................................................... 39F 400 Verification Comments Sheet ............................................................................................................................. 40F 500 Visit Report......................................................................................................................................................... 41

App. C Generic Detailed Verification Scopes of Work Tables ................................................................. 45

A. Purpose of Appendix..................................................................................................................................................... 45A 100 Introduction......................................................................................................................................................... 45

B. Description of Terms Used in the Scope of Work Tables ............................................................................................ 45B 100 Abbreviations and Terms.................................................................................................................................... 45B 200 Audit ................................................................................................................................................................... 45B 300 Surveillance ........................................................................................................................................................ 45B 400 Hold Point ........................................................................................................................................................... 46B 500 Review ................................................................................................................................................................ 46

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Service Specification DNV-DSS-314, October 2010 Page 6 – Contents

C. Overall Project Management ........................................................................................................................................ 46C 100 Availability of Documents.................................................................................................................................. 46C 200 Detailed Scope of Work for Overall Project Management................................................................................. 46

D. Design ........................................................................................................................................................................... 46D 100 General................................................................................................................................................................ 46D 200 Design Verification............................................................................................................................................. 46D 300 Low Level Design Verification .......................................................................................................................... 47D 400 Medium Level Design Verification .................................................................................................................... 47D 500 High Level Design Verification.......................................................................................................................... 47D 600 Safety-critical Elements and Components .......................................................................................................... 47D 700 Scope of Work for Design .................................................................................................................................. 49

E. Construction .................................................................................................................................................................. 62E 100 General................................................................................................................................................................ 62E 200 Construction Verification ................................................................................................................................... 62E 300 Low Level Construction Verification ................................................................................................................. 63E 400 Medium Level Construction Verification........................................................................................................... 63E 500 High Level Construction Verification ................................................................................................................ 63E 600 Verification of Work in Progress........................................................................................................................ 63E 700 DNV Final Report............................................................................................................................................... 64E 800 Scope of Work for Construction ......................................................................................................................... 64

F. Commissioning ............................................................................................................................................................. 71F 100 General................................................................................................................................................................ 71F 200 Commissioning Verification............................................................................................................................... 71F 300 Low Level Commissioning Verification ............................................................................................................ 72F 400 Medium Level Commissioning Verification ...................................................................................................... 72F 500 High Level Commissioning Verification............................................................................................................ 72F 600 Verification of Work in Progress........................................................................................................................ 72F 700 DNV Final Report............................................................................................................................................... 72F 800 Scope of Work for Commissioning Verification ................................................................................................ 72

G. Operations ..................................................................................................................................................................... 77G 100 General................................................................................................................................................................ 77G 200 Operations Verification....................................................................................................................................... 77G 300 Low Level Operations Verification .................................................................................................................... 77G 400 Medium Level Operations Verification .............................................................................................................. 77G 500 High Level Operations Verification.................................................................................................................... 77G 600 DNV Final Report............................................................................................................................................... 77G 700 Scope of Work for Operations Verification........................................................................................................ 77

H. Modifications or Upgrades............................................................................................................................................ 86H 100 General Principles............................................................................................................................................... 86H 200 Verification of Design of Modifications............................................................................................................. 86H 300 Verification of Construction of Modifications ................................................................................................... 87H 400 Verification of Commissioning of Modifications............................................................................................... 87

App. D Major Accident Hazards Versus Safety-critical Elements ........................................................... 88

A. Purpose of Appendix..................................................................................................................................................... 88A 100 Introduction......................................................................................................................................................... 88

App. E Guidance on the Development of Verification Plans .................................................................... 92

A. Purpose of Appendix..................................................................................................................................................... 92A 100 Introduction......................................................................................................................................................... 92

B. The Verification Plan’s Part in Facility Risk Management .......................................................................................... 92B 100 Risk Reduction in Principle ................................................................................................................................ 92B 200 The Major Accident Hazard Process and Integrity Management....................................................................... 92

C. Independent Third-Party Verification ........................................................................................................................... 93C 100 What is Verification? .......................................................................................................................................... 93C 200 How Verification Is Carried Out......................................................................................................................... 93C 300 Content of Verification Plan ............................................................................................................................... 93C 400 Formal Guidance on Verification Plans and Practices ....................................................................................... 94

D. Verification Plan ........................................................................................................................................................... 94D 100 Development of the Verification Plan ................................................................................................................ 94D 200 Development of Examination Scope of Work Documents................................................................................. 94D 300 Methods of Examination..................................................................................................................................... 94D 400 Project Phase....................................................................................................................................................... 94D 500 Control of Verification........................................................................................................................................ 95

DET NORSKE VERITAS

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Service Specification DNV-DSS-314, October 2010 Contents – Page 7

E. Verification Reporting .................................................................................................................................................. 95E 100 Control of Verification Reports .......................................................................................................................... 95E 200 Verification Status Reporting ............................................................................................................................. 96

F. Review and Revision of the Verification Plan.............................................................................................................. 96F 100 Continuous Review of the Plan .......................................................................................................................... 96F 200 Events Initiating Revisions ................................................................................................................................. 96

DET NORSKE VERITAS

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Service Specification DNV-DSS-314, October 2010 Page 8 – Sec.1

SECTION 1INTRODUCTION TO RISK-BASED VERIFICATION

A. Introduction

A 100 Function of this Document

101 This Service Specification gives criteria for and guidance on third-party verification of the safety andintegrity of hydrocarbon refineries and petrochemical facilities during new developments, operations andduring modifications to existing facilities.

102 This document is an object-specific Service Specification conforming to the philosophy defined in DNV-OSS-300 Risk-based Verification, ref. Sec.1 E.

A 200 Objectives

201 The objectives of this document are to:

— describe DNV’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 thosecarrying out verification activities, whether quantitatively as a result of a quantitative risk assessment orqualitatively by simple trigger questions.

— provide a common platform for describing the scope and extent of verification activities.

A 300 Scope of Application for Verification

301 This DSS may be adopted for the verification of all parts of all hydrocarbon refineries or types ofpetrochemical facilities or selected project phases.

302 This DSS describes the principle of a levelled verification involvement, where the extent of verificationinvolvement is linked to the risks associated with part or all of the facility.

303 The primary scope of DNV’s verification work is the verification of the integrity of hydrocarbonfacilities and the safety of its personnel and those in close proximity to it. Other aspects, such as the verificationof the environmental impact of the facility, or its ability to meet the Owner’s business objectives, may beincluded in DNV’s scope of work if desired by the Owner.

304 Statutory verification (or certification) of hydrocarbon facilities to the requirements of NationalAuthorities is not included specifically in the scope of application of this DSS. Such verification (orcertification) shall be governed by the regulations of the relevant Authority. However, if detailed proceduresare not given by these Authorities, this DSS will be used by DNV as a guideline for its work.

A 400 Structure of this Document

401 This document consists of three sections and five appendices:

— Section 1, this section, explains the relationship between this document and DNV’s overall risk-basedverification process.

— Section 2 explains the principles of DNV’s verification process with its risk-based levels of involvement,and how the level of involvement for a particular project is defined.

— Section 3 describes the verification process and the activities for each of the project phases.— Appendix 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.— Appendix B gives examples of verification documents. The use of quality management systems is

addressed here.— Appendix 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.— Appendix D gives typical refinery hazards and their interface with safety-critical elements and risk

mitigation measures.— Appendix E gives guidance on the formulation of plans for the verification of the design, construction and

commissioning of hydrocarbon facilities.

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Service Specification DNV-DSS-314, October 2010 Sec.1 – Page 9

B. Risk-based Verification

B 100 General

101 This DSS describes the principles of verification of the safety and integrity of hydrocarbon facilities forall phases.

102 The risk based verification concept is described in DNV-OSS-300 and visualized in Figure 1 overleaf.

103 The Verification Plan is the pivot element, with the Asset Specification, Risk Assessment and Definitionof Verification Involvement as input and the Verification Execution being the implementation.

B 200 Verification’s Role in Hazard Management

201 Major Accident Hazards are identified in a Formal Safety Assessment by an analysis of the risks to thefacility’s personnel using suitable definitions of such accidents.

202 Safety-critical Elements are those hardware-related measures, including computer software, designed toreduce the risk to the facility’s personnel.

203 Performance Standards are the definitions of how these safety-critical elements perform their riskreduction functions.

204 Verification Plan is how an independent examination of these safety-critical elements is planned toconfirm 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 2 overleaf.

Guidance note:Further details of these terms are given in Appendix E B200.

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Figure 1 DNV Risk-based Verification Flow Chart

Asset Specification including overall company acceptance criteria,

performance requirements and verification objectives

Risk Assessment including identification of hazards and

ranking of hazards based on risk evaluation

Definition of Verification Involvement including detailing of acceptance criteria, and

performance requirements

Verification Plan including list of verification activities

Verification Execution including reporting of compliance or

non-compliance

Asset Planned

Asset Completed

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Service Specification DNV-DSS-314, October 2010 Page 10 – Sec.1

Figure 2 Verification as Part of Hazard Management

B 300 Risk-based Verification Planning

301 The selection of the level of verification shall depend on the level of risk a particular item adds to theoverall risk to the facility. The planning can be simplified or detailed. This is further described in DNV-OSS-300.

302 This Service Specification addresses both approaches as input into the preparation of a verification plan.Guidance note:Risk can be evaluated based on safety, environmental impact, business, schedule, public relations, reputation or othercriteria set by the Owner.The generic scopes of work tables are generated based on safety and integrity risks. Where other risks, such asenvironment or business, are required by the Owner to be considered during the verification process, the principlesset out in this document may be used to modify the generic scopes of work tables given in Appendix C.

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303 In view of the complexity of most hydrocarbon facilities, DNV recommends strongly that theverification 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 consider thatsimplified qualitative verification planning using the trigger questions set out in Appendix A be justifiable.For novel technology for which there are no applicable standards to verify against, Technology Qualificationaccording to procedures as defined in “DNV-RP-A203 Qualification Procedures For New Technology” can be usedas input for Verification.

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B 400 Certificate of Conformity

401 A Certificate of Conformity may be issued by DNV to confirm compliance according to the scope ofwork. An example is given in Appendix B.

402 The DNV Certificate of Conformity confirms that, after performing verification according to a DNVdefined scope of work, DNV has found the hydrocarbon facility to conform to a given DNV Standard oracceptable international standard.

403 Usually DNV performs the complete scope of work. However, in some circumstances, DNV may acceptexternal Independent Review Certificates, for example for pressure vessels. This shall be reflected in theCertificate text.

404 A Statement of Compliance is issued in all instances where Certificate of Conformity is not applicable.See Appendix B for further details.

C. Definitions

C 100 Verbal Forms

101 “Shall”: Indicates requirements to be followed in order to conform to this DSS and from which nodeviation is permitted.

102 “Should”: Indicates that among several possibilities, one is recommended as being particularly suitable,without mentioning or excluding others, or that a certain course of action is preferred but not necessarilyrequired. Other possibilities may be applied subject to agreement.

103 “May”: Verbal form used to indicate a course of action permissible within the limits of this DSS.

Wri tten Sc heme of

Exam ination

Formal Safety

Assessment

1 Hyd rocarbon Co ntainment 2 P rimary Struc tu re 3 S MS 4 ESD 5 F & G S ystems etc etc. .... . 6 7 8 9 10 11

Major Accident Hazards

Safety Critical

Elements Performance Standards

VerificationPlan

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Service Specification DNV-DSS-314, October 2010 Sec.1 – Page 11

C 200 Definitions

201 Certificate of Conformity: A document signed by a qualified party affirming that, at the time ofassessment, the product or service met the stated requirements (BS 4778: Part 2), ref. Sec.1 E.

Guidance note:For this DSS, 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.

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202 Commissioning (phase): The phase, after mechanical completion, where the facility is made ready foroperation. This phase includes any contractual performance trials.

203 Commissioning Completion: is the completion of the commissioning phase where the hydrocarbonfacility is capable of performing to its design specification. This may include contractual performance trials.

204 Construction (phase): All activities during construction, including fabrication, installation and testing upto mechanical completion.

205 Design: All related engineering to design the facility including process, structural, mechanical, electricaland instrumentation disciplines as well as materials and corrosion.

206 Design (phase): An initial project phase that takes a systematic approach to the production ofspecifications, 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).

207 Fabrication: 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 orintegration.

208 Hazard: A physical situation with the potential to cause harm, such as injury or death to workers, damageto property, disruption of business or pollution of the environment.

209 HAZOP (HAZard and OPerability study): The application of a formal systematic detailed examinationof the process and engineering intention of new or existing facilities to assess the hazard potential of operationoutside the design intention or malfunction of individual items of equipment and their consequential effects onthe facility as a whole.

210 Manufacture: 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 morecontractor or supplier.

211 Mechanical Completion: is the completion of the construction phase (qv) where all equipment, such aspumps and compressors, may be energised and pressure vessels may be filled with their contents to enablecommissioning to take place.

212 Modifications: Alterations to an existing hydrocarbon facility by modifying an existing part of thefacility or adding new parts.

Guidance note:In hydrocarbon facilities, this is referred to frequently as “upgrading”.

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213 Operations (phase): The phase when the facility is being used for the purpose for which it was designed.

214 Risk: The qualitative or quantitative likelihood of an accident or unplanned event occurring, consideredin conjunction with the potential consequences of such a failure: in quantitative terms, risk is proportional tothe quantified probability of a defined failure mode times its quantified consequence.

215 Risk Reduction Measures: Those measures taken to reduce the risks to the operation of the hydrocarbonfacility 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.

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Service Specification DNV-DSS-314, October 2010 Page 12 – Sec.1

216 Safety Objectives: The safety goals in terms of functionality, reliability/availability and survivability forthe design, construction and operation of the hydrocarbon facility including acceptance criteria for the level ofrisk acceptable to the Owner.217 Verification: An examination to confirm that an activity, a product or a service is in accordance withspecified requirements.

Guidance note:The examination shall be based on information, which can be proved true, based on facts obtained throughobservation, 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 isultimately decided by DNV (or the national authorities when DNV issues certificates on their behalf).

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218 Verification Plan: A plan, which defines the scope of the work for verification; it includes verificationobjectives, acceptance criteria, elements to be verified, level of involvement by party and type of verificationactivity.

D. Abbreviations

ALARP As Low as Reasonable PracticableBLEVE Boiling Liquid Expanding Vapour ExplosionCCTV Closed Circuit TelevisionD&ID Ducting and Instrumentation DiagramESD Emergency ShutdownESDV Emergency Shutdown ValveFEED Front End Engineering DesignFERA Fire and Explosion Risk AssessmentFGS Fire and Gas SystemFMEA Failure Mode and Effect AnalysisHAZID Hazard IdentificationHAZOP Hard and Operability StudyHVAC Heating, Ventilation and Air ConditioningICS Integrated Control SystemNDT Non-destructive TestingOSS (Offshore) Service SpecificationP&ID Piping and Instrumentation DiagramPCS Process Control SystemPFD Process Flow diagramPFP Passive Fire ProtectionPLEM Pipeline End ManifoldPS Performance StandardPSD Process ShutdownQRA Quantitative Risk AssessmentSCE Safety-critical ElementSIL Safety Integrity levelSPM Single Point MooringUFD Utility Flow DiagramUPS Uninterruptible Power SupplyVAR Verification Activity ReportVCE Vapour Cloud Explosion

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Service Specification DNV-DSS-314, October 2010 Sec.1 – Page 13

E. References

DNV-OSS-300 Risk Based Verification, 2004, Det Norske Veritas, Høvik, NorwayISO 8402 Quality -Vocabulary, 1994 (withdrawn), International Organization for Standardization, GenevaISO 9000 Quality Management Systems - Fundamentals and Vocabulary, 2005, International Organization forStandardization, GenevaISO 9001 Quality Management Systems - Requirements, 2008, International Organization for Standardization,GenevaISO 10005 Quality Management Systems – Guidelines for Quality Plans, 2005, International Organization forStandardization, GenevaISO TR 10013 Guidelines for Quality Management System Documentation, 2001, International Organizationfor Standardization, GenevaEN 10204 Metallic Products - Types of Inspection Documents, 2004, European Committee forStandardization, BrusselsBS 4778 Quality Vocabulary, Part 2 Quality Concepts and Related Definitions, 1991, British StandardsInstitute, LondonHealth and Safety at Work etc Act 1974, HMSO London, ISBN 0 10 543774 3The Offshore Installations (Safety Case) Regulations 2005, Statutory Instrument 2005 number 3117, HMSOLondon, ISBN 0 11 073610 9A Guide to the Offshore Installations (Safety Case) Regulations 2005, HSE Books London, ISBN 0 7176 6184 9Council Decision 93/465/EEC of 22 July 1993 Concerning the Modules for the Various Phases of theConformity 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.

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Service Specification DNV-DSS-314, October 2010 Page 14 – Sec.2

SECTION 2PRINCIPLES OF RISK-BASED VERIFICATION

A. Purpose of Section

A 100 Objectives

101 The objectives of this section are to provide:

— an introduction to the principles of verification the safety and integrity of hydrocarbon refineries andpetrochemical facilities,

— an introduction to the principles of risk-based levels of verification activity and — guidance on the selection of levels of verification.

B. Verification Principles

B 100 Purpose of Verification

101 Verification constitutes a systematic and independent examination of the various phases in the life of ahydrocarbon facility to determine whether it has sufficient integrity to meet its safety objectives.

102 Verification activities are expected to identify errors or failures in the safety and integrity-related workassociated with the hydrocarbon facility and to contribute to reducing the risks to its operation and to the healthand safety of personnel associated with it or in its vicinity.

103 Verification is primarily focused on integrity and human safety, but business risk (cost and schedule)may be addressed also if required by the Owner.

B 200 Verification as a Complementary Activity

201 Verification shall be complementary to routine design, construction and operations activities and not asubstitute for them. Therefore, although verification will take into account the work, and the assurance of thatwork, carried out by the Owner and its contractors, it is possible that verification will duplicate some work thathas been carried out previously by other parties involved in the hydrocarbon facility.

202 The verification plan shall be developed and implemented in such a way as to minimise additional workand cost, and to maximise its effectiveness. The development of the verification plan shall depend on thefindings from the examination of quality management systems, the examination of documents and theexamination of project activities.

B 300 Risk-based Levels of Verification

301 To achieve a DNV Certificate of Conformity for a hydrocarbon facility a verification of the activitiesdescribed by the scope of work defined within this DSS first shall take place.

302 The level of verification activity is differentiated according to the overall risk to the facility and toindividual parts of it. If the risk to the facility (or a particular part) is higher, the level of verificationinvolvement is higher. Conversely, if the risk to the facility (or a particular part) is lower, the level ofverification activities can be reduced, without any reduction in their effectiveness.

303 Verification of hydrocarbon facilities is categorised into Low, Medium and High. A summary of thelevels of involvement is given in Table 2-1.

304 It is the prerogative of the Owner of the hydrocarbon facility to choose the level of verification. Theselection should consider the factors given in Sec.2 C. The selection of the most suitable verification level maybe guided by using the information gained from a Quantitative Risk Assessment, or alternatively qualitativelyby trigger questions, as described in Appendix A. Further guidance is provided in OSS-300 Risk BasedVerification.

305 Where DNV is issuing the Certificate of Conformity for the facility, DNV will decide on the appropriatescope and use the same type of questions to evaluate the suitability of the selected level.

306 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 aparticular component or unit may be innovative and considered high risk whereas the construction andinstallation methods are well-known and considered low risk. The converse might be true also.

307 The level of verification can be reduced or increased during a phase if the originally chosen level isconsidered too rigorous or too lenient, as new information on the risks to the hydrocarbon facility becomesavailable.

308 Verification should be planned in close co-operation with the Owner and each of its contractors, to

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provide a scope of work that is tailor-made to the schedule of each production process or activity, i.e. to makethe 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 personnelto perform, for example, inspection at pressure vessel manufacturers.In that case, not all verification work need be done by DNV personnel. Where applicable, the various inspections maybe carried out by competent persons other than DNV personnel.In that situation DNV’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.

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309 Verification will direct greatest effort at those elements of the hydrocarbon facility whose failure or reducedperformance will have the most significant impact on safety and integrity. 310 The degree of confidence placed in a certificate by its users depends on their degree of confidence in theverification carried out. Therefore, the level of verification will be stated on the Certificate of Conformity forthe facility.311 If more than one verification level has been used for a phase, then the lowest level will be reported onthe facility’s certificate, and the additional verification activities will be identified and described in theverification report.

C. Selection of Level of Verification

C 100 Selection Factors101 The selection of the level of verification shall depend on the criticality of each of the elements that havean impact on the management of hazards and associated risk levels of the facility. This is illustrated by Figure1 below.102 The contribution of each element shall be judged qualitatively and/or quantitatively and shall use, wherepossible, quantified risk assessment data to provide a justifiable basis for any decisions made.

Table 2-1 Levels of Verification - Summary of InvolvementLevel Description of involvement Guidance for application on the level of involvement

Low

— 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

— 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

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

— 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

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103 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 1 Selection of the Required Level of Verification

C 200 Overall Safety Objective

201 An overall safety objective covering all phases of the hydrocarbon facility from design to operation shallbe defined by the Owner. The safety objective should address the main safety goals as well as establishingacceptance criteria for the level of risk acceptable to the Owner. Depending on the facility and its location, therisk could be measured in terms of human injuries as well as environmental, political and economicconsequences.

C 300 Assessment of Risk

301 A systematic review should be carried out to identify and evaluate the probabilities and consequences offailures in the hydrocarbon facility. The extent of the review shall reflect the criticality of the facility, theplanned operation and previous experience with similar facilities. This review shall identify the risk to theoperation of the facility and to the health and safety of personnel associated with it or in its vicinity.

High

— 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

— 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

Guidance note:Completion schedules affect verification involvement in an indirect but important way. The effect of a tightcompletion schedule is pressure on the project team to take less time to carry out the various tasks. Tight completionschedules are more prone to run late, thus adding more pressure on the project team. Problems which have beenencountered in this situation in the past have included:

- design reviews not carried out- incomplete welding- non-destructive testing incomplete- missing structural members- commissioning incomplete.

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Table 2-1 Levels of Verification - Summary of Involvement (Continued)Level Description of involvement Guidance for application on the level of involvement

Consequence of Failure

Probability of Failure

Low

High

High

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302 Once the risks have been identified, their extent can be reduced to a level as low as reasonably practicableby means of one or both of:

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

Guidance note:Reasonable PracticabilityThe term “as low as reasonably practicable (ALARP)” has come into use through the United Kingdom’s “The Healthand Safety at Work etc. Act 1974”.Ref Sec. E109. Reasonable Practicability is not defined in the Act but has acquiredmeaning 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 effortin reducing that risk. Similarly, if the risk were very small it would not be reasonable to expect great expense or effortto be incurred in reducing it.Further guidance on the principles and application of ALARP may be obtained from the United Kingdom’s Heath andSafety Executive web-site at http://www.hse.gov.uk/risk/theory/alarp.htm (July 2009).

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303 The result of the systematic review of these risks is measured against the safety objectives and used inthe selection of the appropriate verification activity level.

C 400 Technical Innovation and Contractor Experience

401 The degree of technical innovation in the hydrocarbon facility system shall be considered. Risks to thefacility are likely to be greater for a facility with a high degree of technical innovation than with a facilitydesigned, manufactured and installed to well-known criteria in well-known locations.402 Similarly, the degree of risk to the facility should be considered where contractors are inexperienced orthe work schedule is tight.403 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.

C 500 Quality Management Systems

501 Adequate quality management systems shall be implemented to ensure that gross errors in the work forfacility design, construction and operations are limited.

502 Factors to be considered when evaluating the adequacy of the quality management system include:

— whether or not an ISO 9001, ref. Sec.1 E 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.

D. Communications

D 100 Notification of Verification Level101 An assessment of the required level of verification for a project should be made by the Owner beforepreparing tender documents for design and construction activities. The Owner can then specify this level inInvitations to Tender. This will give contractors clear guidance and reference when estimating the extent and costof efforts associated with verification activities.

102 The required level of verification can be assessed by the Owner using this DSS. However, if the Ownerrequires the Contractor to carry out this assessment as part of his response to an Invitation to Tender the Ownershould provide the necessary information to enable the Contractor to carry out this work. This informationshould 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.

D 200 Obligations

201 To achieve the purpose and benefits of verification the involved parties shall be mutually obliged to share

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and act upon all relevant information pertaining to the verification scope.202 The Owner shall be obliged to:

— Inform DNV about the basis for selecting the level of verification and the investigations and assumptionsmade in this context.

— Give DNV full access to all information concerning the verification scope for the hydrocarbon facility andensure that clauses to this effect are included in contracts for parties acting on behalf of the Owner andparties providing products, processes and services covered by the verification scope. If information isproprietary and not available, exclusion from verification shall be mutually agreed with DNV.

— Ensure that DNV is involved in the handling of deviations from specified requirements within theverification scope.

— Act upon information provided by DNV with respect to events or circumstances that may jeopardise thesafety 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 onbehalf of the Owner and parties providing products, processes and services covered by the verificationscope.

203 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 with all relevant information pertaining to the verification scope.

204 DNV will be obliged to:

— Inform the Owner if, in the opinion of DNV, the basis for selecting the level of verification or theassumptions 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, may jeopardise the safety orintegrity 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 actualperformance of parties providing products, processes and services covered by the verification scope.

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SECTION 3SERVICE OVERVIEW

A. Purpose of Section

A 100 Objectives

101 The objectives of this section are to provide, for hydrocarbon refining and petrochemical facilities:

— an overview of verification activities— details of DNV’s verification activities for aspects of the facility’s development, operation or modification.

B. Service Process

B 100 General Principles

101 The process of DNV’s verification of hydrocarbon facilities is based on distinct project phases and therecognition of key milestones.

102 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 hydrocarbonfacility but can be stand-alone service for all or part of a project.

B 200 Scopes of Work

201 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.

202 Note that the activity “Audit of the quality management system” may be omitted if there exists a qualitymanagement system in accordance with ISO 9001, certified by an accredited third party for the scope of workbeing carried out in the project.

203 Typical generic detailed scopes of work descriptions, which show all the activities to be verified, aregiven in Appendix C.

204 A specific scope of work description shall be made for each particular project. This description shouldbe similar to the tables in Appendix C and will be part of the final DNV verification report.

205 For operations, which are not mentioned specifically in the tables, but which are still found critical for aparticular project, the same general levels will be described.

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C. FEED

C 100 Verification During FEED101 Verification during FEED, or the conceptual and/or feasibility studies of a project, is not a prerequisitefor verification. However, verification of the early stages of a project can reduce the extent, depth and cost ofverification required during the design, construction and commissioning phases or indicates areas whereverification would be difficult to achieve without further work being undertaken.102 Design verification during FEED can be combined with additional reviews, where required by theOwner, of:

— environmental aspects— project schedule— cost.

103 The FEED design documents shall be reviewed on a sample basis to ensure that the requirements of theproject’s specifications and standards have been incorporated.104 Verification during FEED is the examination of the assumptions, methods and results of the designprocess and is performed to ensure that the specified requirements of the project will be achieved.105 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.

106 Definition of the scope of work for verification of FEED will follow Table 3-1.

D. Project Design, Construction and Commissioning

D 100 General101 All design, construction and commissioning aspects, relevant to hydrocarbon facility safety andintegrity, shall be covered by the verification process.102 Verification describes the individual activities undertaken by DNV at the various stages of the design,construction and commissioning of the hydrocarbon facility to confirm that the safety and integrityrequirements of the Owner have been fulfilled.

D 200 Verification of Overall Project Management201 Verification of the overall project management is the examination of the means of controlling the wholehydrocarbon facility project.202 This verification is to ensure that the necessary controls are in place to ensure information flows betweenthe various interfaces. This is especially important where separate contractors have been employed for differentphases of the project.203 Definition of the scope of work for verification of overall project management will follow Table 3-2.

Table 3-1 Scope of work for verification of FEEDLevel

Verification activity L M HReview of reports and specifications for construction and operation by 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 x1) 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.

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D 300 Verification during Design

301 Design verification is the examination of the assumptions, methods and results of the design process and isperformed at the specified level of verification to ensure that the specified requirements of the hydrocarbon facilitywill be achieved.

302 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.

303 Typical design aspects that shall be verified during the design of hydrocarbon facilities 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.

304 Definition of the scope of work for verification of design will follow Table 3-3.

Table 3-2 Scope of work for verification of overall project management Level

Verification activity L M HReview of the project management process by— 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

Table 3-3 Scope of work for verification of design Level

Verification activity L M HReview of the design process by— review of design quality management documentation x x x— audit of design quality management system x xReview of specifications for design by— review of the design basis with emphasis of the survey results and environmental data:

evaluation of the design criteria x x x

Review of design reports and drawings by— 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

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Guidance note:Design verification activities may be split up between Basic Design and Detailed Design, or other sub-phase,depending on type of contract.

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D 400 Verification During Construction

401 Verification during construction is carried out by means of full time attendance, audits, inspection or spotchecks of the work, as appropriate, in sufficient detail to ensure that the specified requirements of thehydrocarbon facility will be achieved.

402 Verification of these activities relates not only to the contractor’s work but also to the monitoring of thiswork carried out by the Owner.

403 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.

404 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

Performing independent parallel calculations by— 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 xReview of specifications for construction and operation by— spot check of critical aspects x x x— review of main specifications x x— thorough review of main specifications xReview of specific operational challenges— general principles x x x— review of main documents supported by simplified analyses x x

Table 3-3 Scope of work for verification of design (Continued) Level

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— final inspection reports of procured items.

405 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 andacceptance 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.

406 The final documentation to be submitted after construction that should reflect the ‘as-built’ status of thefacility, should include but not be limited to:

— construction test records; visual, NDT, test samples, dimensional, heat treatment, etc.— hydrostatic test reports— as-built drawings.

407 Definition of the scope of work for verification of construction shall follow Table 3-4 for manufacturingand fabrication of critical, high-risk, components, Table 3-5 for manufacturing and fabrication of componentsnot considered to be high-risk and Table 3-6 for site construction activities.

408 Component risk of shall be defined preferably by a quantitative risk assessment but qualitative methodsmay be used for lower-risk facilities.

Guidance note:Materials may be ordered with certificates of independent third-party verification (e.g. 3.2 according to EN 10204,ref. Sec.1 E). 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 conformityassessment 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 ref.Sec.1 E.

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D 500 Verification During Commissioning

501 Verification during commissioning is carried out by means of full time attendance, audits, inspection orspot checks of the work, as appropriate, in sufficient detail to ensure that the specified requirements of thehydrocarbon facility will be achieved.

Table 3-4 Scope of work for verification of manufacturing and fabrication of HIGH-RISK components

LevelVerification activity L M HReview of the manufacturing & fabrication process— Review of manufacturing and fabrication management systems x x x— Audit of the quality management system x xReview of manufacturing & fabrication procedures— Review manufacturing, fabrication and inspection procedures for confirmation of

compliance with the manufacturing specification x x x

— Review method statements x xReview 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 xSurveillance 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

x x

— 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

Review of final documentation x x x

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502 Verification of these activities relates not only to the contractor’s work but also to the monitoring of thiswork carried out by others.

503 During commissioning verification shall consist of one, or more, of:

— reviewing the commissioning process— reviewing commissioning procedures— surveillance during commissioning activities— reviewing final documentation.

504 Typical site activities to be verified during commissioning, including any contractual performance test,are:

Document Review

— commissioning schedule— checking and testing procedures for commissioning work— performance test procedures— audit of as built documentation.

Table 3-5 Scope of work for verification of manufacturing and fabrication of non-HIGH-RISK components

Level

Verification activity L M H

Review of the manufacturing & fabrication process

— Review of manufacturing and fabrication management systems x x

Review of manufacturing & fabrication procedures— Review manufacturing, fabrication and inspection procedures for confirmation of

compliance with the manufacturing specification 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

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

— Visit-based 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

Review of final documentation x x x

Table 3-6 Scope of work for verification of site constructionLevel

Verification activity L M H

Review of the construction process

— Review of construction management systems x x x

— Audit of the quality management system x x

Review of construction procedures

— Spot check of construction procedures, including erection procedures x x x— For critical operations (identified from the FMEA and HAZOP studies or QRA) review the

method statements x x

Review of qualification process— For critical operations, review the qualification process, e.g.— welding— non-destructive testing— site heat treatment

x x x

— Full time attendance during qualification tests x xSurveillance during construction activities— Visit-based attendance during start of each critical operation x x x— Full time attendance during each critical operation x x— Full time attendance for all construction operations xReview of final documentation x x x

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Witnessing Activities

— alarm, fire and gas and shut-down systems tests in accordance with the cause and effect matrix— function and commissioning tests— performance tests— conduct of all commissioning work is carried out in accordance with procedures previously approved.

505 Definition of the scope of work for verification of commissioning will follow Table 3-7.

E. Operations

E 100 General

101 All operations aspects, such as operations, maintenance and inspection, relevant to hydrocarbon facilitysafety and integrity, shall be covered by the verification process.

102 Verification describes the individual activities undertaken by DNV during the operation of thehydrocarbon facility to confirm that the safety and integrity requirements of the Owner continue to be fulfilled.

E 200 Verification of Overall Operations Management

201 Verification of the overall operations management is the examination of the means of controlling theoperation of the whole hydrocarbon facility.

202 This verification is to ensure that the necessary controls are in place to ensure information flows betweenthe various interfaces. This is especially important where separate contractors have been employed for differentaspects of operations.

203 Definition of the scope of work for verification of overall project management will follow Table 3-8.

E 300 Verification During Operations

301 Verification during operations is carried out by means of audits, inspection or spot checks of the work,as appropriate, in sufficient detail to ensure that the specified requirements of the hydrocarbon facility continueto be achieved.

302 Verification of these activities relates not only to the Owner’s work but any work, relevant to the integrityof the facility and the safety of personnel, carried out by contractors.

303 During operations verification shall consist of one, or more, of:

Table 3-7 Scope of work for verification of site commissioningLevel

Verification activity L M H

Review of the commissioning process

— Review of commissioning management systems x x x

— Audit of the quality management system x x

Review of commissioning procedures

— Spot check of commissioning procedures x x x— For critical operations (identified from the FMEA and HAZOP studies or QRA) review the

method statements x x

Surveillance during commissioning activities— Visit-based attendance during start of each critical operation x x x— Full time attendance during each critical operation x x— Full time attendance for all commissioning operations xReview of final documentation x x x

Table 3-8 Scope of work for verification of overall operations management Level

Verification activity L M HReview of the project management process by— 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

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— reviewing the operations, maintenance and inspection processes— reviewing operations, maintenance and inspection procedures— surveillance during operations, maintenance and inspection activities— reviewing documentation of the results of these processes.

Guidance note:The operations processes, procedures and activities to be verified are only those concerned, wholly or in part, with theintegrity of the hydrocarbon facility or the safety of personnel within or in close proximity.Operations processes, procedures and activities that are not concerned with facility integrity or personnel safety willnot be verified.

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304 Typical activities to be verified during operations are:

Document Review

— integrity management strategies— operations, maintenance and inspection procedures— preventative maintenance routines

Witnessing Activities

— alarm, fire and gas and shut-down systems tests in accordance with the cause and effect matrix— function tests— conduct of all operations, maintenance and inspection work is carried out in accordance with procedures

previously approved.

305 Definition of the scope of work for verification of operations will follow Table 3-9.

F. Facility Modifications

F 100 Reasons for Modifications

101 Hydrocarbon facilities are modified or upgraded throughout their lives. Reasons for these modificationsare varied but common reasons are:

— changes in market conditions, e.g. requirements for low-sulphur fuel— changes in source of crude oil, e.g. higher sulphur crudes have to be used instead of low-sulphur as designed— technological change i.e. new, more efficient, processes are developed— changes in facility output, i.e. new products being made requiring new processes to be installed.

102 It is not common that like-for-like replacements are made due to corrosion or other degradationmechanisms.

F 200 Particular Aspects of Modifications to Hydrocarbon Facilities

201 The essential steps for verification of modifications to hydrocarbon facilities are identical to those in anew facility. However, the effects on units upstream and downstream of the new or modified unit and units inphysical proximity must be considered.

202 The design of these existing units may have to be reviewed to ensure that the modified unit has no

Table 3-9 Scope of work for verification of operationsLevel

Verification activity L M H

Review of the operations, maintenance and inspection processes

— Review of integrity management strategies x x x— Review of operations, maintenance and inspection management

systems x x

Review of operations, maintenance and inspection procedures

— Review of operations, maintenance and inspection procedures x x x

— Review of preventative maintenance routines x xSurveillance during operations, maintenance and inspection activities— Visit-based attendance during conduct of each critical operation x x x— Full time attendance during shutdowns (or turn-arounds) x xReview of operations, maintenance and inspection documentation x x x

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harmful effects on parts of the existing facility.

203 Process Proximity. Consideration must be given during the design of the modification to other parts ofthe existing hydrocarbon facility that are in process proximity to the modifications. The effects on unitsupstream or downstream must be considered in terms of, for example:

— incoming or outgoing product composition— corrosion potential of changes in product composition— changes in product:

— flowrates— temperatures— pressures.

204 Physical Proximity. Existing units may be in physical proximity although they may have little or noprocess proximity. The effects on units in physical proximity must be considered in terms of, for example:

— fires and explosions— release of toxic vapour, i.e. HF Alkylation— changes to escape routes and emergency vehicle access.

F 300 Verification During the Design of Modifications

301 The scope of work for verification of the design of hydrocarbon facility modifications will follow Table3-3 previously with the addition of specific aspects related to modifications shown in Table 3-10.

F 400 Verification During the Construction of Modifications

401 The scope of work for verification of the construction of hydrocarbon facility modifications will followTables 3-4, 3-5 and 3-6 previously with the addition of specific aspects related to modifications shown in Table3-11.

402 No additional verification activities have been identified for the verification of manufacturing andfabrication of components.

F 500 Verification During the Commissioning of Modifications

501 The scope of work for verification of the commissioning of hydrocarbon facility modifications will

Table 3-10 Scope of work for verification of design of modified facilitiesLevel

Verification activity L M HReview of specifications for design by— review of the design basis including the effects on existing units x x xReview of effects on existing units upstream and downstream— review main documentation to ensure that the main process effects, including the effects

on units upstream and downstream, have been considered, 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 during this consideration with spot checks of the input data and the calculation results x x

— detail review of main design reports xReview of effects on existing units in physical proximity— review main documentation to ensure that the main physical proximity effects have been

considered, 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 during this consideration with spot checks of the input data and the calculation results x x

— detail review of main design reports x

Table 3-11 Scope of work for verification of site construction of modified facilitiesLevel

Verification activity L M HSurveillance during construction activities— Spot checks of physical effects on existing units, paying particular attention to aspects that

may not have been readily apparent during design, such as:

— access ways and escape routes— valve access.

x x x

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follow Table 3-3 previously with the addition of specific aspects related to modifications shown in Table 3-12.

Table 3-12 Scope of work for verification of site commissioning of modified facilitiesLevel

Verification activity L M HSurveillance during commissioning activities— Spot-checks during commissioning, paying particular attention to the continued proper

operation of safety systems in existing units, such as fire and gas and emergency shutdown systems

x x x

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APPENDIX A SELECTION OF VERIFICATION LEVEL

A. Introduction

A 100 General Principles

101 The selection of the level of verification depends on the criticality of each of the elements that have animpact on the management of risks to the hydrocarbon facility.

102 Verification shall direct greatest effort at those elements of the hydrocarbon facility where the risk ishighest and whose failure or reduced performance will have the most significant impact on the safety andintegrity of the facility. Other risks such as:

— environmental risks— economic risks.

may be considered if required by the Owner.

103 Suitable selection factors include, but are not limited to, 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 or any of its equipment— experience of the contractors in carrying out the work— quality management systems of the Owner and its contractors.

104 Due to the diversity of various hydrocarbon and petrochemical facilities, their contents, their degree ofinnovation, the geographic location, etc., it is not possible to give precise guidelines on how to decide whatlevel of verification is appropriate for each particular facility.

105 In view of the complexity of most hydrocarbon facilities, DNV recommends strongly that theverification 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 consider thatsimplified qualitative verification planning using the trigger questions set out in part C is justifiable.

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B. Quantitative Risk Assessment

B 100 Use of a Quantitative Risk Assessment

101 The outcome of a Quantitative Risk Analysis (QRA) should be a ranking of the risks associated withparticular parts or equipment of the hydrocarbon facility.

102 This ranking shall be used to set the verification level for particular parts of the facility as well as for thefacility as a whole as shown in Figure 1.

Figure 1 Risk Ranking versus Verification Effort

Verification Effort

Risk Ranking

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B 200 Scope of a QRA

201 The scope of QRA shall include tasks typically required to assess risks from hazard events to human life,facility equipment and environment. It shall include:

— hazard identification— frequency estimation— consequence criteria— consequence analysis— domino effect analysis— risk summation and evaluation— sensitivity analysis— assessment of inherent safety, detection, prevention, control, mitigation and emergency response measures.

B 300 Risk Assessment

301 Risk Assessment should be carried out using Event Tree Analysis and probabilistic analysis and basedon the following requirements:

— The results of the probabilistic analysis should be utilized in the Event Tree Analysis to estimate thefrequencies associated with different hazardous outcomes.

— A probability analysis should then conducted to estimate the fatality probability associated with ahazardous consequence.

— Risk summation should be conducted using modern computer programs.

302 The results of the study should be presented in terms of individual risk and societal risk from the facilitiesas follow:

— The individual risk should be presented in the form of iso-contours.— Societal risk should be provided in terms of F-N curves.— Potential Loss of Life will be utilized in assessing the relative risk contribution of different facilities.

303 Risk criteria or guidelines shall identify a level of risk, which is:

— unacceptable or intolerable— acceptable or negligible.

304 The ALARP area, lying between two ranges above, is the area within which risks must be reduced tolevels As Low As Reasonably Practicable.

305 The reasonable practicality of risk reduction should be established by consideration of cost versus riskreduction achieved. Preliminary selection of conceptual measures will be effected by consideration of technicalpracticality.

306 The project documents to be reviewed for risk assessment are:

— PFDs, UFDs and P&IDs— stream composition, inventory of hazard substances, operating and design conditions in different

equipment or piping items, failure of which can result in one of the identified hazardous events— scale plan of the site showing location of all identified failure sources— description of the processes or storage involving the hazardous substances— area distribution of on-site population— other document deemed necessary by the verifier to review for risk assessment.

B 400 Hazard Identification

401 The hazard identification should include the:

— review of previous safety studies or hazard assessment reports— review of hazardous material data sheets— identification of hazard locations— identification of the ways which hazards from every location could become a reality (failure mode analysis)— classification and ranking of hazardous events in terms of accident potential.

B 500 Frequency Estimation

501 This task has to involve the estimation of the frequency of each representative event identified.Frequency estimation should comprise two basic steps:

— quantification of the frequency of the initiating events (different failures)— quantification of the frequency of the various hazardous outcomes (e.g. BLEVE, toxic releases, flash fire,

pool fire, jet fire, tank fire, explosion, etc.).

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B 600 Consequence Criteria601 Consequence criteria should be determined for all effects. More than one criterion determination for aneffect should be carried out where possible.

B 700 Consequence Analysis701 An accurate assessment of the consequences resulting from a hazard event shall be provided as animportant element of risk assessment. The impacts on surrounding population of each identified hazard eventsshall be determined considering consequences arising from hazard events.702 Advanced models shall be used for investigation of consequences of each identified hazardous event.703 The results of the major failure events having high damage potential must be represented graphically todepict potential hazard zones.704 Significant hazard distances (hazard diagrams) with respect to surrounding areas shall be provided inboth tabular and illustrative forms.

B 800 Domino Effect Analysis 801 The analysis of Domino Effect events (i.e. escalation of initial events to cause more widespread andserious consequences) shall cover the potential on-site escalation and off-site escalation.

B 900 Risk Summation and Evaluation901 The risks shall be summarised and assessed in three parts:

— individual risks— group risks— other, non-personnel, risks.

902 Individual risks shall be expressed in terms of location-specific and individual-specific risks, by meansof:

— individual risks per year— fatal accident rate.

903 Group risks shall be expressed in terms of:

— FN curves, showing the relationship between the cumulative frequency (F) and number of fatalities (N).— Annual fatality rates, in which the frequency and fatality data is combined into a convenient single measure

of group risk.

904 Other risks, depending on the Owner’s requirements, may be expressed in terms of:

— damage risks— deferred production— oil spills.

B 1000 Sensitivity Analysis1001 A sensitivity analysis shall be conducted on the risk assessment results to determine how significantlyany particular estimate is concerning the overall risk calculation.

B 1100 Assessment of Risk Mitigation Measures1101 A preliminary identification and analysis of possible risk mitigation measures, i.e. Inherent Safety,Prevention, Detection, Control, Mitigation and Emergency Response, shall be carried out in accordance withALARP principle. Practical and cost-effective risk mitigation measures based on the risk assessment resultsshall be identified. Societal risk concerns should be incorporated if appropriate taking into considerationaggregate risk posed to the hydrocarbon facility neighbouring community.

Guidance note:Appendix D gives typical refinery hazards and the interface with safety-critical elements and risk mitigationmeasures.

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1102 This assessment shall be reported by means of a cost-benefit analysis.

C. Trigger Questions

C 100 Use of Trigger Questions101 In the simplest of hydrocarbon facilities, with consequently lower levels of risk DNV consider that

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simplified qualitative verification planning using the trigger questions may be justifiable.

102 Guidance is given as a series of questions that should be answered when deciding the appropriate levelof verification for a simple hydrocarbon facility. This list is not exhaustive and other questions should be addedto the list if appropriate for a particular facility.

103 It must be emphasised that the contribution of each element should be judged qualitatively and/orquantitatively.

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

C 200 Overall Safety Objective

— 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 facility and its location) measured in terms of human injuries?

Guidance note:Environmental, economic and political risks, amongst others, may be considered if required by the Owner.

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C 300 Assessment of Risk

— Has a systematic review been carried out to identify and evaluate the probabilities and consequences offailures in the hydrocarbon facility?

— Has this review judged the contribution of each element qualitatively and/or quantitatively and used, wherepossible, quantified risk assessment data to provide a justifiable basis for any decisions made?

— Does the extent of the review reflect the criticality of the facility, the planned operation and previousexperience with similar facilities?

— Does this review identify the risk to the operation of the facility and to the health and safety of personnelassociated 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 ofone 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 objective?— Has the result of this review been used in the selection of the appropriate verification activity level?

C 400 Technical Innovation

— Has the degree of technical innovation in the facility been considered?— Has it been considered that risks to the facility are likely to be greater with a high degree of technical

innovation than with a facility designed, manufactured and installed to well-known criteria in well-knownlocations?

— Have factors been considered in the selection of the appropriate verification level such as:

— degree of difficulty in achieving technical requirements?— knowledge of similar facilities?— effect of the new facility on the surrounding area?

C 500 Contractors’ Experience

— Has the degree of risk to the facility been considered where design, construction or installation contractorsare inexperienced?

— Has the degree of risk been considered where the contractors are experienced but not in similar work?— Has the degree of risk been considered where the work schedule is tight?

C 600 Quality Management Systems

— Have all parties involved in the facility implemented an adequate quality management system to ensure thatgross errors in the work are limited?

— Do these parties include the:

— owner?— design contractor?— construction contractors?

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

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— whether or not an ISO 9001 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?

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APPENDIX B VERIFICATION DOCUMENTS

A. Purpose of Appendix

A 100 Introduction101 This appendix defines the documents used by DNV in the verification (and certification) of hydrocarbonrefineries and petrochemical facilities. 102 The following documents are included, with samples where necessary:

— Certificate of Conformity— Statement of Compliance— Verification Comments Sheet— Verification Report— Visit Report.

103 Guidance in the use of quality management systems during verification activities is given also.

A 200 Issue and Filing of Certificates201 The DNV Regional office is responsible for preparation and issue of the certificates. The certificate shallbe given a unique regional number and be signed according to DNV’s Chart of Authority. 202 The Regional office is responsible also for archiving of the certificate and maintaining overview ofcertificates issued.

A 300 Validity of Verification Documents301 Verification documents are, in principle, documents confirming that an examination has been carried out,and are valid only at the time of issue.

B. DNV Certificate of Conformity

B 100 Definition101 The DNV Certificate of Conformity confirms that, after performing verification according to a DNVdefined scope of work, DNV has found the hydrocarbon facility to conform to a given DNV Standard oracceptable international standard.102 Table B-1 below shows the essential differences between a DNV Certificate of Conformity and aStatement of Compliance.103 An example of a typical Certificate of Conformity is shown at the end of this Appendix.

B 200 Scope of Verification to Obtain a DNV Certificate of Conformity201 The scope and depth of the verification necessary to obtain a DNV Certificate of Conformity shall be asdefined in this Service Specification. The basis for the DNV Certificate of Conformity shall always be aVerification Plan tailor-made to the project and in accordance with this Service Specification.202 Part of the Plan may be that DNV relies on Independent Review Certificates to document the workperformed by Others.203 The issue of a DNV Certificate of Conformity shall be based on a dedicated verification report.

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C. Statement of Compliance

C 100 Definition

101 A Statement of Compliance is issued in all instances where Certificate of Conformity is not applicable.

102 A Statement of Compliance can be issued on completion of each particular project phase, or a partthereof, and shall be based on a dedicated verification report.

C 200 Scope of Verification to Obtain a Statement of Compliance

201 A Statement of Compliance shall be issued as a formal statement confirming that verification ofdocuments and/or activities, has found that the hydrocarbon facility, a part thereof, complies with therequirements applicable for that particular scope of work.

202 An example of a typical Statement of Compliance is shown at the end of this Appendix.

D. Other Verification Documents

D 100 Verification Reports

101 Verification Reports are issued to confirm that the verification of the relevant hydrocarbon facility hasbeen completed in accordance with specified requirements.

102 The report shall include information such as:

— hydrocarbon facility description and unit or equipment number, if relevant— application (operational limitations and conditions of use) for which the hydrocarbon facility is intended— codes and standards in conformance with the hydrocarbon facility has been verified— 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.

103 The Verification Report shall always be dated and have two signatures, the originator and the DNVinternal verifier.

D 200 Verification Comments Sheets

201 Reviews of documents shall be reported using Verification Comment Sheets (often called VerComs).These documents give details to the client of aspects of hydrocarbon facility design and construction that DNV:

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

Table B-1 Certificates and Statements Issued by DNVCertificate of Conformity Statement of Compliance

Use

Shall be used when the scope and depth of the verification is defined in this Service Specification (DNV-DSS-314);or defined by the legislation of National Authorities

To be used in all instances where Certificate of Conformity is not applicable

Scope responsibility Scope defined by DNV and/or a National Authority. Scope defined by Customer

Scope execution

DNV normally performs the complete scope.However, DNV may accept an external Independent Review Certificates: this shall be reflected in the certificate text

The preferred option when DNV accepts an Independent Review Certificate from an external party.

Objects covered

Complete hydrocarbon refineries or petrochemical facilitiesStandalone equipment, or equipment in self-contained packages

As for Certificate of Conformity

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Guidance note:Verification Comments Sheets shall be issued, stating, “DNV has no comments to this document”, when DNV has nocomments to make. This will provide evidence that verification of the document has been carried out.

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202 Only in the first two instances does DNV expect a response from the Owner or its contractors.

203 Comments Criticality:

— NC – Non Conformance. May be critical with respect to safety and/or integrity of the hydrocarbon facilityand is not in accordance with the referred rules, standards or specifications. Needs to be closed before thedocument can be accepted.

— TQ – Technical Query. May be critical with respect to safety and/or integrity of the hydrocarbon facility.Needs to be closed before the document can be accepted.

— A – Advice. Does not need any action.

204 Comment Status:

— O – Open comment: The comment has not been answered or not answered satisfactorily and the commentis still open.

— C – Closed comment: The comment has been closed.— CN – Conditionally closed: The comment has been closed based on a reply from the Owner. The comment

is to be implemented (e.g. document revision) or the acceptance is based on applicable conditions (e.g. siteinspection).

205 An example of a typical Verification Comment Sheet is shown at the end of this appendix.

D 300 Visit Reports

301 Visit reports are the documentation of attendance activity by DNV.Guidance note:Visit reports may be called by different names, such as Survey Report, Inspection Report, Site Report, or others.

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302 A visit report shall contain enough information to identify clearly the hydrocarbon facility, or part thereof,that has been examined, the operating conditions or specifications to which it has been examined and theconclusion reached by DNV.

303 The visit report shall be printed on the relevant form and shall contain as much information as possiblein accordance with the standard headings in the form. In addition, the report number shall be shown.

304 An example of a typical Visit Report is shown at the end of this appendix.

E. Use of Quality Management Systems

E 100 General

101 The assurance of hydrocarbon facility safety and integrity requires that gross errors during design,construction and commissioning be minimised. The likelihood of such gross errors shall be reduced in asystematic manner by the operation of a quality management system adequate for the work being carried out.

102 Quality management systems frequently are documented at three levels:

— The quality manual and related procedures document how the organisation, as a whole, manages the qualityof all its products and services.

— The quality plan documents the specific procedures related to a particular project.— The inspection and test plan documents how the quality control activities for a particular project shall be

carried out and recorded.

103 Guidelines on the formation of quality plans may be found in ISO 10005 2005 Quality ManagementSystems – Guidelines for Quality Plans, ref. Sec.1 E.

Guidance on the use of quality management documentation in general may be found in ISO TR 10013 2001Guidelines for Quality Management System Documentation ref. Sec.1 E.

E 200 Quality Plans

201 The basic function of a quality plan is to be a memory aid in the management of a project. In anorganisation with many quality procedures for a variety of functions, the quality plan states those that areapplicable to that particular project. The quality plan acts as a route map through the complexities ofmanagement of the project and highlights those activities relevant to quality management.

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202 The project quality plan normally consists of two parts; firstly, a narrative description of the means ofcontrolling the project, and secondly, a tabular description of the inspections and tests to be carried out duringthe work.

E 300 Inspection and Test Plans301 The tabular description of the inspections and tests to be carried out during the work frequently is knownas the inspection and test plan.302 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.— The use of sub-contractors should be indicated and details of how the verification of sub-contractor’s

quality shall be carried out should be shown.— Hold points established by the constructor, the operator or a third party, where witness or review of the

selected inspection or test is required, should be shown.

E 400 Review of Quality Management Programme401 The contractor’s quality manual shall be reviewed for compliance with ISO 9001. The contractor’soperations should be audited to establish compliance with the documented system.402 If the contractor has a quality system certified by an accredited third party certification body for the scopeof work to be undertaken, this may be taken as evidence of a satisfactory quality system provided the certificateis relevant to the contractor’s scope of work for the project. However, the last two years’ periodical auditreports shall be reviewed to identify if any recurring non-conformities have been revealed.403 Any weaknesses revealed during this audit, or review of periodical audit reports, shall be consideredwhen planning the contractor monitoring activities.404 Surveillance of the continuing acceptability of the contractor’s quality management system is carried outby observing a selection of audits carried out by the contractor as part of its internal audit system. The auditsto be observed should be selected over the length of the project at suitable intervals and should cover as widea selection of activities as possible.405 Contractor’s inspection and test plans for the various activities undertaken during their scope of work forthe hydrocarbon facility shall be reviewed and accepted, if adequate.

F. Verification Forms

F 100 Specimen Forms101 Specimen forms are shown overleaf. These forms may be modified to suit specific projects, providingthat these modified forms contain the minimum information shown here.102 The forms are:

— Certificate of Conformity— Statement of Compliance— Verifications Comments Sheet— Visit Report— Appendix 1 Welding Activities— Appendix 2 Non-destructive testing Activities— Appendix 3 Hydrostatic Testing Activities.

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F 200 Certificate of Conformity

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F 300 Statement of Compliance

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F 400 Verification Comments Sheet

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F 500 Visit Report

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APPENDIX C GENERIC DETAILED VERIFICATION SCOPES OF WORK TABLES

A. Purpose of Appendix

A 100 Introduction

101 This appendix gives the format of the generic detailed scope of work tables for all types of hydrocarbonfacility.

102 The detailed project-specific scope of work tables for the chosen level of verification shall be based onthese tables.

103 For hydrocarbon facilities with aspects or components not covered in this Appendix, similar tables, withthe same degree of detail, shall be developed.

B. Description of Terms Used in the Scope of Work Tables

B 100 Abbreviations and Terms

101 The following abbreviations have been used:

A = auditS = surveillanceH = hold pointR = review.

102 These abbreviations are DNV’s preferred terms and will be used in DNV-generated documents.However, other terms, for example monitoring or witnessing, will be used by DNV if these are the termscommonly used in documents, such as Inspection and Test Plans, generated by others. In that case, it isexpected that these other terms will be defined in these documents.

B 200 Audit

201 Systematic, independent and documented process for obtaining audit evidence and evaluating itobjectively to determine the extent to which audit criteria are fulfilled. (ISO 9000:2005) ref. Sec.1 E.

Guidance note:This activity differs from the Surveillance by being focused on the adherence to procedures including theircompleteness and robustness and not a detailed review of the results of the procedures (although this is not ignored).Further, the audit is normally a ‘one-off’ activity as opposed to the continuity of surveillance.

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202 Note that the activity “Audit of quality management system” may be omitted if there exists a qualitymanagement system in accordance with ISO 9001, certified by an accredited third party for the scope of workbeing carried out in the project.

B 300 Surveillance

301 Continual monitoring and verification of the status of an entity and analysis of records to ensure thatspecified requirements are being fulfilled (ISO 8402:1994) ref. Sec.1 E.

Guidance note:Other commonly used terms for Surveillance are Monitoring or Witnessing.

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302 The amount of work involved in surveillance is not described in detail in the tables. This shall be part ofthe 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’s experience.

303 The following shall are typical descriptions of the frequencies, if nothing else is defined specifically:

S1 = Surveillance on a visit basis

S2 = Surveillance frequency minimum once per day

S3 = Surveillance frequency minimum once per shift

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

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B 400 Hold Point

401 A point, defined in an appropriate document, beyond which an activity must not proceed without theapproval of a designated organization or authority (ISO 8402:1994).

B 500 Review

501 Systematic examination of reports and documentation. The depth of review will depend both on the typeof document and the level of involvement.

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

I = for information only1 = review of principles and general aspectsR2 = comprehensive review.

503 A recommended depth of verification (I, R1, R2, S1, S2, S3) is specified for each generic verificationitem is given in Tables C for the three Verification Levels Low, Medium and High described in D200, D300and D500.

Guidance note:The Verification Level of Low, Medium High defines the overall verification effort for the project. The verificationdepth defines the depth of the verification effort for each identified verification activity.

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504 Documents that are reviewed by DNV will not be signed and stamped, unless otherwise agreed.

C. Overall Project Management

C 100 Availability of Documents

101 The project quality management documentation shall be available at the early stages of the project, preferablybefore design is underway, to ensure that the necessary controls are in place

C 200 Detailed Scope of Work for Overall Project Management

201 A detailed scope of work for the overall project management is given in Table C-1.

D. Design

D 100 General

101 For design verification, a list similar to that given in Tables C-3.2 to C-3.28 shall be made for the specifichydrocarbon facility.

102 It is preferred that the documentation of the items in Table C-3.2 shall be available at the early stages ofthe design.

D 200 Design Verification

201 Design of a hydrocarbon facility shall cover all development phases including construction,commissioning and operation.

202 Tables C-3.3 to C-3.27 describe the issues to be verified and Table C-3.28 identifies the extent ofindependent analyses/calculations included in the three verification levels. Sections D300, D400 and D500following, describe the verification for each of the levels.

Table C-1 Overall Project Management LevelItem Description Low Medium High

1. Review of project quality management documentation R1 R2 R22. Audit of project quality management system A A A3. Review of sub-contractor control R1 R2 R24. Review of interface controls R1 R2 R25. Review of methods of information flow - - R2

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D 300 Low Level Design Verification301 Low level design verification consists of a detailed document review of the design basis, risk assessmentand analysis documentation, quality management documentation and design method or design philosophydocuments. The presumed critical aspects of the project shall be identified by DNV from the initial review andconveyed to the Owner and designer for discussion and agreement on a common understanding.302 The subsequent verification consists of a document review of the calculations and analysis methods usedto conclude the critical aspects. Other design documents are used as information and a few will be spot-checkedfor confirmation of the quality control.303 Implementation of the transfer of conclusions from design calculations and reports into drawings andspecifications is not included.

D 400 Medium Level Design Verification401 Medium level design verification consists of a review of all main design documents related to the safetyand integrity of the hydrocarbon facility. Less critical aspects will be spot-checked. The review will be detailedfor all critical aspects and if deemed necessary independent calculations may be performed to support findings.402 Implementation of the conclusions from design calculations and reports into drawings and specificationswill be included on a spot check basis.

D 500 High Level Design Verification501 High level design verification consists of a full review of most of the produced documents related to thesafety an integrity of the hydrocarbon facility. The review will be detailed for all critical aspects andindependent checks will be performed.502 Implementation of the conclusions from design calculations and reports into drawings and specificationsis included.503 The main specifications are also checked for clearness and ambiguity.

D 600 Safety-critical Elements and Components601 Based on the results of the HAZID, HAZOP or other safety assessments, hydrocarbon refinery andpetrochemical facilities are likely to have many or most of the following safety-critical elements present.602 Verification of design is broken down into consideration of these safety-critical elements andcomponents in isolation but the many interactions between them must not be forgotten.603 Typical Safety-critical Elements for a hydrocarbon facility are shown in Table C-2. These Safety-criticalElements shall be modified to suit a specific facility.

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Table C-2 Refinery and Petrochemical Plants - Typical SCEs and ComponentsFunction Safety Critical Elements (SCE) Component

Inherent Safety Measures

Layout AllHydrocarbon Inventory/Leak Source Minimisation

All

Hazard Prevention Measures

Offloading and Loading Facilities Integrity

SPM (Single Point Mooring)Flexible RiserCrude Oil Pipelines (including pig launcher/receiver and any manifolds)JettiesLoading and Unloading Arms

Process Facilities Integrity

Process SystemRelief Valves and Relief SystemStructural IntegrityAbove Ground Storage TanksControl Systems

Control of Ignition

VehiclesFired Heaters, Hot Surfaces and ExhaustElectrical itemsLightning Protection, Static and Earthing

Dropped Object and Impact Protection All

Hazard Detection and Control Measures

Fire and Gas Detection

Smoke and Gas Detection for Site BuildingsFire and Gas Detection - External AreasFire and Gas Detection - Machinery EnclosuresFire and Gas Control (part of ICS)Personal Toxic Gas Detection and Protection

Visual Monitoring CCTV

Emergency Shutdown System (ESD)

ESD Control SystemEmergency Shutdown Valves (ESDVs)

Blowdown Header & Flare System AllControl Room All

Active Fire Fighting Systems

Fire Water StorageFirewater PumpsFirewater Distribution Ring mainFirewater and Foam SupplyGaseous Fire Fighting SystemsFire-fighting Vehicles

Passive Fire Protection All

Bunding and Drainage All

Hazard Mitigation Measures

Emergency Services

Emergency PowerEmergency Communications and Alarms

Internal and External Communications All

Personnel Toxic Gas Protection AllUninterruptible power source AllHVAC All

Emergency Response Measures

Egress and Evacuation System

Escape RoutesMuster Area

Emergency Services Emergency Lighting

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D 700 Scope of Work for Design701 Detailed scopes of work for design are given in Tables C-3.2 to Table C-3.28.

Table C-3.1 Summary Table – Design ReviewTable No. Table DescriptionC-3.2 General Design MattersC-3.3 Safety, Environmental or Other Functional RequirementsC-3.4 LayoutC-3.5 Hydrocarbon Inventory and Leak Source MinimisationC-3.6 Pressure VesselsC-3.7 Offloading and Loading FacilitiesC-3.8 JettiesC-3.9 Loading and Unloading ArmsC-3.10 Process SystemC-3.11 Relief Valves and Relief SystemC-3.12 Structural IntegrityC-3.13 Above Ground Storage TanksC-3.14 Control SystemsC-3.15 Control of IgnitionC-3.16 Dropped Object and Impact ProtectionC-3.17 Fire and Gas DetectionC-3.18 Emergency Shutdown SystemC-3.19 Blowdown Header and Flare SystemC-3.20 Control RoomC-3.21 Active Fire Fighting SystemsC-3.22 Passive Fire ProtectionC-3.23 Bunding and DrainageC-3.24 Emergency Power and Uninterruptible Power SupplyC-3.25 Communications and AlarmsC-3.26 HVACC-3.27 Egress and Evacuation SystemC-3.28 Independent Calculation

i) Blow-downii) Piping flexibilityiii) Pressure vessels and storage tanks

Table C-3.2 General Design Matters LevelItem Description Low Medium High

1. Safety objective - R1 R2

2. Confirmation that the various contractors and sub-contractors’ quality systems meet the requirements of ISO 9001 - R1 R2

3. Description of hydrocarbon facility and overall project organisation - R1 R1

4. Risk assessment and identification of critical aspects (see Table D-1) R1 R2 R2

5. Document register - - -

6.

Design philosophies for the facilities, typically;

— active and passive fire protection— safety systems (FGS/ESD/PSD/PCS)— shutdown logic— process design— piping design— relief and blowdown— material selection and corrosion management— etc.

R1 R2 R2

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Table C-3.3 Safety, Environmental or Other Functional Requirements LevelItem Description Low Medium High

1. Quantitative Risk Assessment R1 1) R1 1) R2 1)

2. Fire and Explosion Analysis R1 R1 R23. Emergency System Survivability Analysis R1 R1 R24. Fire Mapping and Detection R1 R1 R25. Computational Fluid Dynamics Analysis for gas detection R1 R1 R26. Environmental Impact Assessment - - R1

1) In cases where DNV has not carried out the Quantitative Risk Assessment itself.

Table C-3.4 Layout LevelItem Description Low Medium High

1.Confirm by review of the QRA that the adequacy of the site layout has been demonstrated to show that the level of risk is within the Owner’s acceptable risk criteria

- R1 R2

2. Confirm by review of the QRA that the risk of exposure outside the facility has been reduced to ALARP - R1 R2

3.Confirm by review of equipment layout drawings, bases of design and formal safety assessments that equipment separation within the facility is adequate in terms of the acceptable risk criteria

R1 R2 R2

4.

Confirm by document review that the facility layout demonstrates:

— segregation of different hazards within the plant— minimisation of pipe runs between units— containment of spills and leaks— limitation of risk exposure within and outside plant— access/egress for emergency services— provision of secure site entrance points— access and lay down areas to enable safe construction, operation and

maintenance— adequate provision of escape and evacuation routes to safe muster areas— safe location of control building.

R1 R2 R2

5.

Review plot plan, equipment location plan drawings to confirm location of plant buildings (control room, administration, maintenance workshop, warehouse, laboratories, etc), flare and equipment spacing in accordance with codes and specifications

R1 R2 R2

Table C-3.5 Hydrocarbon Inventory and Leak Source Minimization LevelItem Description Low Medium High

1. Verify the location and size of hydrocarbon and chemical storage facilities - R1 R2

2. Verify that potential leak sources have been challenged and justified through the risk management process - R1 R2

3.The adequacy of the inventory management system and philosophy is to be demonstrated in the QRA to show that the level of risk is within the corporate risk acceptable criteria

- R1 R2

4. Confirm that storage facilities and operating philosophy are in line with maximum allowable inventories - R1 R2

5. Pipe stress analysis philosophy, guidelines and work instructions to identify need for additional information not outlined in the specified piping code or project standards R1 R1 R2

6.

Selection of pipe stress analysis reports and pipe stress isometrics to ensure that the analysis meet the requirement outlined in the specific piping code, project standards and project pipe stress analysis philosophyNote 1: A typical selection may be based on large pipe size, large temperature differential and piping with high pressure.Note 2: Piping line list, piping critical line list and project P&IDs normally will be used as the basis for this selection.

R1 R2 R2

7.

Review of a selected number of piping classes in the piping material specification. Typical this work will consist of spot check of tabulated wall thickness against temperature, pressure, corrosion allowance, impact testing and fitness for service.Note 1: Relevant material data sheets will also be consideredNote 2: The selection may be based on materials not widely used, such as super duplex, 6Mo, titanium and composite.

R1 R2 R2

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8.

Design calculations to confirm pressure vessel design in accordance with applicable codes, standards and specifications.Note 1: See Table C-3.6 for more detailed requirements for pressure vessel design verification

R1 R2 R2

9.

Design calculations to confirm piping system design is in accordance with applicable codes, standards and specifications, including:

— design and fabrication specifications— piping specifications— mechanical flow diagrams— process and instrumentation diagrams for:

— all process piping— all drilling piping— all utilities piping— summary of piping flexibility analyses including description of computer

programs, methods of analysis and flexibility analysis of a few selected pipe runs

— drawings of non-standard components— welding procedure specifications.

R1 R2 R2

10.

Design calculations to confirm pumps and compressors design is in accordance with applicable codes, standards and specifications, including:

— design specification— general arrangement drawings including foundation design— cross-sectional drawings— detailed drawings of rotating and pressure retaining parts— auxiliary system drawings— calculations of pressure retaining parts in both operating and pressure test

conditions— calculations for rotating parts— lateral and torsional vibration analysis— bill of materials— fabrication specification— welding procedure specifications.

R1 R2 R2

11.

Design calculations to confirm gas turbine and combustion engine design is in accordance with applicable codes, standards and specifications, including:

— technical specification— arrangement drawings— detailed sectional and part drawings— rotor bearing drawings— system drawings— safety systems— turbine hood ventilation philosophy— lateral and torsional vibration analysis— material specifications— fabrication specification— testing procedures.

- R1 R2

Table C-3.5 Hydrocarbon Inventory and Leak Source Minimization LevelItem Description Low Medium High

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Table C-3.6 Pressure Vessels LevelItem Description Low Medium High

Guidance note:There are many different types of reactors, heat exchangers, boilers and other types of pressure vessels inhydrocarbon facilities and it is not possible to give detailed verification requirements for each one. However,verification of their design will follow the same general path in considering:

— design pressures— design temperatures— characteristics of contents— structural stability.

This Table lists verification activities that are common to most types of pressure vessels but these activities may bemodified to suit specific types of vessels.

---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

Materials and Corrosion1. Material specification R1 R1 R22. Corrosion protection R1 R1 R2

Pressure Containment3. Design stress R1 R2 R24. Spherical/cylindrical shell - internal and/or external pressure R1 R2 R15. Domed ends - internal and/or external pressure R1 R2 R26. Conical ends/truncated cones - internal and/or external pressure R1 R2 R17. Cylindrical/spherical/conical shell combined loading R1 R2 R28. Local loads on pressure vessel shell R1 R2 R19. Flat ends/flat plates R1 R2 R210. External pressure stiffening rings R1 R2 R111. Flat heat exchanger tube sheet R1 R2 R212. Spherically domed/bolted ends R1 R2 R113. Openings/branch connection R1 R2 R214. Overpressure/vacuum protection R1 R2 R115. Manholes R1 R2 R216. Jacketed vessel R1 R2 R117. Supports (saddles, lugs or foundations) R1 R2 R218. Bolted flange connections R1 R1 R1

General Design19. Construction category - R1 R220. Weld design R1 R2 R221. Fatigue R1 R2 R2

Construction22. Heat treatment extent - R1 R223. NDT extent I R1 R224. Shop/site hydro test pressure I R1 R225. Welding Procedure Specification requirements I R1 R226. Nameplate data - R1 R1

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Table C-3.7 Offloading and Loading Facilities LevelItem Description Low Medium High

SPM (Single Point Mooring)

1.Confirm by document review that the SPM (or its equivalent) has been designed in accordance with DNV-OS-E403 Offshore Loading Buoys or another code or standard giving an equivalent level of safety

R1 R1 R1

Flexible Riser

2.Confirm by review of documents, such as independent design reviews and product certification, that the Flexible Riser (if fitted) has been designed in accordance with a suitable code or standard

R1 R1 R1

Crude Oil Pipelines (including Pig launcher/receiver and any PLEMs or manifolds)

3.Confirm by document review that any pipelines have been designed in accordance with DNV-OS-F101 Submarine Pipeline Systems or another code or standard giving an equivalent level of safety

R1 R1 R1

Table C-3.8 Jetties LevelItem Description Low Medium High

1.

Jetty design has taken account of:

— geotechnical considerations — environmental loads (including dynamic response of the structures to cyclic

loads)— operational loads.

R1 R2 R2

2. Corrosion assessment report and corrosion monitoring system R1 R2 R23. Structural design - R1 R24. Construction and inspection procedures R1 R2 R1

Table C3.9 Loading and Unloading Arms LevelItem Description Low Medium High

1. Pressure containment, thermal, structural and fatigue calculations R1 R2 R22. ESD system, including quick disconnect facilities R1 R2 R23. Specifications and data sheets - R1 R1

Table C-3.10 Process System LevelItem Description Low Medium High

Materials1. Systems description manual and material selection diagram I R1 R2

2.Materials selection report, Corrosion protection reportCoating and insulation specification (e.g. coating procedures)

R1 R2 R2

3.Internal corrosion assessment, calculation and assessment of corrosion rate where applicable (or spot check)Corrosion monitoring system

R1 R2 R2

4.

Materials specification welding specificationNDT-specificationfor critical components

R1 R2 R2

Process Equipment

5.

Design of all process equipment and facilities shall account for all identified operating, testing, start-up and upset conditions (pressure, temperature, flow, composition, internal and external corrosion, erosion), throughout the life of the field without loss of containment

R1 R2 R2

6.Refinery process equipment and facilities shall be designed, fabricated and maintained to account for all foreseeable internal and external corrosion effects by way of material selection, external coating and corrosion inhibition

R1 R2 R2

7.Process equipment integrity is to be maintained in the event of fire by combination of design layout, ESD, passive fire protection, pressure relief valves, blowdown and inherent strength

R1 R2 R2

8. Pumps handling main process hydrocarbon fluids shall be designed to minimise the risk of leakage, e.g. seal-less or dual seals - R1 R2

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9.

P&IDs and associated documentation to confirm: Appropriate safety devices are specified according to codes and project specificationsAdequate margins between operating and design conditions Trip settings are suitable for the intended level of protectionThe status or position of valves does not impair system safety (locked open/closed; fail open/close/fixed; interlocking; etc.)

R1 R2 R2

10.P&IDs to confirm that shutdown valves are located such that systems can be clearly segregated and give suitable segment boundaries and conforms to the assumptions and basis of the risk analysis.

R1 R2 R2

11. P&IDs showing block valves, isolating devices, etc. required for maintenance operations. - R1 R2

12. Specifications and data sheets for equipment such as pressure vessels, valves, heat exchangers, pumps, compressors and turbines - R1 R2

13. Manufacturers design documentation to verify that project specifications and applicable standards are implemented correctly with respect to equipment integrity - R1 R2

Electrical and Instrumentation Equipment

14. Instrument-based overpressure protection facilities shall meet the requirements specified e.g. SIL rating R1 R2 R2

15.

Design documents to confirm electrical equipment design in accordance with applicable codes, standards and specifications, including arrangement drawings showing location of:

— generators— transformers— main distribution and emergency switchboards— large motors— main and emergency cable runs— all electrical equipment in hazardous areas.

The separation between main and emergency power source and distribution should be clearly shown

R1 R2 R2

16.Schedule of type of electrical equipment used in hazardous areas, having regard to the particular area classification, i.e. cable type and make, type and protection of all equipment

- R1 R2

17.One-line diagrams for the complete installationInformation concerning full load, cable type, cross-section and make, type and rating of fuse and switchgear for all distribution circuits

- R1 R2

18.One-line diagrams for intrinsically safe circuits showing part in safe area, part in hazardous area, type of cable and make and type of intrinsically safe relays, barriers and apparatus

- R1 R2

19.

Complete multi-wire diagrams, preferably as schematic diagrams for all control and instrumentation circuits of main switchboards, giving information on:

— cable types— cable and bus bar cross-sections and make— type and rating of all equipment.

- - R1

20.

Arrangement drawings showing:

— front of switchboard panels with equipment and sectional drawings and details of bus bar supports

— personnel protection for high voltage switchboards — battery rooms and their ventilation systems.

- - R1

21. Short circuit calculations showing rms and peak short circuit currents for evaluation of making and breaking capacity for all switchgear R1 R2 R2

22. Information concerning emergency power supply including connections to basic board, chargers and all consumers R1 R2 R2

Table C-3.10 Process System (Continued) LevelItem Description Low Medium High

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Table C-3.11 Relief Valves and Relief System LevelItem Description Low Medium High

1. Confirm that the relief philosophy and design for relief valves, system such as flare and vents is in accordance with good industry practice and international standards R1 R2 R2

2. At least one relief path shall be available to each hydrocarbon vessel at all times R1 R2 R23. Evaluation of possible cases of overpressure leading to determination of worst case R1 R2 R2

4.Process design calculations for the relieving devices (relief valve, rupture disc, etc.), to confirm the sizing case (full flow, gas blow by, fire, thermal relief, etc.) is appropriate and the specified capacity adequate

- R1 R2

5.

Process design calculations focusing on:

— inlet conditions at design relief condition— specific heats— average molecular weight— pressure and temperature— required mass flow through valve— relieving device inlet line pressure drop— outlet line size and backpressure.

R1 R1 R2

6. Sizing calculations for every pressure safety valve and rupture disc - R1 R27. Data sheets to confirm sizing case, set pressure, backpressure and valve type R1 R2 R2

8. Confirm by review of P&IDs that isolation valves for relieving devices are locked open for active devices and locked closed for stand-by devices R1 R2 R2

Table C-3.12 Structural Integrity LevelItem Description Low Medium High

Equipment and Pressure Vessel Supports and Foundations

1.

Equipment support and foundation design has taken account of:

— geotechnical considerations— environmental loads, including the effects of dynamic loads, where applicable— operational loads

R1 R2 R2

2. Corrosion assessment report and corrosion monitoring system R1 R2 R23. Structural design - R1 R24. Construction and inspection procedures R1 R2 R2

Piping

5. Bases of design for piping and mechanical and specifications or data sheets specify the appropriate loadings for the design of piping supports and pipe racks R1 R2 R2

6. Where concrete pipe racks are being used, check design of concrete mix and reinforcement - R1 R2

7. Construction and inspection procedures R1 R2 R2

Table C-3.13 Above Ground Storage Tanks LevelItem Description Low Medium High

Foundations

1.

Tank foundation design has taken account of:

— geotechnical considerations, including any soil improvement— environmental loads— operational loads.

R1 R2 R2

2. Design of foundations R1 R2 R23. Construction and inspection procedures for foundations R1 R2 R2

Tanks4. Tank pressure containment design R1 R2 R2

5.Materials selection report, Corrosion protection reportCoating and insulation specification (e.g. coating procedures)

R1 R2 R2

6. Internal corrosion assessment, calculation and assessment of corrosion rateCorrosion monitoring system R1 R2 R2

7.Materials specification welding specificationNDT specification

R1 R2 R2

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Table C-3.14 Control Systems LevelItem Description Low Medium High

1. Control logic and philosophy is clearly stated and any relationship with the ESD system is clearly defined R1 R2 R2

2.All major process hazards have been assessed and protective managed through the control system functionality as appropriateNote: Where necessary, high integrity protective system may be provided.

R1 R2 R2

3.

Design documents to confirm control system design in accordance with applicable codes, standards and specifications, including:

— process flow diagram— process and instrumentation diagrams for the total hydrocarbon and utility

facilities— process shutdown logic and philosophy— list of set points of safety switches— failure modes of relevant components of system— statement of closing time of the total process shutdown system— statement of quickest pressure build up expected, assuming blockage in the

process or utilities systems— functional description of the facilities for testing the process shutdown system.

R1 R2 R2

4. Pressurized equipment and associated pipework are fitted with protective devices R1 R2 R2

5.

Cause and Effect diagrams, or similar, covering the following aspects:

— PSD; shutdown according to codes and project specifications— PSD; avoid unacceptable cascading effects— PSD; high level shutdown to include lower levels/individual shutdown levels— FGS; initiation of relevant fire extinguishing systems, shutdown actions, ignition

prevention, alarm systems, blowdown (as applicable)— ESD; shutdown of production plants, ESDVs/SDVs as appropriate and initiation

of blowdown

R1 R2 R2

Table C-3.15 Control of Ignition LevelItem Description Low Medium High

1. Confirm that the location of ignition sources meets API separation requirements from process plant R1 R2 R2

2. Confirm that fired heaters and boilers have suitable purge facilities prior to start-up to prevent internal explosions - R1 R2

3. Confirm that fired heaters and boilers have been designed in accordance with the mechanical basis of design - R1 R2

4.

Hazardous area classification drawings and source of release schedule to verify the extent and type of zones, location of ventilation inlets/outlets, overpressure/air locks for local equipment rooms: cross check against P&IDs to confirm classification of vents, segregation of drainage system etc.

R1 R2 R2

5.

Ensure all vehicles comply with industry standards: where required, vehicles used for maintenance access or emergency access on the site shall conform to suitable industry standards for petrochemical plants: this shall include selection of engines with spark arrestors and emergency stops

- R1 R2

6. Verify that electrical equipment is suitable rated and certified for the hazardous area classification within which it is located R1 R2 R2

7. The refinery electrical equipment shall be in accordance with the basis of design - R1 R2

8. Confirm that any external electrical equipment required to operate in a major accident event shall be appropriately certified and meets codes and standard R1 R2 R2

9. Review hazardous area layout drawings and review specifications to ensure compliance R1 R2 R2

10. Review basis of design for safety shutdown for suitability, and review cause and effect drawings R1 R2 R2

11. Review specifications for appropriate shutdown requirements. - R1 R2

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12. Review specifications and confirm certification requirements. - R1 R2

13.

The refinery lightning protection, static protection and earthing on process and electrical equipment shall be in accordance with the basis of design: the site shall be provided with an adequate number of lightning rods to attract and deflect lightning in order to prevent ignition

R1 R2 R2

14. Confirm by review of calculations and studies that a suitable earthing grid is to be provided in accordance with the required standard - R1 R2

15.

A system of bonding and earthing is to be provided to maintain a sufficiently low resistance between equipment enclosures, skids and earth. This system is to be designed in accordance with the basis of design for earthing, bonding and lightening protection

- R1 R2

Table C-3.16 Dropped Object and Impact Protection LevelItem Description Low Medium High

1. Confirm that equipment along roads and in-unit access ways is protected from vehicle impact through the use of curbing, barriers, or by virtue of its distance from the road - R1 R2

2. Confirm that the design of the plant aims to minimise lifting operations over operational vessels or piping - R1 R2

3.Confirm that adequate dropped object protection has been provided for equipment and piping in vulnerable areas (heat exchanger bundles, gas turbines, catalyst containers, jetties, etc.)

- R1 R2

Table C-3.17 Fire and Gas Detection LevelItem Description Low Medium High

General1. Review layout and types of fire and gas detectors R1 R2 R2

2. Review connection between fire and gas detection panels and platform shutdown system R1 R2 R2

Smoke and Gas Detection for Site Buildings

3.Confirm that adequate gas detection is provided on the HVAC inlets with sufficient detection time to ensure that functioning of the dampers will occur before impairment of the protected space

R1 R2 R2

4. Confirm that response times are in accordance with the HVAC study for migration times and damper closure times - R1 R2

5. Confirm that detector types will provide the required detection times - R1 R2

6. Confirm by review of the design report that an adequate fire and gas system is to be implemented R1 R2 R2

7. Confirm by review of the alarm and detection study that smoke and gas detectors are suitably protected and can adequately detect the hazard R1 R2 R2

Fire and Gas Detection - External Areas

8. Confirm by design review that the fire and gas detector coverage is in accordance with the fire area layouts and gas risk volume layouts R1 R2 R2

9. Confirm by review of the design report that an adequate fire and gas detection system is to be implemented - R1 R2

10. Confirm the specification of cables meet required standards R1 R2 R211. Confirm from review of layouts and study that cable routing is appropriate - R1 R2

12.Type (suitability), number and location of detectors taking into account voting philosophy and alarm levels. Review location and number of manual fire alarm stations

R1 R2 R2

Fire and Gas Detection - Machinery Enclosures

13.

Confirm sufficient detection coverage is provided to detect releases of flammable hydrocarbons, including oil mist/vapour, and excessive temperature rise in machinery enclosures

R1 R2 R2

Table C-3.15 Control of Ignition (Continued) LevelItem Description Low Medium High

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14.

Confirm sufficient detection coverage is provided to detect the presence of gas:

— at the air inlet to continuously operated machinery enclosures, (main gas turbine enclosures)

— at the air exhaust to machinery enclosures containing a source of gas, (main gas turbines only)

— in the vicinity of not normally operated machinery within buildings or enclosures (emergency generators, fire pump enclosures, etc.).

R1 R2 R2

Fire and Gas Control (part of ICS)

15.

Confirm that in the event of fire, smoke and/or gas detection, the fire and gas system initiates alarms and executive actions (i.e. Initiate ESD, plant audible and visual alarms, and firewater pumps) appropriate to the incident

R1 R2 R2

16. Confirm that suitable audible and visual, local and central annunciation of detection occurs R1 R2 R2

Personal Toxic Gas Detection and Protection

17.Confirm that personal toxic gas detectors are suitable to detect the range of toxic gases within the plant (typically H2S, SO2, CO and high/low O2 levels) - R1 R2

Table C-3.18 Emergency Shutdown System LevelItem Description Low Medium High

1. Confirm by design review that the emergency shutdown logic and philosophy is adequate R1 R2 R2

2.

General arrangement drawings showing location of:

— emergency shutdown valves— manual emergency shutdown stations and panels

- R1 R1

3. Detailed description of the facilities for testing the emergency shutdown system during normal operations - R1 R2

4. Confirm that in the event of an emergency situation, the emergency shutdown system initiates alarms and executive actions appropriate to the incident R1 R2 R2

5.Confirm by design review that the ESD control system, is protected by location from all credible major accidental events, and from the effects of all credible major accidental events for 30 minutes thereafter, by review of design documentation

- R1 R2

6. Confirm that maximum allowable valve closure times for ESD valves shall be in accordance with the emergency response philosophy R1 R2 R2

7. Confirm by review of basis of design that explosion scenarios have been considered during the design of ESD valves, actuators and supports - R1 R2

8. Confirm by review of specification that status of ESD is to be provided at operator stations R1 R2 R2

9. Confirm by review of layouts that ESDVs are to be suitably protected from potential vehicular impact - R1 R2

Table C-3.17 Fire and Gas Detection (Continued) LevelItem Description Low Medium High

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Table C-3.19 Blowdown Header and Flare System LevelItem Description Low Medium High

1. Review P&IDs showing pressure safety valves and rupture discs R1 R1 R1

2. P&IDs to confirm that isolatable sections are provided with remote operated blowdown possibilities as required by the flare and blowdown philosophy R1 R2 R2

3.Review pressure drop calculations based on an analysis of number of safety valves, rupture discs and depressurising valves likely to be operating simultaneously or within a short interval

- R1 R2

4. Review calculations showing capabilities of knock-out drum R1 R2 R25. Review back pressure calculations for headers and other piping - R1 R26. Review calculated gas outlet temperature for every relevant pressure system - R1 R2

7. Confirm that specifications require the appropriate maximum allowable opening time for the blowdown valves R1 R2 R2

8.

Flare and blowdown documentation to confirm that:

— time to depressurise is appropriate— calculated flow rates do not exceed the system capacity— calculated backpressures do not exceed the system limits— flare system is separated into appropriate systems (e.g. high and low pressure,

hot and cold, wet and dry flare systems)— minimum temperature and material choice is acceptable

R1 R2 R2

9.P&IDs to confirm that flare, relief and blowdown lines are self draining, and where low points are unavoidable these have an appropriate drain connection with locked open isolation valve

R1 R2 R2

10. Flare knock-out drum sizing calculations and drawings to confirm that there will be no liquid carry over to the flare tip R1 R2 R2

11. P&IDs to confirm a suitable purge gas system to prevent air ingress is specified for the flare system (including alarms for low flow, back-up systems, etc.) R1 R1 R2

12. Flare radiation calculations (for worst case flow and wind conditions) to confirm these are acceptable - R1 R2

13. Flare noise calculations to confirm compliance with noise requirements of the verification basis (as applicable) - I R1

14. P&IDs to confirm ‘snuffing’ package is specified for cold vent tip where appropriate R1 R2 R2

15. Flare ignition system to confirm that acceptable reliability of ignition will be achieved during all possible scenarios R1 R2 R2

16.

Reliability documentation to confirm that any overpressure protection system is independent of other systems and have the same or better safety reliability as a system using pressure relief devices: alternatively, confirm compliance with IEC 61508 and that specified SIL level is achieved in accordance with overpressure protection specification

R1 R1 R2

17. System documentation to confirm that requirements for online testing have been accounted for - R1 R2

18. Process design calculations to confirm that the specified response times of protective systems are sufficiently short to prevent unacceptable process conditions R1 R2 R2

Table C-3.20 Control Room LevelItem Description Low Medium High

1.Confirm that design features of the control room shall be available at all times including major accident events where the control functions will be of significant benefit

- R1 R2

2. Confirm that the location and orientation of the control room is such that it is protected from credible worst case fire, blast and toxic events R1 R2 R2

3. Confirm that CCTV coverage is such that all necessary angles of the areas in questions can be viewed at a central protected location - R1 R2

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Table C-3.21 Active Fire Fighting Systems LevelItem Description Low Medium High

Fire Water Storage

1. Confirm by review of fire studies and design calculations that sufficient fire water storage is provided - R1 R2

Firewater Pumps

2.

Review arrangement of power supply to fire pumps including:

— type of supply— support system for driver— power transfer from driver to pump.

R1 R2 R2

3. Confirm that fire pump start requirements are in accordance with performance standard R1 R2 R2

Firewater Distribution Ring main

4. Confirm that the firewater distribution ring main is designed to accommodate the maximum shut-in head of the fire pumps plus any elevation allowance R1 R2 R2

5. Confirm that isolating valves are provided adjacent to the ring main, on branch lines feeding fire fighting equipment other than single fire hydrants R1 R2 R2

Firewater and Foam Supply

6.

Confirm that every area of the process system is covered by at least 2 monitors and 2 hydrants in diverse locations and fed by separate sections of the ring main. Confirm that this equipment is accessible in credible fire scenarios such that they can be operated in an emergency

R1 R1 R2

7. Confirm that foam injection points are accessible in credible fire scenarios such that they can be operated in an emergency R1 R1 R2

8.Layout drawings to confirm adequacy of firewater main routing and adequate number and location of manual fire fighting equipment such as fire extinguishers, hydrants, hoses and monitors

R1 R1 R2

9. Adequacy of selected manual fire fighting equipment R1 R1 R210. Sizing basis for firewater demand to cover process areas R1 R1 R2

11. Firewater P&IDs to confirm requirements for supply to equipment and areas, separation of supplies, bypass and isolation possibilities R1 R1 R2

12. Firewater hydraulic calculations to confirm adequate capacity and pressure to all discharge points - R1 R2

13. Layout drawings to confirm adequate location of deluge valves, choice of areas to be protected and identification of dedicated equipment protection. R1 R1 R2

14. Nozzle type and density in each area I R1 R1

15. Foam and other fire extinguishing systems with respect to application, type, concentration and capacity R1 R1 R2

Gaseous fire-fighting systems

16.

Confirm that gaseous fire-fighting systems are deployed on enclosed equipment which will be damaged beyond repair or will cause escalation if water is applied such as computer server rooms, gas turbine hoods and battery rooms

- R1 R2

17.Confirm that the extinguishing system is linked to an automatic early detection and initiation system which includes a visible and audible warning to personnel in the area before deployment

R1 R1 R2

Fire-fighting Vehicles

18.

Confirm that sufficient fire-fighting vehicles are available to support all credible fire scenarios onsite including the consideration of mutual aid and outside agencies where applicable: down time for maintenance should also be considered

- R1 R2

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Table C-3.22 Passive Fire Protection LevelItem Description Low Medium High

1. Confirm by review of passive Fire Protection (PFP) specification that adequate PFP is to be provided of suitable rating R1 R1 R2

2.PFP on vessels, piping, supports and structure and withhold this with assumptions in Risk Analysis (if relevant), design accidental loads in each specific area, vessel integrity requirements, blowdown time etc.

R1 R1 R2

3.PFP drawings versus specified criteria for heat loads and exposure time, and withhold this against material approval certificates with respect to thickness and application requirements

- R1 R2

4.Separation by fire divisions of individual process areas for compliance with project requirements and conforming to the assumptions in risk analysis and active fire fighting philosophy

R1 R1 R2

5. Requirements for passive fire protection resulting from the project specific design philosophy and risk analysis R1 R1 R2

Table C-3.23 Bunding and Drainage LevelItem Description Low Medium High

1. Confirm by review of calculations that sufficient bunding is provided at all relevant areas and sized for credible leaks. - R1 R2

2.Confirm by review of plans and layouts that the drainage valve shall remain accessible in the event of a bund fire. Adequate separation shall allow for closure after the liquid has been spilt and ignited

- R1 R2

Table C-3.24 Emergency Power and Uninterruptible Power Supply LevelItem Description Low Medium High

1.

Review information concerning emergency power supply including:

— connections to basic switchboard— chargers— all consumers.

R1 R1 R2

2.

Confirm that uninterruptible power is provided for all critical equipment with an emergency function which would otherwise cease to function including:

— ESD systems— control systems— emergency lighting— emergency communication systems.

R1 R2 R2

3.

Confirm by review that the capacity shall be sufficient for the following users:

— integrated control system supply— emergency lighting including— emergency communication system— other systems required for emergency response.

R1 R2 R2

4. Confirm that emergency power is provided by diverse sources such as battery systems, generators and redundant outside sources R1 R1 R2

Table C-3.25 Communications and Alarms LevelItem Description Low Medium High

Emergency Communications and Alarms

1. Confirm by review of specifications that an alarm system is to be provided throughout the site R1 R1 R2

2. Confirm by review of specifications that appropriate equipment protection is provided in the event of flammable gas ingress R1 R1 R2

Internal and External Communications

3.Confirm that adequate external and internal telephone and fax lines are available at all times during an emergency giving the emergency control centre the capability to handle two-way communications with all relevant parties

R1 R1 R2

4.Confirm that the routing of cabling and location of marshalling and power supplies is such that the system is protected from credible fire, explosion and seismic and weather events

R1 R1 R2

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E. Construction

E 100 General

101 Construction consists of a number of different site activities and their associated documentation.

102 Table E-1 gives summaries of the scope of work tables included in this section for various constructionactivities.

E 200 Construction Verification

201 For verification of hydrocarbon facilities, construction activities are considered as:

— initial activities,

Table C-3.26 HVAC LevelItem Description Low Medium High

1. Review flow diagrams showing supply and extract and showing separation between any hazardous and non-hazardous systems R1 R1 R2

2.

D&IDs showing location of:

— inlets and outlets— fire dampers— control dampers— air treatment units and fans.

R1 R1 R2

3.

D&IDs and associated documentation to confirm:

— system is designed according to codes and project specifications— adequate heat bridges exist where ducting penetrates fire boundaries.

- R1 R2

4. Particulars of capacity including air change rates - R1 R2

5. Confirm that HVAC systems physically isolate (dampers) the air supply on flammable or toxic gas, or smoke detection at the HVAC inlet R1 R2 R2

Table C-3.27 Egress and Evacuation System LevelItem Description Low Medium High

Escape Routes

1.Drawings showing layout of internal escape routes marked with direction of escape; the drawings to include location of major equipment R1 R1 R2

2. Description of marking system - R1 R23. Confirm by document review that escape routes have a minimum height and width - R1 R2

4. Confirm by document review that escape routes will allow easy transit of stretcher teams - R1 R2

Muster Area5. Confirm by review of studies that sufficient mustering capacity is to be provided - R1 R2

Emergency Lighting

6. Confirm by review of emergency lighting drawings that lighting is to be provided on all escape routes and at critical locations R1 R1 R2

Table C-3.28 Independent analyses/calculations LevelItem Description Low Medium High

Blow-down

i. Prepare a simplified model of the process plant in order to review critical blow-down design features such as the flare headers, flare KO Drum and flare radiation (x) x

Piping flexibility

ii. Prepare a model of critical lines to evaluate pipe stress and support layout in accordance with ASME B31.3 Part 5 Flexibility and Support (x) x

Pressure vessels and storage tanks

iii.Prepare a structural model of important pressure vessels and storage tanks to evaluate the structural capacity of critical areas for normal and/or accidental loads as found critical during the design of design review

(x) x

x = analysis/check shall be included in the scope of work(x) = analysis/check shall be included in the scope of work if the issue is identified as critical or highly utilised. Then final decision

of inclusion in the scope of work will be a result of the document review of simple analysis.

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— inspection activities— final activities.

202 The initial activities include the review of procedures, attendance during qualification of procedures andpersonnel and other start-up activities. The inspection activities are the site attendance and the final activitiesare the continuous review of production results and records and the completion of documentation and reports.

203 Sections E300, E400 and E500 following, describe the verification activities for each of the threeverification levels.

E 300 Low Level Construction Verification

301 For Low level verification, the procedure review consists of a review of the construction managementprocedures and confirmation that the most important aspects of the main specifications have been included inthe procedures. For the qualification of procedures and personnel, DNV will not attend the actual qualification,but will review the results.

302 During construction, DNV’s verification will be performed during site visits. The verification will focuson the critical items and aspects identified in the detailed scope of work tables.

303 The subsequent verification of the final activities will be by spot-checks of the production recordsincluding non-conformance logs, mechanical completion reports and results from audits, both contractors’internal audits or audits performed by other parties.

304 Implementation of the transfer of design information from drawings and reports into fabrication or shopdrawings is not included.

E 400 Medium Level Construction Verification

401 For Medium level verification, the procedure review consists of a detailed review of constructionmanagement procedures. Other important procedures will be spot checked to confirm that the most importantaspects of the specifications have been included.

402 For the qualification of procedures and personnel, DNV will visit the main qualifications and review the results.

403 During construction, DNV’s verification will be performed by full time attendance at the main site. Theverification will focus on the critical items and aspects as identified in the detailed scope of work tables.

404 Verification of the final activities will be by review of the production records including non-conformancelogs, mechanical completion reports and results from audits, both contractors’ internal audits or auditsperformed by other parties, from the main sites and spot checks of the same from other important sites relevantto the main construction site.

405 Implementation of the transfer of design information from drawings and reports into fabrication or shopdrawings is included on a spot check basis

E 500 High Level Construction Verification

501 For High level verification, the procedure review consists of a detailed review of constructionmanagement procedures. Other procedures will be reviewed to confirm that important aspects of thespecifications have been included.

502 For qualification of procedures and personnel, DNV will attend the main qualifications, spot-check otherqualifications and review the results.

503 During construction, DNV’s verification will be performed by full time attendance at the main site andby visits to the other important sites. Verification will focus on the critical items and aspects as identified in thedetailed scope of work tables.

504 Verification of the final activities will be by detailed review of the production records including the non-conformance log, mechanical completion reports and results from audits, both contractors’ internal audits oraudits performed by other parties, from the main sites and spot checks of the same from other important sitesrelevant to the main construction site.

505 Implementation of the transfer of design information from drawings and reports into fabrication or shopdrawings is included.

E 600 Verification of Work in Progress

601 The monitoring by the Owner during construction relates to the activities of the contractor. Themonitoring of these activities by DNV relates not only to the contractors’ activities but also to the monitoringof these activities carried out by the Owner.

602 The emphasis placed on the various activities in the verification plan varies depending on:

— any areas of concern revealed during design verification— any areas of concern revealed during the audit of the Owner’s or contractor’s quality management systems— the progress of construction

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— the findings of the contractor surveillance personnel.

603 Many contractors have adequate quality control systems and quality control departments, withcompetent personnel to perform, for example, inspection at pressure vessel manufacturers.

604 In that case, not all certification work need be done by DNV personnel. Where applicable, the variousinspections may be carried out by competent contractor personnel. In that situation, DNV’s certificationactivities may comprise:

— reviewing the competence of the contractor’s personnel— auditing their working methods and their performance of that work— reviewing the documents produced by them.

605 In addition, materials may be ordered with certificates of independent third-party verification (e.g. 3.2according to EN 10204). This can this be integrated in the overall verification activities, so not to duplicate work.

606 Furthermore, credit may be given to components that are CE-marked, providing that the appropriateconformity assessment modules have been used, e.g. for equipment for which verification of design is requiredby the Verification Plan, Module H is insufficient and Module H1 is required, irrespective of the requirementof the particular Directive.

607 DNV personnel will spend more time in areas where problems have occurred, or are considered likely tooccur. Conversely, less time is spent in areas where the likelihood of problems is considered lower.

E 700 DNV Final Report

701 All the Scopes of Work tables for construction activities end with a Hold Point entitled “Issue of DNVReport”. This item is not related to the production process as a normal hold point would be, ref. B400. Thisitem is intended as a reminder to the DNV (or other) inspection personnel that a final report of their verificationactivities is required to finish the work.

702 This report may in the form of a Visit Report for an activity that is completed irregularly, such as a visitto a manufacturer’s works or a monthly report of site activities where DNV’s presence is continuous.

E 800 Scope of Work for Construction

801 Detailed scopes of work for the verification of construction are given in Table C-4.2 to C-4.25.

802 Initial and final activities that are common to all construction verification are shown in Table C-4.2 andare not repeated in the tables for individual safety-critical elements.

Table C-4.1 Summary Table - ConstructionTable No. Table Description

C-4.2 Common Construction ActivitiesC-4.3 LayoutC-4.4 Hydrocarbon Inventory and Leak Source MinimisationC-4.5 Offloading and Loading FacilitiesC-4.6 JettiesC-4.7 Loading and Unloading ArmsC-4.8 Process SystemC-4.9 Relief Valves and Relief System

C-4.10 Structural IntegrityC-4.11 Above Ground Storage TanksC-4.12 Control SystemsC-4.13 Control of IgnitionC-4.14 Dropped Object and Impact ProtectionC-4.15 Fire and Gas DetectionC-4.16 Emergency Shutdown SystemC-4.17 Blowdown Header and Flare SystemC-4.18 Control RoomC-4.19 Active Fire Fighting SystemsC-4.20 Passive Fire ProtectionC-4.21 Bunding and DrainageC-4.22 Emergency Power and Uninterruptible Power SupplyC-4.23 Communications and AlarmsC-4.24 HVACC-4.25 Egress and Evacuation System

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Table C-4.2 Common Construction Activities LevelItem Description Low Medium High

Initial Activities1. Review quality management system documents R1 R2 R22. Quality system audit at relevant manufacturers and sub-suppliers 1) - A A3. Review of specifications and procedures R1 R2 R2

4. Technical Meeting / Kick-off Meeting and review of construction or manufacturing documents R1 R1 R2

5. Verify the performance and testing during the Procedure and Personnel Qualification Testing - S1 S3

Inspection Activities6. As detailed in Tables C-4.3 to C-4.23 - - -

Final Activities7. Review of manufacturing and testing records R1 R2 R28. Issue of DNV Report H H H

1) May be omitted if requirements in Sec.3 B202 are complied with

Table C-4.3 Layout LevelItem Description Low Medium High

1.

Confirm that the facility layout conforms to the Plot Plans, especially:

— equipment spacing— location of control buildings— access/egress for emergency services— provision of secure site entrance points— access and laydown areas to enable safe construction, operation and maintenance— adequate provision of escape and evacuation routes to safe muster areas.

S1 S2 S3

Table C-4.4 Hydrocarbon Inventory and Leak Source Minimisation LevelItem Description Low Medium High

1. Confirm that all equipment, pipes and associated equipment which contain hazardous materials are fabricated and installed in accordance with design drawings S1 S2 S3

2. Confirm the pipe supports are of the type and are in the locations shown on the drawings shown in the pipe stress analysis S1 S2 S3

3. Conform that pipework is constructed in accordance with the piping classes S1 S2 S3

4.

For pressure vessels, review:

— report of pressure testing— facsimile of completed vessel name plate— pressure vessel certificate as required by the specified design code.

R1 R1 R2

5.For piping systems, review:

— report of pressure testing.R1 R1 R2

6.

For pumps and compressors, review:

— records of pressure testing— records of performance testing.

R1 R1 R2

7.

For gas turbines and combustion engines, review:

— certification and testing reports of safety devices— records of performance testing.

- R1 R1

Table C-4.5 Offloading and Loading Facilities LevelItem Description Low Medium High

SPM (Single Point Mooring)

1.Confirm by document review that the SPM (or its equivalent) has been constructed and installed in accordance with DNV-OS-E403 Offshore Loading Buoys or another code or standard giving an equivalent level of safety

R1 R1 R1

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Flexible Riser

2.Confirm by review of documents, such as independent design reviews and product certification, that the Flexible Riser (if fitted) has been constructed and installed in accordance with a suitable code or standard

R1 R1 R1

Crude Oil Pipelines (including Pig launcher/receiver and any PLEMs or manifolds)

3. Confirm by document review that any pipelines have been constructed and installed in accordance with a suitable code or standard R1 R1 R1

Table C-4.6 Jetties LevelItem Description Low Medium High

1. Confirm by inspection that jetty construction has been carried out in accordance with construction and inspection procedures S1 S2 S3

2. Confirm by witnessing tests that strength of designed concrete mix is being achieved S1 S2 S33. Review records of concrete construction, installation and inspection I R1 R2

Table C4.7 Loading and Unloading Arms LevelItem Description Low Medium High

1.Confirm by document review that all loading or unloading arms have been constructed and installed in accordance with DNV-OS-F101 Submarine Pipeline Systems or another code or standard giving an equivalent level of safety

R1 R2 R2

Table C-4.8 Process System LevelItem Description Low Medium High

1. Confirm that the process system has been constructed in accordance with the P&IDs S1 S2 S3

2. Confirm that materials and fabrication are in accordance with the Piping and Valve Material Specification, and Vendor Specifications S1 S2 S3

3.

Confirm for critical components that the followed documents, approved during design, have been complied with:

— materials specification — welding specification— NDT-specification.

S1 S2 S3

4. Confirm by review of equipment on site that equipment is supplied and installed in accordance with the design parameters S1 S2 S3

5.Confirm that the fabrication testing and commissioning of all tanks, pressure vessels and spheres are in accordance with the design drawings and fabrication specification i.e. welding, NDT, dimensional control

S1 S2 S3

6.

Confirm by review of Vendor’s documentation that the procured equipment has been designed, fabricated and tested in accordance with the relevant design documentsNote 1: Attention shall be paid to requirements of National Authorities, where appropriate, for Technical Passports and Permits for Use or other requirements

- R1 R2

7. Review vendor documentation to confirm that appropriately sealed pumps (seal-less or dual seal) as required are supplied - R1 R2

8. Confirm by review that relief valve certification is in order and that the appropriate relief valve have been fitted as per the P&IDs S1 S2 S3

9. P&IDs showing block valves, isolating devices, etc. required for maintenance operations

10. Confirm from coating reports that the specified coating has been provided in accordance with the specification S1 S2 S3

11. Confirm by inspection that appropriate PFP is applied as required by analysis S1 S2 S3

12.

Review for electrical equipment:

— certification for all explosion protected equipment— reports of function testing of alarms and disconnections in pressurised equipment— reports of testing of protective devices in switchboards and generators— reports of testing of automatic start of emergency generator— reports of insulation resistance measurements.

R1 R2 R2

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Table C-4.9 Relief Valves and Relief System LevelItem Description Low Medium High

1. Confirm that the relief system has been constructed in accordance with the P&IDs S1 S2 S3

2. Confirm that relief valves conform to the data sheets regarding set pressure, backpressure and valve type S1 S2 S3

3. Confirm that isolation valves for relieving devices are locked open for active devices and locked closed for stand-by devices S1 S2 S3

4. Confirm by review of inspection and test records that relief valves are tested in accordance with API 520 and 521 R1 R2 R2

Table C-4.10 Structural Integrity LevelItem Description Low Medium High

Equipment and Pressure Vessel Supports and Foundations

1.Confirm by inspection that construction of equipment and pressure vessel supports and foundations has been carried out in accordance with construction and inspection procedures

S1 S2 S3

2. Confirm by witnessing tests that strength of designed concrete mix is being achieved S1 S2 S33. Review records of concrete construction, installation and inspection - R1 R2

Piping

4. Confirm by inspection that construction of piping supports and pipe racks has been carried out in accordance with construction and inspection procedures S1 S2 S3

5. Where concrete pipe racks are being constructed, confirm by witnessing tests that strength of designed concrete mix is being achieved S1 S2 S3

6. Review records of concrete construction, installation and inspection - R1 R2

Table C-4.11 Above Ground Storage Tanks LevelItem Description Low Medium High

Tank Foundations

1. Confirm by inspection that construction of tank foundations has been carried out in accordance with construction and inspection procedures S1 S2 S3

2. Confirm by inspection that compacting of tank foundations is carried out in accordance with design and construction documents S1 S2 S3

3. Review records of construction and inspection - R1 R2Tanks

4. Confirm by inspection that fabrication and erection of tanks has been carried out in accordance with construction and inspection procedures S1 S2 S3

5.

Confirm that the followed documents, approved during design, have been complied with:

— materials specification — welding specification— NDT-specification.

S1 S2 S3

Table C-4.12 Control Systems LevelItem Description Low Medium High

1. Confirm that control system has been constructed and installed in accordance with design documents S1 S2 S3

2. Confirm by review that all protective devices are suitably calibrated for their intended pressure, temperature, etc R1 R1 R2

3. Confirm that control system software has been tested and that documentation confirms that it conforms to design requirements R2 S1 S1

4.Confirm that integration testing of control system and at least one of each initiating device has been carried out and that documentation confirms that the system conforms to design requirements

R2 S1 S1

5. Confirm that control system (panels, displays, etc.) has been installed in accordance with design documents and drawings S1 S2 S3

6. Confirm by inspection that the status of control systems has been provided at operator stations S1 S2 S3

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Table C-4.13 Control of Ignition LevelItem Description Low Medium High

1. Confirm that fired heaters and boilers have been constructed in accordance with the design documents S1 S2 S3

2. Confirm that fired heaters and boilers have suitable purge facilities prior to start-up to prevent internal explosions S1 S2 S3

3. Confirm during installation that all fired heaters, combustion source are suitably located and rated for their zone of operation S1 S2 S3

4.

Confirm that construction conforms to the equipment shown of the design hazardous area classification drawings and source of release schedule regarding location of ventilation inlets/outlets, overpressure/air locks for local equipment rooms, location of vents and segregation of drainage system

S1 S2 S3

5. Confirm that all vehicles comply with the design documents regarding potential for ignition, including spark arrestors and emergency stops, etc S1 S2 S3

6. Confirm that electrical equipment is installed in accordance with design documents and drawings S1 S2 S3

7. Ensure equipment is installed in accordance with the appropriate specification. S1 S2 S3

8. Confirm that the lightning rods are installed as per the design documents and drawings S1 S2 S3

9.Confirm by inspection and review of fabrication details that sufficient earthing and bonding arrangements are in place in accordance with the design documents and drawings

S1 S2 S3

Table C-4.14 Dropped Object and Impact Protection LevelItem Description Low Medium High

1.Confirm that equipment along roads and in-unit access ways for protected from vehicle impact through the use of curbing, barriers, or by virtue of its distance from the road in are installed in accordance with the design drawings

S1 S2 S3

2. Confirm by inspection that appropriate barriers are in place. S1 S2 S3

3.Confirm that dropped object protection has been provided in accordance with design documents and drawings for equipment and piping in vulnerable areas (heat exchanger bundles, gas turbines, catalyst containers, jetties, etc.)

S1 S2 S3

Table C-4.15 Fire and Gas Detection LevelItem Description Low Medium High

Smoke and Gas Detection for Site Buildings

1. Confirm by inspection of installation that the smoke and gas detection in site buildings is in accordance with the design S1 S2 S3

2. Confirm that detector types are installed as per the design documents and drawings S1 S2 S33. Confirm during installation that the cables meet required specifications S1 S2 S3

4. Confirm by inspection that cable routing is in accordance with the design and is protected by location where possible. S1 S2 S3

5.Confirm that adequate gas detection is provided on the HVAC inlets with sufficient detection time to ensure that functioning of the dampers will occur before impairment of the protected space

S1 S2 S3

Fire and Gas Detection - External Areas

6. Confirm by inspection of installation that the fire and gas system in external areas is in accordance with the design S1 S2 S3

7. Confirm that detector types are installed as per the design documents and drawings S1 S2 S38. Confirm during installation that the cables meet required specifications S1 S2 S3

9. Confirm by inspection that cable routing is in accordance with the design and is protected by location where possible. S1 S2 S3

Fire and Gas Detection - Machinery Enclosures

10. Confirm by inspection of installation that the fire and gas system in machinery enclosures is in accordance with the design S1 S2 S3

11. Confirm that detector types are installed as per the design documents and drawings S1 S2 S3

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12. Confirm during installation that the cables meet required specifications S1 S2 S3

13. Confirm by inspection that cable routing is in accordance with the design and is protected by location where possible. S1 S2 S3

Fire and Gas Control (part of ICS)

14. Confirm that fire and gas control system (panels, displays, etc.) has been installed in accordance with design documents and drawings S1 S2 S3

15. Confirm by inspection that the status of fire and gas system has been provided at operator stations S1 S2 S3

Table C-4.16 Emergency Shutdown System LevelItem Description Low Medium High

1. Confirm by inspection that the emergency shutdown system has been installed in accordance with the design S1 S2 S3

2. Confirm by inspection that control system (panels, displays, etc.) has been installed in accordance with design documents and drawings S1 S2 S3

3. Confirm by inspection that the status of ESD has been provided at operator stations S1 S2 S3

4. Confirm by inspection and review of vendor data that adequate protection of ESD valves is provided. S1 S2 S3

5. Confirm by inspection that ESDVs are suitably protected from potential vehicular impact. S1 S2 S3

6.Confirm by review of certification that ESD valves, actuators and supports are designed to withstand explosion overpressure drag loads as defined in the project specification

- R1 R2

Table C-4.17 Blowdown Header and Flare System LevelItem Description Low Medium High

1. Confirm by inspection that the blowdown header and flare system has been installed in accordance with the design S1 S2 S3

2.Confirm by inspection that flare, relief and blowdown lines are self draining and where low points are unavoidable these have an appropriate drain connection with locked open isolation valves in accordance with the P&IDs

S1 S2 S3

Table C-4.18 Control Room LevelItem Description Low Medium High

1. Confirm by inspection that the control room has been constructed in accordance with the design drawings S1 S2 S3

2. Confirm by inspection that CCTV coverage is such that all necessary angles of the areas in questions can be viewed at a central protected location S1 S2 S3

Table C-4.19 Active Fire Fighting Systems LevelItem Description Low Medium High

Fire Water Storage

1. Confirm by inspection that fire water storage has been provided in accordance to design documents and drawings S1 S2 S3

Firewater Pumps

2. Confirm by inspection that fire pumps have been installed in accordance with design drawings S1 S2 S3

3. Confirm by review of manufacturer’s documentation the fire pump capacity and discharge rates are in accordance with design R1 R2 R2

4. Confirm by inspection that fire pump start requirements are in accordance with design S1 S2 S3

Firewater Distribution Ring main

5. Confirm by inspection that the firewater distribution ring main is fabricated in accordance with the design drawings S1 S2 S3

6. Confirm that firewater distribution ring main isolation valves have been installed in accordance with the P&IDs S1 S2 S3

Table C-4.15 Fire and Gas Detection (Continued) LevelItem Description Low Medium High

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Firewater and Foam Supply

7. Confirm by inspection that the firewater and foam supply systems have been installed in accordance with the design drawings S1 S2 S3

8. Confirm by inspection that the monitors and hydrants have been installed in accordance with the design documents and drawings S1 S2 S3

Gaseous Fire-fighting systems

9. Confirm by inspection that the gaseous fire-fighting systems have been installed in accordance with the design drawings S1 S2 S3

10. Confirm by inspection that status indicators are provided at all enclosures entrances protected by gaseous fire-fighting systems S1 S2 S3

Fire-fighting Vehicle

11. Confirm by review of manufacturing documentation that any fire-fighting vehicles conform to the requirements of the design documents R1 R2 R2

Table C-4.20 Passive Fire Protection LevelItem Description Low Medium High

1. Confirm by inspection that passive fire protection (PFP) has been provided in accordance with the design on vessels, piping, supports and structures S1 S2 S3

2.

Confirm by inspection that application of PFP has been carried out in accordance with manufacturer’s instructions and guidance, including:

— maximum thickness per coat— inter-coat curing time— depth and type of reinforcement.

S1 S2 S3

3. Confirm by witnessing of application and by review of application records that PFP has been applied in accordance with manufacturer’s instructions and guidance R1 S1 S2

4. Confirm by inspection that penetrations in PFP have been installed in accordance with manufacturer’s instructions S1 S2 S3

5.

Review certification of:

— fire rating of construction, including doors— penetration methods for ventilation ducting, piping or cable penetrations.

R1 R2 R2

Table C-4.21 Bunding and Drainage LevelItem Description Low Medium High

1. Confirm by inspection that bunding and drainage has been installed is accordance with the design drawings S1 S2 S3

Table C-4.22 Emergency Power and Uninterruptible Power Supply LevelItem Description Low Medium High

1. Confirm by inspection that emergency power and uninterruptible power supply (UPS) has been installed in accordance with design documents and drawings S1 S2 S3

2. Confirm by review of records that the supplied UPS batteries are in accordance with the design documents - R1 R2

3. Confirm by inspection that UPS battery load test demonstrate UPS capacity in accordance with the design S1 S2 S3

4. Confirm by inspection that automatic changeover of UPS battery banks operates in accordance with the design S1 S2 S3

Table C-4.23 Communications and Alarms LevelItem Description Low Medium High

Emergency Communications and Alarms

1. Confirm by inspection that all communication and alarm systems have been installed in accordance with design documents and drawings S1 S2 S3

2.Confirm by inspection that the routing of cabling and location of marshalling and power supplies is such that the system is protected from credible fire, explosion and seismic and weather events as per the AFC drawings.

S1 S2 S3

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F. Commissioning

F 100 General101 Commissioning consists of a number of different site activities and their associated documentation.102 Table F-1 gives summaries of the scope of work tables included in this section for variouscommissioning activities.

F 200 Commissioning Verification201 For verification of hydrocarbon facilities, commissioning activities are considered as:

— initial activities— inspection activities— final activities.

202 The initial activities include the review of procedures, attendance during qualification of procedures andpersonnel and other start-up activities. The inspection activities are the site attendance and the final activitiesare the continuous review of production results and records and the completion of documentation and reports.203 Sections F300, F400 and F500 following, describe the verification activities for each of the three

3. Confirm by inspection that appropriate equipment protection is provided in the event of flammable gas ingress S1 S2 S3

Internal and External Communications

4.Confirm by inspection that adequate external and internal telephone and fax lines are available at all times during an emergency giving the emergency control centre the capability to handle two-way communications with all relevant parties

S1 S2 S3

5.Confirm that the routing of cabling and location of marshalling and power supplies is such that the system is protected from credible fire, explosion and seismic and weather events

S1 S2 S3

Table C-4.24 HVAC LevelItem Description Low Medium High

1. Confirm by inspection that the HVAC system has been installed in accordance with the D&IDs S1 S2 S3

2. Confirm by inspection that adequate heat bridges exist where ducting penetrates fire boundaries S1 S2 S3

3. Confirm by review of certification that all HVAC dampers are fire rated according to recognised industry practice and local regulations. S1 S2 S3

4. Confirm by review of vendor data and test results that damper closure occurs within the required limits. - R1 R2

Table C-4.25 Egress and Evacuation System LevelItem Description Low Medium High

Escape Routes

1. Confirm by inspection that escape routes have been constructed in accordance with the design documents and drawings S1 S2 S3

2. Confirm by inspection that escape routes have the minimum height and width specified in the design S1 S2 S3

3. Confirm by inspection that escape routes will allow easy transit of stretcher teams as specified in the design S1 S2 S3

4. Confirm by inspection that escape routes are marked in accordance with design S1 S2 S3Muster Area

5.Confirm by inspection that muster areas have been constructed in accordance with the design documents and drawings S1 S2 S3

6. Confirm by inspection that muster areas are marked in accordance with design S1 S2 S3

7. Confirm by inspection that muster areas have facilities to take muster and report findings to emergency control centre S1 S2 S3

Emergency Lighting

8.Confirm by inspection that escape routes and muster areas are adequately illuminated during periods of operation of emergency lighting to the specified minimum level

S1 S2 S3

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verification levels.

F 300 Low Level Commissioning Verification301 For Low level verification, the procedure review consists of a review of the commissioning managementprocedures and confirmation that the most important aspects of the main specifications have been included inthe procedures. For the qualification of procedures and personnel DNV will not attend the actual qualification,but will review the results.302 During the commissioning, DNV’s verification will be performed during site visits. The verification willfocus on the critical items and aspects identified in the detailed scope of work tables.303 The subsequent verification of the final activities will be by spot-checks of the production recordsincluding non-conformance logs, commissioning completion reports and results from audits, both contractorsinternal audits or audits performed by other parties.

F 400 Medium Level Commissioning Verification401 For Medium level verification, the procedure review consists of a detailed review of commissioningmanagement procedures. Other important procedures will be spot checked to confirm that the most importantaspects of the specifications have been included.402 For the qualification of procedures and personnel DNV will visit the main qualifications and review theresults.403 During commissioning, DNV’s verification will be performed by full time attendance at the site. Theverification will focus on the critical items and aspects as identified in the detailed scope of work tables.404 Verification of the final activities will be by review of the production records including non-conformancelogs, commissioning completion reports and results from audits, both contractor’s internal audits or auditsperformed by other parties.

F 500 High Level Commissioning Verification501 For High level verification, the procedure review consists of a detailed review of commissioningmanagement procedures. Other procedures will be reviewed to confirm that important aspects of thespecifications have been included.502 For qualification of procedures and personnel DNV will attend the main qualifications, spot-check otherqualifications and review the results.503 During commissioning, DNV’s verification will be performed by full time attendance at the site.Verification will focus on the critical items/aspects as identified in the detailed scope of work tables.504 Verification of the final activities will be by detailed review of the production records including the non-conformance log, commissioning completion reports and results from audits, both contractors internal auditsor audits performed by other parties

F 600 Verification of Work in Progress601 The monitoring by the Owner during commissioning relates to the activities of the contractors. Themonitoring of these activities by DNV relates not only to the contractor’s activities but also to the monitoringof these activities carried out by the Owner.602 The emphasis placed on the various activities in the verification plan varies depending on:

— any areas of concern revealed during design and construction verification— any areas of concern revealed during the audit of the Owner’s or contractor’s quality management systems— the progress of commissioning— the findings of the contractor surveillance personnel.

603 DNV personnel will spend more time in areas where problems have occurred, or are considered likely tooccur. Conversely, less time is spent in areas where the likelihood of problems is considered lower.

F 700 DNV Final Report701 All the Scopes of Work tables for commissioning end with a Hold Point entitled “Issue of Visit Report”.This item is not related to the production process as a normal hold point would be, ref. B400. This item isintended as a reminder to the DNV inspection personnel that a final report of their verification activities isrequired to finish the work.702 This report may in the form of a Visit Report for an activity that is completed irregularly, such as a visitto a manufacturer’s works or a monthly report of site activities where DNV’s presence is continuous.

F 800 Scope of Work for Commissioning Verification801 Detailed scopes of work for the verification of commissioning are given in Tables C-5.2 to C-5.15.802 Initial and final activities that are common to all commissioning verification are shown in Table C-5.2

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and are not repeated in the tables for individual safety-critical elements.

Table C-5.1Summary Table - CommissioningTable No. Table DescriptionC-5.2 Common Commissioning ActivitiesC-5.3 Offloading and Loading FacilitiesC-5.4 Loading and Unloading ArmsC-5.5 Process SystemC-5.6 Control SystemsC-5.7 Control of IgnitionC-5.8 Fire and Gas DetectionC-5.9 Emergency Shutdown SystemC-5.10 Blowdown Header and Flare SystemC-5.11 Control RoomC-5.12 Active Fire Fighting SystemsC-5.13 Emergency Power and Uninterruptible Power SupplyC-5.14 CommunicationsC-5.15 HVAC

Table C-5.2 Common Commissioning Activities LevelItem Description Low Medium High

Initial Activities1. Review quality management system documents R1 R2 R22. Quality system audit at relevant contractors and sub-contractor 1) - A A3. Review of specifications and procedures R1 R2 R24. Technical Meeting / Kick-off Meeting and review of commissioning documents R1 R1 R2

5. Confirm by review that there are no outstanding safety critical issues from the mechanical completion punch lists R1 R2 R2

Inspection Activities6. As detailed in Tables C-5.3 to C-5.14 - - -

Final Activities7. Review of commissioning records R1 R2 R2

8. Confirm by review that there are no outstanding safety critical issues from the commissioning completion punch lists R1 R2 R2

9. Issue of DNV Report H H H1) May be omitted if requirements in Sec.3 B202 are complied with

Table C-5.3 Offloading and Loading Facilities LevelItem Description Low Medium High

SPM (Single Point Mooring)

1.Confirm by document review that the SPM (or its equivalent) has been commissioned in accordance with DNV-OS-E403 Offshore Loading Buoys or another code or standard giving an equivalent level of safety

R1 R1 R1

Flexible Riser

2.Confirm by review of documents, such as independent design reviews and product certification, that the Flexible Riser (if fitted) has been has been commissioned in accordance with a suitable code or standard

R1 R1 R1

Crude Oil Pipelines (including Pig launcher/receiver and any PLEMs or manifolds)

3.Confirm by document review that any pipelines have been has been commissioned in accordance with DNV-OS-F101 Submarine Pipeline Systems or another code or standard giving an equivalent level of safety

R1 R1 R1

Table C-5.4 Loading and Unloading Arms LevelItem Description Low Medium High

1.Confirm by inspection during commissioning that the loading and unloading arms ESD system, including quick disconnect facilities, is commissioned in accordance with the commissioning procedures

R1 S1 S2

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Table C-5.5 Process System LevelItem Description Low Medium High

1. Confirm during commissioning that the equipment is commissioned in accordance with the commissioning procedures S1 S2 S3

2. Confirm by inspection and function test that each field device is integrated with the control system based on commissioning acceptance test procedures. S1 S2 S3

3.Confirm by review of vendor’s documentation and relevant punch lists that requirements of National Authorities, where appropriate, for Technical Passports and Permits for Use or other requirements have been complied with

I R1 R2

Table C-5.6 Control Systems LevelItem Description Low Medium High

1. Confirm by inspection during commissioning that the control system is commissioned in accordance with the commissioning procedures S1 S2 S3

2. Confirm by witnessing of a selection of tests that the control system functions in accordance with design S1 S2 S3

3. Confirm by inspection that the status of control systems has been provided at operator stations S1 S2 S3

Table C-5.7 Control of Ignition LevelItem Description Low Medium High

1. Confirm by witnessing a selection of tests that non-certified equipment is isolated in the event of a local loss of containment as per the Cause and Effects matrix S1 S2 S3

2. Confirm by witness and review of test results that shutdowns occur in accordance with the design requirements. S1 S2 S3

3. Confirm by review of records that the commissioning of the lightning rods has been carried out as per the project specifications - R1 R2

4. Confirm by review of records that the commissioning of the earthing grid has been carried out as per the project specifications - R1 R2

5. Confirm by review of records that the commissioning of the bonding and earthing has been carried out as per the project specifications - R1 R2

Table C-5.8 Fire and Gas Detection Level

Item Description Low Medium High

Smoke and Gas Detection for Site Buildings

1. Confirm by inspection during commissioning that the smoke and gas detection in site buildings is commissioned in accordance with the commissioning procedures S1 S2 S3

2. Confirm by witnessing of a selection of tests that the smoke and gas detection in site buildings functions in accordance with design S1 S2 S3

Fire and Gas Detection - External Areas

3. Confirm by inspection during commissioning that the fire and gas system in external areas is commissioned in accordance with the commissioning procedures S1 S2 S3

4. Confirm by witnessing of a selection of tests that the fire and gas system in external areas functions in accordance with design S1 S2 S3

5. Confirm by witnessing tests and a review of test reports that loss of cable integrity provides alarm condition in the control room. - S1 S2

Fire and Gas Detection - Machinery Enclosures

6. Confirm by inspection during commissioning that fire and gas system in machinery enclosures is commissioned in accordance with the commissioning procedures S1 S2 S3

7. Confirm by witnessing of a selection of tests that the fire and gas system in machinery enclosures functions in accordance with design S1 S2 S3

Fire and Gas Control (part of ICS)

8. Confirm by inspection during commissioning that the fire and gas control system is commissioned in accordance with the commissioning procedures S1 S2 S3

9. Confirm by witnessing of a selection of tests that the fire and gas control system functions in accordance with design S1 S2 S3

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10. Confirm by inspection that the status of fire and gas system has been provided by panels, displays or other means at operator stations S1 S2 S3

Personal Toxic Gas Detection and Protection

11.Confirm by inspection that personal toxic gas detectors are suitable to detect the range of toxic gases within the plant (typically H2S, SO2, CO and high/low O2 levels)

S1 S2 S3

12.Confirm by witnessing tests that installed respiratory protective equipment provides protection for the time it takes to don and proceed the maximum potential distance to a safe up-wind area.

S1 S2 S3

Table C-5.9 Emergency Shutdown System LevelItem Description Low Medium High

1. Confirm by inspection during commissioning that the emergency shutdown system is commissioned in accordance with the commissioning procedures S1 S2 S3

2. Confirm by witnessing of a selection of tests that the emergency shutdown system functions in accordance with design S1 S2 S3

3. Confirm by witnessing tests that ESDVs maximum closure times are in accordance with the design requirements S1 S2 S3

4. Confirm by inspection that the status of emergency shutdown system has been provided by panels, displays or other means at operator stations S1 S2 S3

5. Confirm by review of test results that interference does not occur between the various systems. - R1 R2

Table C-5.10 Blowdown Header and Flare System LevelItem Description Low Medium High

1. Confirm by inspection during commissioning that the blowdown header and flare system is commissioned in accordance with the commissioning procedures S1 S2 S3

2. Confirm by witnessing of a selection of tests that the blowdown header and flare system functions in accordance with design S1 S2 S3

3.Confirm by witnessing tests and a review of records that the blowdown system is capable of reducing pressure to the required amount in the required time as specified in the design documents

S1 S2 S3

4. Confirm by review of test results that flare noise and radiation are within the limits specified in the design documents R1 R2 R2

Table C-5.11 Control Room LevelItem Description Low Medium High

1. Confirm by inspection that the control room has been commissioned in accordance with the commissioning procedures S1 S2 S3

2. Confirm that safety functions associated with the control room are commissioned in accordance with the commissioning procedures (i.e. air locks if fitted) S1 S2 S3

3. Confirm by inspection that CCTV coverage is such that all necessary angles of the areas in questions can be viewed at a central protected location S1 S2 S3

Table C-5.12 Active Fire Fighting Systems LevelItem Description Low Medium High

Firewater Pumps

1. Confirm by inspection that the fire pumps have been commissioned in accordance with the commissioning procedures S1 S2 S3

2. Confirm by witnessing tests that the fire pumps capacity and discharge rates are in accordance with design. S1 S2 S3

3. Confirm by witnessing tests that fire pump start arrangements are in accordance with design S1 S2 S3

4.

Review:

— certification and commissioning reports of pump driver— certification and commissioning reports of safety devices— records of performance testing.

R1 R2 R2

Firewater Distribution Ring main

5. Confirm by witnessing tests that flow rates in the firewater distribution ring main are in accordance with the firewater hydraulic analysis S1 S2 S3

6. Confirm by inspection that the firewater distribution ring main isolation valves operate as designed S1 S2 S3

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Firewater and Foam Supply

7. Confirm by inspection that the firewater and foam supply systems have been commissioned in accordance with the commissioning procedures S1 S2 S3

8.Confirm by witnessing tests that the firewater and foam supply systems are capable of delivering sufficient extinguishing to all necessary locations to deal with credible worst case fire scenario as required by the design documents

S1 S2 S3

9. Confirm by review of records that foam is supplied with appropriate certification R1 R2 R2Gaseous Fire-fighting Systems

10. Confirm by inspection that the gaseous fire-fighting systems have been commissioned in accordance with the commissioning procedures S1 S2 S3

11.Confirm by witnessing tests that the firewater and foam supply systems are capable of delivering sufficient extinguishing gas to all necessary locations as required by the design documents

S1 S2 S3

12.Confirm by witnessing of tests that status indicators provided at all enclosures entrances protected by gaseous fire-fighting systems function as intended to give personnel sufficient warning to evacuate the enclosure

S1 S2 S3

Fire-fighting Vehicle

13.Confirm by witnessing tests that the fire-fighting vehicle is capable of delivering sufficient extinguishing to all necessary locations as required by the design documents

S1 S2 S3

Table C-5.13 Emergency Power and Uninterruptible Power Supply LevelItem Description Low Medium High

1. Confirm by inspection that the emergency power and UPS systems have been commissioned in accordance with the commissioning procedures S1 S2 S3

2.

Confirm during testing that the emergency power supply capacity is sufficient for the following users:

— integrated control system supply— communication systems— emergency communication system— any other systems required for emergency response.

S1 S2 S3

Table C-5.14 Communications and Alarms LevelItem Description Low Medium High

Emergency Communications and Alarms

1. Confirm by inspection that the Emergency Communications and Alarms have been commissioned in accordance with the commissioning procedures S1 S2 S3

2. Confirm by witnessing tests that Emergency Communications and Alarms are audible over the whole facility. S1 S2 S3

3. Confirm by witnessing tests that in noisy areas personnel are alerted to Emergency Alarms by flashing beacons or other suitable means S1 S2 S3

Internal and External Communications

1. Confirm by inspection that the Internal and External Communications have been commissioned in accordance with the commissioning procedures S1 S2 S3

2.Confirm by inspection that adequate external and internal telephone and fax lines are available at all times during an emergency giving the emergency control centre the capability to handle two-way communications with all relevant parties

S1 S2 S3

Table C-5.15 HVAC LevelItem Description Low Medium High

1. Confirm by inspection that the HVAC system has been commissioned in accordance with the commissioning procedures S1 S2 S3

2. Confirm by witnessing tests that HVAC systems physically isolate by dampers the air supply on flammable or toxic gas, or smoke detection at the HVAC inlet S1 S2 S3

3. Confirm by witnessing tests that the control room HVAC is shutdown and dampers are closed on confirmed gas at the HVAC inlet. S1 S2 S3

4. Confirm by witnessing tests that commissioning reports that damper closure occurs within the required limits upon gas detection. S1 S2 S3

5.

Review measurements of:

— capacity— pressure differential.

- R1 R2

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G. Operations

G 100 General

101 Operations consists of operating the hydrocarbon facility for the purpose for which it was designed andincludes the ancillary activities of maintenance and inspection.

102 Table C-6.1 gives summaries of the scope of work tables included in this section for various operationsactivities.

G 200 Operations Verification

201 For verification of hydrocarbon facilities, operations activities are considered as:

— initial activities— inspection activities— final activities.

202 The initial activities include the review of strategies and procedures. The inspection activities are the siteattendance and the final activities are the review of operations, maintenance and inspection records and thecompletion of documentation and reports.

203 Sections G300, G400 and G500 following, describe the verification activities for each of the threeverification levels.

G 300 Low Level Operations Verification

301 For Low level verification, the procedure review consists of a review of the integrity managementstrategies and confirmation that the most important aspects of these strategies have been included in theprocedures.

302 During operations, DNV’s verification will be performed during site visits. The verification will focuson the critical items and aspects identified in the detailed scope of work tables.

303 The subsequent verification of the final activities will be by spot-checks of the operations, maintenanceand inspection records including non-conformance logs, operations reports and results from audits, bothinternal audits and audits performed by other parties.

G 400 Medium Level Operations Verification

401 For Medium level verification, the procedure review consists of a detailed review of integritymanagement strategies. Other important operations, maintenance and inspection procedures will be spotchecked to confirm that the most important aspects of the strategies have been included.

402 During operations, DNV’s verification will be performed during site visits. The verification will focuson the critical items and aspects identified in the detailed scope of work tables.

403 Verification of the final activities will be by a review of the operations, maintenance and inspectionrecords including non-conformance logs, operations reports and results from audits, both internal audits andaudits performed by other parties.

G 500 High Level Operations Verification

501 For High level verification, the procedure review consists of a detailed review of integrity managementstrategies and operations, maintenance and inspection procedures.

502 During operations, DNV’s verification will be performed by performed during site visits and by full timeattendance at the site during facility shutdowns or turn-arounds. Verification will focus on the critical items/aspects as identified in the detailed scope of work tables.

503 Verification of the final activities will be by a detailed review of the operations, maintenance andinspection records including non-conformance logs, operations reports and results from audits, both internalaudits and audits performed by other parties

G 600 DNV Final Report

601 All the Scopes of Work tables for commissioning end with a Hold Point entitled “Issue of DNV Report”.This item is not related to the production process as a normal hold point would be, ref. B400. This item isintended as a reminder to the DNV inspection personnel that a final report of their verification activities isrequired to finish the work.

G 700 Scope of Work for Operations Verification

701 Detailed scopes of work for the verification of commissioning are given in Tables C-6.2 to C-6.24.

702 Initial and final activities that are common to all operations verification are shown in Table C-6.2 and

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are not repeated in the tables for individual safety-critical elements.

Table C-6.1 Summary Table - OperationsTable No. Table Description

C-6.2 Common Operations ActivitiesC-6.3 LayoutC-6.4 Offloading and Loading FacilitiesC-6.5 JettiesC-6.6 Loading and Unloading ArmsC-6.7 Process SystemC-6.8 Relief Valves and Relief SystemC-6.9 Structural Integrity

C-6.10 Above Ground Storage TanksC-6.11 Control SystemsC-6.12 Control of IgnitionC-6.13 Dropped Object and Impact ProtectionC-6.14 Fire and Gas DetectionC-6.15 Emergency Shutdown SystemC-6.16 Blowdown Header and Flare SystemC-6.17 Control RoomC-6.18 Active Fire Fighting SystemsC-6.19 Passive Fire ProtectionC-6.20 Bunding and DrainageC-6.21 Emergency Power and Uninterruptible Power SupplyC-6.22 Communications and AlarmsC-6.23 HVACC-6.24 Egress and Evacuation Systems

Table C-6.2 Common Operations Activities LevelItem Description Low Medium HighInitial Activities

1. Review quality management system documents R1 R2 R22. Quality system audit at relevant contractors 1) - A A3. Review of integrity management strategies R1 R2 R24. Review of procedures for operations 2), maintenance and inspection R1 R2 R25. Review of preventative maintenance routines - R1 R26. Technical Meeting / Kick-off Meeting - S1 S2

7. Confirm by review that there are no outstanding safety critical issues from the mechanical and commissioning completion punch lists R1 R2 R2

Inspection Activities8. As detailed in Tables C-6.3 to C-6.26 - - -

Final Activities9. Review of operations, maintenance and inspection records R1 R2 R2

10. Issue of DNV Report H H H1) May be omitted if requirements in Sec.3 B202 are complied with

2) Only those operations procedures wholly or partly related to integrity management or personnel safety will be reviewed

Table C-6.3 Layout Level

Item Description Low Medium High

1. Confirm by inspection that the facility layout continues to conform to the Plot Plans S1 S2 S3

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Table C-6.4 Offloading and Loading Facilities Level

Item Description Low Medium High

SPM (Single Point Mooring)

1. Confirm by inspection that the SPM (or its equivalent) remains in good condition with no leaks or mechanical damage observed S1 S2 S3

2. Confirm by document review that communication systems between the SPM and the refinery control room operate as designed R1 R1 R1

3. Confirm by document review of maintenance and inspection records that SPM remains in good condition R1 R2 R2

Flexible Riser

4. Confirm by review of documents that the Flexible Riser (if fitted) remains in good condition with no leaks or mechanical damage observed R1 R1 R1

Crude Oil Pipelines (including Pig launcher/receiver and any PLEMs or manifolds)

5. Confirm by inspection of the above-ground portions that any pipelines remain in good condition with no leaks or mechanical damage observed S1 S2 S3

6. Confirm by document review of maintenance and inspection records that any pipelines remain in good condition with no leaks or mechanical damage observed R1 R1 R1

7. Confirm by document review of potential readings that the pipelines cathodic protection systems are effective R1 R1 R1

Table C-6.5 Jetties LevelItem Description Low Medium High

1. Confirm by inspection that jetties remains in good condition with no mechanical damage observed S1 S2 S3

2. Confirm by document review of maintenance and inspection records that jetties remain in good condition and continue to operate as designed S1 S2 S3

Table C-6.6 Loading and Unloading Arms LevelItem Description Low Medium High

1. Confirm by inspection that all loading or unloading arms remain in good condition with no leaks or mechanical damage observed S1 S2 S3

2.Confirm by review of maintenance and inspection records that loading and unloading arms ESD system, including quick disconnect facilities continue to operate as designed

R1 R2 R2

Table C-6.7 Process System Level

Item Description Low Medium High

1. Confirm by inspection that the process system remains constructed in accordance with the P&IDs S1 S2 S3

Piping Systems

2.

Inspect for general condition and mechanical damage:

— check for obvious damage— check for incorrectly position, damaged or disturbed supports— check for bending and shearing of support foundation bolts, cracking of welded

foundations or displacement of supports— check saddle, sliding or roller bearing supports.

S1 S2 S3

3. Inspect surface coating or insulation to confirm that it is sealed at discontinuities S1 S2 S3

4. Inspect for signs of water ingress, where equipment potentially is liable to corrosion under insulation S1 S2 S3

5. Inspect small bore connections to confirm that they are adequately supported and not vibrating S1 S2 S3

6. Inspect the electrical insulation of non-ferrous pipework for deterioration S1 S2 S37. Inspect insulating gaskets between dissimilar metals for deterioration S1 S2 S3

8.Confirm by document review of maintenance and inspection records that piping systems remain in good condition with adequate wall thickness for the pressures contained within them

R1 R2 R2

Pressure Vessels

DET NORSKE VERITAS

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Service Specification DNV-DSS-314, October 2010 Page 80 – App.C

9.

Inspect for general condition and mechanical damage:

— check for damage to shell, especially at attachments— check for damage to supports, especially at welds between supports and vessel

and between supports and main beams.

S1 S2 S3

10. Inspect surface coating or insulation to confirm that it is sealed at discontinuities S1 S2 S3

11. Inspect for signs of water ingress, where equipment potentially is liable to corrosion under insulation S1 S2 S3

12. Inspect fitting and support of instruments to the vessel to confirm they are adequately supported and not vibrating S1 S2 S3

13. Inspect that the locking open or closed of isolation valves in relief and drain systems is in accordance with the process and instrumentation diagrams S1 S2 S3

14.Confirm by document review of maintenance and inspection records that pressure vessels remain in good condition with adequate wall thickness for the pressures contained within them

R1 R2 R2

Mechanical Equipment

15.

Inspect general condition and mechanical damage:

— check for obvious damage— check for damaged or disturbed supports— check for bending and shearing of base plate and anchor bolts, cover plate bolts,

cracking of welded foundations or displacement of supports— check condition of associated pipework and valves— check condition of accessories.

S1 S2 S3

16.

Confirm by document review of maintenance and inspection records that mechanical equipment set up remains satisfactory:

— check measurements of clearances, alignment and bolt torques— check results of measurements of vibration.

R1 R2 R2

17. Confirm by document review of the results of tests of governing, alarm and safety systems that mechanical equipment protection remains satisfactory R1 R2 R2

18. Confirm by document review of maintenance and inspection records that mechanical equipment remains in good condition R1 R2 R2

Table C-6.8 Relief Valves and Relief System LevelItem Description Low Medium High

1. Confirm by inspection that the relief system remains constructed in accordance with the P&IDs

2. Confirm by inspection that isolation valves for relieving devices are locked open for active devices and locked closed for stand-by devices S1 S2 S3

3. Confirm by review of documents that relief valves are tested in accordance with the requirements R1 R2 R2

Table C-6.9 Structural Integrity LevelItem Description Low Medium High

1.

Inspect for general condition and mechanical damage of steel structures:

— check straightness and buckling of panels and columns— check for cracking in welds and parent metal— check main connections of cantilevered sections— check cut outs or penetrations— check attachments (potential crack initiators)— check bolted connections (loose or missing bolts, corrosion, deformation to

protective cover or surrounding structure)— check interface between steel and concrete structural parts— check coating damage (including passive fire and cryogenic protection).

S1 S2 S3

2.

Inspect for general condition and mechanical damage of concrete structures:

— check straightness and buckling of columns and beams— check for rust marks and signs of reinforcement corrosion— check for spalling of concrete.

S1 S2 S3

3.Confirm by document review of maintenance and inspection records that steel and concrete structures remain in good condition

R1 R2 R2

Table C-6.7 Process System (Continued) Level

Item Description Low Medium High

DET NORSKE VERITAS

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Service Specification DNV-DSS-314, October 2010 App.C – Page 81

Table C-6.10 Above Ground Storage Tanks LevelItem Description Low Medium High

Tank Foundations1. Inspect for general condition and mechanical damage of tank foundations S1 S2 S3

2. Inspect for signs of tank movement that may indicate unstable foundations or soil conditions S1 S2 S3

3. Confirm by document review of maintenance and inspection records that tank foundations remain in good condition R1 R2 R2

Tanks

4.

Inspect for general condition and mechanical damage:

— check for damage to shell, especially at attachments— check for damage to supports, especially at welds between supports and tank

and between supports and main beams.

S1 S2 S3

5. Inspect surface coating or insulation to confirm that it is sealed at discontinuities S1 S2 S3

6. Inspect for signs of water ingress, where equipment potentially is liable to corrosion under insulation S1 S2 S3

7. Inspect fitting and support of instruments to the tank to confirm they are adequate supported and not vibrating S1 S2 S3

8. Inspect that the locking open or closed of isolation valves in relief and drain systems is in accordance with the process and instrumentation diagrams S1 S2 S3

9. Confirm by document review of maintenance and inspection records that tanks remain in good condition with adequate wall thickness R1 R2 R2

Table C-6.11 Control Systems LevelItem Description Low Medium High

1. Confirm by inspection that the control system remains constructed in accordance with the P&IDs S1 S2 S3

2. Confirm by document review of records that all protective devices are suitably calibrated for their intended pressure, temperature, etc. R1 R1 R2

3. Confirm by witnessing of a selection of tests that the control system functions in accordance with design S1 S2 S3

4. Confirm by document review of maintenance records of control system testing that the control system continues to function in accordance with design R1 R1 R2

5. Confirm by inspection that the status of control systems continues to be provided at operator stations S1 S2 S3

Table C-6.12 Control of Ignition LevelItem Description Low Medium High

1. Confirm by inspection that fired heaters and boilers remain constructed in accordance with the design documents S1 S2 S3

2. Confirm by document review of maintenance records that start-up purge facilities have been tested and remain suitable to prevent internal explosions R1 R1 R2

3. Confirm by inspection that all fired heaters, combustion source are suitably located and rated for their zone of operation S1 S2 S3

4. Confirm by inspection and review of hazardous area classification drawings and source of release schedule that equipment remains suitably protected for its location S1 S2 S3

5. Confirm by inspection that all vehicles comply with the design documents regarding potential for ignition, including spark arrestors and emergency stops, etc S1 S2 S3

6. Confirm by inspection that the lightning rods remain installed as per the design documents and drawings S1 S2 S3

7. Confirm by inspection that sufficient earthing and bonding arrangements remain in place in accordance with the design documents and drawings S1 S2 S3

8. Confirm by witnessing a selection of tests that non-certified equipment is isolated in the event of a local loss of containment as per the Cause and Effects matrix S1 S2 S3

9. Confirm by witness and review of test results that shutdowns occur in accordance with the design requirements. S1 S2 S3

Electrical Equipment

10. Confirm by inspection that all electrical equipment remain in good condition with no mechanical or other damage observed S1 S2 S3

11. Confirm by document review of the results of function test alarms and disconnections that Pressurised Equipment (Ex p) remains satisfactory R1 R2 R2

DET NORSKE VERITAS

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Service Specification DNV-DSS-314, October 2010 Page 82 – App.C

12.

Inspect condition of Flameproof Equipment (Ex d):

— check mechanical strength, corrosion of joint flanges and bolts, missing bolts, general corrosion, cracks, etc.

— dimensions of joint gaps (flame path); if surface of flame path affected by corrosion then equipment to be scrapped

— check that flame path surfaces are covered with a thin layer of non-hardening grease

— check that no external obstructions exist for flame paths.

S1 S2 S3

13.

Inspect condition of Increased Safety Equipment (Ex e) and Ex n Equipment:

— check internally and check entry for cleanliness, corrosion, signs of damage, etc.

— check function of flameproof switch— check setting of protective relays for Ex e motors.

S1 S2 S3

14.

Inspect condition of Intrinsically Safe Equipment (Ex i):

— check connections to earth bars— check separation between intrinsically safe and non-intrinsically safe circuits— inspect barriers and relays for cleanliness and signs of damage.

S1 S2 S3

15. Confirm by document review of the results of function test alarms and disconnections that Pressurised Rooms remain satisfactory R1 R2 R2

Table C-6.13 Dropped Object and Impact Protection LevelItem Description Low Medium High

1. Confirm by inspection that appropriate barriers remain in place for impact protection from vehicles. S1 S2 S3

2. Confirm by inspection that dropped object protection remains in place for equipment and piping in vulnerable areas S1 S2 S3

Table C-6.14 Fire and Gas Detection LevelItem Description Low Medium High

Smoke and Gas Detection for Site Buildings

1. Confirm by inspection that the smoke and gas detection in site buildings remains in accordance with the design S1 S2 S3

2. Confirm by witnessing of a selection of tests that the smoke and gas detection in site buildings functions in accordance with design - S1 S2

3. Confirm by document review of maintenance records that smoke and gas detection in site buildings continues to function in accordance with design R1 R1 R2

Fire and Gas Detection - External Areas

4. Confirm by inspection that the fire and gas system in external areas remains in accordance with the design S1 S2 S3

5. Confirm by witnessing of a selection of tests that the fire and gas detection - external areas functions in accordance with design S1 S2 S3

6. Confirm by document review of maintenance records that fire and gas detection - external areas continues to function in accordance with design R1 R1 R2

7. Confirm by document review of maintenance records that loss of cable integrity provides alarm condition in the control room. R1 R1 R2

Fire and Gas Detection - Machinery Enclosures

8. Confirm by inspection that the fire and gas system in machinery enclosures remains in accordance with the design S1 S2 S3

9. Confirm by witnessing of a selection of tests that the fire and gas system in machinery enclosures functions in accordance with design - S1 S2

10. Confirm by document review of maintenance records that fire and gas system in machinery enclosures continues to function in accordance with design R1 R1 R2

Fire and Gas Control (part of ICS)

11. Confirm by inspection that fire and gas control system (panels, displays, etc.) remains installed in accordance with design documents and drawings S1 S2 S3

DET NORSKE VERITAS

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Service Specification DNV-DSS-314, October 2010 App.C – Page 83

12. Confirm by inspection that the status of fire and gas system has been provided at operator stations S1 S2 S3

Personal Toxic Gas Detection and Protection

13.Confirm by inspection that personal toxic gas detectors are suitable to detect the range of toxic gases within the plant (typically H2S, SO2, CO and high/low O2 levels)

S1 S2 S3

14. Confirm by document review of maintenance records that respiratory protective equipment continues to function in accordance with design R1 R1 R2

Table C-6.15 Emergency Shutdown System LevelItem Description Low Medium High

1. Confirm by inspection that the emergency shutdown system remains installed in accordance with the design S1 S2 S3

2. Confirm by inspection that control system (panels, displays, etc.) remain installed in accordance with design documents and drawings S1 S2 S3

3. Confirm by inspection that the status of ESD remains provided at operator stations S1 S2 S34. Confirm by inspection that adequate protection of ESD valves remains provided S1 S2 S3

5. Confirm by inspection that ESDVs remain suitably protected from potential vehicular impact S1 S2 S3

6. Confirm by witnessing of a selection of tests that the emergency shutdown system functions in accordance with design S1 S2 S3

7. Confirm by witnessing tests that ESDVs maximum closure times are in accordance with the design requirements S1 S2 S3

8. Confirm by document review of maintenance records that emergency shutdown system continues to function in accordance with design R1 R1 R2

Table C-6.16 Blowdown Header and Flare System LevelItem Description Low Medium High

1. Confirm by inspection that the blowdown header and flare system remain installed in accordance with the P&IDs S1 S2 S3

2.Confirm by witnessing tests and a review of records that the blowdown system is capable of reducing pressure to the required amount in the required time as specified in the design documents

S1 S2 S3

3. Confirm by document review of maintenance and inspection records that the blowdown header and flare system continues to function in accordance with design R1 R1 R2

Table C-6.17 Control Room LevelItem Description Low Medium High

1. Confirm by inspection that the control room remains constructed in accordance with the design drawings S1 S2 S3

2. Confirm by inspection that safety functions associated with the control room remain in accordance with the commissioning procedures (i.e. air locks if fitted) S1 S2 S3

3. Confirm by inspection that CCTV coverage is such that all necessary angles of the areas in questions can be viewed at a central protected location S1 S2 S3

Table C-6.18 Active Fire Fighting Systems LevelItem Description Low Medium High

Fire Water Storage

1. Confirm by inspection that fire water storage remains provided in accordance to design documents and drawings S1 S2 S3

2. Confirm by document review of maintenance and inspection records that the fire water storage continues to function in accordance with design - R1 R2

Firewater Pumps

3. Confirm by inspection that fire pumps remain installed in accordance with design drawings S1 S2 S3

4. Confirm by witnessing tests that the fire pumps capacity and discharge rates remain in accordance with design. - S1 S2

5. Confirm by witnessing tests that fire pump start arrangements remain in accordance with design S1 S2 S3

6. Confirm by document review of maintenance and inspection records that the fire pumps continue to function in accordance with design R1 R1 R2

Firewater Distribution Ring main

DET NORSKE VERITAS

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Service Specification DNV-DSS-314, October 2010 Page 84 – App.C

7. Confirm by inspection that the firewater distribution ring main remains provided in accordance with the design drawings S1 S2 S3

8. Confirm that firewater distribution ring main isolation valves remain installed and operate in accordance with the P&IDs S1 S2 S3

9.Confirm by witnessing tests that the firewater and foam supply systems are capable of delivering sufficient extinguishing to all necessary locations to deal with credible worst case fire scenario as required by the design documents

- S1 S2

10. Confirm by review of records that foam is supplied with appropriate certification R1 R2 R2

11. Confirm by document review of maintenance and inspection records that the fire pumps continue to function in accordance with design R1 R1 R2

Firewater and Foam Supply

12. Confirm by inspection that the firewater and foam supply systems remain installed in accordance with the design drawings S1 S2 S3

13. Confirm by inspection that the monitors and hydrants remain installed in accordance with the design documents and drawings S1 S2 S3

14.Confirm by witnessing tests that the firewater and foam supply systems continue to be capable of delivering sufficient extinguishing to all necessary locations to deal with credible worst case fire scenario as required by the design documents

S1 S2 S3

15.Confirm by document review of maintenance and inspection records that the firewater and foam supply systems remain in good condition with adequate wall thickness

R1 R1 R2

Gaseous Fire-fighting Systems

16. Confirm by inspection that the gaseous fire-fighting systems remain installed in accordance with the design drawings S1 S2 S3

17. Confirm by inspection that status indicators remain provided at all enclosures entrances protected by gaseous fire-fighting systems S1 S2 S3

18.Confirm by witnessing tests that the firewater and foam supply systems continue to be capable of delivering sufficient extinguishing gas to all necessary locations as required by the design documents

S1 S2 S3

19.Confirm by document review of maintenance records that status indicators provided at all enclosures entrances protected by gaseous fire-fighting systems continue to function as intended to give personnel sufficient warning to evacuate the enclosure

- R1 R2

20.Confirm by document review of maintenance and inspection records that the gaseous fire-fighting systems remain in good condition and continue to function in accordance with design

R1 R1 R2

Fire-fighting Vehicle

21. Confirm by inspection that any fire-fighting vehicles continue to conform to the requirements of the design documents S1 S2 S3

22.Confirm by witnessing tests that any fire-fighting vehicles remain capable of delivering sufficient extinguishing to all necessary locations as required by the design documents

S1 S2 S3

23.Confirm by document review of maintenance and inspection records that the any fire-fighting vehicles remain in good condition and continue to function in accordance with design

R1 R1 R2

Table C-6.19 Passive Fire Protection LevelItem Description Low Medium High

1. Confirm by inspection that passive fire protection (PFP) remains provided in accordance with the design on vessels, piping, supports and structures S1 S2 S3

2. Confirm by inspection that penetrations in PFP remain installed in accordance with manufacturer’s instructions S1 S2 S3

Table C-6.20 Bunding and Drainage LevelItem Description Low Medium High

1. Confirm by inspection that bunding and drainage remains installed is accordance with the design drawings S1 S2 S3

Table C-6.21 Emergency Power and Uninterruptible Power Supply LevelItem Description Low Medium High

DET NORSKE VERITAS

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Service Specification DNV-DSS-314, October 2010 App.C – Page 85

1. Confirm by inspection that emergency power and uninterruptible power supply (UPS) remains installed in accordance with design documents and drawings S1 S2 S3

2. Confirm by review of records that the supplied UPS batteries remain in accordance with the design documents - R1 R2

3. Confirm by inspection that automatic changeover of UPS battery banks continues to operate in accordance with the design S1 S2 S3

4. Confirm by document review of maintenance records that UPS remains in good condition and continue to function in accordance with design R1 R1 R2

Table C-6.22 Communications and Alarms LevelItem Description Low Medium High

Emergency Communications and Alarms

1. Confirm by inspection that all communication and alarm systems remain installed in accordance with design documents and drawings S1 S2 S3

2. Confirm by witnessing tests that emergency communications and alarms are audible over the whole facility. S1 S2 S3

3. Confirm by witnessing tests that in noisy areas personnel are alerted to emergency alarms by flashing beacons or other suitable means S1 S2 S3

4.Confirm by document review of maintenance records that communication and alarm systems remain in good condition and continue to function in accordance with design

R1 R1 R2

Internal and External Communications

5. Confirm by inspection that the internal and external communications remain installed in accordance with the commissioning procedures S1 S2 S3

6.Confirm by inspection that adequate external and internal telephone and fax lines remain available at all times during an emergency giving the emergency control centre the capability to handle two-way communications with all relevant parties

S1 S2 S3

7.Confirm by document review of maintenance records that internal and external communications remain in good condition and continue to function in accordance with design

R1 R1 R2

Table C-6.23 HVAC LevelItem Description Low Medium High

1. Confirm by inspection that the HVAC system remains been installed in accordance with the D&IDs S1 S2 S3

2. Confirm by witnessing tests that HVAC systems physically isolate by dampers the air supply on flammable or toxic gas, or smoke detection at the HVAC inlet - S1 S2

3. Confirm by witnessing tests that the control room HVAC is shutdown and dampers are closed on confirmed gas at the HVAC inlet. - S1 S2

4. Confirm by witnessing tests that commissioning reports that damper closure occurs within the required limits upon gas detection. S1 S2 S3

5. Confirm by document review of maintenance records that HVAC systems remain in good condition and continue to function in accordance with design R1 R2 R2

Table C-6.24 Egress and Evacuation System LevelItem Description Low Medium High

Escape Routes

1. Confirm by inspection that escape routes remain constructed in accordance with the design documents and drawings S1 S2 S3

2. Confirm by inspection that escape routes remain marked in accordance with design S1 S2 S3Muster Area

3. Confirm by inspection that muster areas remain marked in accordance with design S1 S2 S3

4. Confirm by inspection that muster areas have facilities to take muster and report findings to emergency control centre S1 S2 S3

Emergency Lighting

5.Confirm by inspection that escape routes and muster areas are adequately illuminated during periods of operation of emergency lighting to the specified minimum level

S1 S2 S3

General

6.Confirm by document review of maintenance and inspection records that all components of the egress and evacuation system remain in good condition and continue to function in accordance with design

R1 R2 R2

DET NORSKE VERITAS

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Service Specification DNV-DSS-314, October 2010 Page 86 – App.C

H. Modifications or Upgrades

H 100 General Principles101 The verification of the design, construction and commissioning of modifications or upgrades to existinghydrocarbon facilities shall be carried out in accordance with Sections C, D, E and F previously in thisAppendix as if a new facility was being built on a new site.102 However, unlike a green-field project, modifications or upgrades may have compatibility issues withexisting units in facility.103 The verification scope of work in this Section deals with these possible compatibility issues both withother units in process proximity, i.e. upstream or downstream of the new or modified unit, and units in physicalproximity, which may, or may not, be the same units.

H 200 Verification of Design of Modifications201 Detailed scopes of work for the verification of the design of modifications are given in Table C-6.1.

Table C-6.1 Design of Modifications - Compatibility with Existing Facility LevelItem Description Low Medium High

1.Confirm by review of the QRA that the modifications to site layout have been demonstrated to show that the level of risk remains within the corporate risk acceptance criteria

- R1 R2

2.Confirm by review of equipment layout drawings, bases of design and formal safety assessments that equipment separation within the modified facility remains adequate in terms of the risk acceptance criteria

- R1 R2

3.

Confirm by review of bases of design that the effects on units upstream or downstream have been considered in terms of, for example:

— incoming or outgoing product composition— corrosion potential of changes in product composition— changes in product:

— flowrates— temperatures— pressures.

R1 R2 R2

4.Confirm by review of the fire and explosion analysis that existing units or equipment close to the modifications are not affected by fires, explosions or the release of toxic vapour beyond their original design criteria

R1 R2 R2

5.Confirm by review of drawings that where changes to escape routes and emergency vehicle access result from the modifications, that routes and accesses to an equivalent level of safety are to be provided

R1 R2 R2

6.

Confirm by review of design documents that any modifications do not adversely affect existing systems, such as:

— process control— fire and gas detection— emergency shutdown.

R1 R2 R2

7.Confirm by review of design documents that existing and modified process control, fire and gas detection and emergency shutdown systems are capable of effective communication with each other and act as one complete system

R1 R2 R2

DET NORSKE VERITAS

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Service Specification DNV-DSS-314, October 2010 App.C – Page 87

H 300 Verification of Construction of Modifications301 Detailed scopes of work for the verification of the construction of modifications are given in Table C-6.2.

H 400 Verification of Commissioning of Modifications401 Detailed scopes of work for the verification of the commissioning of modifications are given in Table C-6.3.

Table C-6.2Construction of Modifications LevelItem Description Low Medium High

1. Confirm by inspection that the layout of the modifications is in accordance with the design documents S1 S2 S3

2. Confirm by inspection that there are no layout considerations that were not readily apparent during design S1 S2 S3

3. Confirm by inspection that process control, fire and gas detection and emergency shutdown systems have been constructed in accordance with design documents S1 S2 S3

4. Confirm by inspection that escape routes and emergency vehicle accesses have been constructed in accordance with design documents S1 S2 S3

5. Confirm by inspection that there are no escape routes and emergency vehicle access considerations that were not readily apparent during design S1 S2 S3

6. Confirm by inspection that there are no personnel accesses considerations, such as valve accesses, that were not readily apparent during design S1 S2 S3

Table C-6.3Commissioning of Modifications LevelItem Description Low Medium High

1.Confirm by witnessing of tests that existing and modified process control, fire and gas detection and emergency shutdown systems are capable of effective communication with each other and act as one complete system

S1 S2 S3

2. Confirm by witnessing of tests that no interference occurs between new and existing systems such that their operation is adversely affected S1 S2 S3

DET NORSKE VERITAS

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Service Specification DNV-DSS-314, October 2010 Page 88 – App.D

APPENDIX D MAJOR ACCIDENT HAZARDS VERSUS SAFETY-CRITICAL ELEMENTS

A. Purpose of Appendix

A 100 Introduction101 The purpose of this Appendix is to show typical refinery hazards and the interface with safety-criticalelements and risk mitigation measures.102 A preliminary identification and analysis of possible risk mitigation measures, i.e. Inherent Safety,Prevention, Detection, Control, Mitigation and Emergency Response, shall be carried out in accordance withALARP principle. Practical and cost-effective risk mitigation measures based on the risk assessment resultsshall be identified.103 However, major accident hazards and their related safety-critical elements are specific to a specifichydrocarbon facility as they related to the particular risks to that facility and its personnel. Other similarfacilities may have similar risks (and similar major accident hazards) but each list of major accident hazardsand their related safety-critical elements must be specific to each installation and its specific risks.

Table D-1 Major Accident hazards versus Safety-critical Elements

SAFETY CRITICAL ELEMENT

Fla

mm

able

Pro

cess

L

iqui

d R

elea

se

Fla

mm

able

Pro

cess

V

apou

r R

elea

se

Tox

ic P

roce

ss L

iqui

d R

elea

se

Tox

ic P

roce

ss

Vap

our

Rel

ease

Pip

elin

e R

elea

se

Ves

sel R

uptu

re/

Pre

ssur

e P

ulse

Tan

k R

elea

se

Str

uctu

ral C

olla

pse

Rel

ease

of d

ange

rous

su

bsta

nce

Dro

pped

Obj

ect

Err

ant v

esse

l im

pact

Veh

icle

Im

pact

INHERENT SAFETY a) b) c) d) e) f) g) h) i) j) k) l)

Layout M M M M M M M P P P

Hydrocarbon Inventory/Leak Source Minimisation P/M P/M P/M P/M P/M P/M P/M

HAZARD PREVENTION MEASURESProcess Facilities Integrity/Process System P P P P P P P P

Process Facilities Integrity/Relief Valves and Relief System P P P P P P P P

Process Facilities Integrity/ Structural Integrity P

Process Facilities Integrity/ Control Systems P P P P P P

Control of Ignition/Vehicles P P P P P

Control of Ignition/Fired Heaters, Hot Surfaces And Exhausts

P P P P

Control of Ignition/Electrical Items P P P P

Control of Ignition/Lightning, Static and Earthing P P P P

Pipeline Integrity/Onshore Pipeline P

Pipeline Integrity/Offshore Pipeline/SPM P

Pipeline Integrity/Third Party Interference Protection P P P P P P P P P P P

Dropped Object and Impact Protection P P P P P P P P P P P P

HAZARD DETECTION/CONTROL MEASURES

DET NORSKE VERITAS

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Service Specification DNV-DSS-314, October 2010 App.D – Page 89

Fire and Gas Detection/Smoke and Gas Detection for Site Buildings

D D D D D D

Fire and Gas Detection/Fire and Gas-External Areas D D D D D D

Fire and Gas Detection/ Fire and Gas-Machinery Enclosures D D D D D D

Fire and Gas Detection/Fire and Gas Control (forming part of the Integrated Control System)

D D D D D D

Leak Detection/Pipeline leak Detection D D D D D D D

Visual Monitoring/CCTV D D D D D D D D D D D

Emergency Shutdown System/ESD Control System C C C C C M C

Emergency Shutdown System/Emergency Shutdown Valves (ESDVs)

C C C C C M C

Blowdown Header and Flare System C C C C C M

Control Room C C C C C C C C C C C C

Active Fire Fighting Systems/Fire Water Storage M M M M M

Active Fire Fighting Systems/Fire water pumps M M M M M

Active Fire Fighting Systems/Fire Water Distribution Ring-main

M M M M M

Active Fire Fighting Systems/Fire Water and Foam Supply M M M M M

Active Fire Fighting Systems/Gaseous Fire Fighting Systems M M M M

Active Fire Fighting Systems/Fire Fighting Vehicle M M M M M M

Passive Fire Protection M M M M M P M

Bunding and Drainage C C C CHAZARD MITIGATION MEASURESEmergency Services/Emergency Power M/C M/C M/C M/C M/C M/C M M

Emergency Services/Emergency Communications and Alarms

M M M M M M M M M M M M

Internal & External Communication M M M M M M M M M M P/C/

MP/C/M

Personnel Toxic Gas Protection M M

Uninterruptible Power Supply (UPS) M/C M/C M/C M/C M/C M/C M M

HVAC M M M M M M M

Table D-1 Major Accident hazards versus Safety-critical Elements (Continued)

SAFETY CRITICAL ELEMENT

Fla

mm

able

Pro

cess

L

iqui

d R

elea

se

Fla

mm

able

Pro

cess

V

apou

r R

elea

se

Tox

ic P

roce

ss L

iqui

d R

elea

se

Tox

ic P

roce

ss

Vap

our

Rel

ease

Pip

elin

e R

elea

se

Ves

sel R

uptu

re/

Pre

ssur

e P

ulse

Tan

k R

elea

se

Str

uctu

ral C

olla

pse

Rel

ease

of d

ange

rous

su

bsta

nce

Dro

pped

Obj

ect

Err

ant v

esse

l im

pact

Veh

icle

Im

pact

DET NORSKE VERITAS

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Service Specification DNV-DSS-314, October 2010 Page 90 – App.D

EMERGENCY RESPONSEEgress and Evacuation System/Escape Routes M M M M M M M M M M M

Egress and Evacuation System/Muster Area M M M M M M M M M M M

Emergency Lighting M M M M M M M M M M M

a) Flammable liquid releases result in pool fires, flash fires through evaporation and jet fires if pressurised. Can escalate to BLEVEs if conditions are right.

b) Flammable vapour/gas release result in jet fires if ignition is immediate and vapour cloud explosions if ignition is delayed. Escalation in local area is likely from jet fires and is almost inevitable for VCEs.

c) Toxic liquid release can subsequently flash although typically easily contained if recognised. Liquid releases in aerosol form may be more problematic.

d) Toxic gas releases result can result in large drifting clouds with significant hazard ranges including offsite impact. Most likely scenario to result in large numbers of casualties.

e) Pipeline releases are generally difficult to detect unless in a frequently visited area or ignited.

f) Vessel rupture can result from internal overpressure such as from an internal explosion or uncontrolled increase in pressure. The pressure pulse at rupture can have blast overpressure levels equivalent to VCEs.

g) Tank releases are historically due to overfilling or structural collapse of the tank due to a fire. Full face crude tank fires have a 30-50% chance of escalating to a boil-over with significant impact to a large area around the tank.

h) Structural collapse can result from loss of integrity due to impact, deterioration, subsidence or fire impingement. May escalate to process releases. Structure includes buildings, pipe and vessel supports, jetty trestle and flare stacks.

i) Dangerous substances include high pressure steam, and stored chemicals and gases. Impact will tend to be localised. Unlikely to escalate.

j) Dropped objects originate from crane operations in process areas, and mooring operations at jetty and SPM. Can escalate to structural collapse or process releases.

k) Errant vessel impact at the SPM or jetty may be due to loss of control of near by vessels. Can escalate to structural collapse or process releases.

l) Vehicle impact within the process area can escalate to structural collapse or process releases.

Type Release Fluids Ignition ConsequencesFlammable Events

Small /Medium Jet fire

Continuous release of flammable fluid with significant momentum from a 25 mm or smaller leak

Hydrocarbon gases, two phase mixtures and liquids: fluid needs to be pressurised

Immediate ignition via auto-ignition, static build-up in some leak scenarios, or other form at source of leak

P - Fatalities very improbable: minor injury possibleA – Minor damage to equipmentE – Minimal impact.

Large Jet fire

Continuous release of flammable fluid with significant momentum from a 50 mm or larger leak

Hydrocarbon gases, two phase mixtures and liquids: fluid needs to be pressurised

Immediate ignition via auto-ignition, static build-up in some leak scenarios, or other form at source of leak

P – Serious injury/fatalities probable for those nearbyA – Localised but substantial damage, including structural failure of equipmentE – Minimal impact

Flash fire Continuous release of flammable fluid

Evaporation of C4+ components from pool spill

Delayed ignition some distance from the source of the leak. Flame front burns back to source depending upon the air fuel ratio

P – Can cause flash burns to individuals: Fatality possible but unlikely.A – Negligible damage to equipment.E – Spill may have impactEsc – May escalate to pool fire when burn back ignites originating pool

Table D-1 Major Accident hazards versus Safety-critical Elements (Continued)

SAFETY CRITICAL ELEMENT

Fla

mm

able

Pro

cess

L

iqui

d R

elea

se

Fla

mm

able

Pro

cess

V

apou

r R

elea

se

Tox

ic P

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ss L

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elea

se

Tox

ic P

roce

ss

Vap

our

Rel

ease

Pip

elin

e R

elea

se

Ves

sel R

uptu

re/

Pre

ssur

e P

ulse

Tan

k R

elea

se

Str

uctu

ral C

olla

pse

Rel

ease

of d

ange

rous

su

bsta

nce

Dro

pped

Obj

ect

Err

ant v

esse

l im

pact

Veh

icle

Im

pact

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Service Specification DNV-DSS-314, October 2010 App.D – Page 91

Pool fire Release of flammable fluid

Fluids of C4+ components: may be static or running pools

Ignition of flashing/evaporating vapour by external source

P – Fatalities unlikely where opportunity to escape existsA – Potentially widespread impact if not containedE – Can have significant local environmental impact due to large quantities of smokeEsc – Can escalate to BLEVE in some under vessel/pipe rack fires

Boil-over

Sudden release of large quantities of burning fluid from an atmospheric tank, caused by water boiling in the base of the tank due to a surrounding pool fire or a tank-top fire heating up the contents of the tank

Crude oil and hydrocarbon product liquids

Ignition from existing tank top fire

P – Unlikely to result in injury or fatality as there is plenty of warning of eventA – Potential widespread impact as the contents of the tank can expand by 400 times due to frothing: may overspill the bund wallE - Can have significant local environmental impact due to large quantities of smokeEsc - Rain-out of burning droplets can cause secondary fires up to 5 tank diameters away: thermal radiation can peak well above the value required to start secondary fires at distances up to 200m

Boiling Liquid Expanding Vapour Explosion (BLEVE)

Catastrophic failure of pressure vessel resulting in a sudden release of vapour: failure is due to the internal pressure of boiling liquid and vapour exceeding the reduced tensile strength of rapidly heated vessel wall

Pressurised fluids with C4+ components if above boiling point: affects overhead accumulators and vessels, but not columns where flanges fail first

Ignition due to heat source applied to vessel (pool fire, jet fire etc.)

P – Take time to develop so fatalities should be unlikely if signs are recognisedA – Massive damage over large area due to projectiles, overpressure and fire ballsE – Minimal impactEsc – May result in other events due to damage caused

Vapour Cloud Explosion (VCE)

Release of flammable fluid: very unlikely if volumes are less that 10t (for general hydrocarbon service): it is more likely for Hydrogen and Propylene cloud, e.g. 100 kg

Typically C3, C4 and C5 in storage or any hydrocarbon fluid in process if above its boiling point

Ignition by external source resulting in an explosion: confinement level affect the probability of VCE

P – Fatalities a probable outcomeA – Pressure wave causes significant damage. Extent depends on size of release but considered a major impact.E – Minimal impactEsc – Escalation almost inevitable

Toxic Events

Toxic Release

Release of toxic fluids

Toxic gases such as H2S, SO2 and CO Not applicable

P – Extent of CO toxicity depends upon original concentration and pressure: potential for offsite impactsA – No impactE – May have impact on local fauna and flora but unlikelyEsc – No escalation

P = Personnel

A = Assets (plant and equipment)

E = Environment

Esc = Escalation

Type Release Fluids Ignition Consequences

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Service Specification DNV-DSS-314, October 2010 Page 92 – App.E

APPENDIX E GUIDANCE ON THE DEVELOPMENT OF VERIFICATION PLANS

A. Purpose of Appendix

A 100 Introduction

101 The purpose of the Verification Plan is to describe the philosophy and methods used to ensure that anindependent and competent scrutiny is carried out on the parts of the hydrocarbon facility that are consideredto be critical to its safety and integrity to confirm their initial suitability.

102 Verification Plans are specific to a specific hydrocarbon facility as the plan is related to the particularrisks to that facility and its personnel. Other similar facilities may have similar risks (and similar VerificationPlans) but each Plan must be specific to each installation and its specific risks.

B. The Verification Plan’s Part in Facility Risk Management

B 100 Risk Reduction in Principle101 Risk reduction for hydrocarbon facilities follows three main steps:

Figure 1 Management of Safety

102 ALARP is not defined in any legislation but has arisen from Case Law through the English courts. Theconcept is that the degree of risk from any particular activity can be balanced against the cost, time and troubleof the measures to be taken to reduce the risk. Thus, the greater the risk the more reasonable it would be to incursubstantial cost, time and trouble in its mitigation. Conversely, the smaller the risk the less reasonable it wouldbe to expect great expense or trouble to be taken in reducing it.

Figure 2 Risk Reduction and Verification

B 200 The Major Accident Hazard Process and Integrity Management201 Major Accident Hazards are identified in a Formal Safety Assessment by an analysis of the risks to thehydrocarbon facility’s integrity and the safety of personnel using suitable definitions of such accidents. Thedefinitions of these accidents may be set by National Authorities.202 Prevention, Control and Mitigation Measures are the measures that have been identified to reduce theseidentified risks by preventing their occurrence, controlling them when they have occurred or mitigating theeffects of their occurrence.203 Safety-critical Elements are those items of hardware that perform the prevention, control and mitigationmeasures to reduce risks. It must be noted that in this instance computer software is considered hardware.Furthermore, it should be realised that the identification of safety-critical elements is solely consequence-based

Identification of Major Hazards

Evaluation of Risks

Identification of Measures Taken to Reduce Risks“As Low As Reasonably Practicable” (ALARP)

Major Accident Hazards

Prevention, Control and Mitigation Measures

Safety-critical Elements

Performance Standards

Owner’s Integrity Management

Verification Scheme

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with no consideration of the probability of occurrence.

204 Performance Standards are the definition of the methods by which the safety-critical elements performtheir risk reduction functions. Thus, performance standards are the basis to which the safety-critical elementsare designed, constructed, commissioned and operated. Their formulation is not stand-alone but integral partof design process and must include assumptions in FEED, QRAs, other safety studies and detailed design.Formulation of performance standards is function-based and conventionally lists essential parameters relevantto Functionality, Availability, Reliability and Survivability.

205 Verification Scheme is an independent examination of the safety-critical elements to confirm that theyare suitable for the purpose for which they were designed, constructed, commissioned and operated. It is carriedout by personnel independent of the Owner in order to have an external opinion of the effectiveness of Owner’sand their contractors’ integrity management procedures and practices.

206 Verification activities usually will fall under three categories:

— visual examination— witnessing of construction, commissioning and inspection activities— review of documents.

C. Independent Third-Party Verification

C 100 What is Verification?

101 Verification is a system of independent and competent scrutiny of elements identified as critical to theintegrity of the hydrocarbon facility and the safety of personnel working in it. When requested by the Ownerverification may be extended to personnel located outside the facility.

102 Verification is in addition to routine design checks, construction and commissioning checks andinspections and maintenance and inspection during operation.

103 Verification is expected to:

— be an independent and competent scrutiny of the hydrocarbon facility’s safety-critical elements,performance standards and risk assessments’ assumptions and conclusions

— identify errors or failures in the selection of safety-critical elements and the specification of theirperformance standards

— include examination of the design, procurement, construction, commissioning and operation of thefacility’s safety-critical elements.

104 Verification activities are carried out at any place where a hydrocarbon facility is being designed,constructed, commissioned or operated. Such places would include design offices, fabrication sites, the facilityitself, the Owner’s premises or any of its contractor’s premises.

C 200 How Verification Is Carried Out

201 DNV’s role is to provide an independent examination of the suitability of the safety-critical elements.This includes the adequacy of the selection of these safety-critical elements and the adequacy of theirperformance standards.

202 DNV also provides findings and required remedial actions after completion of these examinations.

203 Examination of safety-critical elements involves activities, such as inspection, testing, review ofdocuments and audit, in order to assess whether these safety-critical elements comply, or confirm that they donot comply, with their performance standards.

C 300 Content of Verification Plan

301 Various aspects of verification must be included in the verification scheme, namely the:

— principles for selecting persons to perform functions under the scheme and to keep the scheme under review— arrangements for the communication of information necessary to the persons referred to above— arrangements for review and revision of the scheme— nature and frequency of examination and testing— arrangements for the making and preservation of records showing;— examination and testing carried out— findings— remedial action recommended and— remedial action performed— arrangements for communicating the records above to an appropriate level in the Owner— arrangements for taking of appropriate action following such reports

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C 400 Formal Guidance on Verification Plans and Practices401 The philosophy of verification of safety-critical elements and their accompanying performance standardsarises from the United Kingdom’s “The Offshore Installations (Safety Case) Regulations 2005”, StatutoryInstrument 2005 number 3117, ref. Sec.1 E.402 Guidance on the United Kingdom’s implementation of verification may be found in “A Guide to theOffshore Installations (Safety Case) Regulations 2005”, ref. Sec.1 E.

D. Verification Plan

D 100 Development of the Verification Plan101 The Verification Plan shall be formulated to provide a written record during its development andimplementation of the independent and competent scrutiny of the design, construction, commissioning andoperation of the hydrocarbon facility. Although presented as a single flow of activities, it is recognised thatthere will be a continuous feedback of modifications and improvements as the project develops. Thedevelopment of the Verification Plan therefore will be an ongoing activity, subject to appropriate formalchange control.102 The requirement for the Verification Plan will be to establish that, for the selected SCEs, the PSs bringtogether the safety and integrity-related performance goals and requirements in such a manner that will allowDNV to demonstrate suitability. Suitability is defined as appropriate for intended use, dependable and effectivewhen required.

D 200 Development of Examination Scope of Work Documents201 The Verification Task List will define specific examination activities to be performed by DNV toconfirm the initial suitability of the SCEs. This initial and suitability will be confirmed against the specificperformance criteria given in the PS.202 Each verification task will contain the following information:

— details of each SCE relevant to the task— against each SCE details of each PS relevant to the task— against each PS a list of examination activities to be completed by DNV— against each examination activity the following details are required:

— activity No. – a unique identification number for the examination activity described— a description of the examination activity to be performed,— the timing of the examination activities— nature of the examination activity— phase of the hydrocarbon facility life-cycle in which the activities occur— reference documents – suggested generic documents required to close or facilitate the examination

activity (the specified documents will not necessarily be an exhaustive list).

D 300 Methods of Examination301 The detailed methods of examination will be identified within the verification tasks. However, theexamination methods will fall into one of these four categories:

D 400 Project Phase401 The phase of the hydrocarbon project cycle in which the activities occur will be identified within theverification tasks. However, the project phase will fall into one of these four categories:

Inspection Visual inspection of the SCE in questionTest Witness or carry out functional testing of the SCE

Audit A documentation check with regard to the effectiveness of assurance activities undertaken by the Owner or its contractors

Review A documentation check with regard to adequacy

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D 500 Control of Verification

501 It is recommended that management and control of verification activities is undertaken electronically,preferably using a database but other suitable methods may be used.

502 The database (or other means of control) should contain the following input fields:

E. Verification Reporting

E 100 Control of Verification Reports

101 A uniquely numbered Verification Activity Report (VAR) shall be produced for each for each activitylisted in the verification task list by the individual Verifier undertaking the examination. Each VAR will beproduced by entering the appropriate information into the verification database described previously. Each

Design Design of the facility or any of its components

Procurement

Procurement of the materials and items of plant intended for the facility

Guidance note:This activity may include design of components if this is a contractual requirement from the Ownerto the Vendor.

---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

Construction

The onsite activities of construction and assembly of the facility

Guidance note:Construction may take place at multiple sites before integration at the main site.

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Commissioning The onsite activities of commissioning the facility

Operations Operation of the facility for the purpose for which it was designed

Table E-1 Verification Control Database – Suggested Input FieldsInput Field DescriptionSafety-Critical Element Safety-Critical Element

Performance Standard

Numbered performance criteria detailed in each Performance Standard document. Each of these will be linked to a SCE within the database. The database architecture shall enable multiple PS to be linked to each SCE.

Examination Activity

Description of the examination activity to be undertaken. As part of this input field the following information is also required:

— type of examination (e.g. review, inspect, etc.)— lifecycle phase (design, construction, etc.)— details of documents required to assist with the verification activity.

Each examination activity will be linked to a PS within the database. The database architecture shall enable multiple activities to be linked to each PS.

Reporting

Description of the examination undertaken. As part of this input field the following information is required:

— description of the verification work undertaken— details of outstanding actions to be completed— date of the examination— details of the individual verifier completing the examination.

Each report will be linked to a verification activity within the database. The database architecture shall enable multiple reports to be linked to each examination activity.

Findings

Description of findings from the verification work undertaken. As part of this input field the following information is required:

— verifier’s findings (comment on whether the activity is closed, the PS is met, etc.)— remedial actions recommended by the verifier— finding close-out date— report/finding status code— report/finding update details.

Each finding will be linked to a report within the database. The database architecture shall enable multiple findings to be linked to each report.

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VAR will include the following information:

— safety-critical element— performance standard— unique examination activity identifier and description— description of the examination completed— details of any outstanding activities— findings of the examination (e.g. has the performance standard been met?)— remedial actions recommended to the Owner.

102 All records shall identify clearly the individual(s) undertaking the examination.

E 200 Verification Status Reporting

201 Each VAR will specify the activity status code as described below:

A - Performance Standard satisfied

B - Performance Standard not met or demonstrated

C - Further verification activities to be completed or additional information required which is not available

202 Status A: issued after any comments relating to the activity have been resolved and it is confirmed thatthe requirements of the relevant Performance Standard have been met.

203 Status B: issued after it is agreed with the Owner that outstanding comments cannot be resolved and thatDNV cannot confirm that the requirements of the relevant Performance Standard have been met, or can confirmthat the requirements have not been met.

Guidance note:Where VAR Status B is issued by DNV, it is up to the owner to justify to himself, and where necessary to the NationalAuthorities, his basis for acceptance of the deviation from his previously stated requirements.

DNV’s final report will simply state that the VAR has been issued at Status B and give the reasons for this.

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204 Status C: not normally issued but the status recorded for progress reporting, if required by the Owner.

F. Review and Revision of the Verification Plan

F 100 Continuous Review of the Plan

101 The Verification Plan will remain live for the lifetime of the design, construction and commissioning ofthe hydrocarbon facility. It is essential that there is a continuous feedback of modifications and improvementsas the project develops. The development of the Verification Plan therefore will be an ongoing activity, subjectto appropriate formal change control.

102 The Owner should ensure that all persons completing activities relevant to the design, construction andcommissioning of the hydrocarbon facility are given the opportunity to comment on the adequacy and possibleimprovement of the Verification Plan.

F 200 Events Initiating Revisions

201 The Verification Plan may require changes that are triggered by events such as:

— major design changes during the design, construction or operations phase— Verification Plan is incorrect, deficient or requires improving— change of record of SCEs (e.g. revised methodology for identifying SCEs)— change of Performance Standards (e.g. current PS inappropriate, or due to technical advances)— inability to confirm that SCE meets the requirements of its PS— major revision to supporting safety documentation (QRA, FERA, etc.)— damage or incidents— change in record-keeping systems— change in responsibilities/accountabilities— change in reporting requirements.

202 When one or more of the above occurs, the Owner shall review, and where deemed necessary update, thePlan. These reviews will be conducted in consultation with DNV, together with any contractor’s personnel asappropriate.

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