Qualification of manufacturers of special materials

Transcription

1 SERVICE SPECIFICATION DNVGL-SE-0079 Edition June 2016 Qualification of manufacturers of special materials The electronic pdf version of this document found through is the officially binding version. The documents are available free of charge in PDF format.

2 FOREWORD DNV GL service specifications contain procedural requirements for obtaining and retaining certificates and other conformity statements to the objects, personnel, organisations and/or operations in question. June 2016 Any comments may be sent by to This service document has been prepared based on available knowledge, technology and/or information at the time of issuance of this document. The use of this document by others than DNV GL is at the user's sole risk. DNV GL does not accept any liability or responsibility for loss or damages resulting from any use of this document.

3 CHANGES CURRENT General This is a new document. Changes current Service specification, DNVGL-SE-0079 Edition June 2016 Page 3

4 Contents CHANGES CURRENT... 3 Sec.1 General Introduction Use of this service specification DNV GL deliverables DNV GL organization and responsibilities Competence of the technical authority Manufacturer's responsibilities...6 Sec.2 Terms, definitions and abbreviations Definitions Verbal forms Abbreviations...7 Sec.3 Work process for certification Work process summary Project initiation Scope of work Qualification parameters Kick-off meeting Document review Manufacturer documents and procedures DNV GL deliverables prior to qualification Site visit - witnessing of the qualification General DNV GL site visit team DNV GL witnessing activities Site visit report...12 Sec.4 Endorsement and certification Endorsement of qualification test record Qualification test record Verification and endorsement of the qualification test record Validity of the qualification test record Renewal of the qualification test record DNV GL final verification report General Range of qualification Other information Certificate of qualification Issuance of a certificate of qualification Validity of the certificate of qualification Listing of certificates of qualification Renewal of certificates of qualification Withdrawal of certificates of qualification...15 App. A Checklist for assessment of testing laboratories App. B Qualification test record example from NORSOK M App. C Example of certificate of qualification Contents Service specification, DNVGL-SE-0079 Edition June 2016 Page 4

5 SECTION 1 GENERAL 1.1 Introduction This DNV GL service specification describes DNV GL s certification scheme for qualifying manufacturers of special materials as defined in NORSOK M-650 for the petroleum, petrochemical and natural gas industries. It also outlines how DNV GL acts as a qualifying company. Key objectives of this service specification are: to ensure quality by defining the competency of the person responsible for the certification to ensure the consistent delivery of NORSOK M-650 qualifications to provide recognizable deliverables to document compliance with NORSOK M-650. NORSOK M-650 states that: The qualifying company can be the company, the main contractor, the purchaser or a party authorized to act on their behalf. For the purpose of this qualification, DNV GL can have different roles: DNV GL can act as the qualifying company with authorization as described in NORSOK M-650. This will be reflected on the front page of the qualification test record (QTR), as further described in [4.1.2]. When the aim of the manufacturer is to obtain a qualification based on NORSOK M-650 without a defined order, DNV GL can verify compliance with this standard without having authorization from the company or main contractors. This will be reflected on the front page of the qualification test record (QTR) and in the certificate of qualification (COQ) as further described in [4.1.2] and [4.3.1]. In both cases, DNV GL will issue a COQ as specified in [4.3]. All documents relevant to the qualification shall be in English. 1.2 Use of this service specification The certification scheme described in this document is the scheme used by DNV GL. Organizations other than DNV GL that provide certification services related to NORSOK M-650 may also use this scheme or may use schemes provided by other parties. However, DNV GL has no obligations regarding, or responsibility for, any services delivered by others. DNV GL has mandatory qualification requirements for the technical authority (refer to [1.5]). This ensures that all qualifications and certifications provided are carried out by competent personnel who understand the intention behind the standard, the limitations and the correct interpretations. The use of this document is at the user's sole risk. DNV GL does not accept any liability or responsibility for loss or damage resulting from any use of this document. DNV GL and the DNV GL logos are trademarks of and shall not be used without the prior permission of DNV GL. 1.3 DNV GL deliverables The key deliverables are: an endorsed qualification test record (QTR) a certificate of qualification (COQ) with reference to the endorsed QTR and DNVGL-SE-0079 DNV GL listing of the COQ. Service specification, DNVGL-SE-0079 Edition June 2016 Page 5

6 1.4 DNV GL organization and responsibilities The custodian unit for qualification services according to this DNVGL-SE-0079 is DNV GL Oil and Gas, Materials Technology at Høvik, Norway. The custodian unit is responsible for carrying out the qualification process and issuing the corresponding deliverables as per this service specification. Each qualification will be organized as a project with a project manager and qualified personnel. The custodian unit is responsible for organizing the project and providing the deliverables, as follows: Appointment of a project manager (PM) and technical authority (TA) for the qualification. The TA's minimum competence requirements are described in [1.5]. Appointment of project team members that will support the TA during activities such as: the document review the overall assessment for acceptance prior to the start of the surveillance activities survey of manufacturing facilities verification of heat-treatment procedure witnessing of qualification testing review and acceptance of the QTR. Issuance of VerComs. Issuance of the COQ. 1.5 Competence of the technical authority Personnel acting as the technical authority (TA) shall hold competence as required by the DNV GL competence management and requirements system. The list of all DNV GL s TAs is available upon request. 1.6 Manufacturer's responsibilities The manufacturer shall be responsible for: performing the qualification production following the manufacturing summary (MS) as defined in NORSOK M-650 providing DNV GL with the essential documentation to be reviewed performing required testing as per NORSOK M-650 issuing the QTR. Service specification, DNVGL-SE-0079 Edition June 2016 Page 6

7 SECTION 2 TERMS, DEFINITIONS AND ABBREVIATIONS In addition to the terms, definitions and abbreviations given in NORSOK M-650, the following shall apply. 2.1 Definitions Table 2-1 Definitions Term certification certificate of qualification (COQ) monitoring qualification verification verification comments (VerCom) witnessing Definition with reference to ISO 17000; the issuance of a third-party statement, based on a decision following a review, that fulfilment of specified requirements related to products, processes or systems has been demonstrated A review shall in this context mean a verification of the suitability, adequacy and effectiveness of selection and determination activities, and the results of these activities, with regard to the fulfilment of specified requirements by an object of conformity assessment. the COQ is a document stating compliance with NORSOK M-650 and this DNVGL-SE-0079 a continual, albeit not necessarily constant and complete, observation of parameters affecting the quality of a process Work may proceed without the presence of, or any special information to, the technical authority (TA), but the TA may attend this activity at any time. an activity carried out to confirm that a procedure, material or technology meets a set of requirements This is commonly associated with an extended volume of testing compared to normal production. (ISO 9000:2005) confirmation, through the provision of objective evidence, that specified requirements have been fulfilled. DNV GL's comments on a document being reviewed. the presence at and observation of a defined and specified event or test. Work shall not proceed until the TA is available to witness the test This is equivalent to a Hold point in the production. The TA may, however, in advance state in writing that the activity can be carried out by a local DNV GL surveyor or that his/her presence is not required. 2.2 Verbal forms Table 2-2 Verbal forms Term shall should may Definition verbal form used to indicate requirements strictly to be followed in order to conform to the document verbal form used to indicate that among several possibilities one is recommended as particularly suitable, without mentioning or excluding others, or that a certain course of action is preferred but not necessarily required verbal form used to indicate a course of action permissible within the limits of the document 2.3 Abbreviations Table 2-3 Abbreviations Abbreviation Name in full CRA corrosion resistant alloy COQ certificate of qualification manufacturers of special materials HT heat treatment ITP inspection and test plan M monitoring MS manufacturing summary NDT non-destructive testing Service specification, DNVGL-SE-0079 Edition June 2016 Page 7

8 Table 2-3 Abbreviations (Continued) Abbreviation Name in full R document review SE service specification SoW scope of work SVR site visit report TA technical authority QTR qualification test record VerCom verification comment W witnessing Service specification, DNVGL-SE-0079 Edition June 2016 Page 8

9 SECTION 3 WORK PROCESS FOR CERTIFICATION 3.1 Work process summary The steps to be followed during the qualification process are summarized in the flow chart below and described in detail in [3.2] to [3.4] and Sec.4. PROJECT INITIATION Establishment of project team Kick-off meeting Pre-review of documentation Assessment based on pre-review of documentation Define detailed SoW and qualification parameters General assessment of manufacturer's technical competence and production capability, including previous experience/deliveries with DNV GL involvement DOCUMENT REVIEW Review of manufacturing procedures and documents Issuance of comments - VerComs (all comments to be closed prior to site visit, production qualification & testing) SITE VISITS, PRODUCTION QUALIFICATION & TESTING Assessment of the manufacturing facilities, including testing facilities Evaluation of the personnel competence Assessment of the implementation of procedures. Evaluation of the final product ENDORSEMENT OF THE QTR Review and endorsement by DNV GL of the QTR issued by the manufacturer ISSUANCE OF CERTIFICATE & LISTING Issuance of the final verification reports and COQ Listing of the COQ on DNV GL's website Figure 3-1 Service specification, DNVGL-SE-0079 Edition June 2016 Page 9

10 3.2 Project initiation Scope of work The scope of work (SoW) shall be determined in cooperation with the customer. The following shall as a minimum be agreed on: Extent of qualification: the number of manufacturing sites and processes, material grades, product forms, wall thicknesses, weight, etc. Extent of the document review: the mandatory documents and procedures, number of review cycles and inspection test plan (ITP). Extent of witnessing activities and hold points: the number and duration of site visits. This will depend on the manufacturer s previous experience with NORSOK M-650 qualifications Qualification parameters The manufacturer shall define the project's parameters, such as the production site, production route, type of product, material grade and size range. The choice of parameters should be guided by the following: If the manufacturer is aiming for a specific project, it is recommended to use the parameters defined by the potential customer. If the aim of the qualification is to obtain a QTR for general commercial purposes, the parameters should reflect the manufacturer's capabilities and the intended market for the product to be qualified. Additional requirements may be applicable through project specification(s) but the qualification process shall fully comply with NORSOK M-650. The project specification(s) can be referenced in the DNV GL qualification report if any supplementary requirements to the previously mentioned standards shall be considered Kick-off meeting A kick-off meeting shall be included in the SoW. This kick-off meeting is intended to: clarify NORSOK M-650 requirements if necessary present the SoW as agreed in the contract obtain information related to the manufacturing facilities and testing laboratories agree upon the documents to be submitted agree upon the project schedule present DNV GL s expectations for the manufacturer review the documentation related to the manufacturer's experience and/or any trial productions. 3.3 Document review The documents listed in [3.3.1] and [3.3.2] shall be prepared prior to the start of the qualification production Manufacturer documents and procedures Table 3-1 outlines the documents that shall be prepared by the manufacturer and submitted to DNV GL prior to the start of the qualification production. The manufacturer's summary and related procedures shall describe the steps in the manufacturing facility/ route that is being qualified and shall present the activities carried out in order to meet the NORSOK M-650 requirements. The document requirements are described in NORSOK M-650. The documents submitted for review for the qualification shall be the same as for a normal production. Service specification, DNVGL-SE-0079 Edition June 2016 Page 10

11 Table 3-1 Documents to be prepared by the manufacturer Documents for review Certificates of relevant experience supported by statistical data and a reference list Quality plan and quality control system procedures Results of trial productions, if applicable A Manufacturing Summary (MS) in accordance with NORSOK M-650 requirements for each product site and production route, type of product, material grade and size range Detailed heat-treatment procedures if relevant NDT procedures used for final control of the product (if applicable) Procedure for dimensional control Material handling, including welding consumables handling, if not in MS (if applicable) Metallographic inspection procedures Checklist for assessing testing laboratories (as per App.A) Documents for information Quality certificates for manufacturing and laboratory facilities DNV GL deliverables prior to qualification DNV GL shall issue the verification conclusion, in the form of verification comments (VerCom) on the manufacturer's documents and procedures, prior to the start of the qualification production. The documents and procedures shall be updated (if required) by the manufacturer and finally accepted by DNV GL before the qualification production can commence. This means that all VerComs shall be closed before the qualification production starts. 3.4 Site visit - witnessing of the qualification General The manufacturer shall conduct the qualification production, which is essentially the same as a normal production. It is strongly recommended that the manufacturer carries out a production trial before inviting DNV GL to witness a qualification production, particularly if the manufacturer has no previous experience of production in accordance with NORSOK M-650. A qualification plan to be used during the witnessing of the qualification activities shall be prepared for each project. The qualification plan will be prepared by DNV GL based on the information in the MS. The minimum items to be included in the qualification plan shall be as per Table 3-2. Table 3-2 Minimum items to be checked during the qualificationexercise Item Description Inspection Level 1 Start material receipt, identification and tracking M/R 2 Production control of the parts M 3 Repair/re-work procedures (if applicable) M/R 4 Temperature uniformity control for heat-treatment furnace M 5 Heat treatment W/H 6 Non-destructive testing, calibration of equipment and testing (if applicable) M/R 7 Sampling and identification of test coupons for testing R 8 Destructive testing (mechanical, chemical) W/M/R 9 Dimensional control M 10 Marking of final product M 11 Handling and storage R 12 Document release R W: Witnessing M: Monitoring R: Review H: Hold point Service specification, DNVGL-SE-0079 Edition June 2016 Page 11

12 3.5 DNV GL site visit team The TA shall be present during the qualification production as specified in the ITP. The TA shall assess the capability of the equipment, the competence of the personnel and the implementation of the procedures which have been accepted by DNV GL. DNV GL surveyors may assist during the qualification production and work under the supervision of the TA DNV GL witnessing activities The qualification plan forms the basis for the witnessing activities. All activities noted in the qualification plan shall be witnessed for at least one representative component to be qualified and subsequently reported in a site visit report, as specified in [3.5.2]. The verification of the heat-treatment procedure shall be witnessed by the TA as described in NORSOK M-650. The capability of all equipment used in the qualification process shall be verified as part of the witnessing activities. All equipment shall be fit for purpose: properly identified, regularly maintained and calibrated as per NORSOK M-650 requirements; all calibration certificates shall be available upon request when the site visit takes place. The final stage of the qualification production is the material testing of the component. Sampling of test coupons and material testing shall be witnessed by DNV GL. The laboratory facilities shall be assessed by the TA before testing in accordance with the ISO criteria. Annex 1 in FAQ for NORSOK M-650 ( ) contains a checklist suitable for this purpose, see App.A. The DNV GL site visit team shall not face any restrictions on access to the production facilities during the qualification production Site visit report A site visit report (SVR) shall be issued by DNV GL after each visit. The SVR shall describe the assessment of the facilities, equipment and implementation of the procedures at the manufacturer's and possibly sub-suppliers' sites. The SVR shall highlight any concerns or nonconformities related to the qualification. All production, testing results or observations that do not meet the requirements shall be reported by DNV GL in the SVR. If, during qualification, some of the testing does not meet the acceptance criteria, the cause shall be established and, if agreed upon, a new qualification production and testing shall be performed with adjusted parameters. The adjustment of parameters shall be based on the result of the assessment of the failed test(s). Service specification, DNVGL-SE-0079 Edition June 2016 Page 12

13 SECTION 4 ENDORSEMENT AND CERTIFICATION 4.1 Endorsement of qualification test record Qualification test record The manufacturer shall issue a qualification test record (QTR) according to NORSOK M-650 that presents the qualification production and results. The format and content of the QTR's front page shall be as per NORSOK M-650. The QTR shall contain all the essential documentation relating to the qualification production; the information shall be accurate, specific and in accordance with the NORSOK M-650 requirements Verification and endorsement of the qualification test record The completed QTR shall be issued by the manufacturer and submitted to DNV GL for review and endorsement. Examples of QTR are shown in App.B. DNV GL shall verify that all results reported by the manufacturer are consistent with DNV GL s witnessing activities and related SVR. The QTR shall refer to NORSOK M-650 only. If the qualification process is based on a project specification, this specification may be referenced in the final qualification report issued by DNV GL. DNV GL reviews the procedures and witnesses the production and the QTR confirms that the qualification production was successful. This means that the manufacturer was able to meet all the requirements during the qualification production. The QTR shall be endorsed by the TA signing and stamping the front page of the QTR. When DNV GL acts as the authorized qualifying company, the QTR front page should be co-signed by the party that has granted the authorization. Otherwise, the QTR will only be signed by the TA and the manufacturer. By signing and stamping the front page of the QTR, DNV GL confirms that the manufacturer has fully met all the relevant NORSOK M-650 requirements during the qualification process Validity of the qualification test record The QTR is valid for five years from the date of endorsement. For manufacturers with less than two years' documented experience of the actual production process, the validity period shall be limited to two years. This shall be stated on the QTR. DNV GL shall be informed if the manufacturing route is altered after the qualification. In such case, the validity of the QTR shall be evaluated Renewal of the qualification test record The renewal of qualifications shall be carried out in accordance with NORSOK M-650 requirements. An assessment of the manufacturing documentation and process, including the heat treatment and its corresponding verification, shall be carried out by the appointed TA and the issuance and acceptance of a new QTR are necessary for this purpose. The certificate of qualification (COQ) shall be renewed in a synchronized manner as described in [4.3.4]. 4.2 DNV GL final verification report General DNV GL shall issue a final verification report that summarizes all DNV GL activities. The conclusion shall be presented and substantiated. The final verification report shall be accepted and signed by the TA. Service specification, DNVGL-SE-0079 Edition June 2016 Page 13

14 The final verification report shall contain all DNV GL's relevant documentation produced during the qualification process. This includes, but is not limited to: a reference to the contract under which the work has been carried out a description of the product and its intended service the SoW a reference to NORSOK M-650 all VerCom correspondence, which shall be closed at this stage all SVRs a reference to all the relevant documents received from the manufacturer on which the report is based, including the QTR if the qualification production was successful Range of qualification The final verification report shall contain a statement of the range of qualification as per the QTR, see App.B Other information If a project specification was used as the basis for the qualification, a reference to this specification shall be included in the final verification report and additional requirements with regard to NORSOK M-650 shall be highlighted. 4.3 Certificate of qualification Issuance of a certificate of qualification The certificate of qualification (COQ) is a certificate stating the name and location of the manufacturer, together with the main qualification parameters. An example of a COQ is included in App.C. The COQ shall be issued by DNV GL as a statement confirming that the document verification and qualification activities have concluded that the object complies with the NORSOK M-650 requirements. The COQ shall be issued by the custodian unit upon successful completion of all the activities in the qualification process. There shall be no verification comments pending. The COQ shall be supported by DNV GL s final verification report and the endorsed QTR. Both of these documents shall be referenced in the COQ. The activities in which DNV GL has been involved during the qualification process shall be listed. The COQ shall be signed by the technical authority (TA) and custodian unit representative Validity of the certificate of qualification The expiry date of the COQ shall be the same as the expiry date of the QTR Listing of certificates of qualification All COQs issued based on this service specification will be listed and can be found and accessed via the DNV GL tool approval finder, which will give access to the valid COQ. The DNV GL approval finder tool can be reached by the following link Renewal of certificates of qualification Application for renewal should be made no later than three months before the certificate expires. The COQ shall be renewed after successful completion of the scope defined in [4.1.4] and a review/ assessment of: claims, queries etc, from customers and others possible problem areas raised in previous audits quality system audit reports (including in connection with ISO quality system certificates) statistical results from testing. Service specification, DNVGL-SE-0079 Edition June 2016 Page 14

15 4.3.5 Withdrawal of certificates of qualification The COQ may be withdrawn at any time if DNV GL finds that the conditions for qualification are no longer met. The validity of the COQ depends upon a valid QTR. Service specification, DNVGL-SE-0079 Edition June 2016 Page 15

16 APPENDIX A CHECKLIST FOR ASSESSMENT OF TESTING LABORATORIES Service specification, DNVGL-SE-0079 Edition June 2016 Page 16

17 Service specification, DNVGL-SE-0079 Edition June 2016 Page 17

18 APPENDIX B QUALIFICATION TEST RECORD EXAMPLE FROM NORSOK M-650 Service specification, DNVGL-SE-0079 Edition June 2016 Page 18

19 APPENDIX C EXAMPLE OF CERTIFICATE OF QUALIFICATION Service specification, DNVGL-SE-0079 Edition June 2016 Page 19

20 DNV GL Driven 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 professionals are dedicated to helping our customers make the world safer, smarter and greener. SAFER, SMARTER, GREENER