Materials and Qualification Procedures for Ships

Transcription

1 Materials and Qualification Procedures for Ships Approval Procedure for Laboratories Engaged in Testing of Coating Systems in Accordance with IACS Z17 and IMO MSC.215(82) and/or IMO MSC.288(87). Revision 4, December 2015

2 Lloyd s Register Group Limited, its subsidiaries and affiliates and their respective officers, employees or agents are, individually and collectively, referred to in this clause as Lloyd s Register. Lloyd s Register assumes no responsibility and shall not be liable to any person for any loss, damage or expense caused by reliance on the information or advice in this document or howsoever provided, unless that person has signed a contract with the relevant Lloyd s Register entity for the provision of this information or advice and in that case any responsibility or liability is exclusively on the terms and conditions set out in that contract. Lloyd's Register Group Limited All rights reserved. Except as permitted under current legislation no part of this work may be photocopied, stored in a retrieval system, published, performed in public, adapted, broadcast, transmitted, recorded or reproduced in any form or by any means, without the prior permission of the copyright owner. Enquiries should be addressed to Lloyd's Register Group Limited, 71 Fenchurch Street, London, EC3M 4BS. Page 2 of 11

3 Approval procedure for laboratories engaged in testing of coating systems in accordance with IACS Z17 and IMO MSC.215(82) and/or IMO MSC.288(87). 1 General Information 1.1 Scope of The Approval This document describes the requirements of Lloyd's Register for the approval of laboratories engaged in testing of coating systems in accordance with IMO Resolution MSC.215(82) and IACS UI SC223 and/or MSC.288(87) It is a requirement of IACS UI SC259 that laboratories engaged in testing of coating systems in accordance with MSC.288(87) be recognised by the Administration The laboratories approved in accordance with this procedure will be subject to surveillance checking by Lloyd s Register surveyors The name of the approved laboratory and the scope of their approval will appear in Lloyd s Register s List of Approved PSPC Test Laboratories which is published on Lloyd s Register s ClassDirect web site. 1.2 Related Documents IACS UR Z17, Procedural Requirements for Service Suppliers, Rev.10, January Performance Standard for Protective Coatings for Dedicated Seawater Ballast Tanks in All Types of Ships and Double-side Skin Spaces of Bulk Carriers, adopted by Resolution MSC.215(82) on 8 December IACS UI SC223, For Application of SOLAS Regulation II-1/3-2 Performance Standard for Protective Coatings (PSPC) for Dedicated Seawater Ballast Tanks in All Types of Ships and Double-side Skin Spaces of Bulk Carriers, adopted by Resolution MSC.215(82), Rev.3, Corr.1, October Performance Standard for Protective Coatings for Cargo Oil Tanks of Crude Oil Tankers, adopted by Resolution MSC.288(87) on 14 May Page 3 of 11

4 1.2.5 IACS UI SC259, For Application of SOLAS Regulation II-1/3-11 Performance Standard for Protective Coatings for Cargo Oil Tanks of Crude Oil Tankers (PSPC-COT), adopted by Resolution MSC.288(87), Rev.1, June Application for Approval 2.1 The five stages involved in the granting of Lloyd s Register approval are as follows: 1. Application for approval form PSPC-1 to be completed and submitted to Lloyd s Register. 2. The documents referred to in Section 5 of this procedure are to be prepared and submitted for review. 3. An audit of the laboratory by a Lloyd s Register Surveyor is to be performed in accordance with Section 6, and the results reported. 4. A review of the submitted documents and the completed audit report will be conducted by the Materials and NDE department (MNDE). 5. A certificate will be issued by MNDE if the laboratory is found to meet the requirements detailed in this procedure. 3 Requirements for Approval 3.1 Companies/Laboratories are to demonstrate the experience and capability necessary to conduct the testing of coating systems in accordance with the test procedures given in IMO Resolution MSC.215(82) and/or IMO Resolution MSC.288(87). Companies/Laboratories will be considered for approval if they comply with the following sections 3.2 to Training of Personnel The applicant is responsible for the qualification and training of their personnel to a recognised national, international or industry standard as applicable. Where such standards do not exist, the supplier is to define standards for the training and qualification of its personnel relevant to the functions each is authorised to perform. The personnel shall also have relevant experience and be familiar with the operation of any necessary equipment. A matrix of the authorisations granted to personnel shall be maintained. Page 4 of 11

5 3.2.2 A documented training programme for laboratory personnel should be in place. Where it is not possible to perform this internally, a programme of external training may be accepted Operators/technicians/inspectors shall have had a minimum of one (1) year tutored on-the-job training. Where it is not possible to perform internal training, a program of external training may be considered as acceptable Supervisors should have had a minimum of two years experience as an operator/technician/inspector involved with the testing of coating systems. 3.3 Supervision Companies/Laboratories shall supervise the activities of its staff or subcontractors for all services supplied. 3.4 Personnel Records A list of qualified personnel, including details of formal education, training and experience, must be maintained and be available for scrutiny by the auditing Surveyor. 3.5 Equipment and Standards Companies/Laboratories must possess equipment that is capable of carrying out the tests required by IMO Resolution MSC.215(82) and/or IMO Resolution MSC.288(87), and meet the requirements of relevant standards specified therein Equipment must be maintained and calibrated regularly in accordance with a documented procedure and the status of calibration is to be displayed on each piece of equipment Companies/Laboratories must possess controlled copies of the standards and reference documents referred to in IMO Resolution MSC.215(82) and/or IMO Resolution MSC.288(87), and any other such documents referred to in their test procedure(s). Page 5 of 11

6 3.6 Quality Assurance System Companies/Laboratories shall have a documented system covering at least the following: code of conduct for the relevant activity, maintenance and calibration of equipment, training programmes for operators/technicians/inspectors, supervision and verification to ensure compliance with operational procedures, recording and reporting of information, quality management of subsidiaries and agents, job preparation; and periodic review of work process procedures, complaints, corrective actions, and issuance, maintenance and control of documents A documented quality system complying with the most current version of ISO 9001, ISO or the appropriate national standard derived from these international standards, including all of the above items, would be considered acceptable. 4 Reports 4.1 Format of the reports should follow IACS Recommendations which are available on the IACS website ( Rec. 101: IACS Model Report for IMO Resolution MSC.215(82) Annex 1 Test Procedures for Coating Qualification. Rec. 102: IACS Model Report for IMO Resolution MSC.215(82) Annex 1 Test Procedures for Coating Qualification, Section 1.7 Crossover Test. 4.2 Other proposed reporting methods may be accepted, subject to special consideration by LR. 5 Approval Submission 5.1 The following documents shall be prepared and submitted for review: Completed Form PSPC-1, together with copies of current quality system certificates. Page 6 of 11

7 Description of the Company/Laboratory s organisation identifying management structure and any branch offices, subsidiary companies or subcontractors. Summary of extent of experience listing any relevant coating system testing work and evidence of approval/acceptance by other bodies, if any. List of personnel to be involved in coating system testing showing job titles, training, extent of experience and relevant qualifications. Record of customer complaints and corrective actions agreed with client. Quality manual and/or documented procedures covering requirements as detailed in Section 3.6. A detailed list of laboratory test equipment used for the IMO Resolution MSC.215(82) and/or IMO Resolution MSC.288(87) coating approval tests. A detailed list of controlled reference documents, comprising a minimum of those referred to in IMO Resolution MSC.215(82) and/or IMO Resolution MSC.288(87) that are available in the laboratory. Copies of test procedure(s) including details of test panel preparation, test panel identification, coating application, site and exposure method for weathering of primed test panels, procedures for testing and post-test inspection of samples, test result storage. A sample test report. Details of exposure method and site for weathering primed test panels. A sample daily or weekly log/form for recording test conditions and observations, including unforeseen interruption of the exposure cycles with corrective actions. Details of any sub-contracting agreements. Comparison test report with an approved coating system or laboratory, if available. Page 7 of 11

8 6 Audit 6.1 An audit will be made by a Lloyd s Register Surveyor to confirm that the test laboratory is suitably organised and managed in accordance with the documents submitted. Audit Checklist MQPS is provided to assist the auditor. 6.2 During the audit the capability of the Laboratory is to be confirmed by practical demonstration of a number of the discrete operations that form the approval test(s) as defined in IMO Resolution MSC.215(82) and/or IMO Resolution MSC.288(87). The number and type of demonstrations should be agreed in advance of the audit and should consist of all operations that it is reasonably possible for the laboratory to demonstrate, i.e. it is not expected that any test in progress should be stopped purely for the audit. Operations to be demonstrated include: Specimen preparation welding of U-bar, attachment of anode, surface preparation, surface roughness assessment, dust assessment, salt level determination, sealing of edges and reverse side; Primer application - dry film thickness of primer - consistency across specimen and between specimens, environmental control (humidity, temperature); Primer weathering - location, ambient condition recording, postexposure cleaning; Coating system characterisation - IR spectrography, specific gravity measurement, pinhole detection; Test machines - type, design and operation of the wave tank, condensation chamber, gas-tight cabinet and oil immersion equipment; Test environments composition, frequency of checks and replenishment schedule of sea-water, test gas and test liquid; Post-test assessments - blister and rust assessments, post -test dry film thicknesses, adhesion values, flexibility, cathodic protection data (anode weight loss, current demand, disbondment from artificial holiday). Safety culture - training, equipment and procedures. 6.3 In all cases the practical demonstrations shall be assessed against the laboratory's internal procedures and the mandatory standards contained in the footnotes to IMO Resolution MSC.215(82) and/or IMO Resolution MSC.288(87). Page 8 of 11

9 7 Review 7.1 A review of the required documents referenced in Section 3 will be undertaken by MNDE. Queries arising from the review by MNDE will be referred back to the Company/Laboratory for clarification. The suitability of the applicant for approval will be determined by reference to the criteria given herein and the details entered on the Audit Checklist MQPS Validity of Approval Certificate 8.1 Initial Approval When a Company/Laboratory has been deemed to satisfy Lloyd s Register s requirements, a certificate of approval will be issued. The Company/Laboratory s name will be entered into the approved PSPC test laboratory database The certificate of approval will contain the following information as a minimum: 1. Name of Company/Laboratory, and address of the office; 2. Scope of approval; and 3. Certificate number, date of issue and date of expiry Approval will normally be valid for a five-year period from the date of issue, subject to the laboratory maintaining the system in accordance with Lloyd s Register requirements and to a satisfactory intermediate audit at around two and half years Lloyd s Register reserves the right to approve Companies/Laboratories subject to clearly stated conditions or non-conformities being resolved to the satisfaction of the auditing Surveyor. All such conditions shall be stated on the approval certificate Where any significant alteration to the certified system, including change of personnel, is made, such alteration is to be immediately advised to Lloyd's Register. 8.2 Withdrawal of Certificate Lloyd s Register reserves the right to cancel or suspend a certificate and inform other IACS members accordingly if: Page 9 of 11

10 tests have been improperly carried out or the results of tests improperly reported; significant alterations to the approved Quality System have been made without notification to Lloyd s Register, or are such as to render the original approval invalid; where corrective actions have not been taken to rectify previously reported deficiencies in the approved system of the supplier; where deliberate distortion or omissions of facts are found; or if the supplier no longer wishes to remain on the list of approved service suppliers If Lloyd s Register considers that a certificate of approval should be withdrawn or cancelled, the supplier will be informed in writing and be given the opportunity to take appropriate corrective action, or give notice of appeal If a certificate is withdrawn, suspended or has expired, the firm s name will be removed from the approved laboratory database A supplier whose approval has been cancelled may apply for re-approval provided that the firm demonstrate that they have made the necessary changes to satisfy Lloyd s Register s requirements. 8.3 Renewal of Approval Renewal of the certificate is to be made at intervals not exceeding five years by verification through audits to confirm that approved conditions are maintained Companies/Laboratories wishing to renew their approval should submit to the local Lloyd s Register office the following documents: Request for Approval Form PSPC-1; a list of current personnel identifying qualifications, extent of experience and job title of each individual; copy of the current test procedure(s) used by the Company/Laboratory; and a sample of a recent test report. Page 10 of 11

11 8.3.3 On receipt of the completed Request for Approval form PSPC-1 arrangements will be made by a Lloyd s Register Surveyor to carry out an audit of the laboratory. During the renewal audit the tests to be demonstrated should, as far as it practicable, be complementary to those witnessed during the initial, and any subsequent, audits Upon satisfactory renewal, the Lloyd s Register approval will be extended for a further five year period. A certificate will be issued with a new expiry date and the Company/Laboratory s entry in the database updated accordingly Page 11 of 11