DNV GL-RP-0423 Manufacturing and commissioning of...

RECOMMENDED PRACTICE

DNVGL-RP-0423 Edition March 2016

Manufacturing and commissioning of offshore substations

DNV GL AS

The electronic pdf version of this document found through http://www.dnvgl.com is the officially binding version. The documents are available free of charge in PDF format.

FOREWORD
DNV GL recommended practices contain sound engineering practice and guidance.
© DNV GL AS March 2016

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

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

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Recommended practice, DNVGL-RP-0423 – Edition March 2016 Page 3

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CONTENTS
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Sec.1 General ......................................................................................................... 61.1 Introduction ...........................................................................................6

1.1.1 Preamble ......................................................................................61.1.2 Motivation.....................................................................................6

1.2 Objectives ..............................................................................................61.3 Scope and application ............................................................................61.4 Certification ...........................................................................................71.5 Informative references ..........................................................................71.6 Definitions..............................................................................................8

1.6.1 Verbal forms .................................................................................81.6.2 Terms ..........................................................................................91.6.3 Typical offshore substation setup ...................................................10

1.7 Acronyms, abbreviations and symbols .................................................101.7.1 Acronyms and abbreviations..........................................................10

Sec.2 Manufacturing and commissioning process and definition of various stages ......................................................................................................... 132.1 General.................................................................................................132.2 Design basis .........................................................................................142.3 Design ..................................................................................................152.4 Manufacturing (supplier) .....................................................................15

2.4.1 Component fabrication..................................................................152.4.2 Factory acceptance tests...............................................................18

2.5 Transport (component manufacturing site - final assembly site) .........192.6 Manufacturing (assembly) ...................................................................19

2.6.1 Final assembly (installation & outfitting)..........................................192.6.2 Mechanical completion..................................................................19

2.7 Onshore commissioning .......................................................................202.7.1 General ......................................................................................202.7.2 Pre-commissioning.......................................................................202.7.3 Commissioning ............................................................................212.7.4 Integration testing .......................................................................22

2.8 Transport and installation (final assembly site - installation site)........232.9 Offshore commissioning.......................................................................23

2.9.1 Pre-energization commissioning .....................................................232.9.2 Post-energization commissioning....................................................24

2.10 Operation and subsequent stages ........................................................24Sec.3 DNV GL’s involvement in manufacturing, testing and commissioning.......... 25Sec.4 Health, safety and environment .................................................................. 26

4.1 Health, safety and environment ...........................................................264.2 DNV GL inspector .................................................................................26

App. A Documentation............................................................................................ 27

App. B Overview of systems ................................................................................... 32

App. C DNV GL’s typical survey categorization for manufacturing (supplier/assembly) ................................................................................... 36


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App. D DNV GL’s typical survey categorization for commissioning.......................... 38
App. E List of survey requirements related to steel structures, mechanical, electrical and safety systems ...................................................................... 40


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SECTION 1 GENERAL
1.1 Introduction

1.1.1 PreambleThis recommended practice (RP) outlines the general best practices that support effective manufacturing, testing and commissioning of the structure and marine and industrial systems on Offshore Substations (OSS) in offshore wind power plants (WPP). For convenience, an extract of relevant rules, standards and codes related to manufacturing, testing and commissioning of structures and marine and industrial systems have been included in this document.

In addition, note that statutory regulations and requirements directly associated with the applied standards for manufacturing, testing and commissioning, shall always be observed.

Systems, components and system categorizations mentioned in the appendices do not claim to be exhaustive and are not always applicable. This document should be used for guidance only.

1.1.2 MotivationDNV GL has recognized that the technical complexity of modern OSS’s is increasing due to systems becoming more complex, more automation and more tightly integrated. At the same time complexity in the project setup has increased with numerous active parties involved in OSS development, design, construction, commissioning, installation and operation. This evolution challenges designers, shipyards, Owners and other involved parties in their management of manufacturing, testing and commissioning the structures, equipment and systems on OSS’s successfully.

1.2 ObjectivesThe main purpose of the RP is to ensure that manufacturing, testing and commissioning procedures are comprehensive and contain all relevant information required by the applied DNV GL service specifications and/or DNV GL standards.

This RP shall be read as a guide to manufacturing, testing and commissioning of the equipment and systems on OSS’s in WPP. Among other objectives this document supports users in preparing or carrying out witnessing of manufacturing, testing and commissioning activities and thereby meeting the requirements made by investors and insurance companies by

— minimizing project risks— improving safety and reliability— covering the interfaces between project stages and technical disciplines— preventing failures/mistakes made elsewhere in the industry— ensuring a thorough verification by a third-party— fulfilling certification requirements.

1.3 Scope and applicationThis RP is applicable for verification and certification of manufacturing, testing and commissioning activities regarding fixed OSS’s for WPP. It is aiming primarily at AC transformer platforms but may also be used analogously for AC/DC converter platforms, accommodation platforms and reactive compensation platforms, where applicable.

It exclusively covers manufacturing, testing and commissioning processes, handled at the supplier’s facility/shipyard or at the offshore site, regarding structures, components and systems intended for offshore substations.

For the development and execution of the manufacturing, testing and commissioning campaign this RP is an OSS-specific supplement to the applied service specification and standards. If applied, all requirements ensuring that manufacturing, testing and commissioning activities are fully in compliance with the certification requirements shall be observed.


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It is noted that the final acceptance of commissioning is the Owner’s responsibility. This RP only covers
activities associated with DNVGL’s third party verification and certification.

The manufacturing, testing and commissioning of array power cables and export power cables including their termination on the OSS are not part of the scope.

1.4 CertificationGeneral safety principles, requirements and guidance for the design of platform installations associated with offshore renewable energy projects, collectively denoted as OSS, are specified in the offshore standard DNVGL-ST-0145.

Principles and procedures related to certification services for project certification of offshore wind farms are specified in the service specification DNVGL-SE-0190.

Principles and procedures related to certification services for project certification of wind farms according to IEC 61400-22 are specified in the service specifications DNVGL-SE-0073.

Details and clarification on the activities necessary to verify compliance with the state-of-the-art of the shop and fabrication procedures are specified in the service specification for shop approval in renewable energy DNVGL-SE-0436.

1.5 Informative references Service specifications, standards, guidelines and recommended practices this RP refers to or information and requirements provided in this RP are extracted from can be found in the following alphabetically arranged list:

Document code TitleAPI RP 2A-WSD planning, designing, and constructing fixed offshore platforms —

working stress design, 22nd edition, November 2014CIGRE 483 Guidelines for the design and construction of AC offshore substations for wind

power plants, December 2011DNV-OSS-304 Risk Based Verification of Offshore StructuresDNV-RP-B401 Cathodic Protection DesignDNVGL-CG-0170 Offshore classification projects - testing and commissioningDNVGL-OS-C401 Fabrication and testing of offshore structuresDNVGL-OS-D301 Fire protectionDNVGL-ST-0145 Offshore substations for wind farmsDNVGL-ST-0358 Certification of offshore gangways for personnel transferDNVGL-SE-0073 Project certification of wind farms according to IEC 61400-22DNVGL-SE-0190 Certification of wind power plantsDNVGL-SE-0436 Shop approval in renewable energyEN 10204:2004 Metallic products - types of inspection documentsGL Rules and guidelines IV industrial services – Part 2 – guideline for the certification of offshore wind

turbines, edition 2012GL Rules for classification and construction

IV industrial services – Part 6 – offshore technology, edition 2007

GL Rules for classification and construction

IV industrial services – Part 7 – offshore substations, edition 2013

IEC 61400-22:2010 Wind turbines - Part 22: Conformity testing and certificationIEC 82079-1 Preparation of instructions for use - structuring, content and presentation –

Part 1: General principles and detailed requirements, edition 2012IMO International code for application of fire test procedures, 2010 (FTP)IMO International code for fire safety systems, 2000 (FSS)IMO International convention for the safety of life at sea (SOLAS), consolidated

edition 1st June 2009, incorporating all amendmentsIMO International life-saving appliances code, October 1998 (LSA)ISO 9712:2012 Non-destructive testing -- Qualification and certification of NDT personnel


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Guidance note:For offshore substations to be installed in the German Exclusive Economic Zone (EEZ) the following additional requirements, national or local regulations may apply:

— Bundesamt für Seeschifffahrt und Hydrographie (BSH) Standard 7005 ”Standard Konstruktion – Mindestanforderungen an die konstruktive Ausführung von Offshore-Bauwerken in der ausschließlichen Wirtschaftszone (AWZ)”, edition 2015 dated 01.12.2015

— Bundesamt für Seeschifffahrt und Hydrographie (BSH) Standard 7005 ”Design of offshore wind turbines”, edition 2007 with supplement dated 03.01.2012

— VdS CEA 4001 Guidelines for Sprinkler Systems - Planning and Installation, edition 2014— WSV - Richtlinie “Offshore-Anlagen” zur Gewährleistung der Sicherheit und Leichtigkeit des Schiffsverkehrs, Version 2, Stand:

01.07.2014— WSV – Rahmenvorgabe zur Gewährleistung der fachgerechten Umsetzung verkehrstechnischer Auflagen im Umfeld von

Offshore-Anlagen – hier: Kennzeichnung, Stand: 01.07.2014

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Please note that the list of references above makes no claim to be exhaustive.

If not stated explicitly always the latest version/edition of the referenced specifications, standards and guidelines shall be considered.

1.6 Definitions

1.6.1 Verbal formsVerbal forms as shown in Table 1-1 are used in this recommended practice.

ISO 3834-2:2005 Quality requirements for fusion welding of metallic materials - Part 2: Comprehensive quality requirements

ISO 9001:2015 Quality management systems - RequirementsISO 19902:2007 Petroleum and natural gas industries - Fixed steel offshore structuresMARPOL 73/78 International convention for the prevention of pollution from ship, 1973/1978,

Consolidated Edition 2001, all Annexes as far as applicableMODU Code Code for the construction and equipment of mobile offshore drilling unitsNFPA 13 Standard for the Installation of Sprinkler Systems, edition 2013NFPA 16 Standard for the Installation of Foam-Water Sprinkler and Foam-Water Spray

Systems, edition 2015NFPA 2001 Standard on Clean Agent Fire Extinguishing Systems, edition 2015NFPA 25 Standard for the Inspection, Testing, and Maintenance of Water-Based Fire

Protection Systems, edition 2014NFPA 72 National Fire Alarm and Signaling Code, edition 2013NORSOK M-101 Structural steel fabrication, edition 5, October 2011NORSOK M-501 Surface preparation and protective coating, edition 6, February 2012NORSOK Z-006 Preservation, edition 3, August 2015NORSOK Z-007 Mechanical completion and commissioning, edition 3, August 2015

Table 1-1 Definitions of verbal forms

Term Definitionshall verbal form used to indicate requirements strictly to be followed in order to conform to the documentshould verbal form used to indicate that among several possibilities one is recommended as particularly

suitable, without mentioning or excluding others, or that a certain course of action is preferred but not necessarily required

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

Document code Title


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1.6.2 Terms
Terms as shown in Table 1-2 are used in this recommended practice.

Table 1-2 Definitions of terms

Term Definitionarray power cable power cable between the wind turbine generator and the substationbuilder builder is the party contracted to build an OSS in compliance with applied service

specification and standardscustomer customer is the party who has requested DNV GL's services and may mean the Owner or

the Builder of the OSSexport power cable power cable between the substation and the main gridfactory acceptance tests (FAT)

sum of work, e.g. conformity checks with specifications and functional requirements as well as quality aspects, typically done for machinery and electrical equipment as well as lifting devices at the supplier’s site before dispatching to final assembly site

foundation part of the support structure for the substation that transfers the loads acting on the structure into the soil

harbour acceptance tests (HAT)

sum of work associated with pre-commissioning, commissioning and integration testing performed at the harbour site or shipyard before sail-out to the offshore site

inspection and test plan (ITP)

list of survey activities in a defined project that have been agreed upon between the Customer and DNV GL

inspector inspector to DNV GL, authorized to carry out surveys and to conclude whether or not compliance has been achieved

non-conformity report (NCR)

non-conformity (NC) is a deviation from a specification, a standard, or an expectationA non-conformity report documents the details of the non-conformity identified in an audit, inspection or during execution and other evaluations of a process. The objective of the report is to make an unambiguous, defensible, clear and concise definition of the problem so that corrective action can and will be initiated.

offshore substation (OSS) term referring to offshore transformer stations or converter stations or platforms, with or without accommodationsAn OSS may be defined as an integral asset of the wind farm project or as a separate asset for DNV GL project certification. Whenever in this recommended practice the term is used, it generally describes the topside structure including the support structure.

owner the registered Owner of the OSS or any other organization or person who has assumed the responsibility for operating the OSS and has agreed to take over all the duties and responsibilities related to the accomplishment and operation of the OSS

site acceptance tests (SAT)

sum of work associated with pre-energization and post-energization commissioning performed at the offshore site before final release for operation

stage in this RP a stage is defined to be a main phase in the lifetime of an OSS, e.g. starting from the ‘Design Basis’ stage and ending at the ‘Operation and Subsequent Stages’ stageA stage may consist of several sub-stages. Figure 2-1 gives an overview of all relevant stages und sub-stages addressed by this RP.

sub-stage in this RP a sub-stage is defined to be a definite part of a stageAll sub-stages need to be passed in order to complete the stage. Figure 2-1 gives an overview of all relevant stages und sub-stages addressed by this RP.

support structure the support structure of a substation including the sub-structure and the foundationApart from the jacket design illustrated in Figure 1-1 this may alternatively be a monopile design instead.

sub-structure term referring to the part of the support structure which extends upwards from the soil and connects to the foundation and the topside or platform

technical query (TQ) TQ is the formal process of asking a clarification or a question from the concerned parties involved in the execution of the projectThe technical query can be raised between owner and contractor, between site operations of the contractor and engineering team of the contractor etc.

topside structure part of the substation connected on top of the sub-structure, which holds the majority of installations and equipment, e.g. power transformer, switch gear, generator set


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1.6.3 Typical offshore substation setup
Figure 1-1 Exemplary sketch of an OSS

Definitions of the used terms are given in [1.6.2].

1.7 Acronyms, abbreviations and symbols

1.7.1 Acronyms and abbreviationsAcronyms and abbreviations as shown in Table 1-3 are used in this standard.

Table 1-3 Acronyms and Abbreviations

Short form In full2D two-dimensional3D three-dimensionalAC alternating currentAIS automatic identification systemALARP as low as reasonable practicalCCTV closed circuit televisionCO carbon monoxideCO2 carbon dioxideCSP commissioning switching programDB distribution board


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DC direct currentE&I electrical & instrumentationESD emergency shutdownFAT factory acceptance testFRA frequency response analysisF&G fire & gas detectionFW fresh waterGIS gas insulated switchgearGWO global wind organisationH holdH2 hydrogenHAT harbour acceptance testHP high pressureHV high voltage (>1kv)HVA/C heating, ventilation and air conditioning (system)ICSS integrated control and safety systemITP inspection and test plankV kilovoltLAN local area networkLER local electrical roomLP low pressureLPS lightning protection systemLV low voltage (≤1kV)M monitorMAC manual alarm call pointMC mechanical completionMWS marine warranty surveyNC non-conformityNCR non-conformity reportNDT non-destructive testingNO2 nitrogen dioxideOFAF oil forced air forced (type of transformer cooling system)OFWF oil forced water forced (type of transformer cooling system)OSS offshore substationP&ID piping & instrumentation diagramPA/GA public address/general alarmPCR process control roomPD partial dischargePMS power management systemPSD process shutdownQA quality assuranceQC quality controlR reviewRP recommended practiceRPM revolutions per minuteSAT site acceptance testSCADA supervisory control and data acquisitionSF6 sulphur hexafluorideSG switchgear

Table 1-3 Acronyms and Abbreviations (Continued)

Short form In full


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SWBD switchboardTQ technical queryU voltageUHF ultra high frequencyUPS uninterruptable power supplyVHF very high frequencyW witnessWPP wind power plantWPS welding procedure specificationsWPQR welding procedure qualification record* For safety issues medium voltage shall be regarded as high voltage

Table 1-3 Acronyms and Abbreviations (Continued)

Short form In full


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SECTION 2 MANUFACTURING AND COMMISSIONING PROCESS
AND DEFINITION OF VARIOUS STAGES

2.1 GeneralManufacturing, testing and commissioning of an OSS is a time-consuming and complex process. A structured approach is a necessity for the manufacturing, testing and commissioning stages of newbuilding projects to be successful.

While the requirements are specified in various applicable DNV GL standards, the actual process of manufacturing, testing and commissioning activities to be carried out for the OSS is largely left to the Builder/Owner of the OSS to decide and specify. For instance there may be logistic necessities applying to the sequence of manufacturing and installation of the various parts of the substation. DNV GL’s surveillance at specific stages for specific components/systems is considered essential to ensure that the requirements to manufacturing, testing and commissioning are met.

It is often required by DNV GL standards that the equipment is to be tested in the “as installed” condition. In some cases this could mean that although similar tests have already been carried out during a factory acceptance test (FAT), a test in as-installed condition is also required. This is mainly to ensure that interfaces and interconnections have been covered acceptably. A typical example could be the offshore cranes that are usually overload tested during FAT but, again, are subject to overload testing in the as-installed condition in order to ensure the connection and behaviour of both crane and its support structure.

Figure 2-1 below illustrates the different stages and sub-stages of an OSS in a chronological order. Passages within this figure that are greyed out are described briefly for reasons of comprehensiveness but are not the focus of this document. On the left-hand side of this flow chart relevant certification services associated with the defined stages are shown. On the right-hand side of this flow chart locations/sites typically associated with the defined stages are indicated. In addition to that sub-stages that are usually summarized with the terms ‘Factory Acceptance Tests’ (FAT), ‘Harbour Acceptance Tests’ (HAT) and ‘Site Acceptance Tests’ (SAT) can be found surrounded with green boxes.

Guidance note:Equipment and systems should be kept maintained in as new / as delivered condition during all preservation phases, until start-up for commissioning or initial operation. Corresponding principles and methods to ensure preservation, e.g. as defined in NORSOK Z-006, should be followed.

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Figure 2-1 Overview of stages and sub-stages

For definitions of ‘FAT’, ‘HAT’ and ‘SAT’, refer to section [1.7.1].

2.2 Design basisThe design basis identifies the basic assumptions, specification, methods and requirements for the design, e.g. site conditions, standards, codes and additional requirements, design criteria, manufacturing,


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transport, installation and commissioning requirements, operation and maintenance requirements. The
design basis shall document all conditions and prerequisites necessary for achieving a safe design and adequate implementation of the topside and its support structure in the specific project.

Further details on the scope and extent of the design basis can be found in the relevant sections of DNVGL-SE-0190 and DNVGL-SE-0073.

2.3 DesignContinuation and finalization of the OSS design based on the design basis.

Having accomplished this stage the design is expected to be fully completed, reviewed and approved. Failure to complete the design in a satisfactory manner may undermine already completed manufacturing, testing and commissioning, especially when it comes to redesign of components or systems. Any duplication in redoing testing and commissioning is inefficient and may result in loss of valuable time and additional cost.

Further details on the scope and extent of the design activities can be found in the relevant sections of DNVGL-SE-0190 and DNVGL-SE-0073.

2.4 Manufacturing (supplier)

2.4.1 Component fabrication2.4.1.1 GeneralAt this sub-stage main components, e.g. tubes, sub-assemblies, topside blocks and 2D frames of a jacket, are being fabricated at suppliers facilities.

According to various standards and certification schemes, e.g. DNVGL-SE-0073, DNVGL-SE-0190 or IEC 61400-22, manufacturing surveillance is an integral element of certification. Apart from regulatory requirements third-party surveillance is a proven tool which is often required by stakeholders, banks, and insurance companies and can also be used to evaluate the manufacturers and employers own quality system. The primary aim of the manufacturing surveillance is to check compliance with the applicable rules and standards, to verify compliance with approved drawings and check that the substation is being built with the intended and required quality.

Prior to the commencement of production the qualification of the manufacturing companies shall be checked. In general there are different ways to do this: Auditing, rely on past experience or by using DNV GL Shop Approval. In most cases a document review in combination with an initial audit should be carried out. This means that the manufacturing surveillance consists of three main columns: the document review, the initial audit and the inspections. For certain components such as electrical installations the content of the inspections are limited to witnessing of tests at the facilities of the manufacturer, and /or at the yard before load out or during offshore commissioning. In some cases only the test reports are reviewed.

Figure 2-2 Definition of manufacturing surveillance

For certification of steel structures according IEC 61400-22 only special and primary elements are included in the scope of the manufacturing surveillance. National requirements may require an extended scope of surveillance.

Initial Document Review

Inspections Initial Audit

Manufacturing Surveillance


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2.4.1.2 Document review
In general the documents which demonstrate the compliant manufacturing of the structure, mechanical and electrical components shall be reviewed and approved by DNV GL before start of production. An exemplary list of required documents for steel structures, mechanical- and electrical components can be found in App.A. The exact extent of required documents and scope of document review depends on the individual project and should be agreed prior to or at a kick-off meeting. Furthermore the number of documents depends on the supply chain (number of involved companies) in the project and the quality management system of the suppliers. In some cases a group of companies (e.g. a joint venture) may be covered by the same quality system enabling the use of the same procedures etc. As a precondition for the document review the following documents are needed:

— approved design drawings, including the definition of materials and tolerances— approved specifications for non-destructive testing (NDT) and corrosion protection.

The document review should mainly be done prior to the initial audit but also throughout the manufacturing inspections (e.g. in case of changes) and includes the following items:

— review of workshop qualification— review of document handling procedure— review of staff certificates (e.g. welder qualifications, NDT operators)— review of welding procedure specifications (WPS) and their related welding procedure qualification

records (WPQRs) for joints on special and primary structural members— review of work procedures for NDT and corrosion protection— review of inspection and test plan (ITP)— review of test programs.

It should be noted that many documents can also be reviewed and checked by the DNV GL inspectors during their visits. This could include a detailed check of work instructions and also a comparison of design drawings and workshop drawings. Also the qualification of staff in production can be checked on-site. However, it is important that documents governing the production are being reviewed before the commencement of production.

Any findings from the document review are communicated by DNV GL to the customer in writing. If possible the review of the documentation should be finalized before the initial audit, enabling an in-depth technical discussion of the findings as part of the audit.

Critical items should be closed before the start of the related manufacturing processes.

2.4.1.3 Initial auditDuring the initial audit the general qualification of the manufacturer and the critical manufacturing processes with respect to the component in question are audited. A further target for the initial audit is the final agreement of the ITP actions with the manufacturer or client.

The audit should already be carried out at a time when production of the relevant components has not started yet but when similar items are being manufactured. The detailed activities at the initial audit at the workshop should be defined from case by case, e.g. depending on obligations from the design review and/or critical manufacturing processes.

The general scope of the audit includes:

— A check that the design requirements are implemented in production, such that it is clear which documentation and which versions are used in the production.

— An agreement on the ITP that includes reference to drawings, specifications, etc. and describes the agreed witness/review/hold points.

— An audit of the critical manufacturing processes.— A check of the staff qualifications (e.g. welding supervisor, welding and NDT staff, test engineer).— Witnessing the application of reviewed procedures and work instructions.

Every manufacturer shall operate an approved quality management system. If the quality management


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system is not certified in conformity with ISO 9001 DNV GL will evaluate the relevant parts of the system,
also ref. DNVGL-SE-0073, DNVGL-SE-0190 or IEC 61400-22 sec. 8.5.2.

Welding workshops shall be qualified according ISO 3834-2.

2.4.1.4 InspectionsThe manufacturing and/or the testing of the structure or component shall be regularly witnessed by the DNV GL inspector.

The detailed scope of work shall be taken from the ITP actions which have been agreed in advance.

The comparison of design drawings and workshop drawings shall be part of the inspection. The drawings that have been reviewed shall be listed in the respective Inspection Report. Furthermore the check of workshop drawings and their correct implementation is an important part of the regular inspections.

For piles, jacket and topside support structures the inspections can be separated in three groups as shown in Figure 2-3.

Figure 2-3 Three groups of inspection activities

The standard inspections focus on the witnessing of processes during manufacturing, e.g. bevelling, assembly, welding, NDT. The intended processes for witnessing shall be marked in the ITP as Witness or Hold Points.

The black can inspection is the visual inspection after welding but before painting (it may be before or after sandblasting) of a structure, e.g. segment of pile, jacket leg, topside 2D frame etc.

The final inspections are approval inspections of final assembled piles, assembled topside structure and jacket structure before and after coating.

The manufacturing surveillance inspections should combine all of the above mentioned inspection types.

If the initial audit for electrical components was successfully performed before start of production, usually no further inspections are necessary during component fabrication. Proper function and quality of the electrical component can be approved during the FAT. However, the individual scope of inspection should be defined in the ITP.

2.4.1.5 Inspection and test planIn general the inspection and test plan (ITP) gives global guidance for the manufacturing processes.

Drawings and specifications, procedures from the supplier, acceptance criteria and responsible departments or staff may also be defined in the ITP.

Additionally, the responsibilities of the different parties (manufacturer, supplier, DNV GL, etc.) during the inspection is stated. The following levels of surveillance and activity codes for the individual manufacturing processes have been established for the ITP:


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M: Monitor
A random monitoring of the manufacturing process is done by the inspector. However, the inspector doesn't need to be informed or invited regarding this manufacturing process; rather the inspections are carried out on a spot check basis with the comment level “Monitor”. This point can be handled as an optional surveillance level.

W: Witness

The inspector shall be informed in advance of the respective manufacturing process. However, the work may be continued in absence of the inspector. A written acceptance by the inspector is not necessary before this manufacturing process is continued.

R: Review

Relevant documents shall be reviewed, at least on a spot check basis by the inspector regarding completeness and correctness.

H: Hold

In case of a “Hold” point, the inspector shall be invited regarding the respective manufacturing process, enabling him to attend. The work may not be continued within the workshop in the absence of the inspector. A written acceptance by the inspector is necessary before further manufacturing processing is permitted.

In general it shall be observed that M, W, R and H points can be modified throughout the manufacturing phase. For example a hold point which was identified as critical during production start can be changed to a witness point or vice versa. For example, should inspections demonstrate that a particular manufacturing process is well controlled and stable then a hold point may be changed to a witness point for subsequent inspections for that process.

2.4.1.6 As-built documentation for steel structuresA major aim of the manufacturing surveillance is to check and confirm that the structures are manufactured in accordance with the design drawings and specifications and to evaluate any later modifications with respect to the structural integrity of the structure and safe operation of the system. For documentation purposes the as-built drawings by the manufacturer shall be based on the initial design drawings. Furthermore non-conformity reports (NCR), technical queries (TQ), change requests and inspection reports shall be reviewed and compared to the approved design. A check and approval of NCRs shall be mandatory because non-conformities affect the approved design and may invalidate previous conformity statements.

2.4.2 Factory acceptance testsThe target of the factory acceptance tests (FAT) is to check conformity with the specifications and functional requirements as well as quality aspects. Usually machinery and electrical equipment as well as lifting devices are subject to a FAT.

Manufacturers shall ensure that their products meet the specified requirements and shall carry out and keep records of quality control tests.

The following components should be covered by FAT surveillance:

— Large main and auxiliary power electrical equipment (e.g. power generator set, main power transformer, main converter, rectifier, HV switchgear, UPS)

— LV switchgear and control gear

— Cranes and davits, if not certified by authority/notified body

— Functional tests between main and emergency switchboard, where possible

Depending on the specified component the FAT may either include a full type test, routine test or just selected tests. The individual scope and pass criteria of the FAT surveillance should be agreed in cooperation with DNV GL.


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2.5 Transport (component manufacturing site - final assembly
site)The OSS is a platform comprising the structure, components and sub-systems that in the end need to functionally interact with each other in order to meet the intended overall performance. All these elements are usually supplied by several suppliers. After a successful FAT at supplier site they are transported to the final assembly site, usually a shipyard. Depending on the unit size, the transport route can be via land, sea or air.

In project certification this stage may be subject to a Transportation Survey performed by DNV GL depending on the identified risk for damage during the transport operation.

Further details on the scope and extent of the transportation survey can be found in the relevant sections of DNVGL-SE-0190 and DNVGL-SE-0073.

2.6 Manufacturing (assembly)

2.6.1 Final assembly (installation & outfitting)This sub-stage is defined by activities of combining several structural subassemblies, mechanical/electrical components and sub-systems in a way that allows the functional interaction between one another to meet the intended overall performance of the OSS. Among other activities this comprises

— Connection of structural subassemblies, e.g. assembly of jacket 2D-frames to the 3D-structure, attachment of boatlanding to a complete jacket/topside structure.

— Equipping topside structure with mechanical components, e.g. drainage and piping systems, HVA/C, generator sets, bunkering and fuel systems.

— Equipping topside structure with electrical systems, e.g. cabling, transformer, reactors, cabinets, battery and UPS systems.

— Equipping topside structure with safety provisions, e.g. passive and active fire protection systems, explosion protection systems, means of rescue and evacuation.

Depending on the project and transport routes the manufacturing of steel structures can either be divided in subassemblies which are manufactured at a different supplier facilities and finally assembled at a harbour/shipyard or the whole process can take place at the harbour/shipyard itself. For the manufacturing of the steel structure the detailed approach described in [2.4.1] is applicable.

The target of the verification activities is the surveillance of manufacturing processes/methods and the monitoring of their conformity with the approved design as well as proper storage of electrical equipment on site.

2.6.2 Mechanical completionFor most offshore projects mechanical completion (MC) is considered a natural and a logical step on the way towards proper project completion. Usually the Builder or system supplier creates MC check lists for the actual equipment or systems in place. Some parts of MC activities are covered in the DNV GL standards and are thus formally included in the DNV GL scope of work. DNV GL generally maintains oversight of most of the MC activities of the project through unscheduled surveys. Where it is mandated by the ITP, a DNV GL inspector may attend certain MC activities. Some examples of such activities are:

— pressure testing of piping— installation of main engines, e.g. of auxiliary or emergency power generator set— rotating equipment cold alignment (e.g. coupling of generator sets)— cable installation/segregation of cable systems— electrical megger tests— lightning protection system— cleaning— flushing and drying of piping


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— wiring check.
As a prerequisite for MC the design shall be fully completed, reviewed and approved by DNV GL. In this RP, MC is accomplished once construction and installation of equipment, piping, instrumentation, cabling, electrical equipment, etc. has been demonstrated to be physically complete. Dynamic tests are limited to non-energized tests like the cold alignment of shafting for engines and generators. Further megger tests, flushing and drying of piping systems, cleaning, etc. is also included in this milestone. Typically, the MC results in a number of outstanding activities that shall be rectified before any actual pre-commissioning and commissioning can commence. Normal findings within this sub-stage typically include lack of electrical equipment grounding, lack of proper shielding of fuel pipes or hot surfaces, insufficient nozzle coverage for deluge systems, etc. The evidence of the required certification of equipment shall be verified during the MC sub-stage to prevent non-conformities during commencement of the onshore commissioning stage.

Typical deliveries from this sub-stage are:

— completed MC checklist— prepared MC punchlist— “system ready for pre-commissioning”-status.

2.7 Onshore commissioning

2.7.1 GeneralThe purpose of commissioning surveillance performed by DNV GL is to witness that the systems and equipment have properties and functionalities as required in relevant sections of the applicable standards/regulations and as defined in the design basis.

Commissioning activities on an OSS represent the gradual transition from the MC status to the “fully functionally tested” status. As DNV GL shall witness selected commissioning tests the schedule of commissioning activities (ITP) shall be duly communicated with DNV GL (see Sec.3).

Commissioning activities can be subdivided into onshore (HAT - harbour acceptance tests) and offshore commissioning activities (SAT - site acceptance tests), see Figure 2-1 above. Due to the high cost of offshore works, onshore commissioning activities should be as comprehensive as possible. Offshore commissioning activities should be limited to the tests and checks that can be carried out only when the OSS is installed on its foundation.

Before the start of the onshore tests, it shall be assured that assemby of the OSS equipment, apart from minor punchlist items, is completed (see [2.6.2]). For example:

— for structural fire protection it shall be verified that bulkheads are of type approved material and installed correctly

— for electrical equipment installed in locations classified to be a hazardous area it shall be verified that the equipment is certified safe according to the applicable explosion protection type and that it is installed accordingly

— for escape routes it shall be verified that they are accessible and that lighting and marking are installed in accordance with design and regulatory requirements.

Before the start of the tests at the offshore site, the manufacturer shall verify that the OSS has been erected properly and - as far as necessary - tested to ensure that safety of further works is ensured.

2.7.2 Pre-commissioningPre-commissioning is the sub-stage before commissioning which involves the verification of the functional operability of the equipment components or the full systems. It requires the energizing of equipment and introduction of fluids in fluid piping systems. Within pre-commissioning the supplier and/or the yard typically carry out independent tests of equipment/systems and it can be regarded as a “trial and error” phase where DNV GL normally does not attend. During review and approval of the commissioning procedures, it is important for the DNV GL inspector to make sure that tests required by the standards are carried out. During the planning it should be considered that if the tests required by the standards are


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carried out during the pre-commissioning without attendance of a DNV GL inspector then there may be
further effort later or impact on the certification. This should be highlighted during the review of the commissioning procedures.

Full control of the ambient conditions may prove impossible during installation, e.g. due to HVA/C system being incomplete at the time. Such circumstances shall be accounted for in the planning and execution of the pre-commissioning activities.

Pre-commissioning (and the verification of the same) typically includes but is not limited to the following activities:

— energization— loop testing/Instrument loop checks— equipment running (engines, pumps, fans,...), no load runs— rotating equipment final alignments.


— clarification of MC punchlist items— prepared pre-commissioning punchlist— completed and signed pre-commissioning procedures— “system ready for commissioning”-status.

2.7.3 CommissioningThe sub-stage after MC and pre-commissioning is often referred to as the the commissioning. The “commissioning of an OSS” is a broad term and for the purpose of verification and certification, it refers to final checks, inspection and tests to be passed by operational components or systems to confirm operational readiness.

This sub-stage can be identified and described as follows:

a) Testing of separate system areas of the platform without HV-energization, typically consisting of:

— General:Cabling, earthing and equipotential bonding, function test of protection systems, checking of controlsystem setting, testing of ESD/PSD systems, etc.

— Transformers:Insulation tests of the magnetic circuit and windings (including core to frame, core to tank, and tankto frame), ratio and vector group confirmation, auxiliary system checks, operation checks of tapchanger, cooling fans, oil sample test, etc.

— Switchgears:Checks on multicore cabling, insulation resistance tests, panel checks, current transformermagnetization curves, flick and loop burden checks, functional tests, transducers, interlocking, tripand control checks, alarm, indication, trip audit, timing tests, etc.

— Generators sets:Operation (running), start fail, over speed /rpm fail, low oil pressure, high cooling watertemperature, high generator temperature, emergency stop

— Other LV systems:Test of storage batteries, LV-control gears, etc.

— HVA/C:Leakage-free operability, ventilation operability check, air flow capacity check, area pressurizationability, checks on the interface to ESD systems, functionality of fire dampers, etc.

— F&G:


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Detection systems - check of functionality, check of the interface with emergency shutdown system;
firefighting systems - extinguishing release check, check of the interface with ESD systems, firedoors closure, etc.

— Load tests of lifting appliances, davits, life-saving appliances, etc.— CCTV:

Functionality check of cameras

— Internal/external OSS lighting: Check of operability and luminosity for operation and emergency escape, explosion protectiondesign (if applicable)

— PA/GA:Sound level and purity testing, amplifier redundancy, activation of visual and audible alarm,automatic announcement, etc.

— Communication:SCADA, communication systems, e.g. LAN, VHF/UHF radio

— Navigational aid:Operability of aviation obstruction lights (5 nautical miles lantern), operability of AIS, etc.

b) Testing of separate system areas with HV-energization of the platform, typically consisting of:

— Equipment performance tests, e.g. HV-SG, interconnection cables between transformer and SG, transformer protection functions, tap changer.

At the commissioning sub-stage it is verified that the installed equipment and systems are working as intended and that the design requirements for the various equipment/system functionalities are met.

For effective commissioning, it is important that the testing and commissioning of the different packages are given the right priority considering the most logical and reasonable sequence/order. Only very few commissioning activities can be performed without the power system, cooling system and other utilities being functional and working properly. Typically, temporary arrangements should not be accepted for commissioning. It shall also be a general principle that commissioned equipment may not be dismantled or modified once the testing and commissioning of it has been completed. Once the equipment/system is tested and commissioning is completed it is good practice to have a close-out meeting where the commissioning procedures are signed by the Owner and outstanding items are agreed on in a punchlist.


— clarification of pre-commissioning punchlist items — prepared commissioning punchlist— completed and signed commissioning procedures— “system ready for operation”-status.

2.7.4 Integration testingIntegration testing is a collective term for testing and commissioning of more than one system (a collection of systems, sub-systems and equipment packages) to ensure compliance with project requirements. Many systems on an OSS are integrated with other systems in one way or another. However, in this context, integration testing is meant to cover the following but not limited to:

— complete functional testing of systems across equipment boundaries— final adjustments of alarm-limits, measuring instruments— end to end testing of ESD/PSD and F&G systems and fire and gas detection systems.


— clarification of commissioning punchlist items— system acceptance.


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2.8 Transport and installation (final assembly site - installation
site)The OSS is transported from the final (onshore) assembly and outfitting site to its final offshore destination. Sometimes piles, jacket and topside are transported together. It may also be the case that the piles are transported first and then the topside and jacket, etc. Typically the structures are either designed to be self-floating or are mounted on barges and are towed out from the harbour to the sea by tugboats. On site the support structure, typically a jacket, is fixed to the seabed and the topside is connected by a grouted or welded connection.

The design envelope of the equipment installed on the OSS shall be such that expected movements, accelerations and loading during transport are sufficiently covered.

Typical steps after installation of the topside on the support structure and before further commissioning work can commence are:

— visual inspection:general appearance, determination of transport damages, bolted connections check, etc.

— removal of transportation bracings, temporary supports, fastenings, door locking plates— fitting of temporarily dismounted components, e.g. ventilation units— read-out/evaluation of transportation/acceleration forces logged by an impact recorder — erection of antennas and lighting masts— establish operation of auxiliary power generator set to provide LV supplies, e.g. for lighting— re-commissioning of previously (onshore-) commissioned components, where relevant.

In project certification this stage is usually subject to transportation and installation survey performed by DNV GL. Additionally the involvement of marine warranty surveyors (MWS) may be considered.

Further details on the scope and extent of the transportation survey can be found in the relevant sections of DNVGL-SE-0190 and DNVGL-SE-0073.

2.9 Offshore commissioning

2.9.1 Pre-energization commissioningGeneral aspects on commissioning can be found in [2.7.1].

This sub-stage defines the situation where the OSS has been transported to and installed at the final offshore site with array power cable as well as export power cables being connected but not online. In this sub-stage final tests and inspections take place before the grid connection is established and the wind turbine generators are set into operation. Additionally, outstanding punchlist items that still remain from the onshore commissioning stage, see [2.7], are subject to clarification.

Typical tasks related to this sub-stage are:

— Visual inspection:General appearance, determination of transport damages (isolation resistance measurement, voltageratio measurement), verification of tightness of connections, etc.

— Checks on LV and safety systems:F&G detection, PA/GA, HVA/C, internal/external lighting, DC system/batteries, control systems

— check of communication system, e.g. SCADA, VHF/UHF radio— check of insulation resistance of primary electrical equipment— Functional and operational tests on switchgear locally and from SCADA:

Resistance measurement of main circuit, SF6 measurement, open/close operation of circuit breaker,open/close operation of earthing switches and disconnectors, check of control functions, check ofmeasuring, display and counting devices, check of interlocks, check of anti-condensation heating for


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motors, check of panel indications, emergency release of the electromechanical interlock in the
disconnector operating mechanism (fail-safe), if applicable.

— check on transformer tap changer operation— check of transformer auxiliaries (incl. testing of cooling system OFAF/OFWF, functional testing of fans

and heaters, connection, settings and testing of protection equipment)— check of helideck readiness for operation— check of davits’ and lifeboats’ readiness for operation— check of platform cranes’ readiness for operation.— HV-tests for power cables:

DC test on overheat, AC insulation withstand test (power frequency testing, very low frequency testing),partial discharge test.

2.9.2 Post-energization commissioningPost-energization commissioning defines the situation of the OSS once the grid connection is established and/or the wind turbine generators have been successfully commissioned and put into operation. Typical tasks related to this sub-stage are:

— monitoring of the operation of transformers, as well as additional tests and checks including oil sampling— monitoring of the operation of switchgears, as well as additional checks on cable connections, auxiliary

systems, etc.— checks of control and cable marshalling panels— checks of generator sets.

2.10 Operation and subsequent stagesOperation defines the stage where the OSS has successfully passed the offshore commissioning, hence all major items related to certification should be clarified. Minor items carried over from the manufacturing, testing and commissioning stages may be followed up during in-service inspections. In addition procedures related to maintenance and period monitoring shall be followed.

Further details on the scope and extent of the transportation and installation survey can be found in the relevant sections of DNVGL-SE-0190 and DNVGL-SE-0073.


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SECTION 3 DNV GL’S INVOLVEMENT IN MANUFACTURING,
TESTING AND COMMISSIONING

Sec.2 above provides information on the different stages and sub-stages and states typical working steps that are related to those. This section describes how customers together with DNV GL identify and process relevant aspects of Sec.2 within certification projects.

DNV GL’s involvement in manufacturing, testing and commissioning in general depends on the requirements of the applied service specifications/standards and customer needs.

Furthermore the level and scope of verification by DNV GL can be defined by means of a risk-based approach, evaluating the consequences and probability of a failure of the structure or a malfunction of the equipment. A respective program for steel structures can be established by making use of DNV-OSS-304.

DNV GL performs a commissioning survey with the purpose of verifying that the substation installed on site is commissioned according to the requirements of the manufacturer and in compliance with relevant documentation provided in the design phase.

An ITP should be prepared by the Builder/Owner (as applicable) and shall at least:

— list the various activities with respect to manufacturing, testing and commissioning

— identify customer’s, DNV GL’s and other agreed standards that are applicable to those activities

— define the extent of surveillance by DNV GL.

This project specific ITP should be submitted to DNV GL by the customer for approval prior to commencement of any corresponding activities. A mutually agreed ITP should form part of the basis for the contract between the customer and DNV GL.

Based on the agreed scope in the ITP, DNV GL inspectors attend manufacturing, testing and commissioning activities. Associated manufacturing and commissioning documentation (manuals, specifications, procedures, drawings, blank protocols, etc.) shall be approved by DNV GL in advance of the actual surveys (see App.A for guidance regarding the content).

The survey scope shall be categorized as follows:

— Survey Category I - Essential processes/components/systems for safety (normally increased attendance by DNV GL).

— Survey Category II - Main processes/systems/functionally important system (extent of attendance is based on the Builder’s/supplier’s experience and the effectiveness of Builder’s/supplier’s QA/QC system).

— Survey Category III – Normally limited or no attendance required by DNV GL inspector.

The tables included in the following appendices detail the survey categorization during manufacturing, testing and commissioning of processes and OSS systems/components.

For reasons of comprehensiveness a table giving an overview of relevant OSS systems can be found in App.B.

Please note that none of the listings in the appendices are intended to be exhaustive and are intended to be used as guidance only. It is emphasized that the appendices have an informative character only and that the actual scope of the manufacturing, testing and commissioning survey performed by DNV GL is highly dependent on the OSS’s design basis, the applied standards and the customer’s demands.

App.C: DNV GL’s typical survey categorization for manufacturing and testing (FAT) of steel structure, mechanical and electrical systems

App.D: DNV GL’s typical survey categorization for commissioning of mechanical, electrical and safety systemsThe tables included in the following appendix detail requirements for manufacturing, testing and commissioning of OSS systems/components related to various applicable standards.

App.E: list of requirements related to steel structures, mechanical, electrical and safety systems


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SECTION 4 HEALTH, SAFETY AND ENVIRONMENT
4.1 Health, safety and environmentIt is important to note that manufacturing, testing and commissioning activities may introduce additional hazards to the process that may not have been considered in the design phase, e.g. use of temporary generators for testing in the absence grid connection. When evaluating the extent of checks and tests the philosophy of primum non nocere (first do no harm) should be considered.

It should also be noted that the manufacturing, testing and commissioning activities themselves may also introduce additional risks and hazards to the workplace. Prior to start of any manufacturing, testing and commissioning activity a safe job analysis (risk assessment) should be performed where relevant dangers are highlighted and adequate precautions are taken in order to minimize the risks, e.g. following the “as low as reasonable practical” (ALARP) principle.

During the installation and offshore commissioning stage of an OSS and its associated wind farm, the substation is commonly manned during daytime for extended periods, normally several months. Adequate provisions shall be made for this period at the design stage. These may include provisions which are normally only expected for manned installations.

It is important to ensure that:

— responsibilities are clearly defined and recognised— there are suitable and sufficient instructions e.g. procedures, method statements, work packs— control and supervision of staff and contractors is adequate— arrangements for calibration of the test equipment to be applied in the commissioning is adequate— there is adequate control of temporary commissioning aids e.g. E&I hardwired links, isolations, spades

in process lines.

For personnel health and safety compliance with local health and safety legislation shall be assured.

Compliance should also be considered with respect to standards such as the series ‘Standard Basic Safety Training’ by the Global Wind Organisation (GWO).

For the certification of offshore gangways for the transfer of personnel DNVGL-ST-0358 should be applied.

4.2 DNV GL inspectorThe customer or other entity having legal responsibility for the premises where DNV GL personnel is supposed to work, shall inform DNV GL of any safety and health hazards related to the work and/or any safety measures required for the work, prior to starting the work, or if such information is not available at that time, during the performance of the work.


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APPENDIX A DOCUMENTATION
A.1 Manufacturing

A.1.1 Steel structuresThe following list is exemplary and the documents therein shall be submitted for review prior to commencement of production or reviewed during the initial audit (pre-manufacturing inspection):

— list of certified design drawings— workshop drawings— document handling procedures— list of sub-suppliers (steel, tubes, etc.)— manufacturing specification— corrosion protection specification and procedures— specification for NDT (extent, methods, acceptance criteria)— traceability procedure— certificate acc. to ISO 9001— certificate acc. to ISO 3834-2— qualification certificates of the welding personnel— qualification certificate of the welding supervisory personnel— NDT qualified personnel list ISO 9712— ITP— welding and test plan— quality certificates for welding consumables— project specific welding instructions (WPS/WPQR)— NDT procedure for visual testing— NDT procedure for ultrasonic testing— NDT procedure for dye penetrant and magnetic testing— NDT procedure for radiographic testing (if applicable)— NDT procedure for flame straightening procedures— action plan for incorrect products.

In the manufacturing surveillance phase the following documents and records shall be available for review at the manufacturing site:

— incoming materials’ inspection reports— material certificates acc. to EN 10204— welding records— traceability records (e.g. material testing)— NDT inspection reports, e.g. dimensional control, visual testing, magnetic particle testing, radiographic

testing, ultrasonic testing— welder certificates— records for daily/weekly internal calibration of test equipment.

A.1.2 Electrical componentsThe following list is exemplary and the documents therein shall be submitted for review prior to commencement of production or reviewed during the initial audit (pre-manufacturing inspection):

— quality plan — valid ISO 9001 certificate of the workshop— general manufacturing plan (e.g. flow chart diagram), process plan


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— data sheet
— list of certified design drawings— assembly instructions— forms and descriptions to intermediate tests— type test report — test instructions/test plan — final inspection and routine test report.


— material certificates acc. to EN 10204, if applicable— traceability records— records for calibration of test equipment as specified by appropriate standards or manufacturer of

equipment— checklist for the assembly— forms for purchases check— incoming goods inspection reports— action plan for handling of incorrect products.

A.1.3 Mechanical componentsThe following list is exemplary and the documents therein are typically submitted for review prior to commencement of production or reviewed during the initial audit (pre-manufacturing inspection):

— list of certified design drawings— workshop drawings— list of sub-suppliers— manufacturing specification— traceability procedure— certificate acc. to ISO 9001— ITP— action plan for handling of incorrect products.


— incoming goods’ inspection reports— load test certificates (i.e. for lifting appliances).

A.1.4 Safety systemsRelevant safety provisions in scope of manufacturing surveillance are passive and active fire protection systems, explosion protection systems as well as means for rescue and evacuation. The following list is exemplary and the documents therein are typically submitted for review prior to commencement of production:

— list of certified design drawings— workshop drawings— list of sub-suppliers— manufacturing specification— traceability procedure— certificate acc. to ISO 9001— ITP— action plan for handling of incorrect products.


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In the manufacturing surveillance phase the following documents and records shall be available for review
at the manufacturing site:

— incoming materials and goods inspection reports— material certificates acc. to EN 10204, if applicable— checklist for the assembly— traceability records— action plan for handling of incorrect products.

A.2 Commissioning

A.2.1 General requirements on commissioning documentationa) Before the surveillance of the commissioning starts, commissioning documentation shall be submitted

for assessment.b) The commissioning documentation may consist of several sub-documents.c) For overall platform systems functionality tests mutual dependences/interconnections of different OSS

systems shall be duly considered. Correspondent commissioning program shall be submitted. For individual equipment and systems tests commissioning documentation may be provided by suppliers.

d) The format and level of detail of the commissioning documentation shall be such that qualified technical personnel performing the required tests are able to understand the instructions. The commissioning program as well as the commissioning documentation shall be in a language which qualified technical personnel at the installation site of the OSS are able to understand. In addition, IEC 82079-1 shall be observed for the preparation of the commissioning instructions.

e) The commissioning documentation shall contain the following information as a minimum:

— type identification of the equipment/system— checks required before the start of a corresponding test e.g. filling up of all operating media (e.g.

lubricants, cooling agents, hydraulic fluid, nitrogen in pressure tanks)— test procedures description: all adjustment settings and set values as well as the expected

measurement results shall be specified— checks required to conclude the commissioning— warnings against hazardous situations— blank commissioning test records— if (re)tests are necessary in case of unplanned delays, they shall be reflected in the commissioning

program as well.

f) The required qualifications for the technical commissioning personnel shall be defined.g) Hazardous situations which may arise during commissioning shall be identified and countermeasures

shall be specified. Such situations can include: grid loss, lightning, icing or extreme environmental conditions.

h) Safety and accident-preventing measures which are necessary to observe before or during commissioning, e.g. use of personal protective equipment, guards or locking devices shall be specified.

i) For personnel that shall enter any confined working space, safety provisions shall be stated.j) The commissioning documentation shall reflect the execution of the individual tests during the

commissioning surveillance. Blank commissioning test records indicating the test requirements or acceptance criteria shall be available.

k) During execution of the commissioning procedures the following information shall be documented:

— manufacturer, type and serial number from the rating plates of the primary components e.g. generators, transformers, reactors etc.

— persons present during commissioning— weather conditions on the day of commissioning


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— confirmation that all checks required before the start of commissioning have been completed
— report on the execution of all working steps of the commissioning— confirmation that all checks required to conclude commissioning have been completed— extra space for possible remarks, items outstanding or parts replaced— date and signature of the person(s) responsible.

A.2.2 Example of commissioning documentationTwo types of procedures are normally submitted for review/approval:

— system commissioning— system integration test.

Typical examples of the lists of contents in the documentation of these procedures are shown in the Figure A-1 and Figure A-2 below.

Figure A-1 Typical content for a system commissioning procedure

SYSTEM COMMISSIONING PROCEDURE

1 SYSTEM IDENTIFICATION/DESCRIPTION1.1 Type identification1.2 Commissioning package1.3 System integration description1.4 Pre-requisites

2 OBJECTIVE

3 GENERAL3.1 Safety requirements and precautions 3.2 Project specific requirements (codes and standards)3.3 Participants (e.g. Owner/supplier/DNV GL representative/Builder)3.4 Kick-off meeting3.5 Special/temporary tools/equipment, spare & consumables3.6 Records/blank form sheets3.7 Punch list system

4 PRE-COMMISSIONING4.1 Each package listed

5 OPERATIONAL MULTI-DISCIPLINE COMMISSIONING5.1 Detailed test procedure with acceptance criteria

AppendicesI. Equipment data sheet/informationII. Commissioning test results/running logsIII. Single line diagram/block diagramIV. P&ID


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Figure A-2 Typical content for a system integration test procedure

SYSTEM INTEGRATION TEST PROCEDURE

1 SYSTEM IDENTIFICATION/DESCRIPTION1.1 Type identification1.2 Commissioning package1.3 System integration description1.4 Pre-requisites

2 OBJECTIVE

3 GENERAL3.1 Safety requirements and precautions3.2 Sequence of events3.3 Participants (e.g. Owner/supplier/DNV GL representative/Builder)3.4 Kick-off meeting3.5 Special/temporary tools /equipment, spare & consumables3.6 Records/blank form sheets3.7 Punch list system

4 PERFORMANCE OF INTEGRATION TEST4.1 Detailed test procedure with acceptance criteria

5 OPERATIONAL MULTI-DISCIPLINE COMMISSIONING5.1 Detailed test procedure with acceptance criteria

AppendicesI. Equipment data sheet/informationII. Commissioning test results/running logsIII. Single line diagram/block diagramIV. P&ID


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APPENDIX B OVERVIEW OF SYSTEMS
The following table provides an exemplary overview of relevant areas, sub-areas, systems and sub-system that have been considered within this recommended practice.

Area Sub-area System Sub-system

Steel structure

Primary Steel

Jacket Structure -Monopile -Foundation, e.g. Piles -Topside (load-bearing parts) -Pad-eyes -Crane Pedestal -Laydown Area -J-Tubes -

Secondary Steel

Fendering Systems/Boatlanding -Topside (non-load bearing parts) -Gangway Docking System -Heli-Hoist Deck/Helicopter Deck -Walkways -Stairs -Ladders -Lifts -Platforms -

Corrosion ProtectionCathodic Protection -Surface Coating -

Electrical

Main Power

Main Power Transformer Cooling SystemMain Power Switchboard -Main Power Cabling -Main Converter Cooling SystemHV Switchgear -Reactor -Surge Arrester -Rectifier -

Auxiliary Power

Aux. Power Transformer Cooling SystemAux. Power Switchboard -Aux. Power Cabling -Aux. Power Generator Set -

Emergency/Transitional Power

Emergency Power Generator Set -Emergency Power Switchboard -Emergency Power Cabling -UPS/Batteries -

Lightning/EarthingElectrical Isolation -Earth Bonding and Continuity -Lightning Protection -

Low Voltage (LV)Main Lighting System -LV Distribution Board -LV Cabling -


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Mechanical

Main Power Main Power Transformer Transformer Oil Drain System

Auxiliary Power

Auxiliary Power Transformer Transformer Oil Drain System

Auxiliary Power Generator Set

Diesel Oil Transfer SystemDiesel Oil Drain SystemFuel Storage TankFuel and Lubrication Oil Filter

Emergency/ Transitional Power Emergency Power Generator Set

Diesel Oil Transfer SystemDiesel Oil Drain SystemFuel Storage TankFuel and Lubrication Oil Filter

HVA/C

…for hazardous areas -…for engine rooms and other machinery spaces -Independent HVA/C System (Local Air Condition Units)

-

Electrical and Auxiliary Machinery Rooms Ventilation Systems

-

Control Equipment -

Heli-Hoist Deck/Helicopter Deck

Refuelling System -Drain System -

Open Drain System (hazardous/non-hazardous)

--

Bunkering System - -Piping - -Oily Water Separator - -Water System - -Sludge Tank - -Potable and Sanitary Supply System - -

Sewage and Grey Water Discharge System

--

Process Heating System - -

Process Cooling System - -Offshore Crane - -DavitLifts - -



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Safety System

Active Fire Protection

Portable Extinguisher -Manual Alarm Call point (MAC) -Fire Alarm System -

Fire Main System

Fire Water Pump SystemFire MainFire Hydrants, Monitors and Hoses

Water-based Extinguishing Systems (with or without foam agent)

Deluge SystemSprinkler SystemPressure Water-Spraying SystemWater Mist System

Foam System High Expansion Foam System for Total Flooding

Gaseous SystemCO2

Inert GasHelideck Fire Fighting System -Heli-fuel Fire Fighting System -

Passive Fire Protection

Walls/Decks Measures preventing Heat Transmission

Penetrations Measures preventing Heat Transmission

Ventilation/Fire Damper Galley Ventilation

Explosion Protection

Blast Protection Blast Walls/ZonesExplosion Venting /Blast Panels/Pressure Relief Panels

-

Ventilation System -

Fire DetectionHeat Detector -Smoke Detector -Flame Detector -

Gas DetectionH2 Detection (Battery) -SF6 Detection (Switchgear) -CO, NO2 (Generator Set) -

Emergency Response

PA/GA Communication -External Emergency Communication -

Escape Routes

Walkway, Stairs, LaddersMuster AreaEmbarkation AreaEmergency Lighting/Escape Route LightingMarking

Manual Shutdown Button/Emergency Pushbutton -ESD/PSD System -

Rescue

Fast Rescue Boat and Launch DeviceMiscellaneous Equipment (e.g. Life Buoy)

Evacuation

Lifeboat and Launch DeviceLife raftsMiscellaneous Equipment (e.g. Life Vest, Survival Suits)

Personnel Protection Equipment -Helideck Status light (Wave Off) -



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Miscellaneous

CCTV - -Marine Growth Protection System

- -



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APPENDIX C DNV GL’S TYPICAL SURVEY CATEGORIZATION FOR
MANUFACTURING (SUPPLIER/ASSEMBLY)

C.1 Steel structure

C.1.1 Category I processes

C.1.2 Category II processes

No. ProcessInitial activities for special and primary components

1 Review quality system documents and certificate 2 Welding qualification certificate (ISO 3834, EN 1090)3 Review of specifications and procedures4 Review of personnel qualifications (NDT operators, welding supervisor, welders)5 Technical initial audit5.1 Incoming goods5.2 Storage of consumables and base material5.3 Maintenance and calibration of welding, test and other equipment5.4 Cutting, welding, machining procedure and geometry check5.5 Quality control of subcomponents of other fabricators5.6 Surface preparation, painting and metalizing

Inspection activities6 Base material identification and tracking7 Plate cutting, forming, alignment and bevelling8 Fit-up and tack welding9 Production Welding including consumable handling10 Calibration of equipment, e.g. NDT, post weld heat treatment equipment11 Verification of NDT inspection12 Weld repairs13 Post weld treatment (if required), e.g. heat treatment, grinding, etc.14 Dimensional and tolerances inspection as per specification15 Cutting and identification of production test coupons (if required)16 Mechanical testing of production test pieces17 Review of Chemical analysis tests18 Final inspection of coating19 Review certificates of NDT and welding personnel

Final activities21 Documentation review of manufacturing records and testing records etc.22 Review of as-built drawings23 Review of NCR and TQ

No. Process1 Surface treatment2 Manufacturing of topside wall and floor panels (steel) – if not load carrying3 NDT of weld repairs4 Transport, storage and handling of finished sections


DNV GL AS

C.1.3 Category III processes
C.2 Mechanical/electrical/fire protection systems

C.2.1 Category I systems

C.2.2 Category II systems

C.2.3 Category III systems

No. Process1 Secondary steel structures, e.g. stairs, ladders, platforms (same activities as defined in [C.1.1])

No. System Relevant for1 Main power transformer FAT and MC2 HV switchgear FAT and MC3 Low-voltage switchgear and control gear MC4 Fire protection systems MC5 Power generator sets FAT and MC6 Cable systems (laying and fixation, especially for voltages U ≥ 1kV; termination boxes) MC7 Earthing and lightning protection system MC8 UPS MC9 HVA/C MC10 Cranes and davits, if not certified by authority/notified body FAT11 Main converter FAT12 Rectifier FAT

No. System Relevant for1 UPS FAT2 Low-voltage switchgear and control gear FAT3 Piping (flushing and drying, pressure testing) MC4 Cranes and davits MC5 Main/emergency switchboard FAT and MC

No. System Relevant for1 Reactors FAT and MC2 Auxiliary Transformer FAT and MC3 Earthing Transformer FAT and MC


DNV GL AS

APPENDIX D DNV GL’S TYPICAL SURVEY CATEGORIZATION FOR
COMMISSIONING

D.1 Independent system testing

D.1.1 Category I systems

D.1.2 Category II systems

No. System1 Lifeboat and Launch Device2 Emergency Lighting (incl. UPS)3 Control System4 PA/GA Communication5 ESD/PSD Systems6 F&G Detection Systems7 Emergency Power Generator Set8 Emergency Power Switchboard9 Auxiliary Power Generator Set10 Transitional Power System11 Engine Starting and Control Equipment12 Diesel Oil Transfer System13 Fast Rescue Craft Launch Device System14 Escape routes15 Life rafts and escape to sea16 Helideck Fire-Fighting System17 Fire Main System18 Heli-fuel Fire Fighting System19 Specific Area Fire Fighting Systems i.e. Foam, Gaseous, Water-based Extinguishing Systems20 HV Switchgear21 Main/Auxiliary Power Transformers22 Platform Crane

No. System1 Miscellaneous Lifesaving Equipment2 Helicopter Refuelling System3 Drain Systems4 Sewage and Grey Water Discharge System5 Main Lighting Systems6 Process Heating System7 Process Cooling System8 HVA/C for Hazardous Areas, e.g. battery rooms, paint rooms9 Individual HVA/C Systems10 Helideck Status Lights (Wave off)


DNV GL AS

D.1.3 Category III systems
D.2 Integration testing

D.2.1 Category I systems

D.2.2 Category II systems

No. System1 Auxiliary Cooling Fresh Water System2 Potable and Sanitary Supply System3 Cold Starter Generator4 Marine Growth Protection System5 Electrical and Auxiliary Machinery Rooms Ventilation Systems6 CCTV7 Navigational aid8 SCADA9 VHF/UHF radio

No. System Integrated with*1 Communication – PA/GA ESD/PSD/F&G2 ESD/PSD Systems ICSS3 F&G Detection Systems ICSS4 Transitional/Emergency Power ESD5 HVA/C Systems ESD/F&G6 Main Power Generation and Distribution ESD/PMS7 Fire Main System ESD/F&G8 Heli-fuel Fire Fighting System ESD/F&G9 Specific Area Fire Fighting Systems i.e. Foam, Gaseous, Water-based

Extinguishing SystemsESD/F&G

* Where an integrated control and safety system is employed the control system architecture defines which systems the integration testing should interface with and may include ICSS/ESD/PSD/F&G/PMS.

No. System Integrated with*1 Process Heating System ESD/PSD2 Process Cooling System ESD/PSD3 Offshore Platform Crane ESD4 Helideck Status Lights (Wave off) F&G5 Auxiliary Power Generation System ESD6 SCADA System ICSS* Where an integrated control and safety system is employed the control system architecture defines which systems the integration testing should interface with and may include ICSS/ESD/PSD/F&G/PMS.


DNV GL AS

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APPENDIX E LIST OF SURVEY REQUIREMENTS RELATED TO STEEL STRUCTURES,

least witnessing of WPQR test), welding

O 3834-2 (see Chapter 3.3.1.2ary steel: Project specific qualification checked by

.rds related to the fabrication of the structure shall e specified requirements. Such records shall be piled records shall be systematic and fully

g, alterations, additions, corrections and revisions information required during the in-service life of

2X (see DNV Classification Note 7, referenced in

ction documents as defined in EN 10204 or in an l certificates according to Table 9-1 shall be

t realization. work for verification of manufacturing and

ding records shall include weld no., number of to parent metal material certificates, time of

rticular for tubular joints.

aterial, inspection requirements for components

pe for initial audits; definition of process for audit

nd of production records

MECHANICAL, ELECTRICAL AND SAFETY SYSTEMS

E.1 Steel structures

System/Equipment/Item Description Reference DNV GL Surveillance Focus

Steel structure

DNVGL-OS-C401, Ch.2 and Ch.3

— Approved welders (card index), approved WPS (or atconsumables

— Welding workshops shall be qualified according to IS— of this document); sub-suppliers for special and prim

initial audits.— Personnel performing NDT shall be qualified /certified— Chapter 3, Section 3: Documentation "Adequate reco

be prepared to document that the structure meets thcompiled in parallel with the fabrication process. Comtraceable. Such records shall reflect all relevant testinmade during the fabrication period in order to providethe structure.

— NDT inspection of tubular TKY nodes according API RPC401).

DNVGL-ST-0145 [10.3.1]Steel materials and products shall be delivered with inspeequivalent standard. Unless otherwise specified, materiapresented.

DNV-OSS-304 Section 2.D and Table D2

Section 2 provides guidance on verification during projecTable D3 can be used as a template for an ITP (scope of fabrication).

NORSOK M-101, Sec.6.1, 6.2 and Appendix F

Weld numbering system shall exist and be used. The welapplied WPS, consumables batch number, welder ID, linkwelding, check points for weld inspection

API RP 2A-WSD, Sec.16.3.2 Qualification of NDT inspectors acc. API RP 2X (UT), in pa

GL IV-7-2, Sec.4 B Inspection requirements for Materials; identification of m

GL IV-7-2, Sec.4 C Requirements for construction facilities -> definition of scoand scope of surveillance

GL IV-7-2, Sec.4 D Survey and testing: Scope of surveillance; content /exte

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documents needed before production (before

2), in particular see table 2 "Qualification of metal

l: NACE coating inspector level III (section 10.2.5)

system:

is carried out. The test method and results shall

rmed after installation.

to EN 10204 or ISO 10474, inspection certificate

tallation shall be described in an ‘installation nt shall include, as a minimum:

including certificates and material data sheetsls for anode installationcations and qualification of personnel carrying out

ried out according to the qualified WPS and by

uilt drawings.ll be documented. installation documentation.


Corrosion protection

NORSOK M-501, Sec.10 and 11

— Pre-qualification of coating systems (section 10.1) ->start of coating activities)

— Qualification of companies and personnel (section 10.spraying" -> qualification test

— Qualification of supervisor, foreman and QC personne— Qualification of procedures, section 10.3

DNVGL-OS-C401, Ch.2 Sec.5 [2.4]

— Installation of impressed current cathodic protection

— Testing of the proper functioning of the systemsbe reported.

Final testing and acceptance of the system shall be perfo

Cathodic protection

DNV-RP-B401 [8.6] + NACE RP0387

Criteria for visual inspection

DNV-RP-B401 [8.7]Documentation and markingContractor shall issue an inspection document according 3.1.B.

DNV-RP-B401 [9.2]

Contractor may specify that all work related to anode insprocedure specification’ (IPS). If applicable, this docume

— specification of materials and equipment to be used,— receipt, handling and storage of anodes and materia— reference to welding and/or brazing procedure specifi

welding/brazing— inspection and testing of anode fastening— documentation of materials and inspection records.

DNV-RP-B401 [9.5.1] All welding associated with anode installation shall be carqualified welders.

DNV-RP-B401 [9.7]The final location of anodes shall be documented on as-bMeasurements for verification of electrical continuity shaPurchaser may specify further requirements to the anode

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E.2 Machinery systems and equipment

commissioning:

ecked design documents and traceability/

s to be verified. Earthing connections are to be

to be fitted with drains sufficient in number and ese drains may be led outside directly to the sea.

lding tank or to be emptied manually.ater, the estimated maximum peak rain intensity

e relevant codes and standards have to be agreed

drains could be led directly to the sea.o pipes to an oily drain holding tank and are to be

ery fire area to prevent a back flash in case of fire.pacity.gest amount of oil, deluge water and firewater ident plus spare capacity (suggest 15 %).shall be led to an oily water separator. sea without any spill to the outside of the helideck

parated from drains in non-hazardous areas.

to be agreed with DNV GL).

System/Equipment/Item Description

Reference DNV GL Surveillance Focus

General

BSH no. 7005 Ed. 2007, Part B, Ch.6.4and analogousBSH no. 7005 Ed. 2015, Part B, Ch.2.4.2

The following checks are performed as part of inspection of

— Conformity of the main components with the certified/chnumbering of the same

— General appearance— Functional tests and test of the safety system— Corrosion protection— Check for damage

Bunkering SystemsGL IV-7-4, Sec.3 G Testing for tightnessGL IV-7-1, Sec.4 C to 4 D Functional test - Visual inspection

Drain/Piping Systems GL IV-7-4, Sec.9 C.1.6.5 Pressure/leakage test

Plastic Pipe Systems DNVGL-ST-0145 [7.7.2.5] After completion of the installation, the resistance to earth iarranged in a way accessible for inspection.

Drain Systems DNVGL-ST-0145 [7.6.1]

Visual inspection:

— Weather decks (i.e. open decks exposed to the sky) aresize to provide effective drainage of the peak rainfall. Th

— Areas with oily leakage shall be fitted with coamings.— Drains for these areas should be led to the oily drain ho— The assumptions like the expected maximum flow of rainw

and the considered average velocity in pipes as well as thfor the specific project.

— Internal decks are to be drained to the bilge tank. Clean— Drains for spaces with oily leakage are to be connected t

well protected.— Fire traps in the pipes or drain pots shall be installed in ev— The pipes for discharge fluids shall have an adequate ca— Oily drain holding tanks shall be dimensioned for the lar

coming from oil filled equipment during the greatest inc— Oily drain water is to be disposed by a supply vessel or — Helicopter deck drain shall be led in a safe way directly to

or to other parts of the installation.— Drain systems in hazardous areas shall be completely se

Tests:

— Test required by the manufacturer of the system (scope

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arator or filter plant for the separation of water/ank for transportation ashore. The reference for nt codes and standards as agreed for the specific

e agreed with DNV GL).

ed products intended to be used are to be


in accordance with an appropriate welding

s and other fittings shall not be employed for the suitability shall be demonstrated.


ks with a risk of leaking in case of damage or fire, tanks capable of being closed from a safe position

e manually operated from outside the concerned

efill of daily tanks does not start).

operable from above the floor plates.

ues can settle out. Fuel tanks shall be fitted with



Oily Water Separators DNVGL-ST-0145 [7.6.2]

Visual inspection:Offshore substations shall be provided with an oily water sepoil mixtures or a sufficiently dimensioned oily drain holding tthe oily water separators is EN 858-1, EN 858-2 or the relevaproject.Tests:Test required by the manufacturer of the system (scope to b

Piping Systems

DNVGL-ST-0145 [7.7.2.1]

Visual inspection:Pipes, elbows, fittings, valve casings, flanges and semi-finishmanufactured according recognized standard.Tests:Test required by the manufacturer of the system (scope to b

DNVGL-ST-0145 [7.7.2.2]

Visual inspection:Pipes shall be seamless drawn steel pipes or pipes fabricatedprocedure to be equivalent to seamless pipes.In general, carbon and carbon-manganese steel pipes, valvetemperatures above 400 °C. For applications above 400 °C Tests:Test required by the manufacturer of the system (scope to b

HVA/C SystemGL IV-7-1, Sec.4 C to 4 D Functional Test- Visual Inspection

Fuel Oil Systems

GL IV-7-1, Sec.4 C to 4 D Testing for tightnessGL IV-7-1, Sec.4 C to 4 D Functional test

DNVGL-ST-0145 [7.7.5.2]

Visual inspection:Filling and suction lines from storage, settling and service tanare to be provided with shut-off devices fitted directly on the outside the space concerned.The remotely operated shut-off devices shall be capable to bspaces.Tests:

— Manual operation— Automatic operation (refill)— Test of alarm on a fault of diesel oil system (automatic r

DNVGL-ST-0145 [7.7.5.3] Visual inspection:Shut-off valves in fuel lines in the machinery spaces shall be

DNVGL-ST-0145 [7.3.3]Visual inspection:Fuel service tanks shall be so arranged that water and residwater drains with self-closing shut-off valves.

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ff valves at the connections to the tank and

level indicating devices.ices or oil-level gauges. tank and cylindrical glass oil gauges are not

dation spaces, nor shall they terminate in spaces might arise. Where this is not possible, the following

unding pipes.te from ignition hazards or they are to be nto contact with the source of ignition.t-off devices and self-closing test cock.

l tank equipment may be fitted to tank walls only

e fitted to free-standing tanks.ges welded to the tank walls. Holes for stud bolts

h flange connections may be welded to the tank



Fuel Oil Systems

DNVGL-ST-0145 [7.3.3.1]

Visual inspection:The following tank gauges are permitted:

— sounding pipes— oil level indicating devices— oil level gauges with flat glasses and self-closing shut-o

protected against external damage.

Sounding pipes need not be fitted to tanks equipped with oilFuel service tanks shall be fitted with oil level indicating devSight glasses and oil gauges fitted directly on the side of thepermitted.Sounding pipes of fuel tanks may not terminate in accommowhere the risk of ignition of spillage from the sounding pipesSounding pipes should terminate outside machinery spaces.requirements are to be met:

— Oil-level gauges are to be provided in addition to the so— Sounding pipes are either to terminate in locations remo

effectively screened to prevent that spillage may come i— The sounding pipes are to be fitted with self-closing shu

DNVGL-ST-0145 [7.3.3.2]

Visual inspection:Appliances, mountings and fittings not forming part of the fueby means of intermediate supports.Only components forming part of the tank equipment may bValves and pipe connections shall be attached to doubler flanare not permitted drilled in the tank walls.Instead of doubler flanges, short, thick walled pipe stubs witwalls.

Power Generator SetGL IV-7-4, Sec.2 B Functional test- Visual inspection

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E.3 Electrical installations

commissioning:

hecked design documents and traceability/

programme, manufacturers shall ensure that the uirements. Records shall be made, containing

ded over to GL on request.uirements covered by the Rules for Construction,

lar application.ocuments. They shall be performed in accordance

50 kW/kVA

operation and installation of the main and to be performed shall be agreed with the DNV GL f the subject equipment and installation.


General


The following checks are performed as part of inspection of

— Conformity of the main components with the certified/cnumbering of the same

— General appearance— Functional tests and test of the safety system— Corrosion protection— Check for damage

GL IV-7-5, Sec.11 A

— Within the framework of their general quality assuranceproducts they manufacture conform to the specified reqquality-assurance measures and tests and shall be han

— It is the aim of the tests to verify conformity with the reqand to prove the suitability of equipment for its particu

GL IV-7-5, Sec.11 B

The tests shall be carried out on the basis of the approved dwith a recognized standard.Components, appliances and installations subject to testing

— Electrical machines

— Generators and motors for essential equipment P ≥— Transformers and reactors P ≥ 100 kVA

— Power electronics

— Essential equipment P ≥ 50 kW/kVA

— Switchboards

— Main switchboards— Emergency switchboards

GL IV-7-5, Sec.11 DProofs are required of the satisfactory condition and properemergency power supply systems. The tests and inspections- Inspector in accordance with the specific characteristics o

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arthing and equipotential bonding of installationsV

ectionst

)bstructure, at the offshore site, visual inspections med to identify possible damages occurred during ring the transportation, the electrical equipment shall be repeated if needed.e activity, the status of the electrical installation

ally and remotely)stems (fans and/or pumps)

arge (PD) test on HV and MV power cables according to tial Discharge Measurement”.

re applicable, specifically if the equipment is not going to .

ght not be required where disassembly of the equipment

d-a-n-c-e---n-o-t-e---

ormal operating conditions. will be tested during commissioning)


General

-

— Visual inspection of: Earthing connections of platform, e— Cable laying and fixation, especially for voltages U ≥ 1k— Cable termination boxes— Erection of components according installation manuals— Completion Lightning Protection System (LPS)— Corrosion protection of electrical components and conn— Installation of storage batteries and charging equipmen— Caution labels and information plates— Active and passive fire protection— Means of evacuation and escape— Life-saving appliances— Platform identification (incl. test of the all outside lights

DNVGL-ST-0145 [5.9.1.4]

After the substation topside has been positioned onto the suand analysis of shock recording device results shall be perforthe transportation. In case of evident damages occurred dushall be removed (if necessary) and repaired; routine tests

DNVGL-ST-0145 [5.9.1.4]

At a minimum, before any main power energization offshorshall be checked through:

— insulation resistance tests— verification of the tightness of the connections— functional checks— no-load switching operations (to be performed both loc— verification of the main power transformers auxiliary sy

Guidance note:Guidance note 1: It is recommended to perform a Partial Dischthe Cigré Brochure 502 “High-Voltage On-Site Testing with Par

PD testing can be completed during the HAT testing period whebe moved in relation to the adjoining termination or equipment

Guidance note 2: Verification of the tightness of connections miis necessary.

---e-n-d---of---g-u-i-

Generator Set GL IV-7-5, Sec.11 D A test run of the generator sets shall be conducted under n(Usually all run-scenarios, e.g. auto-start and load sharing,

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lly inspected:

ons of ventilation ducts.

s and pipes in the vicinity of the switchboards and

d interlocks

o

eck penetrations

ll be conducted under normal operating conditions


Batteries GL IV-7-5, Sec.11 D

The following shall be tested for function, respectively visua

— Installation of storage batteries.— Ventilation of battery rooms and boxes, and cross-secti— Storage-battery charging equipment.— Required caution labels and information plates.

HV Switchgear GL IV-7-5, Sec.11 D

The following items shall be tested:

— Accessibility for operation and maintenance— Protection against the ingress of water and oil from duct

sufficient ventilation— Equipment of main and emergency switchboards— Correct settings and operation of protection devices an

Power Electronics GL IV-7-5, Sec.11 D

The following items shall be tested:

— Ventilation of the place of installation— Function of the equipment and protection devices

Cabling (Main/Auxiliary/Emergency/LV)

GL IV-7-5, Sec.11 D

Inspection cable installation and cable routing with regard t

— Acceptability of cable routing with regard to

— separation of cable routes— fire safety— the reliable supply of emergency consumers

— Selection and fixation of cables— Construction of watertight and fireproof bulkhead and d— Testing of insulation resistance measurement

Emergency Power Generator -

— Generator set ready to start— Operation (running), a test run of the generator set sha— Start fail— Overspeed/rpm fail— Low oil pressure— High cooling water temperature— High generator temperature— Emergency stop

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nt

ted according to the standard mentioned above. sts shall be provided for certification for each type 0 kVA.tional standard series IEC 60076.t least the following tests:

d that the permissible over-temperatures for the ting time. Depending on the wind turbine design, erter. The increased warming caused by the r the temperature-rise test e.g. by applying IEC

e transformers)standard series IEC 62271. This shall be verified taining at least the following tests:

t tests


Emergency Power Switchboard -

— Motor Controlled Breakers— Local/Remote control— Open/Close operation— Over current protection— Interlocking

Transformers (Main/Auxiliary/Earthing), Reactors

-

— Determination of transport damages:

— Isolation resistance measurement— Voltage ratio measurement

— Check of oil level, Venting— Testing of cooling system (OFAF/OFWF)— Functional testing of fans and heaters— Connection, Settings and testing of protection equipme— Communication equipment performance check

GL IV-7-5, Sec.8 CEquipment intended to be installed on OSS shall be type tesA corresponding type test log presenting the results of the teof power transformer having a rated power of more than 10

GL IV-7-5, Sec.8 C

Transformers shall comply with the latest version of internaThis shall be verified through type test records containing a

— Temperature-rise test— Power transformers shall be so designed and constructe

thermal class are not exceeded, irrespective of the operathe transformer might be operated at a frequency convadditional harmonics shall then be taken into account fo61378-1.

— Dielectric type tests (Lightning impulse test for dry-typ

Medium Voltage Switchgear GL IV-7-5, Sec.6 A

Medium-voltage switchgear shall comply with international through manufacturer declaration and type test records con

— dielectric tests— short-time withstand current and peak withstand curren— internal fault

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ectors

the disconnector operating mechanism (fail-safe),

d at a test facility which shall be accredited comply with applicable IEC standards. The set of s shall always be performed and documented..ers, shunt reactors, etc.) after successfully ion yard for installation. The shipping shall include ts that might occur during the transportation.yard, visual inspections and analysis of shock ible damages occurred during the transportation. on, the electrical equipment shall be repaired and as far as practicable.struction yard and prior to the transportation to ipment shall be checked at least through:

cy Response Analysis (FRA) on main transformers tial analysis after the installation offshore in case

ccording to a Commissioning Switching Program .


High Voltage Switchgear(GIS)

-

— Resistance measurement of main circuit— SF6 measurement— Open /close operation of circuit breaker— Open /close operation of earthing switches and disconn— Check of control functions— Check of measuring, display and counting devices— Check of interlocks— Check of anti-condensation heating for motors— Check of panel indications— Emergency release of the electromechanical interlock in

if applicableMain Power System

DNVGL-ST-0145 [5.9.1.2]

— All the substation main power equipment shall be testeaccording to definition in EN ISO/IEC 17025. Tests shallroutine tests as specified in the applicable IEC standard

— Type tests or special tests shall be performed as agreed

DNVGL-ST-0145 [5.9.1.2]Large main power electrical equipment (i.e. main transformcompletion of the FAT are shipped to be sent to the constructa shock-recorder device able to detect harmful shock impac

DNVGL-ST-0145 [5.9.1.3]

After receiving the electrical equipment at the construction recording device results shall be performed to identify possIn case of evident damages occurred during the transportatithe necessary routine tests shall be repeated if needed and

DNVGL-ST-0145 [5.9.1.3]

— After assembling and installation completion at the conthe transportation vessel, the large electrical power equ

— insulation tests— electrical parameters check— functional checks.

— Guidance note: It is recommended to perform a Frequenand reactors, to be repeated and compared with the iniof damages occurred during the transportation.

DNVGL-ST-0145 [5.9.1.4] The main power energization activities shall be performed a(CSP), to be submitted for information to the Grid Operator

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em, consisting of diesel generators, UPS and main y the applicable IEC standards. The set of routine

truction yard, auxiliary power equipment shall be xiliary system, shall be tested together with the

ncy power the operational functioning of the be verified. All safety equipment is to be tested,

manufacturer’s works in the presence of a GL

ard is to be tested during commissioning in the possible under the intended service conditions.s shall also be performed at the manufacturer’s

sessment of the status of the emergency services

n of commissioning:

ed/checked design documents and traceability/

ovals and certificates for fire dampers, als in fire resisting divisions.ces, control stations, machinery spaces and sily accessible position outside the space being tilation serving machinery spaces or hazardous for stopping ventilation of other spaces.esigned for testing without interruption of

ovals and certificates for fixed gas extinguishing tc.


E.4 Fire protection systems

Auxiliary Power System DNVGL-ST-0145 [5.9.1.2]

Major components comprised in the substation auxiliary systand emergency switchboards, shall be tested as prescribed btests shall be always performed and documented.

DNVGL-ST-0145 [5.9.1.3]After the assembling and installation completion at the consgradually powered up and all the systems, including the auSCADA system at its highest practical extent.

Auxiliary/Emergency Power System GL IV-7-4, D.4.4 Ch.4 Sec.1D

After installation of the machinery for auxiliary and emergemachinery including the associated ancillary equipment is tounless adequate testing has already been performed at theinspector, e.g. during FAT.In addition and where applicable, the final installation on boconstitution yard, i.e. Site Acceptance Test (SAT), as far as

Main/Emergency Power Switchboard DNVGL-ST-0145 [5.9.1.2] Functional tests between main and emergency switchboard

facility where possible.Emergency Power System DNVGL-ST-0145 [5.9.1.4] Prior to any main power energization offshore activity, an as

and operational services shall be performed.


General


The following checks are performed as part of inspectio

— Conformity of the main components with the certifinumbering of the same

— General appearance— Functional tests and test of the safety system— Check for damage

Walls/Decks DNVGL-OS-D301, Ch.3 Sec.2 Table 1 Check of the availability and relevance of the type apprpenetrations, fire doors, fire windows, insulation materi

Ventilation DNVGL-ST-0145, [6.4.6]

Power ventilation of accommodation spaces, service spahazardous areas is possible of being stopped from an easerved. The means provided for stopping the power venareas to be entirely separate from the means provided

Active Fire Protection System

DNVGL-OS-D301, Ch.2 Sec.3 [2.1.2] Active fire protection systems and equipment shall be dnormal operation.

DNVGL-OS-D301, Ch.3 Sec.2 Table 1 Check of the availability and relevance of the type apprsystem, fixed foam systems, deluge system, nozzles, e

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d.

al override control.e, including access during fire situations.ntally and vertically in order to permit the

for operating in a selected position. spray discharge.–––rmed and automatically activates start-up of fire

ual in accordance with the design standard:

n shall be cleaned internally after preparation and er’s installation manual pressure without loss within defined time (see

ize shall be in accordance with system drawings. s shall be restrained to prevent unacceptable ischarge nozzle shall be oriented in such a manner d. Location of water and gas storage containers s and mounting brackets shall be fastened in

FPA 16, Sec.8.3.1 shall be checked for proper installation in conduit eld circuits shall be confirmed to be free of ground l be checked for proper type and location as

h locally and remotely at the control station where


Fire Water Monitor DNVGL-OS-D301, Ch.2 Sec.3 [3.5]

A fire-water monitor may be remotely or locally operate(IACS UR D11.3.2)Interpretation:1) A remotely operated monitor should have local manu2) Manual operated monitors should be easily accessibl3) The monitor should have sufficient movement horizomonitor to cover the complete area of protection.4) The monitor should be provided with a locking device5) A monitor should be easy switchable between jet and––––––––––––––– end of Interpretation ––––––––––––

Sprinkler System DNVGL-OS-D301, Ch.2 Sec.3 Confirm that pressure drop in the sprinkler system is alawater pumps.

Deluge System

NFPA 13, NFPA 16, NFPA 25, VdS CEA 4001

Checks and tests as specified in system installation man

— Flushing, cleaning of piping: each pipe or tube sectiobefore assembly in accordance with the manufactur

— Hydrostatic/air tests: the system shall maintain theinstallation manua

— Review mechanical components: nozzles and pipe sPiping joints, discharge nozzles, and piping supportvertical or lateral movement during discharge. The dthat optimum water mist application can be effecteshall be according approved drawings. All containeraccordance with the manufacturer’s requirements.

— Proportioning System Testing: flow tests, refer to N— Review of electrical components: All wiring systems

and in compliance with the approved drawings. All fifaults and short circuits. The detection devices shalspecified on the system drawings.

DNVGL-OS-D301, Ch.2 Sec.3 [3.4] Confirm release of the deluge systems to be possible botthe operating status of the systems is monitored.

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ual in accordance with the design standard, e.g.

ize shall be in accordance with system drawings. s shall be restrained to prevent unacceptable ischarge nozzle shall be oriented in such a manner d. Location of water and gas storage containers s and mounting brackets shall be fastened in he piping shall be pneumatically tested in a closed

that could result in a failure of the enclosure to specified holding period to be located and sealed.

shall be checked for proper installation in conduit eld circuits shall be confirmed to be free of ground l be checked for proper type and location as

torage container release mechanism so that t. Reconnect the release circuit with a functional

se mechanism. Check all supervised circuits for

ystem installation manual in accordance with the

st bottles


Inert Gas System NFPA 2001

Checks and tests as specified in system installation manNFPA 2001, Sec.7.7.2:

— Review mechanical components: nozzles and pipe sPiping joints, discharge nozzles, and piping supportvertical or lateral movement during discharge. The dthat optimum water mist application can be effecteshall be according approved drawings. All containeraccordance with the manufacturer’s requirements. Tcircuit (pressure test); flow test to be conducted.

— Review of enclosure integrity: any significant leaks hold the specified agent concentration level for the Refer to NFPA 2001:2012 Annex C.

— Review of electrical components: All wiring systemsand in compliance with the approved drawings. All fifaults and short circuits. The detection devices shalspecified on the system drawings.

— Preliminary functional testing: Disable each agent sactivation of the release circuit will not release agendevice in lieu of each agent storage container releaproper trouble response.

— Functioning tests: checks and tests as specified in sdesign standard

— System functional operational test/discharge te— Reaction on pressure drop in the pipelines, gas— Remote monitoring operations— Return of the systems to operational condition

Recom

mended practice, D

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ual in accordance with the design standard, e.g. ray systems), Ch.8:

n shall be cleaned internally after preparation and er’s installation manual pressure without loss within defined time (see

rtioning equipment shall be verified by flow tests. l be determined. During the tests, the pressure at inimum design operating pressure of the system

st

s and certificates for fire and gas detectors.perated call point will initiate a visual and audible

If the signals have not received attention within utomatically sounded throughout the crew s and machinery spaces of category A. periodically tested to the satisfaction of the t air at the appropriate temperature, or smoke or nsity or particle size, or other phenomena is designed to respond. they can be tested for correct operation and l of any component.


Foam System NFPA 16

Checks and tests as specified in system installation manNFPA 16 (foam-water sprinkler systems, foam-water sp

— Flushing, cleaning of piping: each pipe or tube sectiobefore assembly in accordance with the manufactur

— Hydrostatic/air tests: the system shall maintain theinstallation manual)

— Proportioning system testing: Operation of the propoThe percentage of foam concentrate in solution shalthe discharge devices shall be at least equal to the mor systems tested.

— Functioning tests:

— System functional operational test/discharge te— Reaction on pressure drop— Remote monitoring operations— Return of the systems to operational condition

Fire and Gas Detection

DNVGL-OS-D301, Ch.3 Sec.2 Table 1 Check of the availability and relevance of type approval

DNVGL-OS-D301, Ch.2 Sec.4

— Confirm that activation of any detector or manually ofire signal at the control panel and indicating units.two (2) minutes, confirm that an audible alarm is aaccommodation and service spaces, control station

— Confirm that the function of the detection system isAdministration by means of equipment producing hoaerosol particles having the appropriate range of deassociated with incipient fires to which the detector

— Confirm that all detectors are of the type such thatrestored to normal surveillance without the renewa

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ed on self-monitoring principals includes facilities tended machinery spaces.ons of engine operation and ventilation (activity .arm system continuously monitors all enclosed able gas may be expected to occur.

y audible and visual alarm in the control centre, ing to 25% and 60% of lower explosion limit.ual in accordance with the design standard, e.g.

tor in battery rooms) detectors, spark detectors mended by the manufacturers tests)

.

ual in accordance with the design standard, e.g.


Fire and Gas Detection

DNVGL-OS-D301, Ch.2 Sec.4 [2.6]

Periodically Unattended Machinery Space:

— Confirm that an approved fire detection system basfor periodical testing is installed in periodically unat

— Confirm fire detection system under varying conditinormally performed during sea trial – smoke tests)

DNVGL-OS-D301, Ch.2 Sec.4 [3]

— Confirm that a fixed automatic gas detection and alareas of the unit in which the accumulation of flamm

— Confirm that gas detection system indicates both, bthe presence of an accumulation of gas correspond

NFPA 72

Checks and tests as specified in system installation manNFPA 72, Ch.10, Table 10.4.2.2:

— Test of initiating devices i.e. fire and gas (H2 detec(heat tests, smoke tests, other approved and recom

— Receipt of alarms/signals by the control equipment— Interface between control panels— Check of conductors (wire, fibre optics) — Battery/UPS tests (if any)

Fire Alarm System NFPA 72

Checks and tests as specified in system installation manNFPA 72, Ch.10, Table 10.4.2.2:

— Short circuit tests— Test of remote annunciators— Audible and visual signal efficiency

SAF

DNV GLDriven by our purpose of safeguarding life, property and the environment, DNV GL enables organizations to advance the safety and sustainability of their business. We provide classification and technical assurance along with software and independent expert advisory services to the maritime, oil and gas, and energy industries. We also provide certification services to customers across a wide range of industries. Operating in more than 100 countries, our 16 000 professionals are dedicated to helping our customers make the world safer, smarter and greener.

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Date post:	20-Jan-2021
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